diff --git a/.gitignore b/.gitignore
index 705e802..d9c5e77 100644
--- a/.gitignore
+++ b/.gitignore
@@ -1,2 +1,7 @@
-#Ignore all pyc files
-*.pyc
\ No newline at end of file
+.DS_Store
+*.egg-info
+*.swp
+tags
+smart_service/docs/current
+*.pyc
+__pycache__/
diff --git a/__pycache__/setup.cpython-38.pyc b/__pycache__/setup.cpython-38.pyc
deleted file mode 100644
index 49175a1..0000000
Binary files a/__pycache__/setup.cpython-38.pyc and /dev/null differ
diff --git a/smart_service/__pycache__/__init__.cpython-38.pyc b/smart_service/__pycache__/__init__.cpython-38.pyc
deleted file mode 100644
index b292cfc..0000000
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diff --git a/smart_service/__pycache__/hooks.cpython-38.pyc b/smart_service/__pycache__/hooks.cpython-38.pyc
deleted file mode 100644
index d4a13e7..0000000
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index 5448894..93c1ef8 100644
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diff --git a/smart_service/add_ons/doctype/captcha_validation/__pycache__/__init__.cpython-38.pyc b/smart_service/add_ons/doctype/captcha_validation/__pycache__/__init__.cpython-38.pyc
index 7853c09..e6643d0 100644
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diff --git a/smart_service/add_ons/doctype/captcha_validation/__pycache__/captcha_validation.cpython-38.pyc b/smart_service/add_ons/doctype/captcha_validation/__pycache__/captcha_validation.cpython-38.pyc
index 39e9483..8c4e721 100644
Binary files a/smart_service/add_ons/doctype/captcha_validation/__pycache__/captcha_validation.cpython-38.pyc and b/smart_service/add_ons/doctype/captcha_validation/__pycache__/captcha_validation.cpython-38.pyc differ
diff --git a/smart_service/add_ons/doctype/circular/circular.js b/smart_service/add_ons/doctype/circular/circular.js
index 424f725..f503a59 100644
--- a/smart_service/add_ons/doctype/circular/circular.js
+++ b/smart_service/add_ons/doctype/circular/circular.js
@@ -2,10 +2,40 @@
// For license information, please see license.txt
frappe.ui.form.on('Circular', {
- validate(frm) {
- if(frm.doc.valid_till < frappe.datetime.nowdate()) {
- msgprint('Valid Till date should be greater than today!');
+ validate(frm) {
+ if (frm.doc.valid_till < frappe.datetime.nowdate()) {
+ msgprint('Valid Till date should be equal or greater than today!');
validated = false;
}
- }
+ if (frm.doc.description.length > 500) {
+ frappe.msgprint("Description: Only 500 character's are allowed")
+ validated = false;
+ }
+ if (frm.doc.circular_image) {
+ console.log("calling")
+ frappe.call({
+ method: "smart_service.add_ons.doctype.circular.circular.file_validation",
+ args: {
+ image: frm.doc.circular_image,
+ name: frm.doc.name
+ },
+ callback: function (r) {
+ if (r.message && r.message[0] == false) {
+ frm.doc.circular_image = ""
+ frm.refresh_fields("circular_image")
+ if (r.message[1] == 1) {
+ frappe.validated = false;
+ frappe.msgprint("Invalid file type")
+ }
+ if (r.message[1] == 2) {
+ frappe.validated = false;
+ frappe.msgprint("Invalid file size")
+ }
+ }
+ }
+ })
+
+ }
+
+ }
});
diff --git a/smart_service/add_ons/doctype/circular/circular.json b/smart_service/add_ons/doctype/circular/circular.json
index 44c035e..1db64d6 100644
--- a/smart_service/add_ons/doctype/circular/circular.json
+++ b/smart_service/add_ons/doctype/circular/circular.json
@@ -25,6 +25,7 @@
"reqd": 1
},
{
+ "description": "Max count (500 character's)",
"fieldname": "description",
"fieldtype": "Small Text",
"in_list_view": 1,
@@ -65,15 +66,15 @@
"label": "Valid Till"
},
{
+ "description": "Upload *.png,*.jpg,*.pdf",
"fieldname": "circular_image",
"fieldtype": "Attach",
"label": "Circular Image"
}
],
"index_web_pages_for_search": 1,
- "is_submittable": 1,
"links": [],
- "modified": "2022-05-14 12:07:39.981829",
+ "modified": "2023-06-28 16:41:53.914998",
"modified_by": "Administrator",
"module": "Add Ons",
"name": "Circular",
diff --git a/smart_service/add_ons/doctype/circular/circular.py b/smart_service/add_ons/doctype/circular/circular.py
index 7126e4a..b0cbbf5 100644
--- a/smart_service/add_ons/doctype/circular/circular.py
+++ b/smart_service/add_ons/doctype/circular/circular.py
@@ -1,8 +1,161 @@
# Copyright (c) 2021, Hard n Soft Technologies Pvt Ltd and contributors
# For license information, please see license.txt
-# import frappe
+import frappe
from frappe.model.document import Document
class Circular(Document):
- pass
+ def validate(self):
+ if self.description and len(self.description)>500:
+ frappe.throw("Description should be less than or equal to 850 characters ")
+
+
+
+@frappe.whitelist()
+def file_validation(image, name):
+ if image:
+ res = check_img_ext(image)
+ res1 = check_png_ext(image)
+ res2 = check_pdf_ext(image)
+ if res == True or res1 == True or res2 == True:
+ return True
+ else:
+ return False, 1
+ # if res== True:
+ # pass
+ # else:
+ # width, height, size = details_of_image(image)
+ # if width > 49 or height > 49 or size > 65 and image:
+ # val = checking_image(image, "Circular","circular_image", name)
+ # if val:
+ # return False, 2
+
+
+
+ # if res2 == True:
+ # pass
+ # else:
+ # width, height, size = details_of_image(image)
+ # if width > 49 or height > 49 or size > 65 and image:
+ # val = checking_image(image, "Circular",
+ # "circular_image", name)
+ # if val == True:
+ # return False, 2
+ # else:
+ # return True
+ # else:
+ # val = checking_image(image, "Circular",
+ # "circular_image", name)
+ if res == False:
+ ret = res
+ elif res1 == False:
+ ret = res1
+ else:
+ ret = res2
+ return ret, 1
+
+
+@frappe.whitelist()
+def check_pdf_ext(path):
+ if path:
+ ext = path.split()[-1]
+ if ext.lower().endswith('.pdf'):
+ return True
+ else:
+ return False
+ else:
+ return False
+
+
+
+@frappe.whitelist()
+def check_img_ext(path):
+ if path:
+ ext = path.split()[-1]
+ if ext.lower().endswith('.jpg') or ext.lower().endswith('.jpeg'):
+ return True
+ else:
+ return False
+ else:
+ return False
+
+
+@frappe.whitelist()
+def check_png_ext(path):
+ if path:
+ ext = path.split()[-1]
+ if ext.lower().endswith('.png'):
+ return True
+ else:
+ return False
+ else:
+ return False
+
+
+
+def details_of_image(image_file):
+ try:
+ # Image dimension validation
+ import os
+ from PIL import Image
+ if image_file.startswith('/private/'):
+ filepath = get_absolute_path(image_file, True)
+ else:
+ filepath = get_absolute_path(image_file)
+ img = Image.open(filepath)
+ width = img.width
+ height = img.height
+ size = os.stat(filepath)
+ size=size[6]/1024
+ return width, height,size
+ except Exception as e:
+ raise e
+
+
+def get_absolute_path(file_name, is_private=False):
+ try:
+ if file_name.startswith('/files/'):
+ file_name = file_name[7:]
+ else:
+ file_name = file_name[15:]
+ return frappe.utils.get_bench_path() + "/sites/" + frappe.utils.get_path('private' if is_private else 'public',
+ 'files', file_name)[2:]
+ except Exception as e:
+ frappe.log_error("get_absolute_path", frappe.get_traceback())
+
+
+
+def checking_image(file_url, attached_to_doctype, attached_to_field, docname, is_child=None):
+ try:
+ import time
+ time.sleep(1)
+ if docname.startswith('new'):
+ image_name = frappe.db.get_list("File", fields={"name"}, filters={"file_url": file_url,
+ "attached_to_doctype": attached_to_doctype,
+ "attached_to_field": attached_to_field,
+ "attached_to_name": docname})
+
+ else:
+ image_name = frappe.db.get_list("File", fields={"name"}, filters={"file_url": file_url,
+ "attached_to_doctype": attached_to_doctype,
+ "attached_to_field": attached_to_field})
+
+ image_name = frappe.db.sql(f"""select name from `tabFile` where file_url='{file_url}' and attached_to_doctype='{attached_to_doctype}' and
+ attached_to_field='{attached_to_field}'""",as_dict=1)
+ # frappe.msgprint("data-"+str(file_url)+"-"+str(attached_to_doctype)+"-"+str(attached_to_field)+"-"+str(docname))
+ if not attached_to_doctype == "Symbol Scanner" and is_child != 1:
+ frappe.db.sql(
+ '''UPDATE `tab{0}` SET {2} = '' where name = "{1}"'''.format(attached_to_doctype, docname,
+ attached_to_field))
+ frappe.db.commit()
+ if attached_to_doctype == "Symbol Scanner":
+ frappe.db.set_value(
+ "Symbol Scanner", "Symbol Scanner", attached_to_field, "")
+
+ if len(image_name) > 0:
+ frappe.delete_doc('File', image_name[0]['name'])
+ return True
+
+ except Exception as e:
+ frappe.log_error("Checking images", frappe.get_traceback())
+
diff --git a/smart_service/add_ons/doctype/refresh_token/__init__.py b/smart_service/add_ons/doctype/refresh_token/__init__.py
new file mode 100644
index 0000000..e69de29
diff --git a/smart_service/add_ons/doctype/refresh_token/refresh_token.js b/smart_service/add_ons/doctype/refresh_token/refresh_token.js
new file mode 100644
index 0000000..9c84db5
--- /dev/null
+++ b/smart_service/add_ons/doctype/refresh_token/refresh_token.js
@@ -0,0 +1,8 @@
+// Copyright (c) 2023, Hard n Soft Technologies Pvt Ltd and contributors
+// For license information, please see license.txt
+
+frappe.ui.form.on('Refresh Token', {
+ // refresh: function(frm) {
+
+ // }
+});
diff --git a/smart_service/add_ons/doctype/refresh_token/refresh_token.json b/smart_service/add_ons/doctype/refresh_token/refresh_token.json
new file mode 100644
index 0000000..3ea5337
--- /dev/null
+++ b/smart_service/add_ons/doctype/refresh_token/refresh_token.json
@@ -0,0 +1,77 @@
+{
+ "actions": [],
+ "allow_rename": 1,
+ "creation": "2023-02-02 11:54:48.885036",
+ "doctype": "DocType",
+ "editable_grid": 1,
+ "engine": "InnoDB",
+ "field_order": [
+ "access_token",
+ "refresh_token",
+ "column_break_3",
+ "access_expiry_time",
+ "refresh_expiry_time",
+ "user",
+ "device_id"
+ ],
+ "fields": [
+ {
+ "fieldname": "access_token",
+ "fieldtype": "Small Text",
+ "label": "Access Token"
+ },
+ {
+ "fieldname": "refresh_token",
+ "fieldtype": "Small Text",
+ "label": "Refresh Token"
+ },
+ {
+ "fieldname": "column_break_3",
+ "fieldtype": "Column Break"
+ },
+ {
+ "fieldname": "access_expiry_time",
+ "fieldtype": "Datetime",
+ "label": "Access Expiry Time"
+ },
+ {
+ "fieldname": "refresh_expiry_time",
+ "fieldtype": "Datetime",
+ "label": "Refresh Expiry Time"
+ },
+ {
+ "fieldname": "user",
+ "fieldtype": "Link",
+ "label": "User",
+ "options": "User"
+ },
+ {
+ "fieldname": "device_id",
+ "fieldtype": "Data",
+ "label": "Device ID"
+ }
+ ],
+ "index_web_pages_for_search": 1,
+ "links": [],
+ "modified": "2023-06-24 12:22:02.491908",
+ "modified_by": "Administrator",
+ "module": "Add Ons",
+ "name": "Refresh Token",
+ "owner": "Administrator",
+ "permissions": [
+ {
+ "create": 1,
+ "delete": 1,
+ "email": 1,
+ "export": 1,
+ "print": 1,
+ "read": 1,
+ "report": 1,
+ "role": "System Manager",
+ "share": 1,
+ "write": 1
+ }
+ ],
+ "sort_field": "modified",
+ "sort_order": "DESC"
+}
\ No newline at end of file
diff --git a/smart_service/add_ons/doctype/refresh_token/refresh_token.py b/smart_service/add_ons/doctype/refresh_token/refresh_token.py
new file mode 100644
index 0000000..531d1bc
--- /dev/null
+++ b/smart_service/add_ons/doctype/refresh_token/refresh_token.py
@@ -0,0 +1,8 @@
+# Copyright (c) 2023, Hard n Soft Technologies Pvt Ltd and contributors
+# For license information, please see license.txt
+
+# import frappe
+from frappe.model.document import Document
+
+class RefreshToken(Document):
+ pass
diff --git a/smart_service/add_ons/doctype/refresh_token/test_refresh_token.py b/smart_service/add_ons/doctype/refresh_token/test_refresh_token.py
new file mode 100644
index 0000000..25cd7f6
--- /dev/null
+++ b/smart_service/add_ons/doctype/refresh_token/test_refresh_token.py
@@ -0,0 +1,8 @@
+# Copyright (c) 2023, Hard n Soft Technologies Pvt Ltd and Contributors
+# See license.txt
+
+# import frappe
+import unittest
+
+class TestRefreshToken(unittest.TestCase):
+ pass
diff --git a/smart_service/add_ons/doctype/token_settings/__init__.py b/smart_service/add_ons/doctype/token_settings/__init__.py
new file mode 100644
index 0000000..e69de29
diff --git a/smart_service/add_ons/doctype/token_settings/test_token_settings.py b/smart_service/add_ons/doctype/token_settings/test_token_settings.py
new file mode 100644
index 0000000..eb4cc13
--- /dev/null
+++ b/smart_service/add_ons/doctype/token_settings/test_token_settings.py
@@ -0,0 +1,8 @@
+# Copyright (c) 2023, Hard n Soft Technologies Pvt Ltd and Contributors
+# See license.txt
+
+# import frappe
+import unittest
+
+class TestTokenSettings(unittest.TestCase):
+ pass
diff --git a/smart_service/add_ons/doctype/token_settings/token_settings.js b/smart_service/add_ons/doctype/token_settings/token_settings.js
new file mode 100644
index 0000000..be6ddf8
--- /dev/null
+++ b/smart_service/add_ons/doctype/token_settings/token_settings.js
@@ -0,0 +1,8 @@
+// Copyright (c) 2023, Hard n Soft Technologies Pvt Ltd and contributors
+// For license information, please see license.txt
+
+frappe.ui.form.on('Token Settings', {
+ // refresh: function(frm) {
+
+ // }
+});
diff --git a/smart_service/add_ons/doctype/token_settings/token_settings.json b/smart_service/add_ons/doctype/token_settings/token_settings.json
new file mode 100644
index 0000000..e788352
--- /dev/null
+++ b/smart_service/add_ons/doctype/token_settings/token_settings.json
@@ -0,0 +1,48 @@
+{
+ "actions": [],
+ "allow_rename": 1,
+ "creation": "2023-02-03 10:17:56.807664",
+ "doctype": "DocType",
+ "editable_grid": 1,
+ "engine": "InnoDB",
+ "field_order": [
+ "access_expiry_time",
+ "refresh_expiry_time"
+ ],
+ "fields": [
+ {
+ "description": "Token Expiry in Minutes e.g. 15",
+ "fieldname": "access_expiry_time",
+ "fieldtype": "Int",
+ "label": "Access Expiry Time"
+ },
+ {
+ "description": "Token Expiry in Hours e.g. 1",
+ "fieldname": "refresh_expiry_time",
+ "fieldtype": "Int",
+ "label": "Refresh Expiry Time"
+ }
+ ],
+ "index_web_pages_for_search": 1,
+ "issingle": 1,
+ "links": [],
+ "modified": "2023-06-29 09:34:46.212738",
+ "modified_by": "Administrator",
+ "module": "Add Ons",
+ "name": "Token Settings",
+ "owner": "Administrator",
+ "permissions": [
+ {
+ "create": 1,
+ "delete": 1,
+ "email": 1,
+ "print": 1,
+ "read": 1,
+ "role": "System Manager",
+ "share": 1,
+ "write": 1
+ }
+ ],
+ "sort_field": "modified",
+ "sort_order": "DESC"
+}
\ No newline at end of file
diff --git a/smart_service/add_ons/doctype/token_settings/token_settings.py b/smart_service/add_ons/doctype/token_settings/token_settings.py
new file mode 100644
index 0000000..3927c5e
--- /dev/null
+++ b/smart_service/add_ons/doctype/token_settings/token_settings.py
@@ -0,0 +1,15 @@
+# Copyright (c) 2023, Hard n Soft Technologies Pvt Ltd and contributors
+# For license information, please see license.txt
+
+import frappe
+from frappe.model.document import Document
+
+
+class TokenSettings(Document):
+
+ def validate(self):
+ if self.access_expiry_time <= 0:
+ frappe.throw("Access exipry time should be valid minutes")
+
+ if self.refresh_expiry_time <= 0:
+ frappe.throw("Refresh exipry time should be valid hours")
diff --git a/smart_service/add_ons/doctype/user_feedback/__pycache__/__init__.cpython-38.pyc b/smart_service/add_ons/doctype/user_feedback/__pycache__/__init__.cpython-38.pyc
index defea26..d61daca 100644
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diff --git a/smart_service/add_ons/report/feedback_report/feedback_report.py b/smart_service/add_ons/report/feedback_report/feedback_report.py
index 66a8237..3b06502 100644
--- a/smart_service/add_ons/report/feedback_report/feedback_report.py
+++ b/smart_service/add_ons/report/feedback_report/feedback_report.py
@@ -28,6 +28,8 @@ def get_data(filters):
def get_columns():
columns = [
+ {"label": _("User ID "), "fieldname": "user_id", "fieldtype":"Data","width": 100},
+ {"label": _("User Name "), "fieldname": "user_name", "fieldtype": "Data", "width": 150},
{"label": _("Date "), "fieldname": "date", "fieldtype": "Date", "width": 100},
{"label": _("Feedback ID "), "fieldname": "name", "fieldtype": "Link", "options":"User Feedback","width": 120},
{"label": _("Feedback Type "), "fieldname": "feedback_type", "fieldtype": "Data", "width": 120},
@@ -35,15 +37,12 @@ def get_columns():
{"label": _("Feedback Description "), "fieldname": "description", "fieldtype": "Text Editor", "width": 250},
{"label": _("Attachments "), "fieldname": "attachments", "fieldtype": "Data", "width": 100},
{"label": _("Feedback Status "), "fieldname": "status", "fieldtype": "Data", "width": 100},
- {"label": _("User ID "), "fieldname": "user_id", "fieldtype":"Data","width": 100},
- {"label": _("User Name "), "fieldname": "user_name", "fieldtype": "Data", "width": 150},
{"label": _("Zone "), "fieldname": "zone", "fieldtype": "Data", "width": 100},
{"label": _("Area Office "), "fieldname": "area", "fieldtype": "Data", "width": 140},
{"label": _("Dealer Code "), "fieldname": "dealer_code", "fieldtype": "Data", "width": 120},
{"label": _("Dealer Name "), "fieldname": "dealer_name", "fieldtype": "Data", "width": 150},
{"label": _("Closure Date "), "fieldname": "closure_date", "fieldtype": "Data", "width": 150},
{"label": _("Closed By "), "fieldname": "closed_by", "fieldtype": "Data", "width": 120}
-
]
return columns
diff --git a/smart_service/add_ons/report/installation_report/installation_report.py b/smart_service/add_ons/report/installation_report/installation_report.py
index f3ec9af..0f5cb30 100644
--- a/smart_service/add_ons/report/installation_report/installation_report.py
+++ b/smart_service/add_ons/report/installation_report/installation_report.py
@@ -31,21 +31,36 @@ def get_data(filters):
def get_columns():
columns = [
- {"label": _("Zone "), "fieldname": "zone", "fieldtype": "Data", "width": 100},
- {"label": _("Area Office "), "fieldname": "area", "fieldtype":"Data","width": 150},
- {"label": _("Dealer Code "), "fieldname": "dealer_code", "fieldtype": "Data", "width": 100},
- {"label": _("Dealer Name "), "fieldname": "dealer_name", "fieldtype":"Data","width": 150},
+ {"label": _("User ID "), "fieldname": "user_id", "fieldtype": "Data", "width": 100},
+ {"label": _("User Name "), "fieldname": "user_name", "fieldtype": "Data", "width": 150},
{"label": _("Installation "), "fieldname": "device", "fieldtype": "Data","width": 100},
+ {"label": _("App Version No "), "fieldname": "app_current_version", "fieldtype": "Data", "width": 150},
+ {"label": _("Activity Type "), "fieldname": "type", "fieldtype": "Data","width": 150},
{"label": _("Device "), "fieldname": "device_type", "fieldtype": "Data","width": 100},
- {"label": _("Device ID "), "fieldname": "device_id", "fieldtype": "Data", "width": 100},
+ {"label": _("Device ID "), "fieldname": "device_id", "fieldtype": "Data", "width": 150},
{"label": _("Device OS "), "fieldname": "os", "fieldtype": "Data", "width": 100},
{"label": _("OS Version "), "fieldname": "os_version", "fieldtype": "Data", "width": 100},
- {"label": _("User ID "), "fieldname": "user_id", "fieldtype": "Data", "width": 100},
- {"label": _("User Name "), "fieldname": "user_name", "fieldtype": "Data", "width": 100},
- {"label": _("Activity Type "), "fieldname": "type", "fieldtype": "Data","width": 100},
{"label": _("App Installation Date "), "fieldname": "date_time_stamp", "fieldtype": "DateTime","width": 200},
- {"label": _("App Last Accessed Date "), "fieldname": "date", "fieldtype": "DateTime","width": 200},
- {"label": _("App Version No "), "fieldname": "app_current_version", "fieldtype": "Data", "width": 150},
+ {"label": _("App Last Accessed Date "), "fieldname": "date", "fieldtype": "DateTime","width": 200}
]
return columns
+# def get_columns():
+# columns = [
+# {"label": _("Zone "), "fieldname": "zone", "fieldtype": "Data", "width": 100},
+# {"label": _("Area Office "), "fieldname": "area", "fieldtype":"Data","width": 150},
+# {"label": _("Dealer Code "), "fieldname": "dealer_code", "fieldtype": "Data", "width": 100},
+# {"label": _("Dealer Name "), "fieldname": "dealer_name", "fieldtype":"Data","width": 150},
+# {"label": _("Installation "), "fieldname": "device", "fieldtype": "Data","width": 100},
+# {"label": _("Device "), "fieldname": "device_type", "fieldtype": "Data","width": 100},
+# {"label": _("Device ID "), "fieldname": "device_id", "fieldtype": "Data", "width": 100},
+# {"label": _("Device OS "), "fieldname": "os", "fieldtype": "Data", "width": 100},
+# {"label": _("OS Version "), "fieldname": "os_version", "fieldtype": "Data", "width": 100},
+# {"label": _("User ID "), "fieldname": "user_id", "fieldtype": "Data", "width": 100},
+# {"label": _("User Name "), "fieldname": "user_name", "fieldtype": "Data", "width": 100},
+# {"label": _("Activity Type "), "fieldname": "type", "fieldtype": "Data","width": 100},
+# {"label": _("App Installation Date "), "fieldname": "date_time_stamp", "fieldtype": "DateTime","width": 200},
+# {"label": _("App Last Accessed Date "), "fieldname": "date", "fieldtype": "DateTime","width": 200},
+# {"label": _("App Version No "), "fieldname": "app_current_version", "fieldtype": "Data", "width": 150},
+# ]
+# return columns
diff --git a/smart_service/add_ons/report/login_report/login_report.py b/smart_service/add_ons/report/login_report/login_report.py
index 884a1a1..548dff8 100644
--- a/smart_service/add_ons/report/login_report/login_report.py
+++ b/smart_service/add_ons/report/login_report/login_report.py
@@ -33,7 +33,8 @@ def get_data(filters):
data = frappe.db.sql("""select dealer.zone,au.user_id,concat_ws(' ',au.first_name,au.last_name) as user_name,
dealer.dealer_code,dealer.dealer_name,dealer.area,ad.os,ad.os_version,
ad.device_type,ad.device_id,ad.app_current_version,al.type,date(al.date_time_stamp) as date,
- al.latitude, al.longitude, au.name, al.device, time(al.date_time_stamp) as last_login_time, mal.count from {current_db_name}.`tabApp Log` al,{current_db_name}.`tabApp Device` ad, {current_db_name}.`tabApp Users` au,{current_db_name}.`tabApp Dealer` dealer,
+ al.latitude, al.longitude, au.name, al.device, time(al.date_time_stamp) as last_login_time, mal.count from {current_db_name}.`tabApp Log` al,
+ {current_db_name}.`tabApp Device` ad, {current_db_name}.`tabApp Users` au,{current_db_name}.`tabApp Dealer` dealer,
(select user,Max(date_time_stamp) as date_time_stam, count(date(date_time_stamp)) as count from {current_db_name}.`tabApp Log`
where date(date_time_stamp) between '{from_date}' and '{to_date}' group by user,date(date_time_stamp)) mal
where mal.user=al.user
@@ -48,19 +49,33 @@ def get_data(filters):
def get_columns():
columns = [
+ {"label": _("User ID "), "fieldname": "user_id", "fieldtype": "Data", "width": 150},
+ {"label": _("User Name "), "fieldname": "user_name", "fieldtype": "Data", "width": 150},
{"label": _("Date "), "fieldname": "date", "fieldtype": "Date", "width": 100},
{"label": _("Time "), "fieldname": "last_login_time", "fieldtype": "DateTime", "width": 130},
- {"label": _("Zone "), "fieldname": "zone", "fieldtype": "Data", "width": 100},
- {"label": _("Area Office "), "fieldname": "area", "fieldtype": "Data", "width": 100},
- {"label": _("Dealer Code "), "fieldname": "dealer_code", "fieldtype": "Data", "width": 150},
- {"label": _("Dealer Name "), "fieldname": "dealer_name", "fieldtype":"Data","width": 150},
- {"label": _("Device "), "fieldname": "device_type", "fieldtype": "Data", "width": 100},
- {"label": _("Device ID "), "fieldname": "device_id", "fieldtype": "Data", "width": 150},
- {"label": _("User ID "), "fieldname": "user_id", "fieldtype": "Data", "width": 150},
- {"label": _("User Name "), "fieldname": "user_name", "fieldtype": "Data", "width": 100},
- {"label": _("Latitude "), "fieldname": "latitude", "fieldtype": "Data", "width": 100},
- {"label": _("Longitude "), "fieldname": "longitude", "fieldtype": "Data", "width": 100},
{"label": _("Count "), "fieldname": "count", "fieldtype": "Data", "width": 100},
+ {"label": _("Device ID "), "fieldname": "device_id", "fieldtype": "Data", "width": 100},
+ {"label": _("Device "), "fieldname": "device_type", "fieldtype": "Data", "width": 130},
+ {"label": _("Latitude "), "fieldname": "latitude", "fieldtype": "Data", "width": 100},
+ {"label": _("Longitude "), "fieldname": "longitude", "fieldtype": "Data", "width": 100}
]
return columns
+# def get_columns():
+# columns = [
+# {"label": _("Date "), "fieldname": "date", "fieldtype": "Date", "width": 100},
+# {"label": _("Time "), "fieldname": "last_login_time", "fieldtype": "DateTime", "width": 130},
+# {"label": _("Zone "), "fieldname": "zone", "fieldtype": "Data", "width": 100},
+# {"label": _("Area Office "), "fieldname": "area", "fieldtype": "Data", "width": 100},
+# {"label": _("Dealer Code "), "fieldname": "dealer_code", "fieldtype": "Data", "width": 150},
+# {"label": _("Dealer Name "), "fieldname": "dealer_name", "fieldtype":"Data","width": 150},
+# {"label": _("Device "), "fieldname": "device_type", "fieldtype": "Data", "width": 100},
+# {"label": _("Device ID "), "fieldname": "device_id", "fieldtype": "Data", "width": 150},
+# {"label": _("User ID "), "fieldname": "user_id", "fieldtype": "Data", "width": 150},
+# {"label": _("User Name "), "fieldname": "user_name", "fieldtype": "Data", "width": 100},
+# {"label": _("Latitude "), "fieldname": "latitude", "fieldtype": "Data", "width": 100},
+# {"label": _("Longitude "), "fieldname": "longitude", "fieldtype": "Data", "width": 100},
+# {"label": _("Count "), "fieldname": "count", "fieldtype": "Data", "width": 100},
+# ]
+# return columns
+
diff --git a/smart_service/add_ons/report/model_download_report/model_download_report.py b/smart_service/add_ons/report/model_download_report/model_download_report.py
index a397f3b..dc8191e 100644
--- a/smart_service/add_ons/report/model_download_report/model_download_report.py
+++ b/smart_service/add_ons/report/model_download_report/model_download_report.py
@@ -21,21 +21,23 @@ def get_data(filters):
from_date=filters['from_date']
to_date=filters['to_date']
modelfilter=filters['model']
- # try:
- # vId=frappe.db.sql("""SELECT myid FROM _d6463952657fa86c.tabVehicle where vehicle='{0}';""".format(modelfilter), as_dict=1)
- # vId=vId[-1]
- # vId=vId['myid']
- # except:
- # frappe.msgprint('Vehicle ID Mismatching.')
- data = frappe.db.sql("""SELECT date(date) as date, device_id, device_type, app_version, download_vehicle_id, download_vehicle_version, download_vehicle_date, download_vehicle_language_id, download_vehicle_current_version, user_id
- FROM {0}.`tabModel Hit` WHERE download_vehicle_id='{1}' and (date(date) between '{2}' and '{3}');""".format(current_db_name, modelfilter, from_date, to_date), as_dict=1)
+
+ data = frappe.db.sql("""SELECT date(date) as date, device_id, device_type, app_version, download_vehicle_id, download_vehicle_version,
+ download_vehicle_date, download_vehicle_language_id, download_vehicle_current_version, mh.user_id,
+ login_name,concat(first_name,' ',last_name) as user_name
+ FROM `tabModel Hit` mh
+ left join `tabApp Users` au on mh.user_id = au.user_id
+ WHERE download_vehicle_id='{1}' and (date(date) between '{2}' and '{3}') order by download_vehicle_id;""".format(current_db_name,
+ modelfilter, from_date, to_date), as_dict=1)
+
for d in data:
d['download_vehicle_id']=modelfilter
if d['user_id']:
try:
dealer_info=frappe.db.sql("""SELECT dealer FROM {0}.`tabApp Users` where user_id='{1}';""".format(current_db_name, d['user_id']), as_dict=1)
dealer_info=dealer_info[-1]['dealer']
- dealer_details=frappe.db.sql("""SELECT dealer_name,dealer_code,area as location,zone FROM {0}.`tabApp Dealer` where name='{1}';""".format(current_db_name, dealer_info), as_dict=1)
+ dealer_details=frappe.db.sql("""SELECT dealer_name,dealer_code,area as location,zone FROM {0}.`tabApp Dealer`
+ where name='{1}';""".format(current_db_name, dealer_info), as_dict=1)
dealer_details=dealer_details[-1]
d['dealer_code']=dealer_details['dealer_code']
d['dealer_name']=dealer_details['dealer_name']
@@ -52,17 +54,19 @@ def get_data(filters):
def get_columns():
columns = [
- {"label": _("Date "), "fieldname": "date", "fieldtype": "Date", "width": 100},
- {"label": _("Zone "), "fieldname": "zone", "fieldtype": "Data", "width": 100},
- {"label": _("Area Office "), "fieldname": "area", "fieldtype": "Data", "width": 150},
- {"label": _("Dealer Code "), "fieldname": "dealer_code", "fieldtype": "Data", "width": 150},
- {"label": _("Dealer Name "), "fieldname": "dealer_name", "fieldtype": "Data", "width": 150},
- {"label": _("Device "), "fieldname": "device_id", "fieldtype": "Data", "width": 100},
- {"label": _("Device Type "), "fieldname": "device_type", "fieldtype": "Data", "width": 130},
- {"label": _("Downloaded Vehicle "), "fieldname": "download_vehicle_id", "fieldtype": "Data", "width": 170},
- {"label": _("Downloaded Version "), "fieldname": "download_vehicle_current_version", "fieldtype": "Data", "width": 150},
+ {"label": _("Date "), "fieldname": "date", "fieldtype": "Date", "width": 150},
+ {"label": _("User ID "), "fieldname": "login_name", "fieldtype": "Data", "width": 125},
+ {"label": _("User Name "), "fieldname": "user_name", "fieldtype": "Data", "width": 125},
+ {"label": _("Downloaded Vehicle "), "fieldname": "download_vehicle_id", "fieldtype": "Data", "width": 150},
{"label": _("Downloaded Language "), "fieldname": "download_vehicle_language_id", "fieldtype": "Data", "width": 150},
- {"label": _("App Version "), "fieldname": "app_version", "fieldtype": "Data", "width": 150}
+ {"label": _("Downloaded Version "), "fieldname": "download_vehicle_current_version", "fieldtype": "Data", "width": 150},
+ {"label": _("App Version "), "fieldname": "app_version", "fieldtype": "Data", "width": 150},
+ # {"label": _("Zone "), "fieldname": "zone", "fieldtype": "Data", "width": 100},
+ # {"label": _("Area Office "), "fieldname": "area", "fieldtype": "Data", "width": 150},
+ # {"label": _("Dealer Code "), "fieldname": "dealer_code", "fieldtype": "Data", "width": 150},
+ # {"label": _("Dealer Name "), "fieldname": "dealer_name", "fieldtype": "Data", "width": 150},
+ {"label": _("Device "), "fieldname": "device_id", "fieldtype": "Data", "width": 150},
+ {"label": _("Device Type "), "fieldname": "device_type", "fieldtype": "Data", "width": 150}
]
return columns
\ No newline at end of file
diff --git a/smart_service/add_ons/report/model_hit_report/model_hit_report.py b/smart_service/add_ons/report/model_hit_report/model_hit_report.py
index 2fbf7ac..971622e 100644
--- a/smart_service/add_ons/report/model_hit_report/model_hit_report.py
+++ b/smart_service/add_ons/report/model_hit_report/model_hit_report.py
@@ -27,9 +27,12 @@ def get_data(filters):
variantfilter=filters['variant']
variantfilter=variantfilter.split(".")
- data = frappe.db.sql("""SELECT date as date, device_id, device_type, module_id, vehicle_id, variant_id, system_id, sub_system_id, procedure_id, steps_id, count(*) as count, user_id, language
- FROM {0}.`tabModel Usage` WHERE vehicle_id='{1}' and variant_id='{2}' and (date(date) between '{3}' and '{4}')
- GROUP BY date(date), user_id, module_id, device_id, vehicle_id, variant_id, variant_mapping_id, system_id, sub_system_id, procedure_id, steps_id, language;""".format(current_db_name, modelfilter, variantfilter[1], from_date, to_date), as_dict=1)
+ data = frappe.db.sql("""SELECT date as date, device_id, device_type, module_id, vehicle_id, variant_id,variant_mapping_id, system_id, sub_system_id, procedure_id, steps_id,
+ count(*) as count, user_id, language FROM {0}.`tabModel Usage` WHERE vehicle_id='{1}' and variant_id='{2}' and (date(date) between '{3}' and '{4}')
+ GROUP BY date(date), user_id, module_id, device_id, vehicle_id, variant_id, variant_mapping_id, system_id, sub_system_id, procedure_id, steps_id,
+ language
+ order by module_id,vehicle_id, variant_id, variant_mapping_id, system_id, sub_system_id, procedure_id, steps_id,language;
+ """.format(current_db_name, modelfilter, variantfilter[1], from_date, to_date), as_dict=1)
for d in data:
if d['user_id']:
@@ -55,9 +58,11 @@ def get_data(filters):
to_date=filters['to_date']
modelfilter=filters['model']
- data = frappe.db.sql("""SELECT date(date) as date, device_id, device_type, module_id, vehicle_id, variant_id, system_id, sub_system_id, procedure_id, steps_id, count(*) as count, user_id, language
- FROM {0}.`tabModel Usage` WHERE vehicle_id='{1}' and (date(date) between '{2}' and '{3}')
- GROUP BY date(date), user_id, module_id, device_id, vehicle_id, variant_id, variant_mapping_id, system_id, sub_system_id, procedure_id, steps_id, language;""".format(current_db_name, modelfilter, from_date, to_date), as_dict=1)
+ data = frappe.db.sql("""SELECT date(date) as date, device_id, device_type, module_id, vehicle_id, variant_id,variant_mapping_id, system_id, sub_system_id, procedure_id,
+ steps_id, count(*) as count, user_id, language FROM {0}.`tabModel Usage` WHERE vehicle_id='{1}' and (date(date) between '{2}' and '{3}')
+ GROUP BY date(date), user_id, module_id, device_id, vehicle_id, variant_id, variant_mapping_id, system_id, sub_system_id, procedure_id, steps_id,language
+ order by module_id,vehicle_id, variant_id, variant_mapping_id, system_id, sub_system_id, procedure_id, steps_id,language;
+ ;""".format(current_db_name, modelfilter, from_date, to_date), as_dict=1)
for d in data:
if d['user_id']:
@@ -84,9 +89,15 @@ def get_data(filters):
to_date=filters['to_date']
variantfilter=filters['variant']
variantfilter=variantfilter.split(".")
- data = frappe.db.sql("""SELECT date as date, device_id, device_type, module_id, vehicle_id, variant_id, system_id, sub_system_id, procedure_id, steps_id, count(*) as count, user_id, language
- FROM {0}.`tabModel Usage` WHERE vehicle_id='{1}' and variant_id='{2}' and (date(date) between '{3}' and '{4}')
- GROUP BY date(date), user_id, module_id, device_id, vehicle_id, variant_id, variant_mapping_id, system_id, sub_system_id, procedure_id, steps_id, language;""".format(current_db_name, variantfilter[0], variantfilter[1], from_date, to_date), as_dict=1)
+ data = frappe.db.sql("""SELECT date as date, device_id, device_type, module_id, vehicle_id, variant_id,variant_mapping_id, system_id, sub_system_id,
+ procedure_id, steps_id, count(*) as count, user_id, language,
+ login_name,concat(first_name,' ',last_name) as user_name
+ FROM `tabModel Usage` mu left join `tabApp Users` au on mu.user_id = au.user_id
+ WHERE vehicle_id='{1}' and variant_id='{2}'
+ and (date(date) between '{3}' and '{4}') GROUP BY date(date), user_id, module_id, device_id, vehicle_id, variant_id, variant_mapping_id,
+ system_id, sub_system_id, procedure_id, steps_id, language
+ order by module_id,vehicle_id, variant_id, variant_mapping_id, system_id, sub_system_id, procedure_id, steps_id,language;
+ ;""".format(current_db_name, variantfilter[0], variantfilter[1], from_date, to_date), as_dict=1)
for d in data:
if d['user_id']:
@@ -111,21 +122,25 @@ def get_data(filters):
def get_columns():
columns = [
{"label": _("Date "), "fieldname": "date", "fieldtype": "Date", "width": 150},
- {"label": _("Zone "), "fieldname": "zone", "fieldtype": "Data", "width": 150},
- {"label": _("Area Office "), "fieldname": "area", "fieldtype": "Data", "width": 150},
- {"label": _("Dealer Code "), "fieldname": "dealer_code", "fieldtype": "Data", "width": 150},
- {"label": _("Dealer Name "), "fieldname": "dealer_name", "fieldtype": "Data", "width": 150},
- {"label": _("Device "), "fieldname": "device_id", "fieldtype": "Data", "width": 150},
- {"label": _("Device Type "), "fieldname": "device_type", "fieldtype": "Data", "width": 150},
- {"label": _("Module "), "fieldname": "module_id", "fieldtype": "Data", "width": 150},
+ {"label": _("User ID "), "fieldname": "login_name", "fieldtype": "Data", "width": 125},
+ {"label": _("User Name "), "fieldname": "user_name", "fieldtype": "Data", "width": 125},
{"label": _("Model "), "fieldname": "vehicle_id", "fieldtype": "Data", "width": 150},
- {"label": _("Variant "), "fieldname": "variant_id", "fieldtype": "Data", "width": 150},
+ {"label": _("Variant Mapping "), "fieldname": "variant_mapping_id", "fieldtype": "Data", "width": 150},
+ {"label": _("Variant "), "fieldname": "variant_id", "fieldtype": "Data", "width": 80},
+ {"label": _("Module "), "fieldname": "module_id", "fieldtype": "Data", "width": 150},
{"label": _("System "), "fieldname": "system_id", "fieldtype": "Data", "width": 150},
{"label": _("Sub System "), "fieldname": "sub_system_id", "fieldtype": "Data", "width": 150},
{"label": _("Procedure "), "fieldname": "procedure_id", "fieldtype": "Data", "width": 150},
{"label": _("Steps "), "fieldname": "steps_id", "fieldtype": "Data", "width": 150},
- {"label": _("Language "), "fieldname": "language", "fieldtype": "Data", "width": 150},
- {"label": _("Count "), "fieldname": "count", "fieldtype": "Data", "width": 150}
+ {"label": _("Language "), "fieldname": "language", "fieldtype": "Data", "width": 80},
+ {"label": _("Count "), "fieldname": "count", "fieldtype": "Data", "width": 80},
+
+ # {"label": _("Zone "), "fieldname": "zone", "fieldtype": "Data", "width": 150},
+ # {"label": _("Area Office "), "fieldname": "area", "fieldtype": "Data", "width": 150},
+ # {"label": _("Dealer Code "), "fieldname": "dealer_code", "fieldtype": "Data", "width": 150},
+ # {"label": _("Dealer Name "), "fieldname": "dealer_name", "fieldtype": "Data", "width": 150},
+ {"label": _("Device "), "fieldname": "device_id", "fieldtype": "Data", "width": 150},
+ {"label": _("Device Type "), "fieldname": "device_type", "fieldtype": "Data", "width": 150}
]
return columns
diff --git a/smart_service/apis/THAR-en-full_v12.00.json b/smart_service/apis/THAR-en-full_v12.00.json
new file mode 100644
index 0000000..7949f51
--- /dev/null
+++ b/smart_service/apis/THAR-en-full_v12.00.json
@@ -0,0 +1,658246 @@
+{
+ "JSON": [
+ {
+ "Variant": {
+ "name": "THAR.AX-0001",
+ "variant": "THAR.AX",
+ "vehicle": "THAR",
+ "family_code": "J08",
+ "vehicle_segment": "Personal",
+ "fuel": "DSL",
+ "transmission": "MT",
+ "drive": "4WD",
+ "active_status": true,
+ "kms_mapping_active_status": true,
+ "Assets": [],
+ "Systems": [
+ {
+ "systemdisplayorder": 99,
+ "sys_id": "THAR.AX-0001-en-SM-Front Axle",
+ "system_name": "Front Axle",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1012,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 102,
+ "sys_id": "THAR.AX-0001-Front Axle",
+ "subsys_id": "THAR.AX-0001-Front Axle-Front LH Drive Shaft",
+ "systems": "Front Axle",
+ "sub_systems": "Front LH Drive Shaft",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A150025.jpg",
+ "myid": 1221,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Front LH Drive Shaft-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150025.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10296.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10297.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove Front LH wheel Hub. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-0001,1014,1245",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Front Stabilizer Bar. For additional information refer to Front Stabilizer Bar \u2014 R &R; section. Using 10 mm socket spanner, Unscrew front LH wheel speed sensor mounting bolt and remove the sensor. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the wheel speed sensor routing clips from the upper control arm. Using cutting plier, remove upper arm ball joint cotter pin. Never reuse the cotter pin, always replace with a new one. Using 24 mm socket spanner, unscrew upper arm ball joint mounting nut. Torque : 90 \u2013 110 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Using suitable lever, partially detach the knuckle and remove the drive shaft. Pull the drive shaft downwards and remove it. Install in the reverse order of removal.
2. Check the drive shaft boot for cracks or other damage, and for grease leakage.
3. If damaged, disassemble the drive shaft to verify the damage, repair or replace if necessary.
4. Check the splines for wear and tear.
",
+ "file": null,
+ "display_order": 25
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 103,
+ "sys_id": "THAR.AX-0001-Front Axle",
+ "subsys_id": "THAR.AX-0001-Front Axle-Front RH Drive Shaft",
+ "systems": "Front Axle",
+ "sub_systems": "Front RH Drive Shaft",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A150032.jpg",
+ "myid": 1222,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Front RH Drive Shaft-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150032.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10306.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10307.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the front differential oil. For additional information refer to Front differential oil draining and filling procedure. Remove Front LH wheel Hub. For additional information refer to Front LH wheel Hub \u2014 R &R; section. Remove Front Stabilizer Bar. For additional information refer to Front Stabilizer Bar \u2014 R &R; section. Using 10 mm socket spanner, Unscrew front RH wheel speed sensor mounting bolt and remove the sensor. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the wheel speed sensor from routing bracket. Using cutting plier, remove upper arm ball joint cotter pin. Never reuse the cotter pin, always replace with a new one. Using 24 mm socket spanner, unscrew upper ball joint mounting nut. Torque : 90 \u2013 110 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Remove E-Disconnect stone guard. For additional information refer to E-Disconnect stone guard \u2013 R &R; section. Disconnect E \u2013 Disconnect electric connector. Provide a jack to support front axle. Using 19 mm socket spanner, unscrew front axle mounting bolts and partially down the axle. Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150037.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using suitable lever partially detach the knuckle and remove the drive shaft. Pull the drive shaft downwards and remove it. Install in the reverse order of removal. Refill the front axle oil upto Max level. For additional information refer to Front differential oil draining and filling procedure.
2. Check the drive shaft boot for cracks or other damage, and for grease leakage.
3. If damaged, disassemble the drive shaft to verify the damage, repair or replace if necessary.
4. Check the splines for wear and tear.
",
+ "file": null,
+ "display_order": 35
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 101,
+ "sys_id": "THAR.AX-0001-Front Axle",
+ "subsys_id": "THAR.AX-0001-Front Axle-Front Axle RH Drive Shaft Oil Seal",
+ "systems": "Front Axle",
+ "sub_systems": "Front Axle RH Drive Shaft Oil Seal",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A150055.jpg",
+ "myid": 1220,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Front Axle RH Drive Shaft Oil Seal-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150055.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10290.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10291.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove Front RH drive shaft. Position the Special tool support piece inside the axle housing and using MST 0502AUA0002ST Front Axle Shaft Inboard Oil Seal Puller, remove the Oil seal from the housing. Replace the Inboard Oil Seal once removed. Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, refit the Oil seal on the housing. Refit Front RH drive shaft. Inspect the axle shaft Inboard Oil Seal for any damage, Replace if necessary. Remove Front LH drive shaft. Using MST 0502AUA0002ST Front Axle Shaft Inboard Oil Seal Puller, remove the Oil seal from the housing. Replace the Inboard Oil Seal once removed. Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, refit the Oil seal on the housing. Refit Front LH drive shaft. Inspect the axle shaft Inboard Oil Seal for any damage, Replace if necessary. Remove Front LH drive shaft. Replace the Inboard Oil Seal once removed. Using MST 0502AUA0002ST Front Axle Shaft Inboard Oil Seal Puller, remove the Oil seal from the housing. Remove E-Disconnect stone guard. For additional information refer to E-Disconnect stone guard \u2013 R &R; section. Disconnect E \u2013 Disconnect electric connector. Using 10 mm socket spanner, Unscrew electric disconnect housing mounting bolts and Carefully remove the E-Disconnect Housing with Fork . Torque : 17\u00b12 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150265.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using circlip plier remove the intermediate shaft circlip from housing. Tool should not damage the splines on the axle shaft this affects disconnect operation. Pull out the axle shaft from wheel end side of e-disconnect housing. Using MST 0502AUA0008ST Front Axle Tube Needle Bearing Puller, remove the Needle bearing from e-disconnect housing LH side. By using MST 0502AUA0007ST - F Axle Tube Needle Bearing Dolly, Install the LH Side needle bearing In the disconnect housing. Clean and Insert the axle shaft through wheel end side of the disconnect housing. Align the shifter sleeve on the intermediate shift through disconnect housing window and Install the circlip on the axle shaft with the help of circlip tool. Ensure there should not be excessive play between two shafts this affects the disconnect . Install the new cover gasket while locating in the dowel on the disconnect housing. Ensure to use New Gasket while Installation. Ensure the cleanliness of disconnect housing cover face and cover resting face. Do not bent the wrap the Gasket while installing. Gasket orientation is fixed by dowel on the disconnect housing hence it will fit in one direction only . Bent or warped cover gasket may lead to leak during running. Locate the disconnect cover on the dowel and install the bolts. Tighten the mounting bolts to specified Torque Value. Ensure to use New bolts while Installation. Apply locktite sealant on the bolts while installing, this avoid the leakthrough cover. Torque : 17\u00b12 Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Connect e-Disconnect electrical connector. Refit E-Disconnect stone guard. For additional information refer to E-Disconnect stone guard \u2013 R &R; section. Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, refit the Oil seal on the housing. Refit Front LH drive shaft. Using 8 mm socket spanner, Unscrew front propeller shaft mounting bolts/nuts at front axle end. Torque : 19\u00b13 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Front LH drive shaft. Drain the front differential oil. For additional information refer to Front differential oil draining and filling procedure. Remove Front RH Wheel Hub. For additional information refer to Front RH Wheel Hub \u2014 R &R; section. Using 10 mm socket spanner, Unscrew front RH wheel speed sensor mounting bolt and remove the sensor. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Detach the wheel speed sensor from routing bracket. Using cutting plier, Remove upper arm ball joint cotter pin. Never reuse the cotter pin, always replace with a new one. Using 24 mm socket spanner, unscrew upper arm ball joint mounting nut and remove the ball joint. Torque : 90 \u2013 110 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Remove E-Disconnect stone guard. For additional information refer to E-Disconnect stone guard \u2013 R &R; section. Disconnect E \u2013 Disconnect electric connector. Provide a jack to support front axle. Using 19 mm socket spanner, unscrew front axle mounting bolts and partially remove the axle downwards. Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Partially detach the knuckle and remove the drive shaft by using a suitable lever. Pull the drive shaft downwards and remove it. Remove the front axle assembly from Vehicle. Install in the reverse order of removal. Refill the front axle oil upto Max level. For additional information refer to Front differential oil draining and filling procedure.
2. Check the axle case for yield, deformation or cracks, replace if necessary.
3. Inspect front axle for any oil leakage, seepage.
",
+ "file": null,
+ "display_order": 39
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 108,
+ "sys_id": "THAR.AX-0001-Front Axle",
+ "subsys_id": "THAR.AX-0001-Front Axle-Front Axle Overhual",
+ "systems": "Front Axle",
+ "sub_systems": "Front Axle Overhual",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A150247.jpg",
+ "myid": 1227,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Front Axle Overhual-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Disassembly and Assembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16224.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16225.pdf",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Disassembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the Front Differential Oil. For additional information refer to Front differential oil draining and filling procedure. Remove the Front Axle Assembly. Mount the Front Axle Assembly on a suitable stand. Using 15 mm socket spanner, Unscrew front axle RH bracket mounting bolts and remove the RH bracket. Using 13 mm socket spanner, Unscrew differential assembly cover bolts and remove the cover. Clean the sealant on cover & banjo housing. Liquid sealant is used to seal cover with banjo beam. Scrap the sealant and clean the cover and banjo surfaces. Using 10 mm socket spanner, Unscrew e-disconnect cover assembly mounting bolts and remove the cover with shifter fork & motor. Using 10 mm socket spanner, Unscrew e-disconnect motor mounting bolts and remove the e-disconnect motor. Hit the shift shaft on suitable block and remove the shift shaft, shaft fork & spring from the disconnect cover. Using MST 0502AUA0002ST - Front Axle Shaft Inboard Oil Seal Puller, remove housing LH Oil seal. Replace the Inboard Oil Seal once removed. Position the Special tool support piece inside the axle housing and using MST 0502AUA0002ST Front Axle Shaft Inboard Oil Seal Puller, remove the RH Oil seal from the housing. Using circlip plier remove the intermediate shaft circlip from housing. Tool should not damage the splines on the axle shaft this affects disconnect operation. Pull out the axle shaft from wheel end side of e-disconnect housing. Remove the shifter shaft thrust washers from e-disconnect housing. Remove the shifter sleeve from e-disconnect housing. Using MST 0502AUA0008ST Front Axle Tube Needle Bearing Puller, Needle bearing from e-disconnect housing LH side. Remove LH Side differential shaft from the housing wheel end side. Using 16 mm socket spanner, Remove the Differential bearing caps mounting bolts. Remove the Differential bearing caps. Identification marks are punched on bearing cap; this is to ensure correct bearing cap is installed on correct side. Ensure correct bearing caps used While reassembly. Mount MST 0502AUA0030ST Front Axle Expander on carrier and Spread carrier by rotating nut on expander. Do not spread more than 0.5 mm. Using MST 0502AAA0001ST - Tommy Bars-X, Pry out differential case from carrier. Remove the expander from housing. Mount the MST 0502AUA0023ST \u2014 Front Axle Diff Case Bearing Puller Adapter and Using MST 0502AUA0012ST \u2014 Axle Bearing Puller on side bearing cone and remove the bearing from differential case assembly. Identify shims and side bearings on both sides, they are not to be interchanged during assembly. Similarly remove ring gear other side bearing cone by using MST 0502AUA0023ST \u2014 Front Axle Diff Case Bearing Puller Adapter and MST 0502AUA0012ST \u2014Axle Bearing Puller. Identify shims and side bearings on both sides, they are not to be interchanged during assembly. Using 17 mm socket spanner, Remove the ring gear mounting bolts and remove the ring gear. If require tap ring gear by mallet to remove the ring gear. By Using MST 0502AUA0033ST \u2014 Front Axle Diff Case Pin Remover & Installer and hammer, remove the roll pin retaining the cross shaft. Using suitable punch & hammer, remove the cross pin from case. To remove side gears and pinion mate gears, rotate the side gears, this will allow the pinion mate gears to turn to opening of the case. Remove pinion mate gears and spherical washers behind the gears. Lift out the side gears and thrust washers. Using MST 203 - Wrench Universal Joint Flange Holding tool hold the companion flange and remove the pinion nut and washer using 30 mm socket spanner from the differential housing. Using mallet tap and remove the companion flange along with dust cover. If not able to remove the companion flange tapping by mallet, use suitable 2 Jaw puller for removal. If companion flange shows wear in the area of seal contact, it should be replaced. Using a mallet, tap the pinion assembly and remove the pinion assembly from the differential housing. Make a centre punch and tap at top of the pinion assembly by using a mallet. Hold the pinion with hand to avoid falling. Gear teeth have sharp edges. Handle gears carefully to avoid injury Discard collapsible washer. Remove the Pinion Oil seal By using Screw driver/ Oil Seal Puller. Remove the slinger and outer bearing. Turn Carrier and Using MST 0502AUA0028ST Front Axle Pinion Inner Bearing Cone Remove Adapter and MST 0502AUA0032ST Front Axle Universal Handle, Remove the Inner Pinion bearing cone. Turn Carrier and Using MST 0502AUA0029ST \u2014 Front Axle Pinion outer Bearing Cone Remove Adapter and MST 0502AUA0032ST \u2014 Front Axle Universal Handle, Remove the outer Pinion bearing cone. Using the MST 0502AUA0022ST Front Axle Pinion Inner Bearing Puller Adapter and MST 0502AUA0012ST Axle Bearing Puller, Remove the Pinion Inner Bearing. Take out the pinion shims from the pinion. Using MST 0502AUA0006ST Front Axle Tube Cyl Roller Bearing Puller, Remove the Cylindrical roller bearing from disconnect housing. If replacement of one gear is required, then both side gears, pinion mate gears and washers have to be replaced. Always replace gears as a complete set, do not mix new gears with old gears, as this may cause uneven wear and short gear life. Ring gear and pinion is supplied as a set. They are matched with each other during service. Matching numbers on both pinion and ring gear are etched for verification. Refer illustration shown below for more clarity. If a new gear set is used, verify numbers on pinion and ring for matching before proceeding with assembly. Standard mounting distance from centre line of ring gear to back face of pinion is 103.5 \u00b1 0.1mm. This dimension is controlled by selecting shims, which are positioned between the inner pinion bearing cone and pinion gear. Best running position of gear set is achieved by proper shim selection. This dimension for front live axle will be different. On the bottom face of pinion, a number is etched. It can be a plus (+) number, a minus (-) number or Zero (0). Required pinion shim selection is achieved with help of this number. If alphabet 'm' appears on pinion face shim, selection has to be done in mm (Metric). If alphabet 'm' does not appear on pinion face, shim selection has to be done in inches (English). Shims with different thicknesses are available for selection. Use tables shown below for selecting correct thickness of shims either for addition or for subtraction from old shim pack. Ring and pinion etched with inch identification. Refer Table A. Ring and pinion etched with metric identification. Refer Table B. Observe the marking on pinion. If \u2018m\u2019 is found etched on the face, refer table B. If not refer table A. Pinion Position shims selection can be done using MST\u2019s Pinion Height Master Block & Pinion Height Setting Gauge, in the absence of removed Ring/Pinion gear or Old shim not available. Position the MST 0502AUA0010ST - Front Axle Pinion Height Master Block on the pinion inner bearing setting area. Fix the dial gauge on MST 0502AUA0009ST Front Axle Pinion Height Setting Gauge and set dial gauge to zero reading on surface plate. Place the MST 0502AUA0009ST Front Axle Pinion Height Setting Gauge with Dial gauge on differential housing as shown. Rock the MST 0502AUA0009ST Front Axle Pinion Height Setting Gauge and load the Dial gauge on MST 0502AUA0010ST - Front Axle Pinion Height Master Block and measure the reading on Dial Gauge (X mm). Say X mm for example which is measured by using special tool - 0.79 mm (i.e X = 0.79 mm) Convert mm to thau, i.e (0.79*39) = 31 Thau Then see the Pinion off set i.e (+ 2) Thou (For example) Final shim size = 31 - 2 = 29 Thau Convert to mm = 29*0.0254 = 0.74 mm If Pinion offset is Positive (+), then subtract the pinion offset value. If Pinion offset is Negative (-), then add the pinion offset value. Using MST 0502AUA0026ST Front Axle Pinion Inner Bearing Cone Press Dolly and MST 0502AUA0032ST Front Axle Universal Handle, refit the pinion inner bearing cone into carrier housing. Using MST 0502AUA0027ST - Front Axle Pinion Outer Bearing Cone Press Dolly and MST 0502AUA0032ST - Front Axle Universal Handle, refit pinion outer bearing cone into carrier housing. Place shims selected as per Shim Selection procedure on pinion gear. Using MST 0502AUA0025ST Front Axle Pinion Inner Bearing Press Dolly, Install pinion inner bearing cone. Take care to avoid damaging the pinion teeth while installing the bearing. Place the Pinion outer Bearing cone and slinger into housing. Using MST - 0502AUA0031ST Front Axle Pinion Oil Seal Installer, Install the New pinion seal into housing. Ensure to replace New Oil seal while Install. Apply a light coat of oil to the lip of oil seal. Install a new collapsible spacer into pinion shaft. Collapsible spacer should rest on bearing inner race and pinion shoulder and it can be fitted in any one direction. Assemble the Pinion into differential housing. Install the end yoke, washer and new pinion mounting nut. Hold the end yoke using (MST203 - Companion Flange Holding Tool) and torque tighten the mounting nut. Tighten nut to Initial torque as 217 Nm. Measure the Pinion Rotational Torque (PTTR), It should be within 17 \u2013 34 Kgf\u2013cm (1.7 to 3.3 Nm). If measured Pinion Rotational Torque (PTTR) not within (1.7 to 3.3 Nm), Then tighten nut to incremental torque from 217 Nm onwards to 678 Nm until specified PTTR ( Pinion torque to rotate) is achieved. Excessive care must be taken during bearing preload torque adjustment. Do not over tighten, loosen and then retighten nut. Do not exceed specified bearing preload torque . Measure and ensure the Final Pinion Rotational Torque (PTTR), It should be within 17 \u2013 34 Kgf\u2013cm (1.7 - 3.3 Nm). PTTR SPEC : 17 \u2013 34 Kgf\u2013 cm (1.7 to 3.3Nm). If preload torque is exceeded, a new collapsible spacer must be installed and torquing sequence as above to be repeated. If only oil seal needs to be changed, measure rotating torque of pinion with the help torque measuring tool. In this case use new collapsible spacer and keep same rotational torque of pinion as before. Apply grease to new side gear thrust washers and hubs of side gears. Assemble both side gears. Apply grease to new pinion mate spherical washers, and pinion mate gears. Assemble pinion mate gears. Assemble both side gears and thrust washers, hold them in place with one hand and then assemble the pinion mate gears with thrust washer to hold the side gears in place. An easy way to assemble the side gears and pinion mate gears is to have all parts lubricated before assembly. Always replace gears as a complete set. Do not mix new gears with old gears, as this may cause uneven wear and shorter gear life. Rotate the side gears until the holes of the spherical washers and pinion mate gears line up with the holes in the case by the help of engaging the splines of axle shaft to side gears. When both the cross bore hole matched and insert the differential shaft. Use MST 0502AUA0033ST Front Axle Differential Case Pin Remover and Installer to line holes of the gears up with case. Assemble differential shaft and pull out MST. Be sure vertical lock pin hole is lined up with that of the case, and that pinion mate washers are in place and lined up with gear and case. Align the differential shaft hole, insert the lock pin and fix using (0502AUA0033ST - Differential gear lock pin removal tool) and hammer. Always replace with new Lock pin while Installation. When roll pin bottoms out, stake (peen) metal of case over pin in two places, 180 degrees apart. Assemble MST 0502AUA0011ST Front Axle Dummy Bearings on to differential case as shown in the illustration. Assemble the differential case with Dummy Bearings on housing (Without Ring Gear). Mount the magnetic dial indicator with magnetic base, locate its tip on that surface of case. Force differential assembly to the extreme in the direction towards indicator, With force still applied set indicator to 0.00. Force differential assembly to the extreme end in opposite direction. Repeat above steps until the same reading is obtained, Record reading in the format given as' A'. Remove dummy bearing and keep aside. Assemble ring gear to the differential case using mounting bolts. Tighten the bolts to specified Torque Value in recommended sequence. Torque : 95 - 122 Nm ",
+ "file": null,
+ "display_order": 208
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Notice",
+ "content": "Always use new ring gear bolts. Assemble MST 0502AUA0011ST Front Axle Dummy Bearings on differential case as shown in the illustration. Position differential assembly into housing and Mount the magnetic base dial indicator on housing and locate the tip of indicator on the surface of one of the ring gear screws. Force differential case assembly away from pinion gear. With force still applied set indicator to zero. Force differential case assembly and ring gear to mesh with pinion gear. Rock the ring gear to allow teeth to mesh, Repeat to obtain the reading and continue the procedure until the same reading is obtained. Record reading in the format given as' B'. Remove dial indicator and dummy differential bearings from differential housing. Calculate the Ring Gear Backlash & Differential Bearing Preload shims based on below calculation. Install the selected shim pack in between side bearing and carrier assembly. Using MST 0502AUA0024ST Front Axle Differential Case Bearing Dolly, Install side bearing cone on hub of differential assembly. It is always preferred to replace side bearings once pulled out. But one can confirm free rolling of bearings and reuse it, if they are defect free. Install the selected shim pack in between other side bearing and carrier assembly. Using MST 0502AUA0024ST Front Axle Differential Case Bearing Dolly, Install other side bearing cone on hub of differential assembly. It is always preferred to replace side bearings once pulled out. But one can confirm free rolling of bearings and reuse it, if they are defect free. Install spreader and dial indicator and expand the carrier. Never expand the differential housing over 0.5 mm to avoid distortion. Remove dial indicator from the differential housing. Install differential case assembly into carrier with the help of mallet. Ensure differential case shim is behind the bearing cap. Carelessness while installing differential case assembly may result in injury. Position the bearing caps and install the mounting bolts and torque tighten the bolts to specified torque. Torque : 47 - 68 Nm ",
+ "file": null,
+ "display_order": 242
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "Notice",
+ "content": "Ensure correct fitment of caps by matching letters on caps and carrier on either side. Remove the expander from differential housing. Check ring gear and pinion backlash at three equally spaced points with dial indicator. Backlash tolerance is 0.13 to 0.20mm and should not vary more than 0.08 mm between the three points checked . Fix the Dial Gauge on Housing, Set the Dial Indicator 0 on Ring gear teeth as shown. Hold the pinion flange at the bottom side. Rotate the ring gear by using ring spanner & measure the backlash. High backlash is corrected by moving ring gear closer to pinion. Low backlash is corrected by moving ring gear away from pinion. These corrections are made by switching shims from one side of differential case to other. If backlash is as per specification, check ring gear and pinion tooth contact pattern. Interpretation of Contact Pattern ",
+ "file": null,
+ "display_order": 251
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/frontaxleoverhaul.JPG",
+ "display_order": 252
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "Description",
+ "content": "The TOE of the gear is the portion of the tooth surface at the end towards the centre. The HEEL of the gear tooth is the portion of the tooth surface at the outer end. The TOP LAND of a gear tooth is the surface of the top of the tooth. Every gear has a characteristic pattern. Measure and ensure the Final Total Torque To Rotate (TTTR) at pinion nut, It should be within 28 - 51 Kgf-cm (2.8 - 5 Nm). TTTR SPEC : 28 - 51 Kgf-cm (2.8 - 5 Nm). Using MST 0502AUA0005ST Front Axle Tube Cyl Roller Bearing Dolly, Install the RH housing cylindrical roller bearing through the oil seal bore In the housing. Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, Install the RH side housing Oil seal. Clean the intermediate shaft and insert the shims in intermediate shaft. Push intermediate shaft in same way the direction used during removal. Install the synthetic bush in the bore of axle shaft with the help of light nylon mallet. Press force must not so high which may damage the bush during pressing. Insert the thrust washers in the sequence opposite to removal in the disconnect housing. Shaft End Play Checking ",
+ "file": null,
+ "display_order": 281
+ },
+ {
+ "step_name": "Step-47",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150129.jpg",
+ "display_order": 282
+ },
+ {
+ "step_name": "Step-47",
+ "content_type": "Description",
+ "content": "Insert the axle shaft through wheel end side of the disconnect housing. Install the circlip on the axle shaft with the help of circlip pressing tool. Check end play with dial gauge at the axle shaft end. End play should be 0.025 to 0.1 mm. End play can be adjusted by adding/deleting shims from the intermediate shaft. After adjusting end play, remove the circlip & axle shaft from the housing. Install the shifter sleeve on the intermediate shift through disconnect housing window while aligning with the splines on it. shift splines and shifter sleeve must be free from foreign particles and burr. Insert the axle shaft through wheel end side of the disconnect housing. Install the circlip on the axle shaft with the help of circlip pressing tool. Ensure there should not be excessive play between two shafts this affects the disconnect . Insert the spring and shaft fork through the disconnect cover window while aligning the spring into bore in the cover and sitting in the slit of shift fork. Insert the shaft shift fork in the opposite way of removal ensuring that it passing through shift fork as well as spring. Orientation of the shift fork is important and it should be in same way while was removing. Ensure old spring is discarded and to use spring during installation. Ensure cleanliness of the disconnect housing cover, shift fork shaft , shift fork and spring. Press the shaft shift fork in the bore by hand. Install the new cover gasket while locating in the dowel on the disconnect housing. Ensure to use New Gasket while Installation. Ensure the cleanliness of disconnect housing cover face and cover resting face. Do not bent the wrap the Gasket while installing. Gasket orientation is fixed by dowel on the disconnect housing hence it will fit in one direction only . Bent or warped cover gasket may lead to leak during running. Locate the disconnect cover on the dowel and install the bolts. Tighten the mounting bolts to specified Torque Value. Torque : 17\u00b12 Nm ",
+ "file": null,
+ "display_order": 311
+ },
+ {
+ "step_name": "Step-54",
+ "content_type": "Notice",
+ "content": "Ensure to use New bolts while Installation. Apply locktite sealant on the bolts while installing, this avoid the leak through cover. Install the electrical motor on the cover assembly and tighten the screw with specified torque. Torque : 12.5\u00b13.5 Nm ",
+ "file": null,
+ "display_order": 315
+ },
+ {
+ "step_name": "Step-55",
+ "content_type": "Notice",
+ "content": "Ensure that the 'O' ring on the electrical motor is not cracked or damaged if so replace the 'O' ring as new one. By using MST 0502AUA0007ST - F Axle Tube Needle Bearing Dolly, Install the LH Side needle bearing In the disconnect housing. By using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, Install the housing LH side Oil seal. Apply the uniform sealant bid along the carrier cover face and avoiding the bolt holes as far as possible. Use Anabond A-676 or 3M sealant on the cover plate. Ensure the cleanliness of the carrier cover face before Installation. Install the carrier cover plate and locate it on the cover plate mounting studs on the carrier Install cover plate bolts and tighten them to specified Torque Value. Torque : 38 - 45 Nm ",
+ "file": null,
+ "display_order": 331
+ },
+ {
+ "step_name": "Step-60",
+ "content_type": "Notice",
+ "content": "Discard the old bolts and Use new bolts for cover plate mounting as the bolts are coming with sealant patch on it and during sealant patch wears off. Reusing cover bolts may leads to leakage from cover bolts sides. Refit the Front Axle Assembly. For additional information refer to Front differential oil draining and filling procedure. ",
+ "file": null,
+ "display_order": 335
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 106,
+ "sys_id": "THAR.AX-0001-Front Axle",
+ "subsys_id": "THAR.AX-0001-Front Axle-E-Disconnect Housing with Fork",
+ "systems": "Front Axle",
+ "sub_systems": "E-Disconnect Housing with Fork",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A150021.jpg",
+ "myid": 1225,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-E-Disconnect Housing with Fork-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150021.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10346.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10347.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove E-Disconnect motor. Using 10 mm socket spanner, Unscrew electric disconnect housing mounting bolts Torque : 17\u00b12 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Carefully remove the E-Disconnect Housing with Fork . Refit in the reverse order of removal. While Installation Apply Locktite sealant on the E-Disconnect Housing bolts to avoid the leak through cover. Check the e-disconnect housing with fork for any damage, Replace if necessary. Remove E-Disconnect stone guard. For additional information refer to E-Disconnect stone guard \u2013 R &R; section. Disconnect E \u2013 Disconnect electric connector. Using 10 mm socket spanner, unscrew E \u2013 Disconnect motor mounting bolts. Torque : 12.5\u00b13.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Carefully remove the E-Disconnect motor. Refit in the reverse order of removal. While Installation ensure to replace the New O Ring for E \u2013 Disconnect motor. Torque : 90 \u2013 110 Nm ",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the E-Disconnect motor, connector for any damage, Replace if necessary. Position the vehicle on 2 post lift/ 4 post lift. Differential Oil Front Replace - Procedure Front Axle Oil \u2013 Mahindra 'MAXIMILE ELITE' New Generation Genuine Differential Fluid , Capacity \u2013 1.25 Litres. Using 10 mm square bit spanner, loosen and remove front axle filler plug. Using 10 mm square bit spanner, loosen and remove front axle drain plug and drain the entire oil. Wait till the entire oil get drained. Place a tray beneath the front axle for collecting the oil while draining. Refit the drain plug and torque tighten to specified value. Clean the drain plug and differential housing with a clean cloth before refitting. Torque : 34 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refill specified quantity of recommended differential oil into differential assembly. Never reuse drained oil. Always use recommended oil only. Never mix different types of oil and use. Clean filler plug area properly using a cloth before filling the oil. Check the oil level and ensure its up to the level. Ensure that the oil level is up to lower most point of the filler plug. Refit the filler plug back and torque tighten to specified value. Clean the filler plug with a clean cloth before refitting. Torque : 34 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Recommend to use only Mahindra 'MAXIMILE Elite' new generation genuine differential fluid. In case of non availability of 'Maximile' brand, other brands meeting API GL5, SAE 80W-90 specification can be used as second preference and oil change period should be reduced as 20,000 km.
2. Visually inspect the front axle for any noticeable signs of mechanical damage.
3. If an obvious cause is found during the inspection, correct the same before proceeding to the next step.
4. If the cause is not found visually during the inspection, refer to the troubleshooting chart.
5. Check for oil level and condition.
",
+ "file": null,
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Mechanical",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "1. Check for any oil leakage in the differential assembly, gasket and axle shaft oil seal.
2. Check for any noise in the bearing, pinion gear, crown wheel and planet gears.
",
+ "file": null,
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "various symptoms, causes and there remedial actions of system",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16394.pdf",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Noise when the vehicle is coasting",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16395.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Intermittent Noise",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16396.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Noise when the vehicle is turning",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16397.jpg",
+ "display_order": 6
+ }
+ ]
+ },
+ {
+ "procedure_name": "Constant Noise",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16398.jpg",
+ "display_order": 7
+ }
+ ]
+ },
+ {
+ "procedure_name": "Vibration",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16399.jpg",
+ "display_order": 8
+ }
+ ]
+ },
+ {
+ "procedure_name": "Oil leakage from Differential carrier leakage",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16400.jpg",
+ "display_order": 9
+ }
+ ]
+ },
+ {
+ "procedure_name": "Axle case oil leakage",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16401.jpg",
+ "display_order": 10
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 262,
+ "sys_id": "THAR.AX-0001-en-SM-Doors, Bonnet & Tail Gate",
+ "system_name": "Doors, Bonnet & Tail Gate",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1025,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 266,
+ "sys_id": "THAR.AX-0001-Doors, Bonnet & Tail Gate",
+ "subsys_id": "THAR.AX-0001-Doors, Bonnet & Tail Gate-Bonnet",
+ "systems": "Doors, Bonnet & Tail Gate",
+ "sub_systems": "Bonnet",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A260051.jpg",
+ "myid": 1383,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Bonnet-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260051.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5906.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5907.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the wiper washer nozzles. For additional information refer to the Wiper Washer Nozzle Front - R &R; section. For additional information refer to the Stay Rod - R &R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the wiper hose routing clips from the bonnet. Remove the bonnet rubber beading from the bonnet. Using 12 mm socket spanner, loosen and remove the bonnet catcher bracket mounting bolts (Both sides). Torque : 13.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W334.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using T40 socket spanner, loosen and remove the bonnet mounting bolts. Torque : 24\u00b14 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260053.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the bonnet from the vehicle. Install in the reverse order of removal. Inspect the bonnet hinges for any crack or damage. Replace if found. Remove Side window RH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Remove Side window LH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Unzip the tail gate window, detach the tail gate bar locking from rear RH & LH belt rails remove the tailgate window. Unhook the \u2018C\u2019 pillar cover from rear RH & LH belt rails and fold the cover at top of the soft top. Using a T30 socket spanner, loosen and remove the belt rear rail Mounting bolts and remove the belt rail from the vehicle. Follow the same procedure for LH side. Remove the seal from the body. Install in the reverse order of removal. Inspect the tail door half seal for any damage or wears. Replace if found any. For additional information refer to Front Door Trim RH- R &R Section. ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Detach the key handle lever from the key lock set. Detach lock holding bracket and remove key lock from the vehicle. Install in the reverse order of removal. For additional information refer to Tail Door Trim RH- R &R Section. ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Detach the key handle lever from the key lock set. Detach lock holding bracket and remove key lock from the vehicle Install in the reverse order of removal. Remove Glove Box Assembly. Using Screw driver, Remove Glove box Latch Mounting Screws. Using Screw driver, Remove Lock from Latch by pressing lock locking clips. Install in the reverse order of removal. Using vehicle key open the fuel filler door. Detach lock holding bracket and remove key lock from the fuel filler door. Install in the reverse order of removal. Inspect the key locks for any damage or wears. Replace if found any. Lift and open the tail gate glass. Using a screw driver carefully lift and open the gas strut lock at both the ends. Inspect the gas strut assembly for any damage, replace if found. Pull the door outer handle and slowly close the door with outer door handle pulled in condition. Check and feel for the condition of latch fouling with striker. If the latch fouling with the striker then loosen the striker mounting screws and align the striker so that there is no fouling. Tighten the striker mounting screws to specific torque. Torque : 23.5 \u00b1 2.5 ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "Ensure that door closing should be smooth and latch is not foul on the striker. Follow the same procedure for other doors. For additional information refer to the Tail Door Trim- R &R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the tail door electrical connector and remove the wiring routing clips from the tail door. Using a screws driver, loosen and remove the mounting screws from the hinges. Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, loosen and remove the stopper mounting bolt from the Body. Torque : 23.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the hinge mounting bolts inside tail door. Torque : 50\u00b15 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260033.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Ensure to hold the tail door with spare wheel properly while remove, failing will lead door falling down which may lead to personal injuries. Using 12 mm socket spanner, loosen and remove the Hinge Mounting bolts from body. Torque :27\u00b14 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260032.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the tail door hinges for any physical damage, replace if found. Lower the window glass to prevent from damage. Disconnect door accessory electrical connector. Protect the electrical connectors to avoid water entry, which may leads to short circuit. Detach the wiring harness bunch from holding bracket \u2018A\u2019 Pillar end. Using 12 mm socket spanner, Unscrew door stopper mounting bolts BIW end. Using T40 Torx Socket, Unscrew door hinge pin at bottom of the hinge. Carefully lift and remove the door assembly from vehicle. Refit in the reverse order of removal. Key IN Reminder & Park Lamp Reminder will not function in case of driver door is removed. Roof lamp will not work with respect to door status. Lock & Unlock functions will not work through Master Actuator in case of driver door is removed. Hinge pin can break if overtightened during door reinstall \u2014 Max. Torque 10 Nm. Doors are heavy, Take at most care when removing the doors, Failing to this may cause personal injury. After Door removal vehicle will be left with only IRVM (as ORVM\u2019s fitted on doors) In such scenario driving the vehicle on road is not permitted as per regulations. Do not drive your vehicle on public roads with the doors removed as you will lose the protection they can provide. This procedure is furnished for use during off-road operation only. All occupants must wear seat belts during off-road operation with doors removed. Disconnect the Door wiring harness electrical connector and detach WH bunch from \u2018A\u2019 pillar lower. Using 12 mm socket spanner, Unscrew door stopper mounting bolt BIW side. Torque : 23.5 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew door hinge mounting bolts from body. Torque : 50 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the door assembly from vehicle. Support the door while removing the bolts. Using star screw driver , Unscrew door hinge mounting screw door end. Torque : 24\u00b1 4.0 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260042.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Before tightening the bolts align the door assembly correctly, else door operation won\u2019t be smooth. Refit in the reverse order of removal. Do the door alignment, if required. Inspect the door hinge for any damage. Replace if required. Disconnect the demister electrical connectors. Using 4 mm Allen key, Unscrew glass hinge mounting screws. Torque : 2.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260115.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using the screw driver Unlock the strut to detach the strut and remove the glass. Ensure to hold the Rear Windshield glass while detach the struts, failing to hold leads to glass falling. Using 10 mm socket spanner, Unscrew strut bracket mounting bolts from glass. Torque : 5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260085.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Ensure not to over tigthen the strut bracket mounting bolts while Installation. Remove strut mounting grommet and cap nuts from the glass. Install in the reverse order of removal. Inspect the rear windshield glass for any damage or wears. Replace if found any. Remove the spare wheel carrier. For additional information refer to the Tail Door Trim - R &R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the tail door latch. For additional information refer to the Tail Door Inner Handle - R &R section. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the tail door outer handle . Remove the tail door Stopper. For additional information refer to the tail door Stopper section. Remove the tail door lock. For additional information refer to the Tail Door Lock section. Remove the tail door weather strip from the tail door. Remove the tail door electrical connector and remove the wiring routing clips from the tail door. Using a Screws driver, loosen and remove the mounting screws from the hinges. Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, loosen and remove the Stopper Mounting bolt from the Body. Torque : 50\u00b15 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, loosen and remove the hinge mounting bolts inside tail door. Torque : 50\u00b15 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Remove the tail door from vehicle. Install in the reverse order of removal. Inspect the tail door for any physical damage, replace if found. Remove the hard top assembly. For additional information refer to Hard Top Assembly section. Remove the seal from the body. Install in the reverse order of removal. Inspect the tail door half seal for any damage or wears. Replace if found any. Remove the scuttle grill. Using T40 socket spanner, loosen and remove the bonnet mounting bolts. Torque : 24\u00b14 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the bonnet hinge mounting bolts from the body and detach hinge. Torque : 24\u00b14 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the hood hinge from the bonnet. Install in the reverse order of removal. Inspect the bonnet hinges for any crack or damage. Replace if found. Drain the Transmission fluid. For additional information refer to Transmission fluid Drain & Filling Section. Remove the Clutch Concentric Slave Cylinder. Using a 14 mm socket spanner remove the clutch housing mounting bolts and then gently tap using plastic mallet & remove clutch housing. Using a screw driver/suitable oil seal remover, remove the input shaft oil seal from clutch housing. Check for any external cracks, if found replace. Check the oil seal for deformation, if found replace. Install the input gear oil seal on the clutch housing by using MST - 0703BBA0001ST - Clutch Housing Oil Seal Installer. Check for correct seating of oil seal on clutch housing. Apply Loctite 5188 on front housing. Install the clutch housing. Refit the clutch housing with the help of mounting bolts torque tighten the bolts to specified value. Torque : 30 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit the Clutch Concentric Slave Cylinder. Refill the Transmission fluid. Front housing is used to provide support for mounting transmission shafts with the help of bearings. It is mounted in between clutch housing and Intermediate plate. Remove the Clutch housing assembly. Using a 22 mm ring spanner, loosen and remove the neutral sensor. Remove the rear housing assembly. Using a snap ring removal tool/ flat end screw driver, remove the input shaft snap ring from the front housing. Using a snap ring removal tool/ flat end screw driver, remove the counter shaft snap ring from the front housing. Using open end spanner, detach the front housing from the intermediate plate. Remove the front housing assembly. Apply loctite 5188 on the front housing in intermediate plate side. Install the front housing assembly. Use 3 nos. of 17 mm dummy bolts (Appox. length of 40 mm) to tighten the front housing to ensure proper sealant application. Ensure to fix the dowels before tighten the front housing. Using a snap ring, removal tool/ screw driver install the counter shaft snap ring. Using a snap ring, install the input shaft snap ring. Refit the Clutch housing assembly. Refit the Rear housing assembly. Install the neutral sensor. Torque tighten the nut to specified value. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 38
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 70,
+ "sys_id": "THAR.AX-0001-Manual Transmission",
+ "subsys_id": "THAR.AX-0001-Manual Transmission-Transmission With Transfer Case",
+ "systems": "Manual Transmission",
+ "sub_systems": "Transmission With Transfer Case",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A110001.jpg",
+ "myid": 1151,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Transmission With Transfer Case-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110001.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/15179.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/15180.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the battery negative terminal. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Remove Rear Propeller Shaft Assembly. For additional information refer to Rear Propeller Shaft R &R; Session. Using a 8 mm socket spanner, loosen and remove the front propeller shaft mounting C clamp bolts from the transfer case. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the cross pin and detach the Shifter cable from the shifter control housing on transmission. Using a 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the Selector cable from the Shifter Control Housing ball pin. Detach the Selector cable & Shifter cable abutments from the cable brackets on transmission by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Using a 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the transfer case cable from the transfer case ball pins. Detach the transfer case cable abutment from the cable bracket on transmission by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Disconnect the GNS sensor & transfer case switch electrical connection. Disconnect the reverse switch electrical connection. Disconnect the transmission wiring routing clips. Disconnect the clutch bundy tube connection from clutch slave cylinder. Using a 14 mm socket spanner, loosen and remove the starter motor mounting bolts then keep aside the starter motor. Torque: 44 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the transmission housing mounting bolts. Torque: 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Provide a jack to support the transmission. Using a 12 mm socket spanner, loosen and remove the transmission bed mounting bolts from transmission. Torque :25\u00b15 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using 14mm, 15mm socket and ring spanners, unscrew transmission cross member mounting bolts, nuts and detach it. Torque: 65 \u00b110.0 Nm ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Lower the jack and remove the transmission along with the transfer case. Install in reverse order of removal. Carry-out clutch bleeding procedure. For additional information refer to clutch fluid Refilling and bleeding procedure. While refit Cables, Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Move the shifter cable quick adjuster outer cover in forward direction and unlock the QA clip in transmission end. Position the shifter control housing in Neutral Position on transmission. Ensure the Selector cable is properly fitted on Shifter Control Housing ball pin on transmission. Ensure the selector cable & shifter cable abutments are properly fitted on transmission cable brackets. Remove the gear shifter lever knob with spring and 4WD selection knob. Using trim removal tool, remove the Gear selection rod cover with trim. Ensure the selector cable & shifter cable abutments are properly fitted on shifter lever bracket Inside passenger cabin. Move the selector cable quick adjuster outer cover in forward direction and unlock the QA clip. Insert the Neutral lock Special tool to shifter housing hole and lock the tool C profile to shifter lever as shown for ensuring selector & shifter arm in neutral position. After Inserting the Neutral lock special tool, Shifter lever should not move in any direction. In this Condition press the selector cable QA clip as shown to lock it fully and release the quick adjuster outer cover. Ensure the proper locking by confirming/ hearing the click noise while install. Ensure the shifter cable end is properly fitted on the shifter lever ball pin inside passenger cabin. Ensure Transmission is in Neutral at transmission end. In this condition press the shifter cable QA clip towards arrow mark as shown to lock it fully and release the cable quick adjuster outer cover. Ensure the proper locking by confirming/ hearing the click noise while install. After adjustment remove the special tool from shifter lever. Refit the Gear selection rod cover with trim. Refit the gear shifter level knob with spring and 4WD selection knob. Inspect the shifter lever smooth shifting & gear engagement to all the gear range. Remove the Transfer Case. Using a screw driver, remove the rear end oil seal from the Rear housing. Position the rear end oil seal along with 0703BBA0002ST - Transmission Rear Housing Oil Seal Installer & install the oil seal using a mallet. Remove the Transmission with Transfer case. Pull the clutch bleeder lock and detach the bleeder from CSC. Using a 12 mm socket spanner, loosen and remove the CSC mounting bolts. Torque: 25 \u00b1 3.5 Nm ( Step UP Torque \u2013 5, 15 , 25) ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 15 mm socket spanner/ combination spanner, loosen and remove the transfer case mounting nuts then detach the transfer case from the transmission. Torque: 45 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110017.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Carry-out clutch bleeding procedure. For additional information refer to clutch fluid Refilling and bleeding procedure. Check the Transmission oil level and topup if needed. For additional information refer to transmission oil level inspection and refilling procedure. Remove the Floor Console. Using a MST 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the Selector cable & Shifter cable from the shift lever ball pins. Detach the Selector cable & Shifter cable abutments from the shifter bracket by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Using a 13 mm socket spanner, loosen and remove the gear shifter lever assembly mounting nuts. Remove the gear shifter lever assembly from the vehicle. Position the gear shifter lever assembly on the vehicle. Refit the gear shifter lever assembly mounting nuts and torque tighten the nuts to specified value. Torque: 21\u00b13 NM ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Refit the Selector cable & Shifter cable abutments on shift lever bracket. Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Refit the Selector cable & Shifter cable on shift lever. Carry out Gear Cable Setting. New Shifter Lever Assembly supplied with Gear shifter Neutral position tool, ensure to remove the tool from shifter housing after Gear cable setting. Support the transmission using jack. Using a 18 mm socket spanner, loosen and remove the transmission bed mount nuts. Torque: 110 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 14 mm & 15 mm socket/ring spanner, loosen and remove the cross member mounting bolts & nuts then remove the transmission cross member. Torque: 65\u00b1 10 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the transmission bed mounting bolts then remove the transmission bed mount from the vehicle Torque: 25\u00b15 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110085.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Detach the Shifter cable abutment from the cable bracket on transmission by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Using a 12 mm socket spanner, loosen and remove the shifter cable bracket mounting bolts and remove the bracket. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the GNS electrical connection and detach the wiring routing clip. Using a 22 mm open end spanner, loosen & remove the Gear Neutral Sensor. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. While Install cable, Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Check for any external damage, if found please replace. Bead width : 2\u00b10.5mm Bead width : 2\u00b10.5mm Bead width : 2\u00b10.5mm Bead width : 2\u00b10.5mm Remove the Air Cleaner Assembly. Remove the Floor Console. Using a 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the Selector cable & Shifter cable from the shift lever ball pins. Detach the Selector cable & Shifter cable abutments from the shifter bracket by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Remove the cross pin and detach the Shifter cable from the shifter control housing on transmission. Using a 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the Selector cable from the Shifter Control Housing ball pins. Detach the Selector cable & Shifter cable abutments from the cable brackets on transmission by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Using a 10 mm socket spanner, loosen and remove the shifter & selector cable grommet mounting bolts. Detach the shifter and selector cable from routing clips & take out from the vehicle. Routing the shifter and selector cable to the vehicle and position the cables on routing clips. While routing the cable ensure to insert Selector cable in the left side of the Gear shifter lever and shifter cable in the right side. Select & Shift cable should not cross each other. Refit the shifter & selector cable grommet mounting bolts and torque tighten the bolts. Torque: 13\u00b1 2 Nm ",
+ "file": "/files/W4A110381.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Caution",
+ "content": "Ensure the cable grommet should get assemble from outside the cabin. Refit the selector cable & shifter cable abutments on transmission cable brackets. Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Attach the Shifter cable on shifter control housing on transmission and refit the cross pin on Shifter control housing. Attach the Selector cable on Shifter Control Housing ball pins by hand. Refit the selector cable & shifter cable abutments on shift lever bracket inside passenger cabin. Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Attach the Selector cable end on Shifter lever ball pin by hand. Refit the shifter cable end on Shifter lever ball pin by hand. Carry out Gear Cable Setting. Refit the Air Cleaner Assembly. Inspect the gear shift & select cables for any damage. Replace if found any. Rear housing is used to protect rear parts of transmission components from external environment. It is used to hold the Shifter Control Housing assembly & detent block. Drain the transmission oil. Using a 12 mm socket spanner, remove the gear control housing mounting bolts and then gently detach and remove the gear control housing assembly. Yellow colored bolts are fitted with dowel inside, this bolts should be removed & refit first. Using a T30 torx spanner, remove the torx bolt from the shift block actuator. Using a 22 mm socket spanner, remove the reverse switch. Using a 12 mm socket spanner, remove the idler shaft front mounting bolt & using a 13 mm socket spanner remove the bottom idler shaft bolt. Using a 12 mm socket spanner, loosen and remove the selector bracket mounting bolts. Using a 12 mm socket spanner, loosen and remove the shifter bracket mounting bolts. Using a 14 mm socket spanner, remove the rear housing bolts from the front housing side. Ensure and take more care on not to breakage the front housing sealant while removing rear housing bolts from the front housing side. Using a 14 mm socket spanner/Open end spanner, remove the rear housing mounting bolts. Turn the shift block actuator & release from the spring support. By using screw driver, release the rear housing dowels and using open end spanner detach the rear housing. Release the dowels from the rear housing and ensure not to remove fully from the housing and it leads to touch the dowels on center housing projection as shown. Use the open end spanner on both the side simultaneously. Lift the rear housing assembly along with the shift block actuator. Remove the rear housing assembly and take out shift block actuator from housing. Using a screw driver/suitable oil seal remover, remove the rear end oil seal from the Rear housing. Using a 12 mm socket spanner, remove the H plate mounting bolts & the H plate assembly from the Rear housing. Using hydraulic press, remove both the detents by pressing from outside to inside. Check for any external oil leakage. Rectify if found. Using suitable tool and hydraulic press, fit the detent (press from outside to inside) Position the rear end oil seal along with 0703BBA0002ST - Transmission Rear Housing Oil Seal Installer & install the oil seal using a mallet. Check for the rear end oil seal correct seating. Refit the H plate mounting bolts & torque tighten the bolts to specified value. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Apply loctite 5188 on Intermediate plate and insert the rear housing assembly. Install the shift block actuator while installing the rear housing. Insert the rear housing mounting bolts, torque tighten the bolts specified value. Torque : 30\u00b15 Nm ",
+ "file": null,
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Insert the rear housing mounting bolt from front housing side and torque tighten the bolts to specified value. Torque : 30\u00b15 Nm ",
+ "file": null,
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110122.jpg",
+ "display_order": 72
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Refit the reverse light switch, torque tighten the switch to specified value. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Insert the front & the bottom idler shaft mounting bolts, torque tighten the bolts to specified value. Torque : Idler Shaft Bolts - 30\u00b15 Nm ",
+ "file": "/files/W4A110120.jpg",
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Refit the shifter bracket with mounting bolts , torque tighten them to the specified value. Torque: 20.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Refit the selector bracket with mounting bolts , torque tighten them to the specified value. Torque: 20.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 84
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Position the shift block actuator, apply Loctite 262 & insert the torx bolt and torque tighten the bolt to specified value. Torque : 10 - 15 Nm ",
+ "file": null,
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110323.jpg",
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Apply 5188 loctite on the rear housing to fit gear control housing. Refit the gear control housing & the mounting bolts. torque tighten the bolts to specified value. Yellow colored bolts are fitted with dowel inside, this bolts should be refit first. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 96
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 68,
+ "sys_id": "THAR.AX-0001-Manual Transmission",
+ "subsys_id": "THAR.AX-0001-Manual Transmission-Shifter Control Housing",
+ "systems": "Manual Transmission",
+ "sub_systems": "Shifter Control Housing",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A110054.jpg",
+ "myid": 1149,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Shifter Control Housing-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Shifter Control Housing is for gear selecting and shifting. It is connecting element between gear shift lever and shift rail through Shifter & Selector cables. Remove the Transmission with Transfer case. Using a 12 mm socket spanner, remove the gear control housing mounting bolts and then gently detach and remove the gear control housing assembly. Position the shifter lever in Natural Position on transmission. Yellow colored bolts are fitted with dowel inside, this bolts should be removed & refit first. While Installation, Apply sealant LOCTITE 5188 on the rear housing shifter control housing seating area. Install in reverse order of removal, before installation apply the sealant if required. Top up the transmission oil. Inspect the shift control housing for any damage. Replace if found any. Drain the Transmission fluid. For additional information refer to Transmission fluid Drain & Filling Section. Using a 12 mm socket spanner, remove the gear control housing mounting bolts and then gently detach and remove the gear control housing assembly. Yellow colored bolts are fitted with dowel inside, this bolts should be removed & refit first. Using a T30 torx spanner, remove the torx bolt from the shift block actuator. Using a 22 mm socket spanner, remove the reverse switch. Using a 22 mm open end spanner, remove the neutral sensor. Using a 12 mm socket spanner,remove the idler shaft front mounting bolt & using a 13 mm socket spanner, remove the bottom idler shaft bolt. Using a 14 mm socket spanner, remove the rear housing bolts from the front housing side. Using a 14 mm socket spanner/Open end spanner, remove the rear housing mounting bolts. Turn the shift block actuator & release from the spring support. By using screw driver, release the rear housing dowels and using open end spanner, detach the rear housing. Release the dowels from the rear housing and ensure not to remove fully from the housing and it leads to touch the dowels on center housing projection as shown. Use the open end spanner on both the side simultaneously. Lift the rear housing assembly along with the shift block actuator. Remove the rear housing assembly and take out shift block actuator from housing. Using a screw driver/suitable oil seal remover, remove the rear end oil seal from the Rear housing. Using a 12 mm socket spanner remove the H plate mounting bolts & the H plate assembly from the Rear housing. Using hydraulic press, remove both the detents by pressing from outside to inside. Remove the idler gear, shaft & the plastic support assembly. Remove washer, idler gear & needle roller bearing from shaft. Remove main shift rod & the washers on both sides. Ensure Gear in neutral position. Using a 14 mm socket spanner remove the counter shaft lock bolt in clock wise direction. The bolt is reverse threaded, hence rotate in clockwise for removing. Using a MST 0703AD2720H116 \u2013 Lock Nut Dolly, loosen the output shaft lock nut. Using a bearing puller (SKF TMMR 120F), remove the counter shaft rear DGBB (Double Grove Ball Bearing). Use Counter shaft dummy bolt for support bearing puller. Using a puller (SKF TMMR 350F), remove the reverse driven gear, washer & CRB (Cylinder Roller Bearing) from output shaft. Remove reverse synchro ring and remove the reverse driven gear needle bearing & remove the bush. Remove reverse synchro stud and reverse fork & rail shift assembly along with reverse synchro sleeve from output shaft. Using a puller (SKF TMMR 350F) remove the reverse synchro hub from output shaft. Using a puller (SKF TMMR 120F), remove the reverse drive gear, thrust washer & 5th drive gear from counter shaft. Remove the 5th drive gear NRB (Needle Roller Bearing) and 6th synchro ring. Using a suitable puller (SKF TMMR 350F) remove the 5th driven gear & bush from output shaft. Remove the 5th & 6 th synchro studs and remove the 5th & 6 th synchro sleeve along with fork & rail shift. Using a puller (SKF TMMR 120F) remove 5th drive gear bush, 5th & 6th synchro hub, synchro ring & 6th drive gear from counter shaft. Remove the 6th drive gear NRB. Using 14 mm socket spanner, remove the clutch housing bolts. Gently tap using plastic mallet & remove clutch housing. Using a screw driver/suitable oil seal remover, remove the input shaft oil seal from clutch housing. Using a snap ring removal tool/ flat end screw driver, remove the input shaft snap ring from the front housing. Using a snap ring removal tool/ flat end screw driver, remove the counter shaft snap ring from the front housing. Using open end spanner, detach the front housing from the intermediate plate. Using a roll punch & hammer, remove the pin spring dowel from the 1st & 2nd shifter fork & rail assembly. Using a roll punch & hammer, remove the pin spring dowel from the 3rd & 4th shifter fork & remove fork rail assembly from intermediate plate. By using snap ring removal tool, expand the output shaft snap ring and release the output shaft from intermediate plate. Using a mallet tap and remove the intermediate plate. Remove the counter shaft assembly. Remove the output shaft assembly from the input shaft assembly. Remove the pilot bearing & Synchro ring from input shaft. Using a circlip plier, remove the circlip from input shaft. By Using a puller (SKF TMBS 150E ) remove the DGBB from input shaft. Using a circlip plier, remove the circlip from counter shaft front end. By using a puller (SKF TMBS 150E) remove the DGBB from counter shaft front end. By using a puller (SKF TMMR 160F) remove the DGBB, 6th drive gear bush & thrust washer from counter shaft rear end. Engage puller legs in the 2nd driven gear. Remove in the sequence of 6th driven gear, output shaft DGBB, 1st driven gear with bush, 1st driven gear NRB, 1st & 2nd synchro pack, 2nd driven gear. Remove the 2 nd driven gear NRB. Using a circlip plier remove the circlip from the output shaft. Remove the 3rd & 4th synchro studs & sleeve. Using puller (SKF TMMR 350F) remove the 3rd & 4th synchro hub & the 3rd driven gear assembly. Remove the 3rd driven gear NRB. Shift Control Components ",
+ "file": null,
+ "display_order": 144
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110195.jpg",
+ "display_order": 145
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check contact and sliding surfaces of shifter fork & rails for wear, scratches, projections and other damage. Gear Components ",
+ "file": null,
+ "display_order": 147
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110196.jpg",
+ "display_order": 148
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Check shafts for cracks, wear and bend. Check gears for excessive wear, chips and cracks. Synchronizers ",
+ "file": null,
+ "display_order": 151
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110198.jpg",
+ "display_order": 152
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Check spline portion of coupling sleeves, synchronizer hubs, and gears for wear, chips, and racks. Check ring for cracks and deformation. Check struts for wear and deformation. Bearings ",
+ "file": null,
+ "display_order": 154
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110199.jpg",
+ "display_order": 155
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Make sure all bearings roll freely and are free from noise, cracks, pitting or wear. Remove the gear shifter level knob with spring and 4WD selection knob. Using trim removal tool, remove the Gear selection rod cover with trim. Using a screw driver , loosen and remove the gear selection rod cover mounting screw and detach boot from trim. Install in reverse order of removal. Transmission Oil \u2013 Replace ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Transmission Oil - replace.mp4",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Transmission Oil \u2013 MAHINDRA \u201cMAXIMILE SYNTEC F2\u201d New Generation Genuine Transmission Fluid. Capacity \u2013 2.25 Litres. Position the vehicle on a 2 post /4 post lift Using a 8 mm square bit spanner, loosen and remove the filler plug. Using a 8 mm square bit spanner, loosen and remove the drain plug & allow the oil to drain out completely. Place a tray or drain oil collecting bin under the drain plug to collect the oil. Install the drain plug. Torque tighten the drain plug to specified value. Always replace the drain plug washer with a new one. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Fill recommended oil using an oil filling machine or by clean transparent pipe attached to the mechanical hand pump. Ensure that the oil level is up to lower most point of the filler plug. Refit the filler plug. Torque tighten the filler plug to specified value. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Recommend to use only Mahindra 'MAXIMILE SYNTEC F2' new generation genuine transmission fluid. In case of genuine oil non-availability, manual transmission oil meeting API GL-4 SAE 80W-90 specification is suggested. This alternate oil or other brand may not provide equivalent performance of recommended genuine oil. Drain Interval should be reduced as 20,000 km. Never mix two different oils. Remove rear front facing Seat Back Rest Assembly. For additional information refer to rear front facing Seat Back Rest Assembly - R &R; Section. Open the seat cover strip back side of back rest assembly. Press the lock and remove the head rest. Unzip the seat cover LH & RH sides. Press the lock and remove the head rest guide inside seat cover. Detach the seat cover with foam from the frame and remove from back rest frame. Install in the reverse order of removal. Check for any damages. Replace if required. Check for any damages on seat trims. Replace if required. Remove Driver Seat Back Rest Assembly. Open the seat cover strip back side of back rest assy. Unzip the seat cover LH & RH sides.
\u2022 Check for any damages on foam and cover. Replace if required.
",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 236,
+ "sys_id": "THAR.AX-0001-Seat System",
+ "subsys_id": "THAR.AX-0001-Seat System-Driver Seat Back Rest Frame",
+ "systems": "Seat System",
+ "sub_systems": "Driver Seat Back Rest Frame",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B230126.jpg",
+ "myid": 1353,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Driver Seat Back Rest Frame-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230126.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5672.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5673.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Driver Seat Back Rest foam with Cover. Check the frame for any damages. Replace if required. Remove Driver Seat Back Rest Foam with Cover. Take extreme care to not to damage the foam and seat cover. Install in the reverse order of removal. Check the foam for any damages. Replace if required. Check for seat cover any damages. Replace if required. Remove the Rear Seat Recliner Cover. For additional information refer to the Rear Seat Recliner Covers - R &R; section. Detach the seat folding cable from the lock and remove the cable. Remove the cable from the bottom cushion routing bracket. Remove the cable from the seat. Install in the reverse order of removal. Check seat folding cable for any damages. Replace if found. Remove Driver Seat Back Rest Assembly. Unlock the seat cover lock from the bottom side. Using Nose plier and Screw driver, Remove the seat cover locking rings. Using star screw driver, Unscrew seat side cover mounting screw and remove the cover. Detach the cover with foam. Install in the reverse order of removal. Check the Cushion and Frame Assembly for any damages. Replace if required. Remove Driver Seat Assembly. Remove seat recliner and height adjustment handle cover. By using star screw driver remove seat height adjustment handle mounting screws & remove the handle. By using star screw driver, remove LH & RH valance cover mounting screws and detach the covers. Detach back cushion cover lock from seat bottom. Using T50 torx socket spanner, Unscrew back rest mounting bolts. Torque: 47.5 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230110.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230111.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Detach the back rest from Seat assembly. Press the Lock and remove the head rest from the back rest assembly. Install in the reverse order of removal. Check for any damages. Replace if required. Check for any damages on seat trims. Replace if required. Remove the Rear Front Facing Bottom Cushion. For additional information refer to Rear Front Facing Bottom Cushion - R &R; Section. Remove the copper locks from the rear front facing bottom cushion. Detach the both side the cable from the lock. Remove the both routing bracket cable tie from the seats. Remove the bottom cushion from the frame assembly and separate the Bottom Cushion Frame. Install in the reverse order of removal. Check for any damages. Replace the frame if required. Check for any damages on seat trims. Remove the Wiper Motor & Link Assembly. For additional information refer to Wiper Motor & Link Assembly - R&R; section. By using screw driver partially remove the wiper link from the motor. Using a 10 mm open end spanner, loosen and remove the wiper motor link assembly mounting bolt. Torque : 10 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A320051.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the wiper motor separately. Install in the reverse order of removal. Check the motor for any damage. Replace if found any. Check the linkage for any damage. Replace if found any. Remove the Scuttle Grill - R&R.; For additional information refer to front Scuttle Grill - R &R; section. Using a screw driver, Carefully remove the dust tray from vehicle. Disconnect wiper motor electrical connector. Using a 10 mm open end spanner ,loosen and remove the wiper motor link assembly mounting bolt. Torque : 10.50 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A320035.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A320036.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the wiper motor and link assembly from vehicle. Install in the reverse order of removal. Check the motor for any damage. Replace if found any. Check the linkage for any damage. Replace if found any. Remove the Roof Speaker LH & RH. For additional information refer to Roof Speaker - R &R; section. Remove the Roof Tweeter LH & RH. For additional information refer to Roof Tweeter - R &R; section. Using a trim removal tool pull out center bow trim and disconnect roof lamp electrical connector. Disconnect the sound bar electrical connector. Using 10 mm socket spanner, Unscrew sound bar mounting bolts. Detach the Wiring Harness from routing and remove from the sound bar assembly. Install in the reverse order of removal. Inspect the Wiring Harness for any physical damage. Replace if found. Inspect the connector for any damage. Remove the Driver Sun Visor. For additional information refer to Driver Sun Visor - R &R; Section. Remove the Co-Driver Sun Visor. For additional information refer to Co-Driver Sun Visor - R &R; Section. Using Torx screw driver, Unscrew Centre bow trim mounting screw and detach the bow trim. Torque Value: 5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280012.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the MIC electrical. Remove the MIC from Centre bow trim. Install in the reverse order of removal. Inspect the MIC unit for any damage. Inspect the electrical connectors for any damage. Using trim removal tool remove the infotainment center bezel. Using trim removal tool remove infotainment top side cover. Using star screw driver, Unscrew infotainment mounting screws. Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W344.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect Infotainment electrical connectors. Remove the Infotainment unit. Install in the reverse order of removal. Inspect the infotainment unit for any damage. Inspect the electrical connectors for any damage. Using star screw driver remove front LH wheel arch mounting screw rivets. Torque Value: 3 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290049.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290051.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the antenna electrical connector through wheel arch. Remove the antenna assembly separately. Inspect the antenna assembly and connector for any physical damage. Replace if found. Using star screw driver unscrew the panel assembly floor console RH screvits and detach the panel from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290031.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console LH screvits and detach the panel from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290034.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew vertical ascent RH mounting screw and detach the vertical ascent RH from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290033.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew vertical ascent LH mounting screw and detach the vertical ascent LH from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290035.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290036.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "partially detach the switch bang assembly and remove electric connector to take out from the vehicle. Carefully pull and remove the Audio Unit port Assembly. Disconnect the Audio Unit port electrical connectors and 12 volt electric connector. Using star screw driver unscrew the,Audio Unit port mounting screws. Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W347.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Remove the USB and DOC station assembly from the trim. Install in the reverse order of removal. Inspect the USB and DOC station assembly unit for any damage. Inspect the electrical connectors for any damage. Remove the Infotainment Assembly. Using star screw driver, Unscrew cluster bezel mounting screw and remove the bezel. Cut the GNSS antenna wire routing tag. Install in the reverse order of removal. Inspect the GPS Antenna for any damage. Inspect the electrical connector for any damage. Using star screw driver unscrew the panel assembly floor console RH screvits and detach the panel from vehicle. Using star screw driver unscrew the panel assembly floor console LH screvits and detach the panel from vehicle. Using star screw driver unscrew vertical ascent RH mounting screw and detach the vertical ascent RH from vehicle. Using star screw driver unscrew vertical ascent LH mounting screw and detach the vertical ascent LH from vehicle. partially detach the switch bang assembly and remove electric connector to take out from the vehicle. Carefully pull and remove the Audio Unit port Assembly. Disconnect the Audio Unit port electrical connectors and 12 volt electric connector. Using a small screw driver pull out the power port and remove the power port. Install in the reverse order of removal. Inspect the 12V power point for any physical damage. Replace if found. Clutch Fluid: Mahindra \u201cMaximile DOT 4\u201d Genuine Brake fluid.
Clutch Fluid: 1.75Liters (Including bleeding quantity).
Check the hose joint at reservoir and clutch master cylinder (CMC) inlet hose connection for any leak and proper fitment. Check clutch master cylinder bundy tube connection for any leak and proper fitment. Check clutch bundy tube connection to concentric slave cylinder and bleeding nipple for any leak. Use recommended fluid & do not mix different brand fluids. In case fluid reservoir replaced, brake and clutch system needs bleeding. Use the same brand fluid for top up; do not top up brake fluid from used and unsealed brake fluid container. The Brake fluid reservoir cap/ container should not be opened with dirty hands. Avoid direct water spray on reservoir while washing engine compartment. Always use Mahindra Maximile DOT 4 genuine Brake fluid. If Maximile DOT 4 brake fluid is not available and in emergency conditions, use Brake Fluid Meeting SAE J1703 FMVSS NO.116 DOT 4 OR IS 8654 TYPE-2 Specification. Change it at 30,000 km or 2 years whichever is earlier.
",
+ "file": null,
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Clutch Problem Causes",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Fluid contamination is the most frequent cause of clutch malfunction. Oil, water on the clutch contact surface will cause faulty operation viz. slip, grab, and judder.
",
+ "file": null,
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Clutch misalignment /Clutch Housing Misalignment",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "The clutch housing has to be aligned with the engine so that the input shaft is aligned with the crankshaft. Absence of this alignment results in clutch noise, incomplete release of the clutch plate. It can normally be judged by uneven wear of the finger and pilot bearing. In severe case it can also damage the spline of the input shaft and clutch hubs well as the clutch splines. The clutch component i.e. the clutch plate, flywheel and the pressure plate have to be aligned with the crankshaft and the transmission input shaft. Misalignment caused by run outs/ warpage will cause clutch to grab judder as well as improper release (also manifesting as hard gearshift). Normally the clutch housing misalignment is a result of Incorrect seating on the engine/transmission. Missing alignment dowel holes. Loose or missing mounting bolt. Mounting surfaces that are damaged/ not parallel. A noisy gearshift operation especially in 1st and 2nd gear can be due to clutch not getting disengaged completely. To check, turn the engine OFF, shift the gear lever to 1st or 2nd gearand then jack up the rear axle till both the wheels gets lifted enough from the ground Now press the clutch pedal completely and start the engine, the wheels should not be spinning after that slowly release the pedal till it has moved about 10 mm, the wheel should still not be spinning. If some spinning is noticed then it indicates improper lift of the pressure plate Do clutch bleeding and, then check for the pressure plate lift. To check the clutch housing misalignment bell housing run out will also need to be checked. If the clutch slip is suspected then drive the vehicle in 1st or 2nd gear at the top speed(corresponding to the gear). Keeping the accelerator fully pressed; slowly apply the brake with your left feet. If the engine stalls then the clutch is not slipping. Remove the transmission assembly with transfer case . For additional information refer to Transmission Assembly With Transfer Case \u2013 R &R; section. Put the dust cap/cotton cloth in CSC nozzle port during clutch or transmission service. Pull the locking clip outwards using a small flat end screw driver and disconnect concentric slave cylinder upper part of bleeder. using a 12mm socket spanner remove concentric slave cylinder mounting bolts. Torque : 25\u00b13.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove concentric slave cylinder assembly. Install in the reverse order of removal. Carry-out clutch circuit bleeding. For additional information refer to Clutch Fluid Air Bleeding Procedure. Inspect clutch slave cylinder for any leakages. Check the clutch slave cylinder Axial movement (Up & down) & bearing rotational movement (Right & left) for any abnormality. Inspect clutch slave cylinder boot condition for any damages. Inspect clutch slave cylinder mountings for any damages. Assemble the extension shaft and flat head to the push rod (Push end) of the Push & pull gauge. The push & pull gauge should be in line with the clutch pedal travel direction. Do not push the gauge by holding the top end. It would give us a wrong reading due to the extra force applied. Measurement taken by hitting the pedal to the bottom stopper would be wrong. Note the peak values on the push & pull gauge during the clutch pedal travel. Repeat the procedure for another 2 times and record the peak values. The average of the three values would be the pedal effort in Kgf. New clutch assembly 9 -12 Kgf (88 -118N). The maximum allowable clutch pedal effort is 17 Kgf (167N) Max. The flywheel run out needs to be checked whenever misalignment is suspected. Flywheel run out should not exceed 0.40 mm. To measure the run out, mount the base of the magnetic dial gauge on the block and then locate the dial gauge\u2019s needle on the outer surface of the flywheel and rotate the flywheel. Some of the common reasons for excessive run out are - Heat warpage. Improper machining. Incorrect bolt tightening. Foreign material on crankshaft flange or flywheel. If the flywheel has been removed for resurfacing or replacing the pilot bearing then while fitting it back ensure that: No dirt and grease present on the mounting face (it can cause cocking & run out). The flywheel bolts have been replaced. Torque tightened as per sequence and perform angular torquing as per the specifications. Absence of any of the above mentioned activities, may result in bolt loosening causing flywheel run out. The pilot bearing is mounted in the crankshaft and supports and locates the input shaft of the transmission. Use of a rolling bearing in place of the conventional bush, reduces the rolling resistance. However it should be noted that because of the bearing, it gives less leeway during assembly procedure. Remove the clutch pressure plate & disc . For additional information refer to Clutch Pressure Plate & Disc - R&R; section. Using a MST 543 - Extractor flywheel bearing, remove the Flywheel Pilot Bearing. Refit the Flywheel Pilot Bearing by using MST 0312CBH0001ST - Flywheel Pilot Bearing Installer. Refit the clutch pressure plate & disc . For additional information refer to Clutch Pressure Plate & Disc - R&R; section . Inspect the pilot bearing for any damage, crack. Replace if found any. Remove the Clutch pressure plate & disc. For additional information refer to Clutch Pressure Plate & Disc - R&R; section. Lock the flywheel using MST 0307ABH0001ST \u2013 Flywheel Locking Tool. Using 19 mm socket spanner, remove flywheel mounting bolts and detach the flywheel 50\u00b13 Nm + 60\u00b0\u00b11. Remove the flywheel assembly. Install in the reverse order of removal. Always replace flywheel mounting bolts with new one before installation. Tighten the flywheel as per sequence and torque tighten the bolts to specified value. 50\u00b13 Nm + 60\u00b0\u00b11\u00b0. Refill the clutch fluid and Carry-out clutch bleeding procedure. For additional information refer to Carry-out clutch bleeding procedure. Check Flywheel face-out and run-out. Check Flywheel Surface Thermal Cracks Condition. Check the flywheel ring gear for worn-out or damage Remove the transmission assembly with transfer case. For additional information refer to the transmission assembly with transfer case \u2013 R &R; section. Lock the flywheel using MST 0307ABH0001ST \u2013Flywheel Locking Tool. Using a 12 mm socket spanner, loosen and remove clutch cover assembly mounting bolts. Insert MST 0801BUA0001ST \u2013 Clutch Disc Aligner Tool, before loosening the clutch cover bolts to prevent clutch plate falling down and getting damage. Torque : 25 \u00b1 5Nm. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the clutch cover assembly along with the clutch disc. Detach the clutch disc from clutch cover assembly. Install in the reverse order of removal. While Installation, the projected part of clutch plate should come towards transmission side only, false installation can lead to clutch plate damage. While Installation, Using MST 0801BUA0001ST \u2013 Clutch Disc Aligner Tool, align the clutch cover assembly and clutch disc and fix the clutch cover assembly with the help of mounting bolts. Carry-out clutch circuit bleeding. Check for abnormal wear in finger, pressure plate. Check pressure plate face-out and run-out. Check thickness of clutch plate, replace if found below MIN value. Remove the clutch pedal box assembly. For additional information refer to Clutch Pedal Assembly - R &R; section. Using a 14 mm socket and ring spanner loosen and remove the Clutch Pedal Pivot Shaft nut and bolt. Remove the pedal pivot bolt and remove the pedal shank from the clutch pedal box. Using a nose plier, pull-down the double torsion Spring downwards and detach from pedal box and then gently pullout spring. Install in the reverse order of removal. Check return spring for proper stiffness. Check the Clutch Pedal Shank & Return Spring for any damage, crack. Replace if found any. Using a flat end screw driver pull the bleeder lock and pull-out the clutch bundy tube upward from bleeder to drain the clutch fluid. Keep a tray beneath, pull-out the clutch bundy tube and collect the drained fluid in the tray. Press the clutch pedal gently for draining the entire fluid. Collect the fluid drained in a tray. Avoid spilling on floor. Drain the complete brake fluid. Connect the bundy tube back and press locking clip to lock the bundy tube. Ensure the bundy tube connected back and locking clip locked the bundy tube in its position. MAX mark on brake fluid reservoir.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100013.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Press and release the clutch pedal gently to full stroke a few times for the fluid to enter completely in the circuit. Remove bleeder plug cap from clutch operating slave cylinder pipe. Attach a vinyl tube to bleeder plug and insert the other end into container. Ensure that the other end of the tube is fully immersed in the bottle having clean clutch /brake fluid. If the bleeding operation is done without connecting a tube and in the open air then the chance of air trapped in the system is high. Ensure that the other end of the tube is fully immersed in the bottle having clean brake fluid. Press and release the clutch pedal 3-4 times slowly to the full stroke and hold the pedal in depressed condition. Using 11 mm open end spanner, rotate the bleeder screw by 90 degree in anticlockwise rotation and allow all the air bubbles to escape into the container. Bleeding plug to be in opened condition during bleeding process only. Remaining time it should be in closed position. Fluid starts flowing through the transparent tube into the container. Tighten the bleeder screw as soon as there is no air bubbles visible in the transparent tube. Repeat this operation until there are no more air bubbles in hydraulic line. Ensure sufficient fluid level in reservoir throughout the bleeding procedure. Remove the transparent tube. Then attach bleeder plug cap. Check fluid level in reservoir, maintain brake fluid at MAX level mark. Close the reservoir cap back and tight properly. Check and ensure proper working of clutch. Ensure to check any leakage in the bundy tube connector & bleeding plug cap, if leak found ensure to fit properly the bundy tube connector & bleeding plug cap. If pedal sponginess is present do the entire bleeding procedure again. Check clutch pedal for sponginess. If found spongy, repeat the entire procedure of bleeding Check and ensure there is no leakage from pipes and joints. Do not spill brake fluid on the vehicle, it may damage the paint, if the brake fluid does contact the paint, wash it off immediately with water. Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. At all times during the bleeding process, it has to be ensured that the fluid level in the reservoir does not drop below minimum. The brake fluid reservoir cap should not be opened with dirty hands. Avoid direct water spray on reservoir while washing engine compartment. During the bleeding operation ensure the container and pipe used is of transparent for better visual. If Maximile DOT 4 brake fluid is not available and in emergency conditions, use Brake Fluid Meeting SAE J1703 FMVSS NO.116 DOT 4 OR IS 8654 TYPE-2 Specification. Change it at 30,000 km or 2 years whichever is earlier. At all times during the bleeding process, it has to be ensured that the fluid level in the reservoir does not drop below minimum. The clutch master cylinder push rod is connected to clutch pedal. The clutch master cylinder converts driver's foot effort to hydraulic pressure and transmits the pressure to the slave cylinder through clutch bundy tube. Remove the clutch pedal box assembly. For additional information refer to Clutch Pedal box Assembly - R &R; section. Detach clutch master cylinder(CMC) fluid inlet hose CMC end. Pull the lock clip upwards and detach clutch high pressure pipe CMC end. Carefully remove the clutch master cylinder. Install in the reverse order of removal. Carry-out clutch circuit air bleeding. For additional information refer to Clutch Fluid Air Bleeding Procedure. Inspect the clutch high pressure tube for any damage. Replace if found Inspect the Clutch Master Cylinder for any damage, crack. Clutch Sensor setting is to be done whenever. Clutch sensor related error is registered in EMS ECU or. The gap between magnetic holder and the sensor body is more than 2 mm Remove the clutch pedal box assembly. For additional information refer to Clutch Pedal box Assembly - R &R; section. Loosen the sensor lock nut with the help of 13 mm open end spanner. Insert a 2 mm spacer in the gap between magnetic holder and sensor body. Using a 12 mm open end spanner, adjust the magnetic holder till it touches the surface of spacer, thus maintain 2 \u00b10.5 mm gap between sensor body and magnetic holder. Tighten the sensor lock nut. Refit the clutch pedal box assembly. For additional information refer to Clutch Pedal box Assembly - R &R; section . After completing the clutch sensor setting, connect i-SMART and navigate to THAR \u2013 THAR_BS6. Select \u201cEMS\u201d in the ECU List. Click on \u201cLIVE DATA\u201d and select \u201cDriveability\u201d. Release the clutch pedal fully, the value of clutch status should be \u201c64\u201d. Press the clutch pedal to 10%, the value of clutch status should be \u201c65\u201d. Press the clutch pedal fully, the value of clutch status should be \u201c81\u201d If the clutch status value is not changing according to different clutch pedal position, re-adjust the clutch sensor. Using a star screw driver, loosen and remove the front splash shield mounting screw rivets from both the sides of vehicle. Using a 10 mm socket spanner, loosen and remove the front stone guard front mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250064.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen and remove the rear stone guard rear mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250033.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the stone guard mounting screw rivets. Remove the stone guard from the vehicle. Disconnect the fog lamp electrical connectors LH & RH sides. Pull and remove the front bumper winch cover clips and remove the panel. Using 10 mm socket spanner, Unscrew front bumper mounting nuts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290005.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscre front bumper bottom mounting bolts. Torque 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290006.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front bumper top side mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290007.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front bumper top centre mounting screw rivets. Remove the front bumper assembly from the vehicle. Install in the reverse order of removal. Inspect the front bumper assembly for any crack or damage. Replace if found. Remove Front Turn Indicator And DRL LH. Remove Splash Shield Front LH. For additional information refer to Splash Shield Front Lower LH - R &R; section. Using a screw driver, unscrew the antenna from the fender LH. Torque : 3\u00b11 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250060.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the front grill mounting screw rivets.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250140.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250139.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm combination spanner, Unscrew show lock mounting nut fender end. Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250142.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew fender top mounting bolts. Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250143.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew fender side mounting bolts. Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250180.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew fender bottom mounting bolts. Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250144.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew fender mounting bolts door side. Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250183.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250182.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the fender from vehicle. Refit in the reverse order of removal. Inspect the fender panel for any damage. Replace if found. Remove the Cladding Rear Wheel Arch RH. For additional information refer to Cladding Rear Wheel Arch RH - R &R; section. Remove the Cladding Rear Wheel Arch LH. For additional information refer to Cladding Rear Wheel Arch LH - R &R; section. Using a star screw driver , loosen and remove the rear fender RH/ LH side mounting screws. Using a star screw driver, loosen and remove the stone guard mounting screw rivets. Using a star screw driver , loosen and remove the rear bumper side mounting screws. Using 10 mm socket spanner, Unscrew the rear bumper mounting bolts body end. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290051.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290042.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Flip the bumper and disconnect the electrical main connectors and remove rear bumper. Remove the wiring routing clips from the bumper assembly. Disconnect the rear parking sensor electrical connectors. Disconnect license plate electrical connector. Remove the rear bumper wiring harness. Remove the parking sensors with holder. Remove the license plate lamp from rear bumper assembly. Remove the license plate lamp from rear bumper assembly. 2 post lift/ 4 post lift.
2. Turn the ignition OFF.
",
+ "file": null,
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "DTC \u2014 Check Procedure using i-Smart diagnostic tester",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Connect the i-SMART diagnostic tester and turn the ignition ON. Select Dearborn Electronics India Pvt Ltd. \u2014 Garuda and then click START. Select THAR from the list of vehicles displayed as in following window then select the HAR_ BS6. Click on the GENERATE button on the bottom right side of the Express View screen to generate DTC report. This will generate and store a report. Once completed, i-SMART will prompt to open Excel file. If any DTC is active, Refer Diagnostic manual for more information. Connect the miniSMART Bluetooth VCI on DLC and turn the ignition ON. Pair the Bluetooth of android tablet / smartphone with miniSMART VCI. Launch the miniSMART App and select the THAR from the vehicle list. Connect the miniSMART Android and select each \u201cECU\u201d from the list of controllers. From the list, select DTC Fetch. The ECU will be analysed and the registered DTCs will be displayed, then take screen shots of all registered DTCs and their Freeze Frame data by clicking over the DTC / FF icon, for records. If any DTC is active, Refer Diagnostic manual for more information. Repeat the above steps 4 to 7 for other ECU\u2019s present in the vehicle. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Disconnect EMS ECU connector with routing clip. Disconnect engine oil pressure switch electrical connector with routing clip. Disconnect e-VGT electrical connector. Disconnect T4 temperature sensor electrical connector. Disconnect T5 temperature sensor electrical connectors. Disconnect Dosing Module electrical connectors. Disconnect DPF sensor electrical connector. Disconnect fuel metering Unit electrical connector. Disconnect fuel injector electrical connectors.(4NOS) Disconnect CAM phase sensor electrical connector. Disconnect Common rail pressure sensor electrical connector. Disconnect coolant temperature sensor electrical connector. Disconnect throttle valve actuator electrical connector. Disconnect engine speed sensor electrical connector. Disconnect alternator telltale electrical connector. Disconnect EGR module electrical connectors. Using 8mm socket spanner unscrew starter motor solenoid electrical connector. Torque : 2.5\u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A03C016.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A03C017.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Disconnect reverse switch electrical connector. Disconnect GNS electrical connector. Disconnect transfercase switch electrical connector Detach Engine WH on intake manifold side. Using a 10 mm socket spanner unscrew wiring carrier mounting nuts. Disconnect fuel filter electrical connector. Disconnect engine compartment to Engine WH inter-connectors (2NOS) and routing clips(2NOS). Disconnect MAP sensor electrical connector. Detach engine wiring harness from engine compartment. Install in the reverse order of removal. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Torque tighten the earth mounting nuts to specified values. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Remove HVAC Control Panel (Manual). Carefully pull the Telltale Bank from inside. Disconnect the Telltale Bank electrical connectors and 12 volt electric connector and remove the Assy from IP. Using star screw driver remove Telltale bank mounting screws. Torque : 1.5 \u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220131.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the telltale bank. Install in the reverse order of removal. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the telltale bank for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. For additional information refer to Instrument Panel Assembly R&R Section. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A05C020.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew fuse box mounting bolts. Torque : 4 .0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A05C046.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the RH side door to IP interconnector and holding clip. Disconnect engine compartment to IP RH side inter-connector and holding clips. Disconnect the MBFM electrical connectors. Using 10 mm socket spanner, Unscrew ground cable mounting nuts and detach the connectors. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A05C003.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Disconnect the ignition key barrel electrical connectors. Disconnect the HVAC assembly electrical connectors. Disconnect LH door electrical connector. Disconnect the IP to Roof wiring harness inter-connector. Disconnect LH side IP to engine interconnectors with holding clip. Using 10 mm socket spanner, Unscrew earth cable mounting nuts. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220111.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Remove the IP wiring routing clips from CCB. For additional information refer to Front LH Scuff Plate \u2013 R &R Section. ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240037.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Detach the LH B pillar partially. Disconnect the Pre tensioner electrical connectors LH side. Disconnect the LH seat electrical connector and routing clips. Disconnect the Airbag ECU electrical connector. Using a 10 mm socket spanner, Unscrew earth cable mounting nut and disconnect the cable. Disconnect the parking brake switch electrical connector. For additional information refer to Front RH Scuff Plate \u2013 R &R section. ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370043.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Detach the RHS B pillar partially. Disconnect the Pre tensioner electrical connectors RH side. Disconnect the floor console inside wiring Harness routing clips. Disconnect the RH seat electrical connector and routing clips. Remove the wiring harness from vehicle. Install in the reverse order of removal. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Torque tighten the earth mounting nuts to specified values. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Remove the Intake Manifold. Disconnect the interconnection glow plug to engine C 435 M connector. Disconnect the glow plug-1 C 39 connector. Disconnect the glow plug-2 C 38 connector. Disconnect the glow plug-3 C 37 connector. Disconnect the glow plug-4 C 36 connector. Remove the wiring harness from the engine compartment. Install in the reverse order of removal. Refit the Intake Manifold. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Remove A Pillar Upper Trim LH. Disconnect speaker electrical pigtail inter-connector. Detach MIC wire from routing. Detach roof wiring harness from routing clips. Disconnect IP to roof WH inter-connector and holding clip with routing clips. Remove IP TOP Cover with PAB Assembly LH. Detach WH routing clip and from vehicle. Install in the reverse order of removal Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Remove the Rear RH Tail Lamp Assembly. Disconnect floor to tail door interconnector and holding clips. Detach the tail door WH grommet. Disconnect BIW pigtail inter-connector and connector holding clip. For additional information refer to Tail Door Trim - R &R Section. ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A12C001.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect door latch electrical connector. Remove the Tail Door Wiring Harness from vehicle. Install in the reverse order of removal Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Disconnect the MBFM electrical connectors. Detach the IP wiring harness holding clip from MBFM bracket. Using 10 mm socket spanner, Unscrew MBFM bracket mounting bolts from BIW and remove MBFM with bracket from the vehicle. Torque : 6.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370060.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370057.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew MBFM mounting bolts from the bracket and detach the MBFM. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the MBFM and bracket for any external damage, If any replace it. Service Reminder Indicator Reset Procedure ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "In the instrument cluster, the service reminder alert will start popping up in the cluster screen at 200 kms before the actual kilometers at which the service is due. This will continue at every ignition cycle. It is necessary to reset the service reminder once the service is rendered to the vehicle. If not reset, the service alert will continue to pop up at every ignition cycle, till it is reset by using recommended procedures. Press the OK button on Driver side switch bank and simultaneously turn the ignition ON. Release the OK button within 5 seconds after ignition on. Check and ensure that the service reminder alert is OFF in the cluster. The above procedure would reset the Service Reminder Alert till the next scheduled maintenance. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Using star screw driver, Unscrew the DEF tank bottom protection cover mounting screws and remove the cover. Disconnect the reduction agent temp sensor C 535 connector. Disconnect the magnetic coil & reduction agent surge pump C 276 connector. Disconnect the chassis C 707 M interconnector. Remove the Wiring Harness from routing clips and detach from the DEF tank. Install in the reverse order of removal.
\u2022 Ensure proper engagement of all the wiring harness mounting clips.
\u2022 Ensure proper routing of wiring harness.
Connect diagnostic tool connector and clear any DTC\u2019s if registered.
",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Disconnect the HFM sensor C 19 connector. For additional information refer to Spash shield \u2013 R &R section. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C045.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect EMS ECU connector with routing clip. Using 10 mm socket spanner remove earth cable mount nut and a routing clip. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C046.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove LH Side marker lamp connector with a routing clip. Disconnect LH side turn lamp electrical connector. Disconnect LH DRL connector and detach grow mat to take out connector. Disconnect LH Head lamp and levelling motor(HLLD) electrical connectors. Disconnect Horn electrical Connectors (2Nos) and 3 routing clip. Disconnect Electrical fan electrical connector. Disconnect LH Crash sensor electrical connector. Disconnect fog lamp electrical connector routing clips. Disconnect ambient temperature sensor electrical connector. Using 10 mm socket spanner, Unscrew engine compartment fuse box mounting bolts. Torque : 10\u00b11 Nm ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370065.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using 8 mm socket spanner remove fuse box positive cable mounting nut and disconnect from battery fuse connection. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370017.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Disconnect engine compartment to engine wiring harness inter-connector. Detach WH routing clips from fire wall. Using 10 mm socket spanner unscrew earth cable mounting nut from fire wall and detach cable. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C005.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Disconnect NOx Sensor electrical connector. Remove Air Cleaner Assembly. Using 10 mm combination spanner Remove LH fender ground mounting nut and detach it. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C003.jpg",
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Disconnect brake fluid level sensor electrical connector. Disconnect ABS ECU electrical connector. Disconnect HVAC triple pressure switch electrical connector. Disconnect EWP electrical connector and routing clip. Disconnect RH Crash sensor electrical connector. For additional information refer to Splash Shield Front RH - R &R section. ",
+ "file": null,
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C009.jpg",
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Description",
+ "content": "Disconnect RH fog lamp electrical connector routing clips. Disconnect RH head lamp electrical connector. Disconnect RH head lamp levelling motor(HLLD) electrical connector. Disconnect RH side marker lamp electrical connector with a routing clip. Disconnect Front RH indicator and DRL connector and detach grow mat to take out connector. cxc Using 10 mm socket spanner unscrew earth cable mounting nut from RH fender and detach cable. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370030.jpg",
+ "display_order": 80
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370029.jpg",
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "Description",
+ "content": "Detach WH routing clips from fender. Disconnect engine compartment to IP electrical connectors. Disconnect accelerator pedal electrical connector. Disconnect brake switch electrical connector with a routing clip. Disconnect clutch sensor electrical connector. Detach WH routing clips and take out wiring. Remove the scuttle Grill. Disconnect Wiper motor electrical connector and a routing clip. Disconnect IP to Engine compartment wiring harness inter-connectors. Disconnect engine compartment to chassis WH inter-connector. Disconnect washer tank electrical connector. Using 12 mm socket spanner remove fuel filter mounting bolts and partially detach it. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 110
+ },
+ {
+ "step_name": "Step-48",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370007.jpg",
+ "display_order": 111
+ },
+ {
+ "step_name": "Step-48",
+ "content_type": "Description",
+ "content": "Detach Engine compartment Wiring Harness from engine compartment. Install in the reverse order of removal. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Torque tighten the earth mounting nuts to specified values. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. For additional information refer to edisconnect stone guard - R &R section. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A16C005.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the Front RH wheel speed sensor C 361 connector. Detach wiring harness routing clips on front cross member. Disconnect the e-disconnect motor C 231 connector. Disconnect the front LH wheel speed sensor C 360 connector. Detach wiring harness routing clips on chassis. Disconnect engine compartment WH to Chassis WH inter-connector. Detach routing clips on chassis LH side. Disconnect the chassis to FDM C 485 F inter-connector. Disconnect the rear LH wheel speed sensor C 362 connector. Disconnect the chassis to bumper C 434 F inter-connector. Disconnect the DEF pigtail C 707 F inter-connector. . Detach rear chassis routing clips. Disconnect the rear RH Wheel Speed Sensor C363 connector. Detach routing clips on chassis rear RH side. Remove the Rear LH Tail Lamp Assembly. Using 10 mm socket spanner unscrew LH tail lamp earth cable mounting nut and detach it. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370016.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370015.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Detach routing clip and grow mate. Remove the Rear RH Tail Lamp Assembly. Using 10 mm socket spanner unscrew RH tail lamp earth cable mounting nut and detach it. Disconnect the tail lamp RH C 153 connector. Disconnect the tail lamp LH C 154 connector. Disconnect the chassis to tail gate-2 C 708 F inter- connector. Disconnect the chassis to tailgate-3 C 709 F inter-connector. Remove the chassis wiring harness from vehicle. Install in the reverse order of removal. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Torque tighten the earth mounting nuts to specified values. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Remove the HVAC Control Panel. Open the glove box and remove the glove box by detaching the lock. Remove the Driver side IP panel assembly. Disconnect the HVAC control panel C 720 connector. Disconnect the intake actuator C 722 connector. Disconnect the blower motor C 721 connector. Disconnect the blower resistor C 723 connector. Disconnect the thermo amplifier C 724 connector. Disconnect the HVAC unit C 117 M connector. Disconnect the blower switch C 720A connector. Using 10 mm socket spanner, loosen and disconnect the HVAC ground G 2 connector. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Remove the wiring harness separately. Install in the reverse order of removal. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Torque tighten the earth mounting nuts to specified values. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Remove the sensor from the routing slot. Take out the sensor and disconnect the electrical connector. Install in the reverse order of removal. Inspect the ambient temperature sensor for any external damage, If any replace it. Remove the hard top assembly. Inspect the Hard-Top windshield upper frame Seal and replace if needed when the seal loses its softness or if found any damages. Peel the sticker label sheet from the new Seal, then paste on the roof rail outer frame followed by press the X-mas tree clips. The Seal must be replaced along with X-mas tree clips, when the seal loses its softness or if found any damages, don't reused the X-mas tree clips. This seal is for preventing the water leakage and wind noise only. Seal coming with Two-way pasting tape. Install in the reverse order of removal. Using a star screw driver, Unscrew hard top quarter glass frame mounting screws from the rear window. Pull - out the glass beading from Quarter Glass. Carefully push from inside to outside and remove the rear window from the vehicle. Install in the reverse order of removal. While Installation always replace with New frame mounting screws. Inspect the hard top quarter glass for any damage/crack etc. Replace if found any. Inspect the hard top quarter glass mounting fasteners for any damage. Replace the fasteners if required. Remove the B pillar lower trim. For additional information refer to B pillar lower trim \u2013 R &R; section. Remove the centre roof bow trim. Open the top cover and Using a 14 mm socket spanner, loosen and remove the seat belt upper mounting bolt. Torque :38 \u00b16 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210069.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210071.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the upper trim from vehicle. Install in the reverse order of removal. Inspect the B-pillar upper trim for any damage/crack/cut etc. Replace if found any. Inspect the B-pillar upper trim fasteners for any damage. Replace the fasteners if found any damage. Remove the Hardtop Assembly. Remove the Seal from the vehicle. Install in the reverse order of removal. Inspect the Front Lateral trim for any damage/crack/cut etc. Replace if found any. Inspect the Front Lateral trim mounting legs for crack/bend etc. Remove Side window RH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Remove Side window LH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Unzip the tail gate window, detach the tail gate bar locking from rear RH & LH belt rails remove the tailgate window. Unhook the \u2018C\u2019 pillar cover from rear RH & LH belt rails and fold the cover at top of the soft top. Follow the same procedure for LH side. Using a T30 socket spanner, loosen and remove the belt center rail Mounting bolts and remove the belt rail from the vehicle. Follow the same procedure for LH side. Torque : 5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S25.png",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using T30 socket spanner, loosen and remove the belt vertical rail mounting bolts and remove the belt rail from the vehicle. Follow the same procedure for LH side. Torque : 5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W354.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the belt corner rail from the vehicle.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Caution",
+ "content": "Follow the same procedure for LH side. Torque : 5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S24.png",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using T30 socket spanner, loosen and remove the belt door rail mounting bolts and remove the belt rail from the vehicle. Follow the same procedure for LH side. Torque : 5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S23.png",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S20.png",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S21.png",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S22.png",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the Seal/rail for any damage/crack/cut etc. Replace if found any. Using a trim removal tool pull out center bow trim and disconnect roof lamp electrical connector. Remove the centre bow trim from the vehicle. Remove the roof lamp from bow trim. Install in the reverse order of removal. Inspect the trim for any damage/crack/cut etc. Replace it if found. Remove the B Pillar Upper Trim. Using a 10 mm socket spanner unscrew Grab handle mounting bolts. Torque : 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240065.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner unscrew front lateral trim mounting bolt. Torque : 2 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240066.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the Front lateral trim. Install in the reverse order of removal. Inspect the Front Lateral trim for any damage/crack/cut etc. Replace if found any. Inspect the Front Lateral trim mounting legs for crack/bend etc. Remove driver sun visor. For additional information refer Driver Sun Visor \u2013 R &R.; Remove co-driver sun visor. For additional information refer Co-Driver Sun Visor \u2013 R &R.; Using a T40 Torx Socket spanner unscrew centre bow trim mounting screws. Torque : 5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240011.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a trim removal tool carefully detach the trim and remove electrical connector. Detach the MIC carefully from the trim. install in the reverse order of removal. Inspect the trim for any damage/crack/cut etc. Replace it if found . Remove Front Roof Bow Trim. Remove Front Lateral Trim. Using a 10 mm socket spanner unscrew A pillar trim mounting bolt. Torque : 2 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240032.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the A pillar upper trim from vehicle. Install in the reverse order of removal. Inspect the A-pillar upper trim for any damage/crack/cut etc. Replace if found any. Inspect the A-pillar upper trim mounting legs for crack/bend etc. The Passenger Airbag Module is a bag within the module inflates to protect the passenger in the event of a collision severe enough to deploy the system and located on LH side of Instrument panel, above the glove box and its functioning is controlled by the airbag ECU. , Within the passenger airbag module is a squib which, when given the correct current by the airbag ECU, inflates the airbag by initiating a chemical reaction. In deployment, the airbag inflates within a fraction of a second and then deflates at a controlled rate as the passenger body regions; typically head and chest interact with airbag. Vents in the airbag control its deflation. Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Before disconnecting the battery, check for the audible sound of EWP ON Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Glove Box Assembly. Remove the IP grab handle cover. Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts. Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220024.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting screws. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220025.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle. The Airbag ECU is installed on the floor panel under the floor console. It deploys the proper Airbag according to the signals from the impact sensors. This ECU communicates with other ECU\u2019s through CAN directly. Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Before disconnecting the battery, check for the audible sound of EWP ON Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Front console assembly. For additional information refer to Front Console Assembly R &R; section. Using star screw driver remove the Airbag ECU Cover screw from airbag ECU. Disconnect the SRS/ Airbag ECU electrical connectors. Using a 10 mm socket spanner, loosen the SRS/ Airbag ECU mounting nuts on the floor panel. Torque :8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210053.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210054.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the SRS/ Airbag ECU from the body. Install in the reverse order of removal. Inspect the airbag ECU for any damage, replace if found any. Inspect the airbag ECU connectors for any damage. Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Before disconnecting the battery, check for the audible sound of EWP ON Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250193.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front splash shield lower mounting screws. Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts. Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield. Disconnect the front Crash sensor electrical connector. Using a 10 mm socket spanner, loosen and remove the front Crash sensor mounting bolt from the vehicle. Torque :8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210058.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the front crash sensor from the vehicle. Install in the reverse order of removal. Inspect the front crash sensor for any damage. Replace if found. The driver airbag module is located in the steering wheel and its function is controlled by the airbag ECU. A bag within the module inflates to protect the driver in the event of a collision severe enough to deploy the system. , The driver airbag module connects to the steering column wiring harness via a rotary coupler called as clock spring. Within the driver airbag module there is a squib which, when given the correct current by the airbag ECU, inflates the airbag by initiating a chemical reaction. In deployment, the airbag inflates within a fraction of a second and then deflate at a controlled rate as the driver body regions; typically head and chest interact with airbag. Vents in the airbag control its deflation Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Steering Column Shrouds. Turn the steering wheel to 90\u00b0 counter clockwise direction from the steering wheel straight position and using a screw driver press the RHS DAB lock then release the lock. DAB locks are made up of plastic, ensure to press the locks softly by screwdriver. Turn the steering wheel to 90\u00b0 clockwise direction from the steering wheel straight position and using a screw driver press the LHS DAB lock then release the lock. DAB locks are made up of plastic, ensure to press the locks softly by screwdriver. Gently pull-out the DAB module from the steering wheel. Using a small flat end screw driver release the lock of the DAB electrical connector, then disconnect the DAB and horn electrical connectors. While refit ensure wires are routed out of the snapping zones to avoid damage. Remove the DAB module separately. Install in the reverse order of removal. Inspect the DAB module for any physical damage. Replace if found any Inspect the DAB connector for any damage. When the engine is stopped and the ignition switched off, the battery feeds accessories which are directly connected to battery, such as alarms, clock, radio code and certain computers that operate continuously. Dark currents are considered normal if they do not exceed a few tens of milli amperes. If the value is more than that, one or more permanent electrical component is drawing too much current. They can be isolated by withdrawing the fuses one by one until the faulty circuit is identified. A multi-meter is the best tool for these measurements. A current clamp cannot accurately measure currents of less than 1 A. The measurement must be taken at the battery itself.
Set the current measuring range of the ammeter to 10 A. Disconnect the negative terminal from the battery. Connect the positive terminal of multimeter (Red probe) with the negative terminal removed from the battery and connect the negative terminal of multimeter (black probe) with negative pole of the battery. Read the value in multi-meter. (For MT Variants \u2013 7 mA (Max) & for AT Variants \u2013 12 mA (Max)) , check for any:",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "1. Loose connection in ground points.
2. Check for any active loads ( like roof lamp, etc).
",
+ "file": null,
+ "display_order": 12
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 34,
+ "sys_id": "THAR.AX-0001-Charging System",
+ "subsys_id": "THAR.AX-0001-Charging System-Alternator",
+ "systems": "Charging System",
+ "sub_systems": "Alternator",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A080018.jpg",
+ "myid": 1116,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Alternator-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "An alternator consists of two main components rotor and stator. The rotor is connected directly to the Over running Alternator Pulley (OAP). The drive belt drives the pulley by taking power from engine, which in turn spins the rotor. The stator is mounted to body of the alternator and remains stationary. The rotor is an electromagnet which rotates past the stator windings, and thus the rotor induces an alternating current in the stator. The induced current is proportional to the energizing current of the electromagnet. Alternating current cannot be used to recharge the battery, so it must be converted to direct current before use. The voltage regulator incorporated in the alternator adjusts the electricity produced to the requirements of the battery and the vehicle. If the alternator output voltage is too low, the regulator increases the energizing current in the rotor windings. If the output voltage is too high, the regulator decreases the energizing current in the rotor windings. Voltage regulator ensures the alternator voltage upper limit to 14.0 V. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Using 10 mm socket spanner, Unscrew degassing tank mounting bolts and partially detach the degassing tank and keep aside. (Without detaching the hoses). Torque : 4.5\u00b10.5 Nm. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen and remove the engine fead cover mounting bolts. Torque : 11 \u00b1 1Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the engine fead cover from engine compartment. Using 14 mm ring spanner, turn the hexagon knob in the belt tensioner Anti clockwise direction to release the tension and detach the accessory belt. Using 14 mm socket spanner, loosen and remove the auto tensioner mounting bolt then remove the auto tensioner to access the alternator mounting. Torque : 45\u00b13 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect the alternator electrical connector. Remove alternator positive cable cover. Using 13 mm socket spanner, loosen and remove the alternator positive cable nut. Torque : 15 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 12 mm socket and ring spanner, Remove the alternator top mounting bolt and nut. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the alternator bottom mounting bolt and nut. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080014.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Carefully remove the alternator from engine compartment. Install in reverse order of removal. Check alternator pulley for any damage. Check free play of alternator pulley. Check alternator drive belt for any damage. If found replace with a new one. Hydrometer is a float-type device used to determine the State-of-Charge by measuring the specific gravity of the electrolyte in each cell. It is an accurate way of determining a battery's state of charge and weak or dead cells. Wear suitable eye protectors (goggles). With the help of a flat end screw driver, remove the vent caps or covers from the battery. Squeeze the hydrometer bulb and insert the pickup tube into the cell close to the battery positive terminal. Slowly release the bulb to draw in only enough electrolyte to cause the float to rise. Do not remove the tube from the battery. Read the specific gravity indicated on the float. Be sure the float is drifting free, and does not contact with sides of the barrel. Read the hydrometer at eye level. Disregard the slight curvature of liquid on the float. The specific gravity for fully charged battery is as follows: AMARON - 1.270 \u00b1 0.010 at 27\u00b0C. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "Specific gravity readings ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080030.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "By measuring the specific gravity of the electrolyte, you can identify whether the battery is fully charged, requires charging, or must be replaced. Specific gravity varies with the temperature. If the electrolyte temperature is substantially above 27\u00b0 C add seven points (0.007) to the observed specific gravity reading for every 10\u00b0 C by which the actual temperature is above 27\u00b0 C. Deduct seven points per 10\u00b0 C where the observed reading is below 27\u00b0 C to obtain the temperature corrected reading at 27\u00b0 C. Inspect battery electrolyte specific gravity whenever required.
2. Open the bonnet and lock it in open position using bonnet stay rod.
",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Preliminary Activities/ Conditions",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080023.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Health Testing",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Connect the MDX - 650P battery tester to battery terminals connecting probes on the battery posts respectively. When you start a new test, the last test results in memory are overwritten. Remember to record or print the results if you need to retain them. Enter button and confirm the BATTERY LOCATION by selecting the \u201cIN VEHICLE\u201d in the tester using navigation button Up or Down. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16403.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Press the Enter button and confirm the POST TYPE by selecting the \u201cTOP POST\u201d in the tester using navigation button Up or Down . Press the Enter button and confirm the APPLICATION by selecting the \u201cAUTOMOTIVE\u201d in the tester using navigation button Up or Down . Press the Enter button and confirm the BATTERY TYPE by selecting the \u201cREGULAR FLOODED\u201d in the tester using navigation button Up or Down . Press the Enter button and confirm the BATTERY STANDARD by selecting the \u201cJIS\u201d in the tester using navigation button Up or Down . Press the Enter button and get the recommended JIS Number value by pressing button Up or Down . Press the Enter button and perform the TESTING. Once the TESTING done, the initial battery result will be display. Press the PRINT button to get the hard copy print out. Disconnect the battery tester probes from battery terminals. Follow the below table for Battery Testing test results condition and remedial action: ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/15133.jpg",
+ "display_order": 30
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 40,
+ "sys_id": "THAR.AX-0001-Charging System",
+ "subsys_id": "THAR.AX-0001-Charging System-Charging System Technical Spec",
+ "systems": "Charging System",
+ "sub_systems": "Charging System Technical Spec",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1122,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Charging System Technical Spec-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Battery Specifications",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/6042.png",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 38,
+ "sys_id": "THAR.AX-0001-Charging System",
+ "subsys_id": "THAR.AX-0001-Charging System-Checking Electrolyte Level",
+ "systems": "Charging System",
+ "sub_systems": "Checking Electrolyte Level",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A080023.jpg",
+ "myid": 1120,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Checking Electrolyte Level-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080023.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the electrolyte level. Add distilled water to all the cells which require water. Ensure the electrolyte level between MIN and MAX marks. Refit the vent plugs properly. Topping up should be done with distilled water only. . Never use normal water or mineral water to top battery electrolyte. . Vent holes should be clear. . Clean the terminals. . Tighten terminals to specified torques. Check battery electrolyte level whenever required. Do battery electrolyte level inspection when required. Turn ON the head lamp high beam for 30 seconds to remove any surface charge. Digital voltmeter checks the battery\u2019s open circuit voltage. Analogue meters do not show accurate readings and should be avoided. Turn OFF the head lamp, disconnect the battery and connect the digital voltmeter across the battery terminals. Note the readings in the voltmeter. A fully charged battery will have an open-circuit voltage based on below table value. Verify the customers concern. Visually inspect the charging system for any noticeable signs of mechanical or electrical damage. If any obvious cause is found, correct the same before proceeding to the next step. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. , Before disconnecting the battery, check for the audible sound of EWP ON. Using 10 mm socket spanner, loosen battery positive cable mounting nut and disconnect the cable. Torque : 6 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, loosen and remove the battery holding clamp mounting nuts. Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the battery from the vehicle. Install in reverse order of removal.
2. Check for any cracked or broken cables/connections, and replace the cables if necessary.
3. Check for corrosion on terminals and dirt/acid on the battery case top. Clean the terminals and the battery case top with mixture of water and baking soda. A battery wire brush tool can also be used to clear heavy corrosion on the terminals. Prevent further corrosion by applying petroleum jelly to the outside of the terminals.
",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 362,
+ "sys_id": "THAR.AX-0001-en-SM-Fuel System",
+ "system_name": "Fuel System",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1002,
+ "active_status": true,
+ "Assets": [
+ {
+ "systemdisplayorder": 3,
+ "system_asset": "/files/Fuel System_Diesel Engine.mp4",
+ "active_status": true
+ }
+ ],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 380,
+ "sys_id": "THAR.AX-0001-Fuel System",
+ "subsys_id": "THAR.AX-0001-Fuel System-IQA Management",
+ "systems": "Fuel System",
+ "sub_systems": "IQA Management",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A040221.jpg",
+ "myid": 1056,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-IQA Management-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Precautions to be followed: ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "1. Never interchange injectors between engines / ECU's.
2. Never change ECU's between vehicles.
3. Never interchange injectors between cylinders in same engine.
4. When Injectors are replaced/Changed Injector IQA values must be loaded correctly as per cylinder order. For additional information refer to EMS diagnostic manual.
",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040221.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " Whenever an injector or ECU need to be replaced, the new injector\u2019s IQA code need to be written in to the ECU, using i-FLASH/ i-SMART. IQA code is engrave on the top of the injector. It is a 6 character alphanumeric code. Park the vehicle on level work bay Open the bonnet and lock it in open position using bonnet stay rod Connect the transparent pipe to the drain plug outlet of the fuel filter assembly Using a Nose plier, rotate drain plug anticlockwise till the water starts flowing from the tube. Drain plug requires hand tight only; do not use any tool and avoid over tightening. Do not over tight the drain plug Rotate drain plug in clockwise directio to stop the flow as soon as water gets over and fuel flow starts. Tighten the drain plug. Start the engine and check for any leaks. Remove the engine top encapsulation cover. Using 10 mm socket spanner, Unscrew engine wiring harness carrier mounting stud from Cam cover and detach it partially. Press the lock and disconnect fuel control unit electrical connector. Using 17 mm open end spanner, Unscrew High pressure pipe mounting flare nut from common rail end. Using 19 mm open end spanner, unscrew High pressure pipe flare nut from injection pump end. Press the lock and disconnect fuel control unit inlet and outlet pipes. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Using nose plier release fuel return hose spring band clamp and detach hoses from fuel injection pump & FCU. Using 10 mm socket spanner, Unscrew fuel return line 'T' bracket mounting bolts. Using 12 mm socket spanner, Unscrew Cam box mounting bolts and remove the bolts. Rotate the Cam Box Assembly as direction shown in the image to access fuel high pressure pump mounting bolts. Using T30 socket spanner unscrew fuel high pressure pump mounting bolts and detach pump. Remove Cam box assembly along with FCU from engine. While taking out Cam box, ensure to move the tappet in upward direction by hand. Using 5 mm Allen socket spanner unscrew tappet roller guide bolt. Remove roller tappet from the cam box housing. Using 12 mm socket spanner Unscrew Fuel Control Unit mounting bolts and separate the CAM Box. Inspect the CAM box for any damage. Replace if found any. Refit Fuel Control Unit and install the mounting bolts. Tighten the bolts to specified torque value. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refit the roller tappet and install the guide bolt. Tighten the bolt to specified torque value. Torque : 20\u00b12 Nm ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011182.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Insert the roller tappet in correct orientation so that the locking pin will seat properly in the slot. ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Position the Cam box on Intake cam shaft rear end. While Installing Cam box, ensure to move the tappet in upward direction by hand. Ensure to replace New Cam box gasket during Installation. Before Installation of Cam box mounting bolts, Rotate the Cam Box Assembly as direction shown in the image to install fuel high pressure pump mounting bolts. Position the fuel pump on Cam box and install mounting bolts. Tighten the mounting bolts to the specified torque value. While Installing the pump always replace the Gasket with a new one. While torque tighten the Pump mountings, hold the Cam box Assembly by second technician asshown. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011138.jpg",
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Rotate the Cam Box Assembly direction as shown in the image to original position. Install the Cam box mounting bolts.Tighten the bolts to the specified torque value. Torque : 25 \u00b1 3 Nm , Torque : 25 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010061.jpg",
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Heading",
+ "content": "Tightening Sequence ",
+ "file": null,
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install fuel return line 'T' bracket mounting bolts. Tighten the bolts to the specified torque value. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Refit fuel return hoses and lock it by spring band clamp. Connect fuel inlet tube quick coupler at pump end & FCU. Position the Fuel HP pipe and tighten the mounting on Common rail end to the specified torque value. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Position the Fuel HP pipe and tighten the mounting on FIP end to the specified torque value. Torque : 30 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 85
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Refit the engine wiring harness carrier mounting studs on Cam cover and torque tighten the studs. Torque : 8 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Connect the fuel control unit electrical connector. Refit the engine top encapsulation cover. Other observations ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "No error codes registered.Parts Required ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Test tube with graduations, capacity 30 to 75 ml (Quantity : 04 Nos). Engine tube connection injection, Part Number : 9350042680, Length 310 mm (Quantity : 04 Nos.). The ID of the tube is important hence use only the part number specified. Remove engine top encapsulation cover from engine. Blow air around the injectors to remove the dust. Remove injector leak-off hose clips and then gently pullout and remove leak-off hose from injectors. Keep the removed leak-off pipe behind injectors. Do not remove overflow tube connection from the fuel return line \u2018T\u2019 joint. Insert the hose firmly in each injector and insert the other end in test tubes as shown in illustration below. (Use rubber band to hold the test tubes in stand). Images are only for representation. Actual image for this vehicle may vary. Start engine and keep it in idle. Collect fuel in test tube for one minute. Stop the engine, ignore first reading.Empty the test tubes & reconnect. If any test tube gets filled during the test, \u201cSTOP\u201d the test and replace that cylinder injector. Start engine & repeat test for exactly one minute. Observe the quantity of leakage fuel corresponding to each injector. If the leakage quantity of any injector is higher than 3 times the minimum of any three injector, then that injector is faulty. Replace the injector. Replace the defective injector's. Repeat the test with new replaced injector & confirm the resolution of for starting problem. Images shown is just for representation. The fuel tank is a reservoir for the fuel and incorporates the Fuel delivery module inside. Remove the fuel tank assembly Disconnect the fuel tank electrical connector and remove the FDM pigtail from the fuel tank. Remove the Fuel tank heat Shield mounting clamp from the tank. Using screw driver, loosen and remove the Fuel tank Bracket mounting clips from the tank. Remove the fuel supply and return hose quick coupler from the fuel delivery module. Remove the fuel supply and return hose from the fuel tank. Using suitable metal shaft and hammer,tap the FDM lock ring and remove the lock ring from FDM unit Remove fuel delivery module and O ring from the tank Drain the fuel from the fuel tank and refill the fuel in new tank Install in the reverse order of removal. Always replace the O ring with a new one once FDM removed. Ensure the FDM top flange extension should be matched with the arrow mark on the fuel tank shell as shown in the above illustration. Using a suitable metal shaft and hammer, tap the FDM lock ring to get properly lock. Check the fuel tank for any damage and replace it if necessary. Check the tank ventilation hose for clog/debris. Check for free movement of float assembly without any restriction. Fuel System Low Pressure Circuit Test Gauge. ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040231.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Fuel System Low Pressure Circuit Test Gauge tool kit is used to diagnose Fuel System Low pressure circuit related concerns only. Without removing FDM Assembly or Fuel Tank assembly from vehicle, we can able to check the Fuel Delivery Module supply pressure. Any blockages/ choke or air entrapment in Fuel line low pressure circuit can be diagnosed by using this Kit. This high pressure fuel line connects High pressure pump with common rail and supplies compressed high pressure fluid to common rail. Remove the engine top encapsulation cover. Using 10 mm socket spanner, Remove engine WH carrier mounting nuts and detach partially. Torque : 8 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 17 mm open end spanner loosen the mounting nut from the common rail. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 19 mm open end spanner, Unscrew fuel injection pump mounting. Torque : 30 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the high pressure pipe. Install in the reverse order of removal. Inspect the high pressure fuel pipes for any damage. Replace if found any. Inspect the high pressure fuel pipes for leakage, rectify if found. Press the lock and disconnect fuel control unit electrical connector. Using 10 mm socket spanner, Unscrew engine wiring harness carrier mounting stud from Cam cover and detach it partially. Using 19 mm open end spanner, unscrew High pressure pipe flare nut from injection pump end. Disconnect fuel inlet tube quick couplers from fuel injection pump & FCU. All are quick fix connectors, press gently and remove it carefully to avoid seal damages. Using nose plier release fuel return hose spring band clamp and detach hoses from fuel injection pump & FCU. Using 10 mm socket spanner, Unscrew fuel return line 'T' bracket mounting bolts. Using 12 mm socket spanner, Unscrew Cam box mounting bolts and remove the bolts. Rotate the Cam Box Assembly as direction shown in the image to access fuel high pressure pump mounting bolts. Using T30 socket spanner unscrew fuel high pressure pump mounting bolts and detach pump. Remove Cam box assembly along with FCU from engine. While taking out Cam box, ensure to move the tappet in upward direction by hand. Position the Cam box on Intake cam shaft rear end. While Installing Cam box, ensure to move the tappet in upward direction by hand. Check the condition of Cam box gasket during Installation and replace if it damaged. ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011137.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Before Installation of Cam box mounting bolts, Rotate the Cam Box Assembly as direction shown in the image to install fuel high pressure pump mounting bolts. Position the fuel pump on Cam box and install mounting bolts. Tighten the mounting bolts to the specified torque value. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040214.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "While Installing the pump always replace the Gasket with a new one. While torque tighten the Pump mountings, hold the Cam box Assembly by second technician as shown. Rotate the Cam Box Assembly direction as shown in the image to original position. Install the Cam box mounting bolts.Tighten the bolts to the specified torque value Torque : 25 \u00b1 3 Nm , Torque : 25 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010061.jpg",
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Tightening Sequence ",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install fuel return line 'T' bracket mounting bolts. Tighten the bolts to the specified torque value Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refit fuel return hoses and lock it by spring band clamp. Connect fuel inlet tube quick coupler at pump end & FCU. Position the Fuel HP pipe and tighten the mounting on Common rail end to the specified torque value. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Position the Fuel HP pipe and tighten the mounting on FIP end to the specified torque value. Refit the engine wiring harness carrier mounting studs on Cam cover and torque tighten the studs. Torque : 8 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Connect the fuel control unit electrical connector. Refit the engine top encapsulation cover. The injector uses electronically controlled solenoid actuation for precise control of injection. The solenoid injectors can inject very small quantities of fuel. The injection can be split into pilot, main and post injection. Or without pilot, post and only main injection. Each fuel injector is mounted directly above the piston within the cylinder head and is connected to the fuel rail by rigid steel lines that can withstand the high fuel pressure. The actuation of injectors is done by EMS ECU. Remove the Injectors 3rd & 4th HP Pipes. Using a 10 mm socket spanner, loosen and remove the engine WH carrier mounting nuts and detach partially. Torque : 8 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 17 mm open end spanner, loosen and remove the HPP pump to common rail at rail end. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 19 mm open end spanner , loosen and remove the HPP pump to common rail at pump end. Torque : 30 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove injector leak-off pipe lock clip and detach leak off pipes from the injector end. Disconnect Injectors 3rd & 4th electrical connectors from the injectors. Using 8 mm Allen socket spanner, loosen and remove the injector clamp mounting bolt. Torque : 32 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the Injectors 3rd & 4th from cylinder head. Injector Bore must be covered with lint free cloth/Masking tape to avoid foreign objects entering injector bore/ cylinder. Plug the fuel inlet and wiring harness connector slot as soon as injector is removed. Store the injector in a neat tray. Never drop the injectors. Never clean the injector using pressurized water. Install in reverse order of removal. Always replace the injector lower copper washer and O\u2013 ring with new ones when ever injector is removed. ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040234.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "For New Injector replacement carry out Component Replacement Procedures Injector replacement by using i-SMART. For additional information refer Diagnosis Manual. Fuel control unit consists of a solenoid valve which controls the amount of fuel entering the PF pump according to the instruction from EMS ECU and thus regulates the optimum fuel pressure desired for various engine conditions. Press the lock and disconnect fuel control unit inlet and outlet pipes. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Using hose clamp plier, Release metering unit fuel return hose clamp and disconnect hose. Using 12 mm socket spanner Unscrew Fuel Control Unit mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove fuel control unit assembly from vehicle.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040162.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040164.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect Fuel Control Unit for any physical damage, replace if found any. . Inspect fuel pipes for any damage. Replace if found any. Remove the splash shield rear wheel LH. For additional information refer to the splash shield rear wheel LH (Rear)- R &R; section Using hose clip plier release the hose clip from the fuel filler neck Disconnect the fuel vent hose quick coupler from fuel filler neck. Using vehicle key open the fuel lid Rotate the fuel cap anti-clockwise to remove from the fuel filler neck. Using 10 mm socket spanner, Unscrew fuel filler neck mounting nuts. Torque : 5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040124.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Gently pull out the fuel filler neck from the vehicle. Install in the reverse order of removal. Inspect the filler neck for any damage. Replace if found any Check the mounting clips for any damage. Replace the clips if found damaged. Fuel Delivery Module delivers the fuel to the low pressure line and to measure the fuel level in the tank. Fuel delivery module consists : ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040184.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": " 1. Float assembly for fuel level status. 2. An electric motor with inbuild reservoir for pumping the fluid. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The entire fuel delivery module is immersed in fluid and the electric motor is lubricated by fuel itself. Remove the fuel tank assembly. Disconnect the pig tail electrical connector. Using screw driver, loosen and Remove the Fuel tank heat Shield mounting clamp from the tank. Press the lock and disconnect the fuel supply line and return line pipe from the fuel delivery module and remove the hoses from the fuel tank. Using suitable metal shaft and hammer, tap the FDM lock ring and remove the lock ring from FDM unit. Remove fuel delivery module and O ring from the tank Install in the reverse order of removal. Always replace the O ring with a new one once FDM removed. Ensure the FDM top flange extension should be matched with the arrow mark on the fuel tank shell as shown in the above illustration Using a suitable metal shaft and hammer, tap the FDM lock ring to get properly lock. Inspect fuel delivery module for any damage. Inspect the float assembly for any damage. The common fuel rail is a high pressure accumulator in which the fuel from high pressure PF Pump is accumulated and is maintained at required pressure. This pressure sensor is fitted on the fuel rail and gives a close loop control of the rail pressure. Fuel is maintained at a high pressure in the fuel rail depending on requirement of the engine. Remove the intake manifold. Press the lock and disconnect the rail pressure sensor electrical connector. Using 17 mm open end spanner, loosen and remove the HPP pump to common rail at rail end. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 17 mm open end spanner loosen the high pressure pipe flare nuts at common rail side and injector side. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040094.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "While loosening the high pressure pipes at Injector end, hold the injector pipe connector by 13 mm Open end spanner. Using 12 mm socket spanner, loosen and remove common rail mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the common rail from the vehicle. Install in the reverse order of removal. Inspect the common rail for any damage. Replace if found. Inspect the connector for any damage. Inspect the rail pressure sensor for any damage. The fuel tank is a reservoir for the fuel and incorporates the Fuel delivery module inside. Disconnect the fuel tank electrical connector Remove the fuel supply and return hose quick coupler from tank side. Detach the vent hose to fuel tank quick fix coupler. Using hose clip plier remove the fuel filler hose clip then remove the fuel filler hose. Using hydraulic jack support tank to remove from the vehicle Using 14 mm socket spanner, loosen and remove the fuel tank mounting bolts and nut. Torque : 50\u00b15 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using Supported hydraulic jack lower the fuel tank from the vehicle . Install in the reverse order of removal. Check the fuel tank for any damage and replace it if necessary. Check the tank ventilation hose for clog/debris. The fuel filter filters impurities that may be present in the fuel. The fuel system operates under high pressure which makes it absolutely essential for the fuel to be dust free and moisture free. The fuel filter also has the water separator which filters the moisture that may have crept into the fuel. The high pressure pump in the fuel system operates at high speeds and fine clearance which needs the diesel to be dust free and also be free of moisture at the same time. Since the diesel itself lubricates the PF Pump, If water content is present in fuel, the fuel looses its lubrication property and thus PF Pump and injectors will get damaged. Also the moisture content may lead to formation of rust on the pump elements. This makes it advisable not to use diesel with additives which may cause damage to the PF Pump. Press the lock and disconnect the electrical connector from the fuel filter Press the lock and disconnect fuel filter supply line from the fuel filter All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Press the lock and disconnect fuel filter return line from the fuel filter. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Using 12 mm socket spanner loosen and remove the fuel filter assembly mounting bolts from the vehicle. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the filter from the vehicle Install in the reverse order of removal. Check and ensure proper fitment of fuel lines, any leakage can lead to fire. Inspect the fuel filter assembly for any physical damage, replace if found. Inspect the fuel lines and connectors for any damage. Replace if damaged Fuel Delivery Module delivers the fuel to the low pressure line and to measure the fuel level in the tank. Fuel delivery module consists : ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": " 1. Float assembly for fuel level status. 2. An electric motor with inbuild reservoir for pumping the fluid. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The entire fuel delivery module is immersed in fluid and the electric motor is lubricated by fuel itself. Remove the Fuel Delivery Module Assembly. Press the level sensor towards swirl pot center with moderate strength and unlock the sensor from the clip of the holder Then move the level sensor in upward direction with moderate strength towards swirl pot center from the holder and remove the sensor assembly from the FDM. Detach the wiring from the FDM housing. By Using suitable pin take out the wiring pins from sensor. Pressing the both sided snap-on tabs of the cable connector through the opening of the housing and cover carefully and simultaneously pull out the wire connectors from float unit. Prior to the Installation, both the wiring connector snap-on tabs have to be bent back to the right position as shown below (By using Knife or suitable tool) Plug the wiring connectors pins on the New sensor housing at appropriate place with moderate force Ensure to Plug the wiring connectors pins on the New sensor housing at appropriate slots based on wiring colour as shown. The firm snap-on of the wire connectors is to be examined by a moderate pulling examination. Attach the wiring on FDM housing Lock the sensor on the mount & refit the sensor assembly on the FDM. Refit the Fuel Delivery Module Assembly. Check for free movement of float assembly without any restriction. Inspect the float assembly for proper working condition. Check for any damage in float assembly, If any damage found replace it. The fuel filter filters impurities that may be present in the fuel. The fuel system operates under high pressure which makes it absolutely essential for the fuel to be dust free and moisture free. The fuel filter also has the water separator which filters the moisture that may have crept into the fuel. The high pressure pump in the fuel system operates at high speeds and fine clearance which needs the diesel to be dust free and also be free of moisture at the same time. Since the diesel itself lubricates the PF Pump, If water content is present in fuel, the fuel looses its lubrication property and thus PF Pump and injectors will get damaged. Also the moisture content may lead to formation of rust on the pump elements. This makes it advisable not to use diesel with additives which may cause damage to the PF Pump. Park the vehicle on level work bay Open the bonnet and lock it in open position using bonnet stay rod Ensure that the fuel is drained from filter assembly before the fuel filter element is removed. Do not hold fuel filter body part and avoid damage to the fuel filter body. Press the lock and disconnect the electrical connector from the fuel filter. Disconnect the fuel supply pipe by disconnecting the quick coupler. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Disconnect the fuel return pipe by disconnecting the quick coupler. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Using a 12 mm socket spanner, loosen and remove the fuel filter assembly mounting bolts. Remove the filter from the vehicle. Use two approx. 2\u2013 3 inches long size M12 bolts and nuts to hold fuel filter assembly in a bench vice as shown in illustration. Using a 36 mm ring/socket spanner, rotate the fuel filter bottom cover in anticlockwise direction and loosen. Remove the fuel filter body. Take out the filter element from the fuel filter housing. Remove the O-ring from the fuel filter housing. Assemble the new O-ring back on to filter housing, which is supplied along with new filter element. Ensure little oil is smeared on to the surface of O-ring before assembly on to head. Insert the filter element correctly into housing as shown in illustration. Press the filter element by gentle push into the head. Refit the fuel filter element into the fuel filter housing. Assemble filter element on to head in the direction shown. Ensure open end of filter element goes inside first. Tighten the filter body using 36 mm size socket spanner to specified torque value. Do not over tighten beyond 25\u00b15 Nm. This may cause damage to the bowl and Head. Is it recommended to tight the fuel filter using torque wrench. Remove the filter assembly from the wise. Refit the fuel filter assembly and install the mounting bolts. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Reconnect the fuel filter fuel return line quick coupler. All are quick fix connectors, press gently and refit it carefully; avoid seal damages. Check and ensure proper fitment of fuel lines, any leakage can lead to fire. Reconnect the fuel filter fuel supply pipe quick coupler. All are quick fix connectors, press gently and refit it carefully; avoid seal damages. Check and ensure proper fitment of fuel lines, any leakage can lead to fire. Reconnect the fuel filter electrical connector. Always use recommended filter element only. Before removing the fuel filter, open the fuel tank cap to release the pressure from the tank and fuel lines. Fuel filter cartridge needs to be replaced earlier in case of repeat water in fuel warning in cluster even after the water is drained from the system. The injector uses electronically controlled solenoid actuation for precise control of injection. The solenoid injectors can inject very small quantities of fuel. The injection can be split into pilot, main and post injection. Or without pilot, post and only main injection. Each fuel injector is mounted directly above the piston within the cylinder head and is connected to the fuel rail by rigid steel lines that can withstand the high fuel pressure. The actuation of injectors is done by EMS ECU. Remove the Injectors 1st & 2nd HP Pipes. Remove injector leak - off pipe lock clip and detach leak off pipes from the injector end. Disconnect the Injectors 1st & 2nd electrical connectors from the injectors. Using socket spanner 10 mm, Unscrew engine WH carrier mounting nuts and detach the carrier partially. Torque : 8 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 8 mm Allen socket spanner, Unscrew the injector clamp mounting bolt. Torque : 32 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the Injectors 1st & 2nd from cylinder head. Injector Bore must be covered with lint free cloth/Masking tape to avoid foreign objects entering injector bore/ cylinder. Plug the fuel inlet and wiring harness connector slot as soon as injector is removed. Store the injector in a neat tray. Never drop the injectors. Never clean the injector using pressurized water. Install in reverse order of removal. Always replace the injector lower copper washer and O\u2013 ring with new ones when ever injector is removed. For New Injector replacement carry out \u201cComponent Replacement Procedures \u2013Injector replacement\u201d by using i-SMART. For additional information refer Diagnosis Manual. Check for any cracks, damage etc, replace if found any. This high pressure fuel lines connects common rail with injectors and thus supplies high pressure fluid to injectors. Remove the engine top encapsulation cover. Using 17 mm open end spanner loosen the high pressure pipe flare nuts at common rail side and injector side. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040094.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "While loosening the high pressure pipes at Injector end, hold the injector pipe connector by 13 mm Open end spanner. Remove the high pressure fuel pipes from the vehicle. Install in the reverse order of removal. Remove the wheel. For additional information refer to Wheel \u2013 R &R; Section. Remove the tyre from the rim. Using a T10 Socket Spanner, loosen and remove the TPMS sensor mounting screw and detach the sensor. The TPMS and Valve cannot be replaced separately. These can be replaceable as assembly. The valve must be positioned just left of the start position to avoid sensor damage. Do not touch the sensor with the tyre tool. Starting to mount the tyre from the valve location is a wrong fitment. The fixing tool/ stem may hit the sensor and damage it. Start from the opposite direction. By using suitable TPMS removal/Installer tool, remove the valve from the rim. Install in the reverse order of removal. Ensure that the TPMS Sensor is not damaged while removing the tyre. Check the tyre inner surface for cuts and punctures. TPMS Manual Learning is the process by which the identities of 5 sensors installed inside the tyres are learnt & programmed in to the memory of receiver module. It should be mandatory to performe on any of the following conditions or operations done. Any of the old TPMS sensors are damaged & sensors are replaced. Any of the tyre among 5 tyres are replaced. If any of the tyres or set of tyres are shuffled or swapped in position. If tyres rotation operation is performed. If observed that the alert indications in TPMS screen are not correlating with respect to their actual position in vehicle. Once the manual learning is initiated the sensors inside the tires needs to triggered by leaking the air from each tire one at a time and should be completed within 90 secs post to each event for learning all 5 tires. Do not perform Manual learning process at the same time on two vehicles with in the radius of 20 meters. Any of the tyre among 5 tyres are replaced. If any of the tyres or set of tyres are shuffled or swapped in position. It is mandatory that manual learning of tyres should follow the sequence of \u2018front left tyre position, front right tyre, rear right tyre, rear left tyre and spare tyre\u2019. It is required to ensure the tires are having pressure > 32 psi & < 36 psi before initiating the manual learning process. Post to manual learning all tire should be filled with recommended tyre pressure value . At any point of time during the learning process if learning takes more than 90 secs of time for each tire position then the system shall exit the learning mode and show the Learning not successful screen. At a time, only one tyre can be swapped with the spare wheel and then follow the learning procedure. Press the Scroll Up arrow button on Driver side switch bank and simultaneously turn the ignition ON. Wait for cluster\u2019s tachometer & speedometer self-check rotation and then release the arrow button. If failed to enter in to manual learning mode Try initiating the manual learning once again. Check if reverse gear is engaged, if engaged disengage it. Check MBFM, Infotainment & Cluster software versions. Check if variant coding is done in all three. Check if Scroll Up arrow button on Driver side switch bank button is working fine. 1. Front left tyre
2. Front right tyre
3. Rear right tyre
4. Rear left tyre
5. Spare tyre
",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160044.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Start leaking the air from front left tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If front left tyre is learned 1 siren chirp sound is heard and FL tyre shows learned in infotainment system. Start leaking the air from front right tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If front right tyre is learned 1 siren chirp sound is heard and FR tyre shows learned in infotainment system. Start leaking the air from rear right tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If rear right tyre is learned 1 siren chirp sound is heard and RR tyre shows learned in infotainment system. Start leaking the air from rear left tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If Rear left tyre is learned 1 siren chirp sound is heard and RL tyre shows learned in infotainment system. Start leaking the air from the spare wheel tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If spare tyre is also learned then 1 siren chirp sound is heard and ALL tyres show learned at respective tyre positions and \u2018All tyres Learned successfully\u2019 in the center of the screen. At any point of time during the learning process, if learning takes more than 90 seconds of time for each tyre position then the system shall exit the learning mode and show the \u201cLearning not successful\u201d screen. After tyre rotation or TPMS sensor replacement, TPMS must be learnt,otherwise the system will show TPMS malfunction indicator. TPMS learning need to be carried out whenever : 1. Tyre rotation happens. 2. 2 or more wheels are swapped. 3. TPMS sensor is replaced. 4. MBFM is replaced. The TPMS should not be used as a tyre pressure gauge while adjusting vehicle tyre pressure. No two vehicles should be done with manual learning process at a time in same location with in radius of 20 meters. Post to manual learning all tire should be filled with recommended tyre pressure value.
2. Visually inspect the transfer case for any noticeable signs of mechanical damage.
3. If an obvious cause is found during the inspection, correct the same before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom and refer to troubleshooting chart.
",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Heading",
+ "content": "Mechanical ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Check for any oil leakage in the transfer case. Check the yoke, flange and drive gear for any damage. Check for loose mounting bolts. Remove the gear shifter level knob and 4WD selection knob by rotating them in anticlock wise direction. Using trim removal tool, remove the gear selection rod cover with trim. For AT Variants top trim removal follow (Steps 3 - 8) : , Remove the 4WD selection knob by rotating it in anti-clock wise direction. Pull and fold the gear shifter boot from gear shifter bezel. Partially detach the bezel from the console. Excessive pull may leads to damage of the electrical connector. Disconnect the AT gaiter electrical connector from the bezel. Carefully remove the bezel trim from the TGS lever. Handle bezel assembly carefully to prevent it from damage or scratches. Using trim removal tool, carefully remove the floor console top trim with transfer case shifter boot. Detach the transfer case cable abutment from the shifter bracket by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Using 13 mm socket spanner unscrew transfercase shifter lever assembly mounting nuts. Take out the shifter and tilt the lever assembly gear shifter lever side to remove the TC shifter cable 'R' clip. Detach the TC shifter cable from shifter assembly. Remove the transfer case shifter from the vehicle. Inspect the transfer case shifter for any damage. Replace if found any. Position the transfer case cable on shift lever bracket. Install the shifter cable locking R clip Position the transfer case shifter lever assembly Position the transfer case shifter lever at 2H position. Ensure that the transfer case link should be in 2H position on transfer case (Extreme Rear end position from front of the vehicle). Refit the transfer case cable abutments on shift lever bracket. Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Refit the shifter lever assembly mounting nuts. Tighten the mounting nuts to specified torque value. Torque : 22.51\u00b14 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120007.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120048.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from '2H' to other range. If Shifting not smooth Carry-out Transfer Cable setting. For AT Variants top trim Installation follow (Steps 8 \u2013 12) : , Refit the floor console top trim with transfer case shifter boot. Connect the AT gaiter electrical connector with the bezel. Refit the bezel trim with shifter bezel Handle bezel assembly carefully to prevent it from damage or scratches. Unfold the gear shifter boot and refit the boot with gear shifter bezel. Refit the Manual transmission gear selection rod cover with trim. Refit gear shifter level knob and 4WD selection knob by rotating them in clock wise direction. Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from 'N' to other range Inspect that engine can be started with shift lever only 'N' or 'P', but not in other range (For AT variants) Inspect that indicating lamp can be turned on correctly in PRND positions (For AT variants). Remove the Air Cleaner Assembly. Using MST 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the transfer case shifter cable from the transfer case ball pins. Detach the transfer case cable abutment from the cable bracket on transmission by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Using 10 mm socket spanner unscrew shifter cable grommet mounting bolts on fire wall. Remove the gear shifter level knob and 4WD selection knob by rotating them in anticlock wise direction. Using trim removal tool, remove the gear selection rod cover with trim. For AT Variants top trim removal follow (Steps 7 \u2013 12) : Remove the 4WD selection knob by rotating it in anti-clock wise direction. Pull and fold the gear shifter boot from gear shifter bezel. Partially detach the bezel from the console. Excessive pull may leads to damage of the electrical connector. Disconnect the AT gaiter electrical connector from the bezel. Carefully remove the bezel trim from the TGS lever. Handle bezel assembly carefully to prevent it from damage or scratches. Using trim removal tool, carefully remove the floor console top trim with transfer case shifter boot. Remove the floor console side trim mounting screw rivet and remove the trim both sides. Detach the transfer case cable abutment from the shifter bracket by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Detach the transfer case cable from the cable bracket routing clamp. Using nose plier, remove cable cross pin from the transfer case shifter and detach shifter cable. Keep the Transfercase shifter in 4L position while remove R Clip. Detach the cable from lever and take out from vehicle. Keep the Transfercase shifter in 2H position while remove the cable. Inspect the transfer case for any damage. Replace if found any. Position and route the cable inside the vehicle. Move shifter to 2H position and attach the cable with the shifter lever. Keep the Transfercase shifter in 2H position while refit the cable. Refit shifter cable R clip with the transfer case shifter cable. Keep the Transfercase shifter in 4L position while refit R Clip. Attach the transfer case cable abutment with the shifter bracket by pressing locking clip. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Attach the transfer case cable with the cable bracket routing clamp. Refit the floor console side trim and install the mounting screw rivet. Refit the gear selection rod cover with trim. Refit gear shifter level knob and 4WD selection knob by rotating them in clock wise direction. For AT Variants top trim Installationfollow (Steps 9 \u2013 13) : , Refit the floor console top trim with transfer case shifter boot. Connect the AT gaiter electrical connector with the bezel. Refit the bezel trim with shifter bezel. Handle bezel assembly carefully to prevent it from damage or scratches. Unfold the gear shifter boot and refit the boot with gear shifter bezel. Refit the 4WD selection knob by rotating it in clock wise direction. Refit shifter cable grommet and install the mounting bolts on fire wall. Ensure the cable grommet should get assemble from outside of the cabin. Torque :10 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120013.jpg",
+ "display_order": 89
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Position the transfer case lever at 2H position on transfer case (Extreme Rear end position from front of the vehicle). Refit the transfer case cable abutments on transmission cable brackets. Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. For adjust cable length, move the cable quick adjuster outer cover in forward direction and unlock the QA clip. Adjust the cable length to fix the cable on link ball pin. After adjusting the length, position the quick adjuster body on link ball pin. Once quick adjuster body snap on ball pin, press the QA clip towards arrow mark shown to lock it fully and release the cable quick adjuster outer cover. Ensure the proper locking by confirming/ hearing the click noise while install. Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from '2H' to other range. Using a 10 mm socket spanner, loosen and remove the battery negative terminal. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance . Before disconnecting the battery, check for the audible sound of EWP ON. Remove Rear Propeller Shaft Assembly. For additional information refer to Rear Propeller Shaft R &R; Session. Using a 8 mm socket spanner, loosen and remove the front propeller shaft mounting C clamp bolts from the transfer case. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120021.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the transfer case electrical connector. Using a MST 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool , detach the transfer case cable from the transfer case ball pins. Pressing locking clip and detach the transfer case cable abutment from the cable bracket on transmission and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Provide a jack to support the transmission. Using a 12 mm socket spanner, loosen and remove the transmission bed mounting bolts. Torque : 70\u00b15 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110012.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 14 mm, 15 mm socket and ring spanners, unscrew transmission cross member mounting bolts, nuts and detach it. Torque : 65 \u00b110.0 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110030.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using a 15 mm socket spanner, loosen and remove the transfer case mounting nuts. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110393.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. While Installation of transfer case cable abutments on transmission cable brackets, Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. After Installation of Transfer Case Assembly on vehicle, Carry-out below cable setting Procedure. , Ensure that the transfer case link should be in 2H position on transfer case (Extreme Rear end position from front of the vehicle). For adjust cable length, move the cable quick adjuster outer cover in forward direction and unlock the QA clip. Adjust the cable length to fix the cable on link ball pin. After adjusting the length position the quick adjuster body on link ball pin. Once quick adjuster body snap on ball pin, press the QA clip towards arrow mark shown to lock it fully and release the cable quick adjuster outer cover. Ensure the proper locking by confirming/ hearing the click noise while install. Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from '2H' to other range. Check transfer case oil level & top up if required. Inspect the transfer case for any damage. Replace if found any. Drain the Transfer case fluid. For additional information refer to Transfer case fluid Drain & Filling Section. Remove the Transfer case from the vehicle. Position the transfer case on the suitable Wooden/ Nylon blocks. Ensure the oil is drained prior to disassembly of the transfer case. Using a Special tool MST 203 Companion Flange Holding Tool, hold the transfer rear flange. Using a 30 mm socket spanner, loosen and remove rear flange center nut. Torque Value : 340 - 370 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120066.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120131.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120132.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120067.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a magnetic stick, take out flange washer and remove seal from transfer case rear flange. Ensure the use New washer & Seal while installation. Using a mallet, remove the transfer case rear flange. Use suitable 2 Jaw puller to remove the flange, In case of flange not able to remove by mallet. Using a 10 mm square bit spanner, remove the transfer case draining & filling oil plugs from the cover. Using a 15 mm socket spanner remove the assembly cover mounting bolts and remove the mounting bolts & identification tag. To avoid damage of the metal surface, apply limited force to the bosses on the cover and the transfer case while breaking the sealant bond. Using a flat end screw driver, remove transfer case Rear output shaft oil seal from the cover. Remove the Spacer from the cover. Separate the return spring from the front assembly cover by pulling them outwards. Using flat screw driver& circlip plier, remove the ball bearing snap ring. Rotate the cover and by using MST 0707BBA0003ST - Universal Mandtral remove the ball bearing from the cover. By using suitable Internal puller, pull out the needle bearing from the cover. Care must be taken not to damage the metal surface while removing the needle bearing. Position the transfer case casing and remove the shift collar hub from the output shaft. Remove the 2W-4W lock up assembly and lock up fork together from output shaft and separate lock up fork from the 2W-4W lock up assembly. To dismantle 2W-4W lockup assembly, remove snap ring, lock up hub return spring from lock up collar. Using a circlip plier & flat screw driver, remove the snap ring from the output shaft and remove the spacer. Remove the drive chain with sprocket and drive sprocket from the output shaft. Separate the drive chain, driven sprocket and drive sprocket. Remove the magnet from the slot in the case. Remove the coupler from the case. Remove the output shaft and the gear rotor (Gearotor) pump from the case. Rotate and align the guide pin of the shaft to the slot on the pump body and Separate the gear rotor pump and strainer assembly from the output shaft. By using nose plier, remove the hose clip and remove the hose from pump and remove the strainer. Remove the rail shaft assembly from the case. Remove the reduction hub and the reduction fork from the case. Separate the reduction hub and the reduction fork. Remove the two shift fork facings from the shift fork assembly (if required). Using a Special tool MST 203 Companion Flange Holding Tool, hold the transfer case output shaft yoke. Using a 30 mm socket spanner, loosen and remove rear output shaft yoke center nut. Torque Value : 340 - 370 Nm ",
+ "file": null,
+ "display_order": 94
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120142.jpg",
+ "display_order": 95
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120143.jpg",
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "Description",
+ "content": "Using a magnetic stick & flat screw drive , take out flange washer and remove seal from transfer case output shaft yoke. Ensure the use New washer & Seal while installation. Using a mallet, remove the transfer case rear flange. Use suitable 2 Jaw puller to remove the flange, In case of flange not able to remove by mallet. Remove the lower output shaft from the casing. Using a 15 mm socket spanner, remove the adapter assembly, input shaft and carrier assembly bolts. Take out the adapter assembly with input shaft and carrier assembly. Using an outer circlip plier, Expanding the long ends snap ring unlock the bearing lock circlip and remove the input shaft and carrier assembly. Remove snap ring and oil seal from adapter assembly. Remove the input shaft bearing retaining ring. Remove the bearing by hitting input shaft by mallet and remove the thrust washer from input shaft. Remove the ASM Carrier from the input shaft. Remove the sun gear snap ring from ASM Carrier. Remove the thrust plate & sun gear from ASM Carrier. By using suitable Internal puller, remove the copper bush from the input shaft. By using suitable Internal puller, remove the needle bearing from the input shaft. By using 17 mm Open end spanner, remove the Breather (For MT variants located at Adapter plate & for AT variants at Adapter case assembly). By using 13 mm socket spanner, remove the hexagonal nut of the shift shaft. By using T25 torx spanner, remove the transfer case and shift cam torx screws. By using flat end screw driver & mallet, remove the clip ring and pull out shift shaft & lever. Remove shift lever from shift shaft. By using flat end screw driver, remove the \u2018o\u2019 ring from shift shaft. Remove 4L assist spring and roller, shifter cam. Remove plunger and spring from the transfer case. By using 24 mm ring spanner, remove 4WD indicator switch from the transfer case (If required). By using flat end screw driver, remove the oil seal from the assembly case. By using flat end screw driver, remove the retaining ring from the assembly case. By using MST 0707BBA0003ST \u2014 Universal Mandtral remove the ball bearing from the case. By using cutting plier, remove the dowel pin from transfer case. Do not remove the ring gear shown in the below figure from the case. Using a cleaning solvent, clean the old oil and dirt deposits. Before cleaning, check the magnet for the presence of metal particles which indicate internal chipping of the transfer case. After cleaning dry the parts with low pressure (20 psi maximum) compressed air. Lubricate the ball bearings and needle bearing with Transfer Case oil. Protect lubricated bearings from dust. Visually check all the parts for damage. Referring to normal gear tooth face, specifically inspect the uneven wear and chips of gear tooth. Replace or repair if necessary. Always replace the hose coupling, O-ring , oil seal and flange/Yoke Nut with new parts. Insert dowel pins to the ring gear casing. Use respective Special tools for Bearings & Oil Seal Installation. Do not directly use hammer/mallet for Installation. Lubricate oil seals, O-rings, bushings and matching metal parts before assembly (with Transfer Case oil). Lubricate the ball bearings and needle bearing with Transfer Case oil. Protect lubricated bearings from dust. Dropping of heavy/large objects will damage the part and cause personal injury. Press the ball bearing to the front casing by using MST\u2019s (0707AUA0005ST - Trasfer case Case Covers Ball Bearing Pressing tool) & (0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer). Check the ball bearing for functionality prior to installation. Using a snap ring removal tool/screw driver install the retainer ring to the front casing. Install the new output oil seal into the case by using MST\u2019s (0707BBA0001STTransfer Case Output Shafts Oil Seal Installer) & (0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer). Install new \u2018O\u2019 ring on the shift shaft and lubricate it. Refit the shift shaft in to the shift lever. Position spring and plunger in the hole of the transfer case. Ensure spring and plunger are properly seated in the hole of the transfer case and not to unseat plunger while Install Cam assembly. Partially Insert star splined end of the shift shaft into the transfer case. Position shift cam into transfer case with flat end of cam approximately parallel with front face of case (as shown in the picture). Install 4L assist spring roller in groove of shift cam and Install other end to slot of transfer case. Pressing cam against plunger and compressing spring align splines in cam and on shift shaft and press shaft fully into cam and Install clip ring in groove near inside end of shift shaft. Refit the transfer case and shift cam torx screws by using screwdriver. Torque Value : 7 \u2013 8 Nm ",
+ "file": null,
+ "display_order": 212
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Notice",
+ "content": "Make sure that shift shaft is fully engaged so that second screw end enters groove in shaft. Refit the hexagonal nut of the shift shaft, Torque tighten mounting nut to specified value. Torque Value : 41 \u2013 48 Nm ",
+ "file": null,
+ "display_order": 216
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120178.jpg",
+ "display_order": 217
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Install 4WD indicator switch to transfer case. Torque Value : 34 \u2013 48 Nm ",
+ "file": null,
+ "display_order": 219
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120180.jpg",
+ "display_order": 220
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120179.jpg",
+ "display_order": 221
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Press the needle bearing into the input shaft by using MST\u2019s (0707AUA0004ST - T Case Input Shaft NRB Pressing tool & 0707BBA0003ST - Universal Mandtral - Oil Seal/ Bearing Installer). Press the new sleeve bearing into the input shaft by using MST\u2019s (0707AUA0003ST - T Case Input Shaft Sleeve Pressing tool & 0707BBA0003ST - Universal Mandtral - Oil Seal/ Bearing Installer. Install the sun gear & thrust plate on ASM Carrier. Install the sun gear snap ring on ASM Carrier. Refit the input shaft to the carrier assembly by matching the splines. Install the thrust washer onto the input shaft. Position and press the bearing onto the input shaft by using a MST 0707AUA0002ST - T Case Input Shaft Ball Brg Pressing tool. Install the retaining ring on the input shaft assembly by using circlip plier. Install snap ring by making sure that snap ring is correctly install in the groove. Using a circlip plier expand the snap ring and insert the carrier assembly with input shaft to the adapter case and release the snap ring. Ensure that carrier assembly with input shaft position properly to the adapter case and snap ring seated properly to hold the assembly. Install the oil seal on carrier assembly body by using a MST\u2019s For MT Variants : 0707BBA0002ST - Transfer Case Input Shaft Oil Seal Installer - MT For AT Variants : 0707BAJ0001ST \u2014 Transfer Case Input Shaft Oil Seal Installer - AT and 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Apply a 1.6 mm bead of Loctite RTV598 sealant on the mounting face for the transfer case. Refit the carrier assembly to the case and using a 16 mm socket spanner, tighten the mounting nuts to specified torque. Torque Value : 34 \u00b1 6 Nm ",
+ "file": null,
+ "display_order": 263
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120204.jpg",
+ "display_order": 264
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Refit the breather nipple. Torque Value : 5 \u2013 8 Nm ",
+ "file": null,
+ "display_order": 266
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120205.jpg",
+ "display_order": 267
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120206.jpg",
+ "display_order": 268
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Description",
+ "content": "Position the output shaft in the transfer case. Position the output shaft in transfer case, and install the end yoke assembly, seal, washer and the lock nut. Using a Special tool MST 203 Companion Flange Holding Tool, tighten the front flange mounting lock nut to specified torque. Torque Value : 340 - 370 Nm ",
+ "file": null,
+ "display_order": 279
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120216.jpg",
+ "display_order": 280
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "Description",
+ "content": "Install the two forks facing on the reduction shift fork assembly. Install the reduction hub in to the fork. Refit the reduction hub and reduction shift fork into the planet carrier. Slide roller of fork in to the cam groove. Insert shift rail in reduction fork bore, to match with case bore. Align rotor slot of the pump and slot of the pump body in line. Align the slide the pump assembly on output shaft over pump pin. Align the guide pin of the shaft to the slot on the pump body and slide the pump assembly onto the output shaft over pump pin. Assemble the strainer and hose to the gear rotor pump. Install the output shaft and gear rotor pump assembly into the reduction hub housing by matching the splines. Couple strainer with case and insert the magnet into the transfer case slot. Install the drive chain onto the sprockets. Position the drive sprocket to the rear output shaft end and driven sprocket to the front output shaft end. Holding each sprocket with the drive chain tight and parallel with the transfer case, install the drive chain assembly to the output shaft. Rotate the driven sprocket slightly to engage splines on the front output shaft. Install the spacer to the front output shaft. Install the snap ring into the groove of the front output shaft. Install the lockup hub and return spring to the lockup collar and insert the snap ring. Install new facings to the fork. Engage the lockup fork in the groove in 2WD-4WD lockup assembly and slide this assembly down over output shaft and rail shaft. Install shift collar engaging splines on output shaft and in 2WD-4WD lockup assembly. Position the cover with the open end facing up on the table. Position the end of the needle bearing with the identification mark and up the press into the cover by using a MST\u2019s (0707AUA0006ST \u2014 T Case Rear Cover NRB Pressing tool & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer). Press the ball bearing into cover by using MST\u2019s (0707AUA0005ST \u2014 T Case Covers Ball Brg Pressing tool & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer). Install snap ring over the ball bearing into cover by using screw driver or circlip plier. Install the return spring over rail shaft in the transfer case. Position the cover with the open end facing down on the table. Install the spacer over output shaft spline in the cover assembly. Press the new oil seal into the cover assembly by using MST\u2019s (0707BBA0001ST \u2013 Transfer Case Output Shafts Oil Seal Installer & 0707BBA0003ST \u2013 Universal Mandtral - Oil Seal/ Bearing Installer). Apply 1.6 mm bead of Loctite RTV598 to the transfer case mounting surface. Position and align the transfer case with cover. Do not use excessive force. Follow the below steps while Installing the cover into the transfer case Align the cover holes with the transfer case dowel pins. Align the cover bearing with output shaft. Align the cover blind hole with rail shaft and make sure that return spring is not cocked. Do not apply excessive force while Installation. Refit the front and rear housing cover mounting bolts along with identification tag and torque tighten the bolts to specified value. Torque Value : 34 \u00b1 6 Nm ",
+ "file": null,
+ "display_order": 369
+ },
+ {
+ "step_name": "Step-61",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120274.jpg",
+ "display_order": 370
+ },
+ {
+ "step_name": "Step-61",
+ "content_type": "Description",
+ "content": "Install the two oil plugs to the cover, torque tighten the nuts to specified value. Torque Value : 34 \u00b1 6 Nm ",
+ "file": null,
+ "display_order": 372
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120275.jpg",
+ "display_order": 373
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120276.jpg",
+ "display_order": 374
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120277.jpg",
+ "display_order": 375
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120278.jpg",
+ "display_order": 376
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "Description",
+ "content": "Install the flange,seal, washer and lock nut to the output shaft. Do not fully tighten the bolts at this stage. Using a Special tool MST 203 Companion Flange Holding Tool, hold the transfer case output shaft yoke and torque tighten the nut to specified value. Refit the Transfer case on the vehicle. Refill the Transfer case fluid. For additional information refer to Transfer case fluid Drain & Filling Section. Position the transfer case shifter lever at 2H position. Ensure cable cross pin is properly fitted on transfer case shifter Ensure the transfer case cable abutment is properly fitted on shifter bracket. Ensure the transfer case cable abutment is properly fitted on transmission cable bracket. Using a 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the transfer case cable from the transfer case ball pins. Ensure that the transfer case link should be in 2H position on transfer case (Extreme Rear end position from front of the vehicle). For adjust cable length, move the cable quick adjuster outer cover in forward direction and unlock the QA clip. Adjust the cable length to fix the cable on link ball pin. After adjusting the length, position the quick adjuster body on link ball pin. Once quick adjuster body snap on ball pin, press the QA clip towards arrow mark shown to lock it fully and release the cable quick adjuster outer cover. Ensure the proper locking by confirming/ hearing the click noise while install. Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from 2H to other range. Transfer case Oil \u2013 MAHINDRA MAXIMILE POWER STEERING FLUID Genuine Power Steering Fluid Capacity \u2013 1.2 Litres. Using a 10 mm square bit spanner,remove the oil filling plug from the transfer case. Place a tray beneath the drain plug for collecting the oil while draining. Using a 10 mm square bit spanner, loosen and remove the drain plug. Collect the drained oil in a suitable container. Refit the drain plug. Torque tighten the drain plug to specified value. Torque : 34\u00b16 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110414.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110412.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Fill recommended transfer case fluid with the help of a mechanical pump through filler plug. Ensure that the oil level by insert the 8 mm allen key and check the oil level mark. Refit the filler plug and torque tighten the filler plug to specified torque value. Torque : 34\u00b16 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Recommend to use only MAHINDRA MAXIMILE POWER STEERING FLUID Genuine Power Steering Fluid. In case of non-availability of Genuine fluid, SHELL MAKE SPIRAX S3 ATF MD3 can be used. In emergency conditions, fluid meeting DEXRON III specification can be used and oil change interval should be at every 40000 km. It is a structure of a pipe, which carries air into the combustion chamber in an engine. The primary function of the intake manifold is to evenly distribute the air to each intake port in the cylinder head. Even distribution is important to optimize the efficiency and performance of the engine. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the terminal. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Remove the throttle assembly. Remove the alternator assembly. Remove the EGR module assembly. Using a 10 mm socket spanner, Unscrew NVH cover mounting bracket mounting bolt. Using a 10 mm socket spanner, Unscrew wiring routing bracket mounting bolt from manifold end. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020080.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew dipstick routing bracket mounting bolt. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020115.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 8 mm socket spanner, Unscrew boost temperature sensor mounting bolt and remove it. Torque : 6 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020081.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, Unscrew intake manifold mounting bolts from cylinder block. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020112.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the intake manifold carefully from the engine. Replace the gaskets to the intake manifold whenever removed from the engine. Install in the reverse order of removal. Check the intake manifold for the external damage. If any damage found replace it. The boost downstream temperature sensor is used to monitor the intake air temperature at the intercooler outlet. The sensor is an NTC type sensor. EMS ECU uses signal from this sensor for Air-intake system control & flow rate modelling. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the terminal. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Disconnect the boost pressure sensor electrical connector. Using 10 mm Socket Spanner, Unscrew Boost pressure sensor mounting bolt. Torque : 2.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020089.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the boost pressure sensor. Install in the reverse order of removal. Check for any external cracks or damage, replace if found any. Using 10 mm socket spanner, Loosen battery negative terminal mounting nut and disconnect the terminal. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Using 7 mm socket spanner, Loosen the intercooler inlet hose clip and disconnect the hose intercooler end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020036.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner, Loosen the intercooler outlet hose clip and disconnect the hose intercooler end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020113.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, remove boost pressure sensor mounting bolt and detach it. Torque : 2.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020114.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect the boost pressure sensor electrical connector. Using 10 mm socket spanner, Unscrew degassing tank mounting bolts and partially detach it. Torque : 4.5\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020034.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 13 mm Socket Spanner, Unscrew the Intercooler mounting bolts. Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020090.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020037.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Carefully remove the intercooler from vehicle. Install in the reverse order of removal. Check for the external damage. If found replace it. Check for any oil seepage ,if found please inspect the turbocharger for any oil leakage. Inspect intercooler hoses for any damage. Replace if found any. Inspect intercooler rubber Isolators for any damage. Replace if found any. The air filter housing is made up of two parts. The bottom housing and top housing with the air filter element sandwiched in between. Air is drawn through the dirty side intake duct into the bottom housing. It gets filtered and passes on via top housing, throttle valve into the intake manifold. Using 10 mm socket spanner, Loosen battery negative terminal mounting nut and disconnect the terminal. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Using 7 mm socket spanner, Loosen the intercooler inlet hose clip and disconnect the hose intercooler end. Torque : 6.5 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Ensure the sensor is stored in a dust free area. ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020117.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew air cleaner assembly mounting bolts from BIW. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020118.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully take out the air cleaner assembly and air intake dirty duct. Using a 5 mm allen key, loosen and remove the dirty side duct mounting bolts from the air cleaner assembly then separate the air cleaner assembly. Install in the reverse order of removal. Check the air cleaner housing for the external damage. If any damage found replace it. The air cleaner element is Non woven +Pleated Media type (Dry Type). Filtration happens in two stages. Coarser particles are filtered in first stage by foam media and fine particles are filtered by Paper media in second stage. The dust and other fine particles which are sucked inside along with air gets trapped in the air cleaner while passing through the filter element. Don\u2019t tap or hit the filter element.
2. Open the bonnet and lock it in open position using bonnet stay rod.
",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5.png",
+ "display_order": 7
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020018.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020014.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "The air filter element should be inspected and replaced from time to time, when driving under the following conditions: Unpaved road. Dusty air-polluted road. Long-term driving in rainy weather. Using 5 mm allen key, Unscrew air cleaner dirty duct mounting screws and lift the top housing. Gently take out the air cleaner element from the housing. Clean the inner side of the air cleaner housing using a lint free cloth. Refit the New air filter element gently inside the air cleaner housing. During Installation ensure to keep foam side of the filter element in the bottom side. Ensure dust should not fall inside the clean hose area while fitting. Always use recommended genuine air filter element. Do not tap or hit the filter element. Position the air cleaner assembly top cover and refit the mounting screws. Torque : 10 Nm ",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 339,
+ "sys_id": "THAR.AX-0001-Air Intake",
+ "subsys_id": "THAR.AX-0001-Air Intake-Intake Manifold Sensor",
+ "systems": "Air Intake",
+ "sub_systems": "Intake Manifold Sensor",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A020083.jpg",
+ "myid": 1007,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Intake Manifold Sensor-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020125.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Intake manifold pressure sensor is mounted located at the plenum of the intake manifold. This sensor continuously monitors the variation in intake air pressure. EMS ECU uses this information for fuel correction, EGR control & turbocharger pressure control. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the terminal. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Remove the engine top encapsulation cover. Disconnect boost temperature sensor electrical connector. Using a 8 mm socket spanner, loosen and remove the boost temperature sensor mounting bolt. Torque : 6 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020089.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully remove the sensor from intake manifold. Install in the reverse order of removal. Check for any external cracks, replace if found any. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Remove the engine top encapsulation cover. Disconnect the throttle valve electrical connector. Using a 7 mm socket spanner, loosen intercooler outlet hose clip from throttle valve end. Torque : 6.5 \u00b1 0.6Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020060.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew the throttle body assembly mounting bolts. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020091.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully remove throttle body from intake manifold. Install in the reverse order of removal. Check for any external cracks, replace if found any. The HFM sensor is used to find out the mass flow rate of air entering into fuel injection internal combustion engine. The air mass information is necessary for the ECU to balance and deliver the correct fuel quantity to the engine. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the terminal. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Disconnect the HFM sensor electrical connector. Using a 7 mm socket spanner, loosen the hose clip and detach hose from HFM sensor. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020030.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the HFM sensor mounting bolts. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020031.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020032.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the HFM sensor from the air cleaner assembly. Install in the reverse order of removal. Check for any external cracks, replace if found any. Check for the obstruction of the air flow, if found please replace. The air cleaner element is Non woven +Pleated Media type (Dry Type). Filtration happens in two stages. Coarser particles are filtered in first stage by foam media and fine particles are filtered by Paper media in second stage. The dust and other fine particles which are sucked inside along with air gets trapped in the air cleaner while passing through the filter element. Don\u2019t tap or hit the filter element.
2. Open the bonnet and lock it in open position using bonnet stay rod.
",
+ "file": null,
+ "display_order": 7
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020123.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "The air filter element should be inspected and replaced from time to time, when driving under the following conditions: Unpaved road. Dusty air-polluted road. Long-term driving in rainy weather. Using a 5 mm allen key, Unscrew air cleaner top housing mounting allen screws and lift the top housing. Gently take out the air cleaner element from the housing. Clean the inner side of the air cleaner housing using a lint free cloth. Blow the compressed air from the top clean side of filter element. Blow the compress air from the top clean side of filter element (From Paper side). Do not blow the air from bottom dirty side (Foam side). While cleaning, ensure the air pressure should be less than 2 bar. Clean the inner side of the air cleaner housing using a lint free cloth. Gently insert the air cleaner element inside the air cleaner housing. During Installation ensure to keep foam side of the filter element in the bottom side. Ensure dust should not fall inside the clean hose area while fitting. Ensure dust should not fall inside the clean hose area while fitting. Always use recommended genuine air filter element. Do not tap or hit the new filter element. Refit the air cleaner top housing and install the mounting allen screws. Torque : 10 Nm ",
+ "file": null,
+ "display_order": 28
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 120,
+ "sys_id": "THAR.AX-0001-en-SM-Wheel & Tyre",
+ "system_name": "Wheel & Tyre",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1014,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 127,
+ "sys_id": "THAR.AX-0001-Wheel & Tyre",
+ "subsys_id": "THAR.AX-0001-Wheel & Tyre-Front Wheel",
+ "systems": "Wheel & Tyre",
+ "sub_systems": "Front Wheel",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A160002.jpg",
+ "myid": 1511,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Front Wheel-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160002.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/56024.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/56025.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 21 mm Wheel spanner/ deep socket spanner, loosen and remove the wheel mounting bolts. Torque :140\u00b110 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the mounting bolts and then remove the wheel. Install in the reverse order of removal. Check for any external damage in the tyre or the rim, if found replace. Check for any foreign material on tyre or rim, remove if found. Using 13 mm socket spanner, loosen and remove the spare wheel carrier mounting bolts. Torque : 50\u00b17.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the spare wheel carrier from the vehicle. Install in the reverse order of removal. Check for any external damage in the spare wheel carrier , if found replace. Using 21 mm socket spanner, loosen and remove the wheel nuts on the spare wheel carrier. Torque :70\u00b110 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the spare wheel from the vehicle. Install in the reverse order of removal. Check for any external damage in the tyre or the rim, if found replace. Check for any foreign material on tyre or rim, remove if found. Tyres on the front and rear side of vehicles operate at different loads and perform different steering, handling, and braking functions. For these reasons, they wear at unequal rates and develop irregular wear patterns. Rotation will increase tread life. help to maintain mud, snow, and wet traction levels, and contribute to a smooth quiet ride Follow the recommended tyre rotation frequency for your type of driving more frequent rotation is permissible f desired. The reasons for any rapid or unusual wear should be corrected prior to rotation being performed It is recommended to rotate the tyres as per 'Maintenance Schedule'. Below illustration shows suggested tyre rotation method: ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10396.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "TPMS Learning needs to be carried out for vehicle models equipped with TPMS(Tyre Pressure Monitoring System), procedure as below. TPMS Learning - Procedure ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090057.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Press the Scroll Up arrow button on Driver side switch bank and simultaneously turn the ignition ON. Wait for cluster\u2019s tachometer & speedometer self-check rotation and then release the arrow button. Identifying weather the learning is initiated. Infotainment will show popped out screen TPMS Learning screen. TPMS telltale in cluster shall keep blinking. Three vehicle siren chirps will be heard. If failed to enter in to manual learning mode. Try initiating the manual learning once again. Check if reverse gear is engaged, if engaged disengage it. Check MBFM, Infotainment & Cluster software versions. Check if variant coding is done in all three. Check if Scroll Up arrow button on Driver side switch bank button is working fine. 1. Front left tyre
2. Front right tyre
3. Rear right tyre
4. Rear left tyre
5. Spare tyre
",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Start leaking the air from front left tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If front left tyre is learned 1 siren chirp sound is heard and FL tyre shows learned in infotainment system. Start leaking the air from front right tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If front right tyre is learned 1 siren chirp sound is heard and FR tyre shows learned in infotainment system. Start leaking the air from rear right tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If rear right tyre is learned 1 siren chirp sound is heard and RR tyre shows learned in infotainment system. Start leaking the air from rear left tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If Rear left tyre is learned 1 siren chirp sound is heard and RL tyre shows learned in infotainment system. Start leaking the air from the spare wheel tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If spare tyre is also learned then 1 siren chirp sound is heard and ALL tyres show learned at respective tyre positions and \u2018All tyres Learned successfully\u2019 in the center of the screen. At any point of time during the learning process, if learning takes more than 90 seconds of time for each tyre position then the system shall exit the learning mode and show the \u201cLearning not successful\u201d screen. After tyre rotation or TPMS sensor replacement, TPMS must be learnt, otherwise the system will show TPMS malfunction indicator. TPMS learning need to be carried out whenever : Tyre rotation happens. 2 or more wheels are swapped. TPMS sensor is replaced. MBFM is replaced. The TPMS should not be used as a tyre pressure gauge while adjusting vehicle tyre pressure. No two vehicles should be done with manual learning process at a time in same location with in radius of 20 meters. Post to manual learning all tire should be filled with recommended tyre pressure value. Remove the front wheel - R&R.; For additional information refer to front WHEEL - R &R; Section. Using chisel Remove the drive shaft mounting nut caulking. Using 36 mm socket spanner, loosen and remove Drive shaft mounting nut by Applying brake. Torque : 240 \u2013 260 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the caliper stem mounting bolts then hang the caliper. Torque : 31 \u2013 38 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Pull the Brake Pad outwards upto pad contact with clip as shown in the illustration. Twist the pad in anti clock wise direction, lift the pad upwards and remove the pad. Using 19 mm socket spanner, loosen and remove the caliper bracket mounting bolts then remove the caliper bracket. Torque : 90 \u2013 100 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using star screw driver, remove the brake disc mounting screw and detach the disc from the front wheel hub. Remove the disc separately. Using 19 mm socket spanner, loosen and remove Hub mounting bolts and remove the hub with carrier plate. Torque : 87 - 90 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160030.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Before assembly clean the mating faces of the front wheel hub and brake disc. Check for any external damage in the wheel hub, if found replace. Check for any wheel hub bearing condition, if found replace. Tyre Pressure- Inspect & Adjust ",
+ "file": "",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": "TYRE PRESSURE LABEL: ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160038.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Tyre Label is located on the driver side inner B-pillar. This label tells you important information about tyre size designed for your vehicle, and the tyre inflation pressures for the front & rear tyres. Never overload the vehicle. Overloading can cause tyre failure, affect vehicle handling, and increase your stopping distance, resulting in an accident and/ or personal injury. Improper inflated tyres can adversely affect vehicle handling or can fail unexpectedly, resulting in an accident and or personal injury. If weight is not equally distributed around the wheel, unbalance centrifugal force by the wheel rotation produces vibration. As the centrifugal force is produced proportional to the square of the rotating speed, the wheel weight should be balanced even at high speed. There are two types of the tire and wheel balancing: static and dynamic. Abnormal vibration may also occur due to unbalanced rigidity or size of tyres Static Balance ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A180032.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "When the free rotation of the wheel is allowed, the heavier part is stopped on the bottom if the wheel weight is unbalanced and this is called 'Static Unbalance' Also, the state at which tyre's stop position is not same is called 'Static Balance' when the wheel is rotated again. If the part A is heavier as shown in the figure, add the \u201cbalance weight\u201d corresponding to unbalanced weight from B to A to maintain the static balance. If the static balance is not maintained, tramping, up and down vibration of the wheels, occurs. Dynamic Balance ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/wheelbalancing.JPG",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "The static unbalance of the wheel creates the vibration in the vertical direction, but the dynamic unbalance creates the vibration in the lateral direction. As shown in the figure (A) , if two parts, (2) and (3), are heavier when the wheels are under the static balance condition, dynamic unbalance is created, resulting in shimmy, left and right vibration of the wheels, and the torque Fxa is applied in the axial direction. To correct the dynamic unbalance, add the balance weight of a same weight for two points of the circumference of the rim, M1 and M2, as shown in the figure (B) , and apply the torque in the opposite direction to the torque Fxa to offset in order to ensure smooth rotation of the wheel. The wheel should always be balanced and aligned in order to provide: 1. Enhanced tyre life 2. Driving safety and steering control. 3. Better performance of the vehicle. 4. Unbalanced tyre may lead to premature tyre wear and driver fatigue due to vibration. Tyres should always be balanced when they are mounted on wheels for the first time 5. When they are remounted after repair 6. When there are signs of shimmy or vibrations. For balancing a wheel, follow the manufacturer\u2019s (of balancing machine) manual for balancing instructions, recommendations and any other additional information. Using 21 mm Wheel spanner/ deep socket spanner, loosen and remove the wheel mounting bolts. Torque :140\u00b110 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the mounting bolts and then remove the wheel. Install in the reverse order of removal. Check for any external damage in the tyre or the rim, if found replace. Check for any foreign material on tyre or rim, remove if found. Remove the Instrumental Panel Assembly. Using a star driver,loosen and remove the IP driver side switch bank mounting screws. Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270121.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Detach the IP driver side switch bank from the Instrumental Panel Assembly Install in the reverse order of removal. Inspect the IP driver side switch bank condition, if required replace. By using Trim Removal tool, remove the bezel rest from front door RH. Disconnect the electrical connector from the bezel. Using flat screw driver detach the switch from the bezel. Install in the reverse order of removal. Check the mounting clips condition to avoid rattling and falling down. Check the switch condition. If required replace. Pull and remove the tail lamp cover from vehicle. Using 10 mm socket spanner, loosen and remove tail lamp mounting bolts and partially detach it. Torque : 4 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270044.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect tail lamp electrical connector. Remove tail lamp from vehicle. Install in the reverse order of removal. Inspect the tail lamp/ rear lamp assembly for any physical damage/crack etc. Inspect the glass for fading. Inspect the condition of bulbs. Inspect the connectors for proper fitment. Remove the IP center switch bank assembly. Using a star driver, loosen and remove the center switch mounting screws. Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270005.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the center switch from IP center switch bank assembly. Install in the reverse order of removal. Check the mounting clips condition to avoid rattling and falling down. Check the switch condition. If required replace. Remove tail lamp cover from tail lamp. Using 10 mm socket spanner unscrew tail lamp mounting bolts. Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270044.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect tail lamp electrical connector. Remove and turn the backup lamp bulb socket in the direction of the arrow. Remove the reverse lamp bulb from holder. Install in the reverse order of removal. Check the bulb condition to avoid rattling and falling down. Check the bulb condition. If required replace. Remove front grill assembly. Pull the lock disconnect head lamp electrical connectors. Using 10 mm socket spanner, loosen and remove the head lamp mounting bolts. Torque : 6 \u00b11Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270022.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the head lamp assembly separately. Install in the reverse order of removal. Inspect the head lamp for any damage, crack and glass fading. Inspect the bulbs. Using a star screw driver, Unscrew front splash shield lower mounting screws. Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts. Torque : 6.5 \u00b10.7Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield. Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270037.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the electrical connector. Using hand, Push the side marker lamp assembly from the cladding and remove. Remove the Side Marker Lamp from vehicle. Install in the reverse order of removal. Inspect the side marker lamp assembly for any physical damage/crack etc. Inspect the glass for fading. Inspect the condition of bulbs. Inspect the connectors for proper fitment. Using a star screw driver, Unscrew front splash shield lower mounting screws (Front side screws). Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nut. Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the front side of shield to access front turn indicator and DRL. Disconnect the front turn indicator and DRL electrical connectors. Using a 10 mm socket spanner loosen and remove the front turn indicator and DRL mounting bolts. Torque : 4\u00b11 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270112.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully remove front turn indicator and DRL. Refit in the reverse order of removal. Inspect the front turn indicator and DRL for any damage, replace if required Using a star screw driver, Unscrew front splash shield lower mounting screws. Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts. Torque : 6.5 \u00b10.7 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield. Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270047.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Rotate the bulb holder in anti clock wise direction and remove the holder with bulb. Remove the bulb from the holder. Install in the reverse order of removal. Check the bulb condition to avoid rattling and falling down. Check the bulb condition. If required replace. Remove tail lamp cover from tail lamp. Using 10 mm socket spanner unscrew tail lamp mounting bolts. Torque :4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270044.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect tail lamp electrical connector. Remove the bulb from holder by turning the bulb in counter clock wise direction. Gently pull out the bulb from holder. Install in the reverse order of removal. Check the bulb condition to avoid rattling and falling down. Check the bulb condition. If required replace. Using a star screw driver, Unscrew front splash shield lower mounting screws. Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts Torque : 6.5 \u00b1 0.7 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield. Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270058.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect parking lamp electrical connector. Rotate and remove the bulb holder from vehicle. Remove bulb from holder by turning the bulb in counter clock wise direction. Detach the bulb from holder. Install in the reverse order of removal. Check the bulb condition to avoid rattling and falling down. Check the bulb condition. If required replace. RIGHT TURN INDICATOR ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "For inspection, push the lighting control stalk clockwise (to stop position B) to indicate a right turn. The instrument cluster arrow lamp pointing towards the right flashes along with the right side turn signal lamps with chime indicating your intention of turning towards right After you have completed your right turn, the stalk will automatically return to the neutral position. Both the right turn lamp and the right turn signal lamp switch OFF. LEFT TURN INDICATOR ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "For inspection, push the lighting control stalk anti-clockwise (to stop position A) to indicate a left turn. The instrument cluster arrow lamp pointing towards the left flashes along with the left side turn signal lamps with chime indicating your intention of turning towards left. LAMPS OFF ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "For inspection, rotate the outer rotary switch on the lighting control stalk aligning the \u2018Arrow\u2019 on the switch to \u2018O\u2019 on the stalk to switch OFF all lamps. LANE CHANGING ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "For inspection of signal a lane change, move the light control stalk clockwise or anti-clockwise to the limit point of free movement of the lever and release. The turn signals will flash three times and stop. PARKING LAMPS ON ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "For inspection, rotate the outer rotary switch on the lighting control stalk aligning the \u2018arrow\u2019 on the switch to the \u20181st d\u00e9tente\u2019 position on the stalk to switch ON the parking lamps. HEAD LAMP ON ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "For inspection, rotate the outer rotary switch on the lighting control stalk aligning the \u2018Arrowt\u2019 on the switch to the \u20182nd d\u00e9tente\u2019 position on the stalk to switch ON the head lamps. HEAD LAMP HIGH BEAM/LOW BEAM ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "For inspection, with the head lamp ON, push the lighting control stalk down (away) from steering wheel to switch ON the head lamp high beam. The head lamp high beam tell-tale lamp in the instrument cluster illuminates indicating high beam option selected. With the head lamp high beam ON, pull the lighting control stalk up towards the steering wheel to switch ON the head lamp low beam. HEAD LAMP FLASH ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "For inspection, pull the lighting control stalk (from the head lamp low beam position) towards the steering wheel to instantaneously flash the head lamp high beam. The head lamp flash works even when the head lamp is OFF. FOG LAMPS OFF ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "For inspection, align the inner rotary switch on the lighting control stalk to the fog lamp off \u2018dot\u2019 on the inner fixed stalk as shown to switch OFF the fog lamps. FRONT FOG LAMPS ON ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "To inspect the front fog lamps, switch ON the ignition and the parking lamps. Turn the inner rotary switch on the lighting control stalk to align to the fog lamp symbol on the inner fixed stalk as shown. The front fog lamp indicator in the instrument cluster indicates the operation status. HAZARD WARNING LAMP ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "For inspection, press the hazard switch ON, All the turn signal lamps flash. To turn OFF, press the switch again. CENTER ROOF LAMP ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "The Roof lamp switch has three operation modes to choose from; The lamp remains permanently ON in this position irrespective of the door open status The lamp remains permanently OFF in this position The lamp remains in AUTO mode in this position. WIPER CONTROL STALK ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "Wiper Off ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "For inspection, move the wipe stalk in neutral position (B). Wiper remains OFF. Flick-Wipe (Mist) ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "For inspection, push the wipe control stalk to position A for a flick-wipe, hold to operate the wipe continuously (simultaneously lift the wiper stalk towards the steering wheel to operate the wash). The stalk automatically comes back to position B when released. Intermittent (INT) Mode ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "For inspection, push down the stalk down to position C. In the INT mode, the wiper operates on preset intervals. Low Speed Wiping ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "For inspection, push the wipe control stalk up to the position D to operate the wiper at a fixed low speed. High Speed Wiping ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "For inspection, push the wiper control stalk up to position E to operate the wiper at a fixed high speed. FRONT WIPE/WASH ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "For inspection, pull/lift the wiper control stalk towards the steering wheel from any position to activate the front wipe/wash function. Washer fluid is sprayed on the front windshield and the wipers wipe the windshield 3 times after the washer spray is stopped and wipe once after 4 sec. Hold the stalk in position for continuous spray of washer fluid. HORN ",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "For inspection, press the pad on the steering wheel to sound the horn. The horn functions even when the ignition has been switched OFF. STOP LAMP/HIGH MOUNTED STOP LAMP ",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "For inspection, Press the brake pedal and the Stop Lamp /high mounted stop lamp will illuminate. REVERSE LAMP ",
+ "file": null,
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "For inspection, Engage the reverse gear and the reverse lamp will illuminate.
2. Check and ensure all four tyre pressures as per specification.
3. Head lamp levelling switch position is on zero (0). Vehicle needs to be parked 10 meters or 3 meters away from the aiming board. (L = 10 meters / 3 meters which is the distance from starting point of front tyre to the aiming board as shown in illustration below).
4. Select the aiming board according to the value of \u201cL\u201d.
",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "Heading",
+ "content": "Refer illustration for \u201cL= 10 Meters\u201d ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10713.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270086.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Refer illustration for \u201cL= 3 Meters\u201d. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270091.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Heading",
+ "content": "Refer the illustration for the head lamp adjustment arrangement - ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270087.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270088.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Heading",
+ "content": "Refer the illustration for the head lamp aiming board dimensions of Head Lamps - ",
+ "file": null,
+ "display_order": 12
+ }
+ ]
+ },
+ {
+ "procedure_name": "Low Beam Setting Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270089.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270090.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Refer below illustration for the head lamp aiming board dimensions of Head Lamps : ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Low beam & high beam aiming settings are common. Hence if adjust low beam, high beam will also get aligned with low beam. Using 5 mm socket spanner, rotate the adjusting screw on motor to vary the Low beam cut-off pattern in vertical direction. Clockwise rotation \u2013 Downwards. Anti-clockwise rotation \u2013 Upwards. Using star screw driver, rotate the RH side lamp adjusting screw to vary the low beam cut-off pattern in horizontal direction. Clockwise rotation \u2013 Left side. Anti-clockwise rotation \u2013 Right side. RH & LH Head lamps are common for New THAR vehicle. Using star screw driver, rotate the LH side lamp adjusting screw to vary the low beam cut-off pattern in horizontal direction. Clockwise rotation \u2013 Right side. Anti-clockwise rotation \u2013 Left side. Check the function of system, by operating the switch from '0' to '3' and observe the cutoff pattern movement in downward direction accordingly. At zero position of switch, the cut- off should come at \u201ch\u201d heights 833 mm (For L= 10,000 mm) & 924 mm (For L=3,000 mm) on screen. Low beam & high beam aiming settings are common. Hence if adjust low beam, high beam will also get aligned with low beam. Remove the switch bank driver side . Remove the aiming switch lock by using flat screw driver. Insert the screw driver one side to release lock & release other side. Detach the IP driver side switch bank from the vehicle. Install in the reverse order of removal. Inspect the aiming switch condition, if required replace. Using a star screw driver, Unscrew front splash shield lower mounting screws. Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts. Torque :6.5\u00b10.7 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield. Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270033.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect front indicator electrical connector. Rotate and remove the bulb holder from vehicle. Remove bulb from holder by turning the bulb in counter clock wise direction. Install in the reverse order of removal. Check the bulb holder condition to avoid rattling and falling down. Check the bulb condition. If required replace. Using star screw driver unscrew the panel assembly floor console RH screvits and detach the panel from vehicle Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290031.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console LH screvits and detach the panel from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290034.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew vertical ascent RH mounting screw and detach the vertical ascent RH from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290033.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew vertical ascent LH mounting screw and detach the vertical ascent LH from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290035.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290036.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270129.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "partially detach the switch bank assembly and remove electric connector to take out from the vehicle. Install in the reverse order of removal. Inspect the center switch for any physical damage. Replace if found. Remove the Convertible Soft top Canopy. Remove the support centre Rexine rivets other side. Remove the Support Side Rexines rivets RH & LH. Using star screw driver, loosen and remove the Bow 1 Injection Mould mounting screws (locate 1 screw at bottom side of centre rexine support). Using star screw driver, loosen and remove the Latch mounting screws. Remove the Bow 1 Injection mould from front side bow and remove the Convertible Soft top Frame Complete assembly. Refit in the reverse order of removal. Inspect the Convertible Soft top Frame Complete assembly for any crack or damage. Replace if any. Remove Side window RH Velcro and Unzip the window. Remove Side window LH Velcro and Unzip the window. Unzip the tail gate window, detach the tail gate bar locking from rear RH & LH belt rails remove the tailgate window. Unhook the \u2018C\u2019 pillar cover from rear RH & LH belt rails and fold the cover at top of the soft top. Slide the Sun visors and Remove the Footman's loops from front header. While unlock the Footman loop hook from the front header metal bracket, ensure to press & move the softtop assembly slightly in forward direction and release the hook from the bracket. Slide back the convertible top from front header to rear and roll up properly. Lift the convertible soft top assembly upwards (both sides), sliding towards front and position on the vehicle as shown. Properly open rolled convertible soft top assembly from the rear side. Slide convertible top from rear end to front header and position on front header properly. Lock the Footman's loops to the front header and slide the Sun visors. Lock the Footman loop hook on the front header metal bracket & press the loop handle. While locking ensure top plastic support project on top of the header metal bracket for proper locking as shown. Attach the tail gate bar locking to rear RH & LH belt rails and zip tailgate window. Position and hook LH side window to the vertical and horizontal belt rail. Position and hook RH side window to the vertical and horizontal belt rail. Check the Convertible Soft Top Assembly for any damage, replace if required. Remove Front Roof caps using trim remover and Using a T30 socket spanner, loosen and remove the roof front top mounting bolts. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250210.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250213.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250211.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250212.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Rear Roof caps using trim remover and Using a T30 socket spanner, loosen and remove the roof rear top mounting bolts. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250214.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250215.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250216.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250217.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a trim remover pull out center bow trim and disconnect roof lamp electrical connector. Ensure to use trim remover while removing centre roof bow trim, and avoid the press clip damage. Replace the press clip for proper fixing, if it is damaged. Remove the centre bow trim from the vehicle. Using a T30 socket spanner, loosen and remove the roof top mounting bolts inside bow trim. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250219.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "By Using T30 Torx Socket Spanner remove the RH & LH roof side upper frame mounting bolts. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250102.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250103.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "By Using T30 Torx Socket Spanner remove the RH & LH roof side lower frame mounting bolts.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250104.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250104.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "By Using T30 Torx Socket Spanner remove the RH & LH rear lower bracket mounting bolts. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250206.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250207.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a T30 socket spanner, loosen and remove the roof top mounting bolts from roll cage. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250208.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250209.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Disconnect the HMSL electrical connector. Insert and split the panel with trim remover, in between Hard-Top and frame mounting plate. Lift and Carefully remove the hard top assembly from the vehicle with sufficient manpower and keep it in Trolly bench or flat working bay. Use the recommended safety equipment\u2019s; Safety goggles, Cotton gloves, Safety shoes etc. while lifting the Hard-Top. Don't use ordinary solvent for HardTop cleaning. (it may result some undefined problems in Hard-Top). ",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250107.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250225.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Inspect the Hard-Top windshield upper frame Seal and replace if needed when the seal loses its softness or if found any damages.The Seal must be replaced along with X-mas tree clips, when the seal loses its softness or if found any damages, don't reused the X-mas tree clips. This seal is for preventing the water leakage and wind noise only. Seal coming with Two-way pasting tape. Before Installation, Apply the silicon sealant on inner side edges of Hard-Top by manual Sealant gun. A triangular V- shaped notch will provide the optimal bead shape. (Height 4 mm/ width 5 mm). After sealant application, immediately fix the Hard-Top assembly, with help of sufficient manpower. Silicon sealant must be applied for water leakage and wind noise prevention. Refit in the reverse order of removal. While Installation hand tighten all the Hard top mounting bolts first for proper positioning and finally torque tighten all the bolts. Don\u2019t over tighten the screws to avoid the thread slipping and other damages. While Installation properly position the Hard top dowels in the body for proper positioning & fitment. Inspect the hard top assembly for any damage. Replace if found. Remove the Spare Wheel Carrier. Remove the air extractor from the vehicle. Refit in the reverse order of removal. Inspect the air extractor for any crack or damage. Replace if any. Using 12 mm socket and 13 mm combination spanner, Unscrew front bracket mounting bolt and nut. Using 12 mm socket and 13 mm combination spanner, Unscrew front centre bracket mounting bolt and nut. Using 13 mm socket combination spanner, Unscrew rear bracket mounting bolt. Remove the front foot step assembly from vehicle. Front extreme portion of foot step is not to stand, Since front portion is aesthetic part to merge the design theme with cladding. Refit in the reverse order of removal. Check for any damages or crack in foot step assembly. Replace if found. Pull out cover cap from the wiper arm. Using a 13mm socket spanner, loosen and remove the Wiper arm mounting nuts. Torque : 15 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250008.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the wiper arms from vehicle. Torque : 1.9\u00b10.5Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250011.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the Scuttle Grill mounting Scrivets.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250010.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the Scuttle Grill from the vehicle. Refit in the reverse order of removal. Inspect the Scuttle grill for any damage. Replace if found. Inspect the mounting push buttons, replace if required. Using a star screw driver, loosen and remove the front splash shield mounting screw rivets from both the sides of vehicle. Using a 10 mm socket spanner, loosen and remove the front stone guard front mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250032.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen and remove the rear stone guard rear mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250064.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the stone guard mounting screw rivets. Remove the stone guard from the vehicle. Disconnect the fog lamp electrical connectors LH & RH sides. Pull and remove the front bumper top panel trim clips and remove the panel. Using a 10 mm socket spanner, Unscrew front bumper mounting nuts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290003.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290004.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "using a 13 mm socket spanner, Unscrew front bumper bottom mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290005.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew front bumper top side mounting bolts. Using a star screw driver, Unscrew front bumper top centre mounting screw rivets. Remove the front bumper assembly from the vehicle. Using a 13 mm socket spanner, Unscrew front bumper center bracket mounting bolts and remove the front bumper center mounting bracket. Torque : 10.0\u00b11 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290010.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the front grill mounting screw rivets. Using a star screw driver, loosen and remove the bottom side front grill mounting screw rivets. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290011.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the front grill mounting bolts. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250061.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Remove the front grill assembly from the vehicle. Using star screw driver, Remove centre grill mounting screws and locking clips from front facia. Remove the centre grill from front facia. Refit in the reverse order of removal. Inspect the front bumper assembly for any crack or damage, Replace if found any. Check the front grill assembly for any external cracks, replace if found any. Remove the Soft top canopy. Using a 10 mm socket spanner, loosen and remove the rear side cover LH mounting bolts. Using a 10 mm socket spanner, loosen and remove the rear side cover RH mounting bolts. Carefully remove the rear side covers LH and RH sides. Using a 10 mm socket spanner, loosen and remove the rear side member RH mounting bolts. Carefully remove the rear side member RH from vehicle. Using a 10 mm socket spanner, loosen and remove the rear side member LH mounting bolts. Carefully remove the rear side member LH from vehicle. Using a 10 mm socket spanner, loosen and remove the rear centre panel assembly mounting bolts. Using a T40 torx socket spanner, loosen and remove the rear structure frame mounting torx bolts. Remove the rear structure frame from vehicle. Refit in the reverse order of removal. Check the rear structure frame for any external cracks and damages, replace if found any. Using a star screw driver, loosen and remove Canopy mounting screws from the front side bow assembly RH and LH. Remove the lock from the RH and LH Front side bow assembly. Using star screw driver, loosen and remove Canopy mounting screws from Front side bow assembly inner side. Remove the Canopy from the front side bow assembly. Using star screw driver, loosen and remove the canopy mounting screws from bow 2 pivot assembly and detach canopy. Using star screw driver, loosen and remove the canopy mounting screws from bow 3 assembly and detach canopy. Remove the Center Support Rexine Rivets. Remove the Canopy from the Frame. Refit in the reverse order of removal. While Installation, Insert the cable from bracket side to Spring side (Insert spring inside from top). ",
+ "file": null,
+ "display_order": 33
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the convertible soft top canopy for any crack or damage. Replace if any. Remove the front door inner trim. For additional information refer to the Front Door Inner Trim - R &R; section. Remove the ORVM from the vehicle completely. Refit in the reverse order of removal. Inspect the ORVM for any crack or damage. Replace if any. Remove front lateral trim. Remove Roof Speaker trim assembly Open the top cover and Using a 14 mm socket spanner, loosen and remove the seat belt upper mounting bolt. Torque :38 \u00b16 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210079.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210080.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the seat belt lower mounting bolt. Torque :38 \u00b16 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210081.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the hand support belt. Remove the floor mate partially from the vehicle. Using a 13mm socket spanner, loosen and remove the roller gage bar rear mounting bolt. Torque : 25 \u00b1 4Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250025.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 13mm socket spanner, loosen and remove the roller gage bar front mounting bolt. Torque : 25 \u00b1 4Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250026.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 13mm socket spanner, Unscrew roller gage bar side mounting bolts. Torque : 25 \u00b1 4Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250027.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the roller gage bar from vehicle. Remove the roller bar cover and separate roller gage bar. Refit in the reverse order of removal. Check for any damages or crack in roller gage bar assembly. Replace if found. Using a 10 mm socket spanner, loosen and remove the rear mounting tube pipe structure mounting bolts. Remove the side cover from window bracket LH and RH sides. Using a 10 mm socket spanner, loosen and remove the front mounting tube pipe structure mounting bolts. Using a star screw, loosen and remove the canopy front LH and RH screw rivets. Using a 10mm socket spanner, Unscrew canopy front end mounting bolts. Remove the Canopy from the vehicle. Refit in the reverse order of removal. Check the canopy assembly for any external cracks, replace if found any. Recover the AC gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. Remove the Air Cleaner Assembly. Remove the Steering Lower Intermediate Shaft. Using 12 mm open end spanner, Remove suction and discharge hose mounting nut from compressor. Torque Value: 14.0+1.0 Nm For additional information refer to AC/Water Pump Belt - R &R. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200094.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect the AC compressor electrical connector. Using 12 mm socket spanner, Remove the compressor mounting nuts from the crank case. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200096.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the compressor from the vehicle. Install in the reverse order of removal. For additional information refer to Steering Lower Intermediate Shaft - R &R. ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Refit the Air Cleaner Assembly. For additional information refer to AC/Water Pump Belt - R &R. ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Recharge the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. During installation, fix the new O-ring into both liquid tube and discharge hose mounting joints without any damage. Damage to the O-ring may cause A/C refrigerant leakage which leads to A/c failure. Inspect the compressor for any physical damage. Replace if found. Inspect the clutch pulley for any damage. Replace if found. Inspect the drive belt and Pulley for any physical damage. Replace if found. Remove the HVAC Mode Actuator. Using star screw driver, Unscrew plate mode main link mounting screws and remove the link. Remove the lever sub assembly and lever foot from the plate mode main link. Install in the reverse order of removal. Inspect the plate mode main link for any damage. Replace if found. Using screw driver, remove the floor console RH panel assembly scrivet and detach the panel from the vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220006.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220007.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the floor console LH panel assembly scrivet and detach the panel from vehicle.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220008.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W749.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the RH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220010.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W750.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the LH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290036.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Partially detach bezel HAVC control panel assembly and disconnect electrical connectors. Disconnect Heater, Mode selection control cables from the HAVC control panel. Disconnect the cable routing clips and take out the bezel Assembly with HVAC control panel. By using star screw driver, remove the HVAC control panel mounting screws and remove the panel from the bezel assembly. Torque : 1.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the HVAC Control Panel Assembly for any damage. Replace if found. Do not release the refrigerant into the atmosphere. Use approved recovery/ recycling equipment to capture the refrigerant whenever the air conditioning System is discharged. Always wear eye and hand protection (goggles and gloves) when working with any Refrigerant or air conditioning system. Close the high pressure and low pressure refrigerant lines with dust caps to avoid air entry and/or contamination. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Recover AC gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. Remove Front Grill Assembly. Using 12 mm Combination Spanner, Unscrew the AC pipe compressor side mounting nut. Torque : 14.0+1.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200071.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew radiator LH seal mounting bolt and remove the seal. Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200069.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Remove HVAC pipe condenser side mounting nut. Torque : 6.0+1.0 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both pipe ends mounting joints without any damage. Damage to the Oring may cause A/C refrigerant leakage which leads to A/c failure. Remove the HVAC pipe assembly from the vehicle. Install in the reverse order of removal. Recharge the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. Inspect the AC pipe for any damage. Replace if found. Whenever over voltage/under voltage situation will occur over ignition Line. These voltages will get sense by MCU and based on these sense voltages panel functionality will disabled or in case of under/over Voltage system will not detect any switch command. It is a kind of Security over connector Pins except Power supplies Pins. If any shorting occur on connector pin either short to battery or short to ground there should be no damage to control panel or circuitry. Over Current/Short to Ground: Air Intake Indicator on off with Frequency 1000 mSec Interval. Short to Battery/ Actuator Stuck: Air Intake Indicator on off with Frequency 500 mSec Interval. Over Current/Short to Ground: Defrost Indicator on off with Frequency 1000 mSec Interval. Short to Battery/ Actuator Stuck: Defrost Indicator on off with Frequency 500 mSec Interval. AC Indicator Blink with 500 mSec Frequency. For additional information refer to AC gas recovery procedure. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Radiator LH & RH seal. For additional information refer to the Radiator LH & RH Seal R&R section. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew HVAC Suction and return pipe mounting nuts. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0+1.0 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both pipes mounting joints without any damage. Damage to the O-ring may cause A/C refrigerant leakage which leads to A/c failure. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200185.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew condenser mounting bolts from radiator end. ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 5 \u00b11 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200075.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Remove the radiator bottom seal mounting bolts and detach it. ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 7\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200196.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200074.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Detach the ambient temperature sensor from the routing clip. ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200076.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Carefully remove the condenser from vehicle. ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200077.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Refit the Radiator LH & RH seal. For additional information refer to the Radiator LH & RH Seal R&R section. ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Recharge the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. ",
+ "file": null,
+ "display_order": 27
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the condenser for any physical damage, leakages etc. Replace if found any. Using screw driver, remove the floor console RH panel assembly scrivet and detach the panel from the vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220006.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220007.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the floor console LH panel assembly scrivet and detach the panel from vehicle.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220008.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220009.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the RH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220010.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220011.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the LH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290035.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200152.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200153.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Partially detach HAVC control panel bezel and remove the mode cable from HVAC control panel end and routing clip. Disconnect the mode cable from HVAC unit end. Remove the cable from the vehicle. Install in the reverse order of removal. Inspect the HVAC mode cable for any damage, Replace if required. Inspect the Mode Cable locks for any damage, Replace if required. The Airbag ECU is installed on the floor panel under the floor console. It deploys the proper Airbag according to the signals from the impact sensors. This ECU communicates with other ECU\u2019s through CAN directly. Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Before disconnecting the battery, check for the audible sound of EWP ON Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Front console assembly. For additional information refer to Front Console Assembly R &R; section. Using star screw driver remove the Airbag ECU Cover screw from airbag ECU. Disconnect the SRS/ Airbag ECU electrical connectors. Using a 10 mm socket spanner, loosen the SRS/ Airbag ECU mounting nuts on the floor panel. Torque :8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210053.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210054.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the SRS/ Airbag ECU from the body. Install in the reverse order of removal. Inspect the airbag ECU for any damage, replace if found any. Inspect the airbag ECU connectors for any damage. For additional information refer to AC Gas Recharging Procedure. ",
+ "file": "",
+ "display_order": 11
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Inspect the heater core assembly for any damage. Replace if found. Remove the IP lower panel from the vehicle. Disconnect the mode actuator electrical connector. Using star screw driver, Unscrew mode actuator mounting screws. Install in the reverse order of removal. Inspect the actuator for mechanical damage. Check and clean the connector pins for sulphation and deposits. 1. AC Filters \u2013 Clean if necessary.
2. AC gas \u2013 Use only R134a A/C gas and only from recommended suppliers.
3. Ensure correct amount of A/C gas is filled in the system.
4. Ensure cleanliness of the condenser surface at regular interval.
5. Ensure proper function of condenser fan. 6. For A/C System testing use only approved Tools & Equipment.
",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "This A/C performance test is only to check mechanical performance of the HVAC system and not the flow or circulation related complaints. Open the glow box and detach the stopper by pressing it. Disengage the glow box from the assembly. Press and remove the HVAC particulate filter cover from HVAC unit. Remove the HVAC particulate filter. Install the HVAC particulate filter on HVAC unit. Install the HVAC particulate filter cover. Engage the glow box stopper and refit the glow box in its position. While installing the filter take sufficient care to prevent bent, damage etc. Close the co-driver door. Use only genuine filter element. Never clean and reuse the HVAC particle filter element. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220006.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220007.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "1. Using screw driver, remove the floor console LH panel assembly scrivet and detach the panel from vehicle. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220008.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W747.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the RH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220010.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W748.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the LH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290035.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200156.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200157.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Partially detach HAVC control panel bezel and remove the heater cable from HVAC control panel end and routing clip. Open the glove box and remove the glove box by removing the glove box lock. Disconnect the heater cable from the HVAC unit end. Remove the cable from the vehicle. Install in the reverse order of removal. Inspect the HVAC heater cable for any damage, Replace if required. Inspect the heater Cable locks for any damage, Replace if required. Position the vehicle on 2 post lift/ 4 post lift. Check the HVAC drain pipe locking grommet fitment condition on BIW. Ensure that pipe is straight downwards. Do not pull the water drain pipe excessively. Remove the Cross Car Beam (CCB) Assembly. Recover the AC gas. For additional information refer to AC gas recovery procedure. Using 10 mm open end spanner, Remove the HVAC Pipe mounting nut from expansion valve end. Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both liquid tube and discharge hose mounting joints without any damage. Damage to the O-ring may cause A/C refrigerant leakage which leads to A/c failure. Detach heater inlet and outlet hose quick couplers. Do not open the degassing tank cap when the coolant is hot. Failure to follow this instruction will lead to personal injury. Before removing the heater core hoses, open the degassing tank cap for releasing the coolant pressure. Coolant will leak, while removing the heater core hoses, as a result drain the coolant into a container. Using 10 mm Socket Spanner, Unscrew the HVAC unit assembly mounting bolt and nuts. Torque : 7 \u00b11 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 7 \u00b11 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 7 \u00b11 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200104.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm Socket Spanner, Remove the HVAC earth cable mounting nut. Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200102.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200103.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the HVAC unit assembly from vehicle. Install in the reverse order of removal. Refit the Cross Car Beam. Recharge the Refrigerant. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. Start the engine, check the coolant level. Refill if required. Check the coolant leak when engine is started. Check the A/C system cooling and operation. Inspect the HVAC assembly for any physical damages. Repair if found. Inspect the kinematics for proper functioning. Inspect the actuators / cables for proper operation. Inspect the filter element and clean/replace if required. Disconnect air fresh and recirculation actuator electrical connector. Using star screw driver, Unscrew the actuator mounting screws. Remove the air fresh and recycling actuator . Install in the reverse order of removal. Inspect the actuator for mechanical damage. Check and clean the connector pins for sulphation and deposits. Do not release the refrigerant into the atmosphere. Use approved recovery/ recycling equipment to capture the refrigerant whenever the air conditioning System is discharged. Always wear eye and hand protection (goggles and gloves) when working with any Refrigerant or air conditioning system. Close the high pressure and low pressure refrigerant lines with dust caps to avoid air entry and/or contamination. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Recover the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. Remove the Front Grill Assembly. Remove the Air Cleaner Assembly. Using 10 mm open end spanner, Liquid pipe pipe mounting nut from expansion valve end. Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200062.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Remove Liquid pipe routing bracket mounting nut from the vehicle. Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200063.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200129.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen and remove the suction hose routing bracket mounting nut. Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200064.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect the pressure switch electrical connector. Using 10 mm socket spanner, Unscrew radiator LH seal mounting bolt and detach it. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200067.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew Liquid pipe mounting nut from condenser end. Torque : 6.0+1.0 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both end of liquid tube mounting joints without any damage. Damage to the O-ring may cause A/C refrigerant leakage which leads to A/c failure. Remove the liquid pipe from the vehicle. Install in the reverse order of removal. Refit the Air Cleaner Assembly. Refit the Front Grill Assembly. Recharge the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. Inspect the suction hose assembly for any physical damage, leakages etc. Replace if found any. Inspect for any foreign materials on condenser. Clean if found. Check and ensure free flow of condenser. Remove the HVAC control panel. Remove the Glove Box Assembly. Remove the driver side IP panel assembly. Remove the wiring harness routing clips from the HVAC assembly. Disconnect the fresh air actuator, mode actuator, blower motor, blower resistor, evaporator temperature sensor and blower switch Connectors. Carefully remove the HVAC wiring harness from the IP assembly. Install in the reverse order of removal. Inspect the electrical connectors for mechanical damage. Replace if found. Check and clean the connector pins for sulphation and deposits. Remove the IP Centre Switch Bank Assembly. Using a star screw driver, Unscrew HVAC control unit mounting screws. Torque : 1.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200083.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the HVAC Control panel. Install in the reverse order of removal. Inspect the HVAC Control Panel Assembly for any damage. Replace if found. By using screw driver remove the TVD screw. Make aligning marks on the flange, UJ and propeller shaft before removal. Torque : 14 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130031.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 14 mm ring and socket spanners unscrew rear propeller shaft mounting bolts and nuts from transfer case end. Torque : 55 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130032.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W315.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W316.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the TVD assembly from vehicle and hang the Rear propeller shaft aside. Install in the reverse order of removal.
2. Inspect the propeller shaft for any bend, crack, twisting and stone penetration, if foun replace the propeller shaft assembly.
3. Check the propeller shaft for any flyweights missing. Replace the propeller shaft if found.
4. Clean the propeller shaft if any foreign materials like dirt found.
",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 94,
+ "sys_id": "THAR.AX-0001-Propeller Shaft",
+ "subsys_id": "THAR.AX-0001-Propeller Shaft-Propeller Shaft Imbalance - Check",
+ "systems": "Propeller Shaft",
+ "sub_systems": "Propeller Shaft Imbalance - Check",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A130002.jpg",
+ "myid": 1215,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Propeller Shaft Imbalance - Check-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "If the propellers shaft unbalance is suspected then it can be verified by the following procedure, removing & rendering the propeller shaft by 180\u00b0 may eliminate some vibrations. Clean all the foreign material from propeller shaft and the universal joint. Ensure that the propeller shaft is not worn, are properly installed and are correctly aligned with the propeller shaft. Check the companion flange mounting bolts. Raise the vehicle and remove rear wheels & tyres. Install the wheel nuts to lock the brake drum. Mark & number the shaft 6 inches from pinion end at four positions 90\u00b0 apart. Run and accelerate the engine until vibration occurs. Note the intensity & the speed at which the vibration occurs. Install a screw clamp at position \u201c1\u201d Start the engine and recheck for vibrations. If there is little vibration or no change in vibrations then move the clamp to the other 3 positions. If there is no difference in vibration at the other position then the vibration is not due to the propeller shaft imbalance. If the vibration decreases, install a second clamp and repeat the test. If the clamps cause an additional imbalance, separate the clamp (\u00bc inch above & below the mark). Repeat the vibration test. Increase the distance between the clamps until the vibration is at the lowest level. At this position bend the slack end of the clamp so that it does not loosen. Install the wheel & tyres. Lower the vehicle. If the amount of the vibration remains unacceptable then repeat the exercise at the gearbox end. After completing above procedure, if vibration is reduced, which indicates there is some imbalance in the propeller shaft. Replace the propeller shaft. Tyres that are out of round or wheels that are out of balance causes a low frequency vibration. \u2022 Brake drums that are unbalanced cause a harsh low frequency vibration. Drive line vibrations can also result from loose or damaged engine mountings Propeller shaft vibrations will keep on increasing as the vehicle speed increase. The propeller shaft does not cause a vibration that is present only in a narrow speed range. Refer below chart for various symptoms, causes and their remedial actions \u2013 ",
+ "file": null,
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Component Inspection and Testing Table",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10325.jpg",
+ "display_order": 4
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 95,
+ "sys_id": "THAR.AX-0001-Propeller Shaft",
+ "subsys_id": "THAR.AX-0001-Propeller Shaft-Propeller Shaft Run out \u2013 Check",
+ "systems": "Propeller Shaft",
+ "sub_systems": "Propeller Shaft Run out \u2013 Check",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A130007.jpg",
+ "myid": 1216,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Propeller Shaft Run out \u2013 Check-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the propeller shaft from vehicle. Remove dirt, rust, paint & undercoating from the propeller shaft surface. Keep the propeller shaft on surface plate along with \u2018V\u2019 block at both ends. The dial indicator must be installed perpendicular to the shaft surface. Measure the run out at the center and at the ends by rotating propeller shaft assembly by hand \u2013 away from the weld. Replace the propeller shaft if the run out is beyond the specified limit. Position the vehicle on 2 post lift/ 4 post lift. Rotate Steering wheel from one end to other for better visualization of boots. Inspect the RH side drive shaft condition for cracks or damage. Replace if necessary. Inspect the inboard and outboard joint LH side drive shaft boots, clamps for cut, nick, loose, bend, crush or abrasion. Replace if necessary. Rotate Steering wheel from one end to other for better visualization of boots. Inspect the LH side drive shaft condition for cracks or damage. Replace if necessary. The combination switch is mounted on the steering column and houses the switches for head lamps, fog lamps and wipers. It comprises a central switch assembly and 2 stalks for controlling the lamps and wipers. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Disconnect the electrical connector from combination switch. Using a star screw driver, loosen and remove the mounting screw to remove combination switch. Gently remove the combination switch from the vehicle. Install in the reverse order of removal. Tighten the combination switch mounting screw as per specification over tighten will lead to damage of the switch. Start the engine and place the wheels at straight ahead direction. For additional information refer to Steering straight ahead setting procedure. Turn the steering wheel until the tyres starts to move and measure the free play on the circumference of the steering wheel. Free Play Value \u00b1 5\u00b0 If the free play is out of the specified value, check the free play in steering column shaft connection and steering linkage. Replace or repair if necessary. The rack and pinion design is a simple design. However it is still susceptible to various problems in particular to leaks. If the bellows are ripped or are unable to keep the contaminant\u2019s away then it can cause damage to oil seal and subsequent leaks. One complaint, which can be present, is that the steering may be stiff and jerky when the unit is cold and as the vehicle is driven and it warms up the power assist gradually comes back. This normally indicates that grooves have worn into the bore of the pinion aluminum housing by control valve seals which may have hardened due to ageing. Wear in the centre housing causes the fluid to leak around the rack piston. Causing either steering wander or lack of straight- ahead stability. Another cause of steering wander and erratic control often accompanied by clumping, thunking noise is the deterioration of rack mounting bushings. Fluid leaks can be hard to locate. Sometimes you will see a low level in the pump reservoir but no evidence of escaping fluid. Squeeze the bellows and you will probably find that they are full of fluid. To confirm if that side of the rack is the root cause, then remove the both the bellows, clean the rack housing and then operate the system to observe the seepage directly. A rusty input shaft U joint or deteriorated flexible textile coupling could imitate rack problems If the cause is not visually evident, verify the symptom and refer to the Troubleshooting Chart Remove the Front RH wheel. For additional information refer into Front Wheel - R &R; Section. By using Star Screw driver, remove the scrivets and remove the front RH wheel arch apron. Using a 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially detach the degassing tank. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190123.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the front differential breather hose routing clip. Using a 12 mm socket spanner loosen and remove the steering return line routing bracket mounting bolts. Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190087.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a hose clamp plier, unclip the hose clamp from power steering side. Using a 17 mm open end spanner, loosen the flare nut and detach the return line from the rack and pinion side. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190112.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the steering return line hose gear end from the vehicle. Install in the reverse order of removal. Fill the fluid and carry-out air bleeding procedure. For additional information refer to Power steering fluid filling procedure. Inspect for any external damage or bent, if found replace. Power Steering Oil - MAHINDRA 'MAXIMILE POWER STEERING FLUID' GENUINE POWER STEERING FLUIDCapacity \u2013 0.85 Litres Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Before disconnecting the battery, check for the audible sound of EWP ON Remove the Driver Airbag. Disconnect the electrical connection from steering switches. Using a star screw driver, loosen and remove the steering switches mounting screw then remove the steering switches from the vehicle. Install in the reverse order of removal. Inspect for any external damage or bent, if found replace. Remove the front RH wheel. For additional information refer into Front Wheel -R &R; Section. By using Star Screw driver, remove the scrivets and remove the front RH wheel arch apron. Using a 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially detach the degassing tank. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190083.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner, loosen and detach the pressure hose flare nut from the power steering pump. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190128.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner, loosen and detach the pressure hose flare nut from the power steering gear. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Position a tray below the rack to collect the fluid Using a 12 mm socket spanner, loosen and remove the routing bracket mounting bolt. Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190114.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the supply hose from the vehicle. Install in the reverse order of removal. Fill the fluid and carry-out air bleeding procedure. For additional information refer to Power steering fluid filling procedure. Inspect for any external damage or bent, if found replace. The steering pump is a constant flow, vane type incorporating a flow control valve (with an integrated relief valve) and it is belt driven by engine. Drain the power steering fluid. For additional information refer to Power steering fluid draining section. Using a 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially detach the degassing tank. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the engine feed system cover. For additional information refer into the Engine Feed System Cover \u2013R &R; Section. Using 14 mm rings spanner rotate the auto tensioner in counter clockwise Partially detach the power steering belt. Using a 17 mm open end spanner, loosen and detach the pressure hose flare nut from the power steering pump. Torque :22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190082.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a hose clip plier, unclip the return hose to reservoir hose clamp from pump. Using a 12 mm socket spanner, loosen and remove the power steering pump mounting bolts. Torque :25\u00b1 3 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Notice",
+ "content": "While loosening the bolt hold the nut using 12 mm ring spanner. Remove the power steering pump from the vehicle. Install in the reverse order of removal. While tightening the bolt hold the nut using 12 mm ring spanner. Carry-out power steering fluid filling and bleeding procedure. Inspect the pump for any physical damage. Replace the pump if found Inspect the pump for any fluid leakages. Inspect the pulley for any damage. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Before disconnecting the battery, check for the audible sound of EWP ON Remove the Driver Airbag. Disconnect the electrical connection from steering switches. Using a star screw driver, loosen and remove the steering switches mounting screw then remove the steering switches from the vehicle. Install in the reverse order of removal. Inspect for any external damage or bent, if found replace. The steering column is bolted to the bulk head. It is a tiltable and collapsible column. The steering column shaft is mounted on two needle bearings internally at the ends suspended by rubber mountings in the steering column assembly. An intermediate shaft connects the steering column to the steering gear. For reasons of safety, the steering column assembly incorporates a collapsible steel cage and an intermediate shaft with a deformation zone designed to crumple progressively in the event of a headon collision. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Remove the steering wheel. Disconnect the ignition key barrel electrical connector. Using a Small chisel or punch hit and unscrew the mounting screw of ignition switch barrel with support of hammer. Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft bottom mounting bolts and detach the intermediate shaft bottom from the steering column. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190039.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering column mounting bolts and nuts then remove the steering column from the vehicle. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190108.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190040.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the mounting bolt and remove top intermediate shaft from column. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190133.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Ensure to Assemble Upper & Lower I shaft connector according to the marking. Inspect the steering column for any external damage or bent, if found replace. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Remove the steering wheel. Disconnect the ignition key barrel electrical connector. Disconnect the combination switch & clock spring electrical connectors. Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft bottom mounting bolts and detach the intermediate shaft bottom from the steering column. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190039.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering column mounting nuts then remove the steering column from the vehicle. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190120.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190111.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the grommet mounting bolts then remove the grommet from vehicle . Torque : 22 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190133.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Ensure to fit the Grommet Projection should face driver side. Ensure Shaft to Grommet clearance is 5 mm in top side. Ensure to install Upper & Lower I shaft connector according to the marking. Inspect for grommet any external damage or cracks, if found replace. Remove the Front wheel. For additional information refer to Front Wheel \u2013 R &R; Section. Remove the respective side Front Wheel Hub. Using a 10 mm socket spanner , loosen and remove the wheel speed sensor mounting bolt & routing bracket mounting bolt. Torque :8 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190009.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a cutting plier and 17 mm socket spanner, remove the tie rod end cotter pin and tie rod end nut and detach from knuckle. Torque :45\u00b19Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190010.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a cutting plier and 24 mm socket spanner, remove the lower ball joint cotter pin and Lower ball joint nut and detach from knuckle. Torque :130 \u2013 150 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190011.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 22 mm socket spanner, loosen and remove the knuckle Lower Half mounting bolts. Torque :140 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190012.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a cutting plier and 24 mm socket spanner, remove the upper ball joint cotter pin and ball joint nut and detach from knuckle. Torque :90 \u2014 110 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190013.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190014.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the knuckle from the vehicle. After installation of knuckle assembly, Carry out the wheel alignment. Install in the reverse order of removal. Torque tightening should be done without load and with the tyres on level ground. Always use new split pin. Inspect for any external damage or bent, if found replace. If the steering angle is out of the specified value, check and adjust the toe. The steering wheel is the part of the steering system that is rotated by the driver; the rest of the steering system responds to driver inputs. The steering wheel houses the driver airbag and audio controls. It is connected to the collapsible steering column. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Remove the driver air bag. For additional information refer to Driver Airbag -R &R; Section. Using a 17 mm socket spanner, loosen and remove the steering wheel mounting nut. Torque : 47\u00b17Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190021.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect clock spring electrical connector. Remove the steering wheel from the vehicle. Do not use excessive force to the steering wheel for removal. This may cause steering wheel bend. Gently tap if needed. While installing steering wheel ensure the splines are aligned properly and the steering wheel slides easily on the column shaft. Remove electrical connectors and mounting screws from the steering switch (both side) Install in the reverse order of removal. Ensure the front wheels are in straight ahead position. Improper or incorrect removal and installation of the Restraint components will cause unintentional activation of the system which may lead to personal injury. The service operations should be followed in the correct sequence. Failure to do so may cause the SRS to unexpectedly deploy during service leading to a serious accident. Inspect the steering wheel for any external damage or bent, if found replace. Position the Vehicle on 2 post /4 post lift Power Steering Oil - MAHINDRA 'MAXIMILE POWER STEERING FLUID' GENUINE POWER STEERING FLUID Capacity \u2013 0.85 Litres Check Power Steering fluid level , if found less than MIN mark, top up to MAX mark. Always maintain fluid level at MAX mark on reservoir. Fluid reservoir outlet and return hose connection to reservoir. Power steering pump inlet and outlet connection. Power steering gear fluid inlet and outlet connection. Power steering rack feed tube connections. In case of non-availability of Genuine fluid, SHELL MAKE 'SPIRAX S3 ATF MD3' can be used. NO OTHER BRANDS RECOMMENDED. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Remove the Steering Column Shrouds. For additional information refer into Steering Column Shrouds Section. Remove the steering wheel. Disconnect the clock spring electrical connectors. Dis-engage the clock spring mountings (3 points) and lift out the clock spring assembly from the steering column. Install in the reverse order of removal. If the contact coil is not aligned correctly, the steering wheel may not be able to rotate properly during turning. This kind of restricted turning ability may cause the vehicle to crash or damage the contact coil and prevent the air bags from deploying in a crash event. Carry-out the clock spring setting procedure. Failure to do clock spring setting may result in clock spring damage. Check the clock spring assembly of steering wheel for any malfunctioning or damages, replace if found any. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Remove the steering wheel. Disconnect the ignition key barrel electrical connector. Disconnect the combination switch & clock spring electrical connectors. Using a 12 mm socket spanner, loosen the steering intermediate shaft top bolt and remove bottom mounting bolts and detach the intermediate shaft bottom from the steering column. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190039.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering column mounting nuts then remove the steering column from the vehicle. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190108.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190109.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the top intermediate shaft mounting bolts then remove the top intermediate shaft from the steering column. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190133.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Ensure to install Upper & Lower I shaft connector according to the marking. Inspect for any external damage or bent, if found replace. Remove the E-Disconnect Motor. Remove the engine feed system cover. For additional information refer to Engine Feed System Cover - R &R; section. Remove the Front wheels (Both RH & LH). For additional information refer into Front Wheel - R &R; Section. The wheels should be in straight ahead position before disconnecting the steering rack assembly from the vehicle. Using a 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially detach the degassing tank. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190121.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a cutting plier remove the cotter pin from the LH & RH tie rod . Using the 17 mm socket spanner, loosen and remove the LH & RH tie rod end ball joint nuts from the knuckle assembly. Torque : 45 \u00b1 9 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190044.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft mounting nut from the rack and pinion assembly and detach the intermediate shaft. Torque : 22\u00b14 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190047.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner, loosen and remove the flare nuts and detach the steering rack and pinion supply and return lines. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": "Plug the steering rack assembly inlet and outlet hose oil passage with dust cap to avoid any foreign particles entry. Drain the power steering fluid. Using a 12 mm socket spanner, loosen and remove the supply line routing bracket mounting bolt. Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190049.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a 19 mm socket spanner, loosen and remove the steering rack and pinion assembly mounting bolts. Torque : 85 \u00b1 13 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Notice",
+ "content": "Use open end torque wrench for tightening RH side mountingbolt. Detach the front differential breather hose routing tag. Remove the steering rack and pinion assembly from the vehicle. Install in the reverse order of removal. Always use a new cotter pin. Ensure I shaft connector is assembled as per given marking. At straight ahead condition bolt head should face top side for easy torquing Fill the power steering fluid and do the air bleeding procedure. Carry out the wheel alignment. Check the steering rack assembly for cracks, damages or leakages. Replace the steering rack assembly if required. Check the steering inner ball joint for any damage. Replace the steering rack assembly if required. Check the steering rack dust boot for any wear or deterioration. Replace if necessary. Position the vehicle on 2 post lift/ 4 post lift. Check the steering rack assembly RH side boots, clamps for cut, nick or abrasion, replace if necessary. Check the steering rack assembly LH side boots, clamps for cut, nick or abrasion, replace if necessary. Check the steering rack assembly RH side linkage condition (Without removing boots) for play, damage, replace if necessary. Rotate Steering wheel from one end to other for better visualization of boots. Check the steering rack assembly LH side linkage condition (Without removing boots) for play, damage, replace if necessary. Rotate Steering wheel from one end to other for better visualization of boots. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Remove the steering wheel. Disconnect the ignition key barrel electrical connector. Disconnect the combination switch & clock spring electrical connectors. Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft bottom mounting bolts and detach the intermediate shaft bottom from the steering column. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190039.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering column mounting nuts then remove the steering column from the vehicle. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190120.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190111.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the grommet mounting bolts then remove the grommet from vehicle . Torque : 22 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190133.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Ensure to fit the Grommet Projection should face driver side. Ensure Shaft to Grommet clearance is 5 mm in top side. Ensure to install Upper & Lower I shaft connector according to the marking. Inspect for grommet any external damage or cracks, if found replace. Disconnect the RPAS sensor electrical connectors. Unlock the RPAS sensors from the cover. Detach the sensors from vehicle. Check sensor, wiring, connector for any damage. Check for mud on sensor, clean gently if found. Remove selective diesel particulate filter (SDPF). Drain the engine coolant. For additional information refer into coolant draining and refilling procedure. Using a 10 mm socket spanner, loosen and remove the OCFM side Mounting bolt. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050190.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the OCFM routing bracket bolt. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050140.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a hose clip plier, loosen and remove the EGR quick coupler from the engine . Using a hose clip plier, loosen the Dosing Module inlet hose clip and remove the hose. Remove the pipe takeout from the vehicle. Install in the reverse order of removal. Carry-out coolant filling and de-aeration process. For additional information refer into coolant draining and refilling procedure. Check inlet pipe for any damage, cracks, kinks and degradation found replace the inlet pipe with a new one Check inlet pipe mounting for proper tightness and damages, replace the inlet pipe if required. Remove the thermostat valve from the thermostat housing. Thermostat and thermometer bulb should be suspended in water. If they touch bottom or the sides then temperature in which thermostat / thermometer operate will not be correct and wrong diagnosis will take place. Insert the thermostat valve in to a container filled with water. Heat the container and measure the temperature of water by Using digital thermometer. Keep track of water temperature and respective valve opening/ travel. Thermostat should start opening at 88 \u00b1 2 \u00b0 C (0.1 mm travel) . Once temperature reaches 96 \u00b1 2\u00b0 C valve should be fully open , at this moment, valve travel will be approximately 8 mm . In case thermostat valve behavior does not confirm to above specifications, it should be replaced. Disconnect the electrical connectors from resistor. Using screw driver, loosen the resistor mounting screw and remove the resistor. Install the reverse order of removal. Check the resistor for any damages, if found then replace it . Coolant flow within the cooling system is shown in the above mentioned schematic diagram. Using 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially remove the degassing tank (Without disconnecting the hoses). Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050052.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect radiator fan electrical connector. Using a 10 mm socket spanner, loosen and remove fan mounting bolts. Torque : 6.5\u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050058.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050057.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the shroud holder clips from radiator and fan then remove the clips (Top & Bottom). Using 7 mm socket spanner, loosen the hose clamp and disconnect the intercooler inlet hose from the intercooler assembly. Torque : 6.5 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050186.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050130.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Detach the fan assembly from radiator bottom seating and remove the radiator fan assembly. While Installing ensure the fan bottom seating are properly seated on radiator. Install the reverse order of removal. Check electric fan blades for any damages. 2 post lift/ 4 post lift.
2. Open the bonnet and lock it in open position using bonnet stay rod.
Coolant \u2013 Mahindra 'MAXIMILE ULTRA COOL' Genuine Long Life Coolant (READY TO USE COOLANT. NO NEED TO MIX WATER).Refilling Capacity \u2013 ~5.0 Litres.Coolant Level And Leak Inspection Procedure: ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the degassing tank pressure cap for any damage or coolant leakage. Rectify the leakage if found. Check the coolant level in the degassing tank, it should be between MAX and MIN marks. Check the coolant level when the engine is cold. If found below MIN mark then top it up with MAHINDRA 'MAXIMILE ULTRA COOL' (ready to use coolant. no need to mix water). Inspect the degassing tank to radiator vent hose for any coolant leakages, also check the mounting spring band clamp for any damage. If found any damage or leak, rectify Inspect the engine to T connection vent hose for any coolant leakages, also check the mounting spring band clamp for any damage. If found any damage or leak,rectify. Inspect the degassing tank outlet hose assembly at every joints such as degassing tank end, T-connector connections, EWP inlet and outlet sides, OCFM side for any coolant leakage, also check the mounting spring band clamp for any damage. If found any damage or leak, rectify. Inspect the radiator inlet hose at radiator and engine block for coolant leakage, rectify the leakage if found. Also inspect the mounting spring band clamp for any damage, replace the mounting spring band clamp if found damaged or loose. Inspect the radiator inlet hose at radiator and engine block for coolant leakage, rectify the leakage if found. Also inspect the mounting spring band clamp for any damage, replace the mounting spring band clamp if found damaged or loose. Inspect the heater inlet & outlet hoses for any coolant leakage at the heater core side, EGR module side, coolant outlet pipe side and coolant nipple heater inlet side, also check the mounting spring band clamp for any damage. If found any damage or leak, rectify. Inspect the Dosing Module inlet hose, Dosing Module outlet hose also check the mounting spring band clamp and bolts for any damage. If found any damage or leak, rectify. Inspect the Coolant Inlet & outlet pipes bolts at OCFM for any damage. If found any damage or leak, rectify. Never remove the degassing tank cap when the engine is hot. Brand Specific. Don't use other Coolants / Water for top up. In case of emergency, Coolant meeting JIS K2234 Specification should be used (30% Concentration Diluted with Distilled water) and coolant change period has to be reduced as 30,000 KM Never mix MAHINDRA MAXIMILE ULTRA COOL with water Drain the engine coolant. For additional information refer into coolant draining and refilling procedure. Using hose clamp plier, release the radiator vent hose spring band clamp and disconnect the hose. Never work with cooling system when the engine is hot. failing to this may cause personal injury. Using hose clamp plier, Release the degassing tank outlet hose spring band clamp and detach hose degassing tank end . Using 10 mm socket spanner, Unscrew degassing tank mounting bolts. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050129.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully remove the degassing tank. Install in the reverse order of removal. Carry-out coolant filling and de-aeration process. For additional information refer to Coolant filling and de-aeration section.
2. Inspect the hoses for any damages, cracks or kinks, if found replace the hose assembly
3. inspect the coolant hoses clamps for proper fitment, if found loose then replace the clips.
",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 385,
+ "sys_id": "THAR.AX-0001-Cooling System",
+ "subsys_id": "THAR.AX-0001-Cooling System-Coolant - Replace",
+ "systems": "Cooling System",
+ "sub_systems": "Coolant - Replace",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.34,
+ "rts": null,
+ "mat": "J08-MAT-0100",
+ "cover_image": "/files/W4A050126.jpg",
+ "myid": 1061,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 33,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 75,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 116,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 155,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 195,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 234,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 243,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 314,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 354,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 394,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 434,
+ "kilometers_applicable": 0
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Coolant - Replace-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Coolant - Replace.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050126.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/15017.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "Description",
+ "content": "1. Position the Vehicle on 2 post lift/ 4 post lift.
2. Open the bonnet and lock it using bonnet retaining lever.
3. Place a tray under vehicle for collecting the coolant.
Coolant \u2013 Mahindra 'MAXIMILE ULTRA COOL' Genuine Long Life Coolant (READY TO USE COOLANT. NO NEED TO MIX WATER).Refilling Capacity \u2013 ~5.0 Litres.Switch OFF the Ignition and allow Engine to cool down. Never remove the degassing cap when the engine is hot Open the degassing tank cap. Using star screw driver, remove the front stone guard screvits. Using a 10 mm & 13 mm socket spanner, loosen the front & rear mounting bolts and remove the front stone guard. Remove the radiator drain plug and allow the entire coolant to get drained. Place a tray beneath the drain plug to collect coolant drained. Start filling the recommended coolant in degassing tank. While filling, open the drain Plug & wait for the coolant to drop & close drain Plug. Check coolant level in degassing tank, add coolant to MAX level and close the degassing cap. Check all the hoses and clips for leakage and correct fitment. Start the engine and run at 3000 rpm for about 10 minutes. (For Thermostat Opening). Maintain Coolant level at MAX level always and ensure coolant never goes below MIN level. Switch OFF the Ignition and allow the engine to cool down, Check coolant level in degassing tank and add coolant to MAX level. Refit the front stone guard screvits & mounting bolts, torque tighten the bolts to specified value. Torque: 4.0 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Inspect the coolant circuit for any leakages. For additional information refer to Coolant level & leak inspection section. Never remove the degassing cap when the engine is hot. Never mix MAHINDRA MAXIMILE ULTRA COOL genuine coolant with water. Brand Specific. Don't use other Coolants / Water for top up. In case of emergency, Coolant meeting JIS K2234 Specification should be used (30% Concentration Diluted with Distilled water) and coolant change period has to be reduced as 30,000 KM Do not overfill the system; allow free space in the degassing tank for expansion of the fluid. Drain the engine coolant. For additional information refer into coolant draining and refilling procedure. Using a hose clamp plier, release electric water pump inlet hose spring band clamp and disconnect the hose. Using a hose clamp plier, release electric water pump outlet hose spring band clamp and disconnect the hose. Disconnect the EWP electrical connector. Using a 10 mm socket spanner, Unscrew EWP clamp mounting bolts and remove the EWP. Install in the reverse order of removal. Carry-out coolant filling and de-aeration process. For additional information refer into coolant draining and refilling procedure. Check EWP for any damage, cracks, kinks and degradation. If found replace the EWP with a new one. Check EWP hose clamps for proper tightness and damages, replace the clamps if required. Drain the engine coolant. For additional information refer into coolant draining and refilling procedure. Using a 7 mm socket spanner, loosen hose clip and detach radiator outlet hose OCFM end. Torque : 6.5 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050084.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the turbocharger oil return pipe routing bracket mounting bolt. Torque : 25\u00b13Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050085.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove coolant inlet pipe bolts and remove coolant inlet pipe OCFM end. Torque : 11\u00b11Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050087.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050162.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Always replace the O ring with New one while removing the thermostat. Carry-out coolant filling and de-aeration process. For additional information refer into coolant draining and refilling procedure. Check thermostat valve opening and closing temperatures, if found deviation from specified value, replace the thermostat. Check travel of thermostat valve, if found deviation from specified value, replace the thermostat. Remove the selective diesel particulate filter (SDPF) . Drain the engine coolant. For additional information refer into coolant draining and refilling procedure. Using a 10 mm socket spanner, loosen and remove the Turbocharger oil drain pipe bottom mounting. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050142.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the Turbocharger oil drain pipe routing bracket. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050143.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the outlet pipe mounting bolt at OCFM end. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050144.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the pipe routing bracket bolt. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050145.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a hose clip plier, loosen and remove Heater outlet hose clamp and detach the hose. Using a hose plier, loosen and remove the EGR quick coupler from the engine . Remove the Pipe EGR Cooler Outlet. Install in the reverse order of removal. Carry-out coolant filling and de-aeration process. For additional information refer into coolant draining and refilling procedure. Check outlet pipe for any damage, cracks, kinks and degradation. If found replace the outlet pipe with a new one. Check outlet pipe mounting for proper tightness and damages, replace the outlet pipe if required. Remove the front grill assembly. Using 10 mm socket spanner, Unscrew the LH and RH radiator seal mounting bolts. Torque : 4.5 \u00b10.5Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050048.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver, loosen and remove the LH and RH radiator seal mounting screw rivets. Torque : 4.5 \u00b10.5Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050134.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the both LH and RH radiator seal from the vehicle. Install the reverse order of removal. Check for any external cracks, replace if found any Check for the obstruction of the air flow, if found please replace. The radiator assembly is a cooler located at the front of the vehicle. The radiator is a heat exchanger that removes the excess heat from the coolant passing through it. The coolant flows inside the radiator from RH to LH. The cool ambient air flows through the fins of the radiator. The heat exchange happens between the coolant to air. Drain Cock is located in the bottom of the Radiator and used to Drain the engine coolant. Drain the engine coolant. For additional information refer into coolant draining and refilling procedure. Remove the Intercooler assembly. Remove the Degassing Tank assembly. Using 10 mm socket spanner, Unscrew degassing tank mounting brackets mounting bolts LH & RH. Torque : 10 \u00b1 0.5Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050179.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect radiator fan electrical connector. Using 10 mm socket spanner, loosen and remove cooling fan mounting bolts. Torque : 6.5\u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050058.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050057.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect the shroud holder clips from radiator and fan then remove the clips (Top & Bottom). Detach the fan assembly from radiator bottom seating and remove the radiator fan assembly. While Installing ensure the fan bottom seating are properly seated on radiator. Using Hose clamp plier, release radiator inlet and outlet hose spring band clamps and disconnect the hoses radiator end. Using hose plier, release vent hose spring band clamp and disconnect hose radiator end. Using 13 mm socket spanner, Unscrew radiator mounting bolts. Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050035.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050036.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew radiator LH & RH seal mounting bolts. Torque : 4.5 Nm ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050033.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050034.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050187.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew condenser mounting bolts and partially detach the condenser from the radiator. Torque : 5 \u00b11Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050032.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Remove the radiator from the vehicle. Install in the reverse order of removal. Carry-out coolant filling and de-aeration process. For additional information refer to Coolant filling and de-aeration section.
2. Check the radiator for coolant leakage, refill if found any.
3. Check the radiator for dust accumulation, clean with compressed air if dust accumulation is noticed.
4. Check for free flow of water from radiator top to bottom.
5. Check the radiator drain plug for any leakage.
",
+ "file": null,
+ "display_order": 49
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 403,
+ "sys_id": "THAR.AX-0001-Cooling System",
+ "subsys_id": "THAR.AX-0001-Cooling System-Troubleshoot - Cooling System",
+ "systems": "Cooling System",
+ "sub_systems": "Troubleshoot - Cooling System",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1454,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Troubleshoot - Cooling System-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Troubleshoot",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10012.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10013.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10014.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Refer below chart for various symptoms, causes and there remedial actions - Position the Vehicle on 4 post lift. Inspect and ensure the following nuts/bolts are with proper torque as recommended: Front shock absorber assembly on chassis (LH/RH). Torque value: 40 \u00b1 5Nm Torque Wrench Type - Open end Torque Wrench Front shock absorber mounting bolt on LCA (LH/RH). Torque value: 120 \u00b1 12 Nm Front stabilizer bar mounting bracket bolts. Torque value: 50 \u00b1 5 Nm Front stabilizer bar link mounting bolts on LCA (LH/RH). Torque value: 90 \u00b110 Nm Front upper control arm pivot mounting bolts on chassis (LH/RH). Torque value: 97\u00b1 10 Nm Front Lower arm mounting bolts on chassis (LH/RH). Torque value: 250 \u00b1 20 Nm Ensure to do the torquing in the nut side and holding the bolt while torquing. Knuckle bottom mounting bolts LHS & RHS. Torque value: 140 \u00b1 10 Nm Torque Wrench Type - Open end Torque Wrench Rear stabilizer bar mounting on Rear Axle (RH/LH). Torque value : 70 \u00b1 7 Nm Rear stabilizer bar link rod mounting on chassis (LH/RH). Torque value : 90 \u00b110 Nm Torque Wrench Type - Open end Torque Wrench Rear lower link mounting on chassis and axle (LH&RH;). Torque value: 230 \u00b1 20 Nm Torque Wrench Type - Open end Torque Wrench for LH chassis side While torquing axle side, hold the nut by open end spanner & do the torquing in the bolt side. Rear upper link mounting on chassis and axle (LH&RH;). Torque value: 230 \u00b1 20 Nm Torque Wrench Type - Open end Torque Wrench for LH chassis & axle side Rear shock absorber bottom mounting on Rear axle (LH&RH;). Torque value : 110\u00b111 Nm Torque Wrench Type - Open end Torque Wrench Rear shock absorber top mounting on chassis (LH&RH;). Torque value : 65\u00b110Nm Pan hard rod mountings on axle & chassis. Torque value: 230 \u00b1 20 Nm Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON Torque :6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010903.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect temperature sensor (T4) electrical connector. Using 17 mm open end spanner, Unscrew temperature sensor T4 mounting on SDPF Torque :35\u00b15 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach T4 sensor from routing clip and remove it Install in the reverse order of removal. Yellow colour tape provided on T4 Sensor wiring pigtail and engine wiring harness connector for easy identification while refit and ensure to properly connect the T4 Sensor wiring pigtail connector with engine wiring harness Mismatch connection of wiring connectors may leads to affect the engine performance and occur engine trouble. Check for any external cracks, replace if found any Position the vehicle on a 2 post / 4 post lift. Exhaust pipe mountings and damage/leakage - Procedure ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Position the vehicle on a 2 post / 4 post lift. Check the insulators of the exhaust front pipe, exhaust intermediate pipe with muffler and exhaust tail pipe, Replace if found elongated or damaged. Check the joint between exhaust tail pipe with intermediate pipe, if found leakage then replace the gasket and torque tighten the nuts to specified value. Check the joint between exhaust intermediate pipe with front pipe for any leakage, if found leakage then replace the gasket and torque tighten the nuts to specified value. Check the joint between exhaust front pipe with SDPF for any leakage, if found leakage then replace the gasket and torque tighten the nuts to specified value. Do not work when the exhaust system is hot. Failure to follow this instruction will result in personal injury. Check all the exhaust joints for leakage and correct fittings. If leakage is found, check the exhaust pipe gasket. Replace if required. The exhaust after treatment system uses SCR (Selective Catalytic Reduction) technology which requires Diesel Exhaust Fluid (DEF) for reduction of NOx in order to enable the vehicle to comply with emission regulations. DEF is a NOx reduction agent. It is recommended to use MaxiCLEAN DEF meeting IS 17042 (or) ISO 22241 specification. It is basically an aqueous urea solution, having a urea content of 32.5% and remaining 67.5% of water. DEF is a nonflammable, non-toxic, colorless and water-soluble liquid. DEF is stored in vehicle in a tank and provision is provided to refill it as per requirements. To enable SCR system to work efficiently and to ensure emission conformance, DEF meeting quality requirements of IS 17042 (or) ISO 22241 standard is mandatory. Even when DEF of correct specification is filled, it\u2019s useful life remain limited depending upon extent of exposure of storage tank/vehicle to varying environmental temperature conditions. Refilling DEF is part of regular maintenance service. DEF consumption is highly dependent on driving conditions/pattern. It may be necessary to refill DEF reservoir in-between the scheduled service, Need to monitor DEF Indicator Tell Tale and symbols/ Alert messages displayed on Cluster screen. It is unlawful to tamper with or remove any component of the after treatment system. It is also unlawful to use a DEF that does not meet the specification provided or to operate the vehicle without DEF. The exhaust after treatment system uses SCR (Selective Catalytic Reduction) technology which requires Diesel Exhaust Fluid (DEF) for reduction of NOx in order to enable the vehicle to comply with emission regulations. DEF is a NOx reduction agent. It is recommended to use MaxiCLEAN DEF meeting IS 17042 (or) ISO 22241 specification. It is basically an aqueous urea solution, having a urea content of 32.5% and remaining 67.5% of water. DEF is a nonflammable, non-toxic, colorless and water-soluble liquid. DEF is stored in vehicle in a tank and provision is provided to refill it as per requirements. To enable SCR system to work efficiently and to ensure emission conformance, DEF meeting quality requirements of IS 17042 (or) ISO 22241 standard is mandatory. Even when DEF of correct specification is filled, it\u2019s useful life remain limited depending upon extent of exposure of storage tank/vehicle to varying environmental temperature conditions. Refilling DEF is part of regular maintenance service. DEF consumption is highly dependent on driving conditions/pattern. It may be necessary to refill DEF reservoir in-between the scheduled service, Need to monitor DEF Indicator Tell Tale and symbols/ Alert messages displayed on Cluster screen. It is unlawful to tamper with or remove any component of the after treatment system. It is also unlawful to use a DEF that does not meet the specification provided or to operate the vehicle without DEF. Do\u2019s & Don\u2019ts ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1E030276.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Do not hold the Supply Module while carry DEF tank. Do not handle Supply Module using connectors, complete housing to be held to avoid any type of damages. Handle Dosing Module using housing and not on connectors to avoid any type of damages. Structural changes of the Dosing Module is not permitted. Dismounting of dosing valve out of the cooling body is not allowed Avoid painting or application of other coatings on Dosing Module (DM) & Supply Module (SM) to ensure lifetime & functionality.
2. Always remove (manually) protection caps of DM & SM just before assembly of its mating pipes/cables, to avoid contamination of the system.
3. Only use recommended tools for remove & Installation of DM & SM. After removing, cover the openings with protective caps to prevent the entry of contaminants.
4. The entry of contaminants in the interfaces of the DM must be prevented during Installation & removing of DM.
",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Storage Guidelines
2. Parts have to be stored in original M&M; packaging
3. Parts needs to be protected against rain, snow, heat sources and dust
4. Max. storage period of DM & SM should be not more than 4 years
5. Avoid any damages to Supply Module while storing DEF tank
",
+ "file": null,
+ "display_order": 10
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 356,
+ "sys_id": "THAR.AX-0001-Exhaust & Emission Control",
+ "subsys_id": "THAR.AX-0001-Exhaust & Emission Control-DEF Tank",
+ "systems": "Exhaust & Emission Control",
+ "sub_systems": "DEF Tank",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W729.jpg",
+ "myid": 1031,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-DEF Tank-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The DEF tank is the reservoir to store and supply the DEF to the dosing module. The supply module is welded along with the DEF tank and consists of the following parts,
1. Integrated DEF filter with filtering size upto 20 microns
2. Supply Pump : Solenoid operated plunger pump - Supplies DEF on Demand
3. Back Flow Pump : Solenoid operated plunger pump - Regulate the pressure and empties the DEF supply line to avoid crystallization
4. Temperature Sensor : NTC type sensor used to measure the temperature of the DEF inside the tank
5. DEF Level Sensor : Ultrasonic level sensor accurately detects the quantity of DEF available in tank. The ultrasonic sensor sends ultrasonic waves from the bottom of the tank. The waves are reflected back to the sensor from the highest level of the DEF present in the tank. The sensor then converts the ultrasonic signal to level and sends it to the EMS ECU multiplexed as a PWM signal. EMS ECU decodes the PWM signal & converts the level to height of DEF present in the tank.
",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W742.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Notice",
+ "content": "Both the supply and back flow pump is integrated as one unit - DEF Pump is a serviceable part and is screwed to supply module ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W729.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "DEF storage",
+ "content_type": "Description",
+ "content": "DEF is stored in vehicle in a tank and provision is provided to refill it as per requirements. For refilling DEF, Filler and Vent Pipe Assembly is provided in the vehicle. DEF filler lid is located in the RH side of Quarter panel, while DEF Tank is located underbody.
The DEF is required to be pumped from DEF tank to the Dosing Module at required rate and under specified range of pressure. Fluid level inside storage tank needs to be monitored. To enable these functions, DEF Supply Module is integrated with the DEF Tank.
Even when DEF of correct specification is filled, it\u2019s useful life remain limited depending upon extent of exposure of storage tank/vehicle to varying environmental temperature conditions.
",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Primary Function",
+ "content_type": "Description",
+ "content": "1. To store DEF in sufficient quantity for specified period so that the customer can refill and maintenance at specified intervals.
2. To assist filling, venting and draining of DEF from tank at specified rate.
3. To enable dynamic venting while preventing dust, foreign particles, moisture or water from getting inside the tank.
4. To enable integration of DEF Supply module and assist in pumping, level sensing.
5. To enable uninterrupted DEF supply when vehicle is negotiating longitudinal grades and side slopes.
6. To contain vibration levels of DEF Supply module below specified limit.
7. To contain fluid sloshing noise to acceptable levels.
",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "DEF Minimum Refill Quantity",
+ "content_type": "Notice",
+ "content": "Always ensure to refill the DEF greater than or equal to the \u2018Minimum Refill Quantity\u2019 DEF level monitoring system will not detect the refill which is lower than the \u2018Minimum Refill Quantity\u2019. The DEF is available under MaxiCLEAN brand. MaxiCLEAN is available in 10 lit, 6 lit & 2 lit packs. DEF can be filled up to the filler neck, if filled very slowly towards the end. Ensure that the maximum refill quantity is calculated so that the available SKUs are used fully. In the event of requirement of less quantity than the full SKU, use a clean measuring can for calculating the billing amount to the customer. The measuring can should be for the exclusive use of DEF only and should not be used to measure any other fluids like Engine oil or Coolant. MDW/DMS accepts \u201cDecimal\u201d billing It is always recommended to fill the Maximum qty to maximise the range of vehicle operation. For removing any SCR hydraulic connections carry out below \u201cSCR ROUTINES\u201d by using i-SMART. For additional information refer Diagnosis Manual. \u2013 EMPTYING of SCR System After removal of supply hose, Cover the DEF tank & Dosing Module with dust caps to avoid entry of dust and Contamination of the DEF. Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Before disconnecting the battery, check for the audible sound of EWP ON. Using star screw driver, Unscrew DEF tank bottom protection cover scrivet clips and detach the cover. Disconnect DEF tank drain hose quick coupler and Drain the DEF firmly. After draining DEF, Cover the drain pipe with dust caps to avoid entry of dust and Contamination of the DEF. Disconnect DEF filler pipe quick coupler DEF tank end. Disconnect DEF vent hose DEF tank end hose. Disconnect DEF supply tube quick coupler and routing clip DEF tank end. Disconnect DEF supply module electrical connectors and routing clip. Using 12 mm socket spanner unscrew DEF tank mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Carefully remove the DEF tank from vehicle. Install in the reverse order of removal. After Refill check and ensure DEF level. For additional information refer to DEF Filled Level Inspection Procedure. DEF First Filling DEF Pressure Preparation DEF Leak Test EMPTYING of SCR System 2. For New DEF Tank Replacement carry out \u201cComponent Replacement Procedures \u2013 DEF Tank Replacement\u201d by using i-SMART. For additional information refer Diagnosis Manual. Check for any external damage and DEF leak, if found please replace. Check for proper functioning of DEF pump, if found any malfunction please replace. Check the DEF supply module, drain tube, fillar & vent hoses for any leakages The Electric-Variable Geometry Turbocharger (e-VGT) system variably controls the passages of the turbine housing to regulate the flow rate of the exhaust gas. The actuator for e-VGT has been changed from traditional vacuum actuator to DC motor actuator (E-Actuator), thereby enabling to achieve more fast and precise control The engine ECU controls the E-actuator electronically as follows: At low speed: Narrows the flow passage for the exhaust gas, resulting in increasing the flow speed of the exhaust gas and running the turbine quickly and powerfully. At high speed: Expands the flow passage for the exhaust gas, resulting in increasing the mass flow of the exhaust gas. eVGT Learning: At the end of every driving cycle when ignition is switched OFF, EMS ECU triggers a learning on the eVGT. In the learning EMS ECU will move turbocharger actuator to the open & close end positions. At the end positions, the eVGT position sensor will read and store the signal voltage. At the end of every driving cycle, EMS ECU will read, store & compare the value with the stored value from the previous driving cycle & an absolute value. Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury. For removing any SCR hydraulic connections carry out below \u201cSCR ROUTINES\u201d by using i-SMART. For additional information refer Diagnosis Manual. -EMPTYING of SCR System
After removal of supply hose, Cover the DEF tank & Dosing Module with dust caps to avoid entry of dust and Contamination of the DEF. Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. Torque :6.0\u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Remove Diesel Exhaust Fuel(DEF) tank. Turn over the DEF tank and position the tank to face bottom side to access Supply Module Using T30 Torx spanner, Unscrew DEF supply Pump Mounting torx screws Firmly release the supply pump from Module & take out from DEF tank. Install in the reverse order of removal. Avoid painting or application of other coatings on Supply Module (SM) to ensure lifetime & functionality Always remove (manually) protection caps of SM just before assembly of its mating pipes/cables, to avoid contamination of the system Only use recommended tools for remove & Installation of SM. After removing, cover the openings with protective caps to prevent the entry of contaminants Do not hold the Supply Module while carry DEF tank Do not handle Supply Module using connectors, complete housing to be held to avoid any type of damages. The Number of Supply Pump Remove & Refit from Supply Module limited to 3 times. If remove & refit beyond 3 times it can affect the torquing of screws leading to un tight assembly of pump with module. Failing to do may affect the supply module performance Always use new Dampers & Sleeves while replace new Supply Pump. Clean Supply Pump seating area on module thoroughly before insert the pump.
\u2022 DEF First Filling
\u2022 DEF Pressure Preparation
\u2022 DEF Leak Test
\u2022 DEF metered dosing test
\u2022 EMPTYING of SCR System
2. For New DEF Supply Pump Replacement carry out \u201cComponent Replacement Procedures \u2013 DEF Pump Replacement\u201d by using i-SMART. For additional information refer Diagnosis Manual.
",
+ "file": null,
+ "display_order": 24
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external damage, replace if found any. SCR Routines assist in checking the functionality of the SCR system components (DEF supply pump, DEF back flow pump, Dosing module, leaks in system) and also to initialize some SCR system components after replacement. There are 10 routines that can be performed using i- SMART. They are represented in the below table along with serviceable components. Numbers in the cell indicate the order in which a routine has to be done after the respective component replacement. To access these routines Open i-SMART \u2192THAR\u2192THAR_BS6\u2192 EMS \u2192 ROUTINES \u2192SCR ROUTINES. PRE-CONDITIONS FOR SCR ROUTINES: ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/101.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "All SCR routines have certain pre-conditions which have to be met before they can be performed. Pre-conditions for the routines will be displayed in i-SMART along with actual and acceptable values. SCR routines will not proceed, if even one pre-condition is not met. DEF first filling test when actuated by i-SMART will fill this air gap with DEF. Performing this routine is mandatory on tank / pump replacement to ensure SCR system performance. WHEN TO DO ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "If DEF tank or DEF pump module is replaced. Refer Diagnostic manual for DEF First Filling SCR ROUTINE Procedure. Pressure preparation routine will build up a moderate pressure in the DEF supply hose and vent any air in the supply hose when actuated by i-SMART. Performing this routine is mandatory when any hydraulic component (DEF pump module, DEF tank, supply hose) is removed and re-fitted. WHEN TO DO ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " 1. If DEF tank or DEF pump module is replaced. 2. If DEF supply hose is replaced. ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Refer Diagnostic manual for DEF Pressure Preparation SCR ROUTINE Procedure. SCR system emptying routine when actuated by i-SMART will purge / suck the DEF from the supply line back to the DEF tank using the backflow pump. This routine can be done during diagnosis process before removing and SCR system hydraulic connections. WHEN TO DO ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Before removing any SCR hydraulic connections. Refer Diagnostic manual for EMPTYING of SCR System SCR ROUTINE Procedure. DEF leak test is a smart test that can indicate if there could be any DEF leaks. WHEN TO DO ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " 1. When diagnosing for any DEF pressure DTCs. 2. After refitting any SCR system hydraulic connectors to check for leaks. ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Refer Diagnostic manual for DEF Leak Test SCR ROUTINE Procedure. DEF dosing module spray test is a smart test that simulates the spray pattern of DEF dosing. The dosing module has 7 holes through which DEF is sprayed into the exhaust. WHEN TO DO ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "1. When diagnosing for Dosing module stuck DTC.
2. To check dosing module functioning.
3. After refitment of new dosing module.
",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Refer Diagnostic manual for Dosing Module Spray Test SCR ROUTINE Procedure. Dosing module dry actuation test is a smart test that can indicate if the dosing module is not opening or is stuck. WHEN TO DO ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " 1. When diagnosing for Dosing module stuck DTC. ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Refer Diagnostic manual for Dosing Module Dry Actuation Test SCR ROUTINE Procedure. DEF metered dosing test when actuated by i-SMART will build up DEF pressure and dose DEF through the dosing module. This routine can be done to test the dosing module. WHEN TO DO ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " 1. After replacing a new dosing module. ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Refer Diagnostic manual for DEF Metered Dosing Test SCR ROUTINE Procedure. DEF static dosing test when actuated by i-SMART will build up DEF pressure and dose DEF through the dosing module. This routine can be done to test the dosing module. This routine is intended to simulate high mass flow rate dosing. WHEN TO DO ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " 1. After replacing a new dosing module. ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Refer Diagnostic manual for DEF Static Dosing Test SCR ROUTINE Procedure. DEF static dosing test when actuated by i-SMART will build up DEF pressure and dose DEF through the dosing module. This routine can be done to test the dosing module. This routine is intended to simulate low mass flow rate dosing. WHEN TO DO ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " 1. After replacing a new dosing module. ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Refer Diagnostic manual for DEF Dynamic Dosing Test SCR ROUTINE Procedure. The SDPF is a combination of Selective Catalytic Reduction (SCR) and Diesel Particulate Filter (DPF). The DOC assembly connected to turbocharger as input and SDPF as output, the SDPF output connect with exhaust pipes. DOC treated exhaust gaseous enters mixer zone where a multiple plate like structure is constructed in such a way it promotes swirl The SDPF functions to reduce particulates and NOx values from the engine out emissions. The Particulate filter filters the particulate emissions coming from the engine and the NOx in the engine out is reduced using the Diesel Exhaust Fluid (DEF) dosed into the exhaust. The SDPF consists of Parallel channels with alternate cells closed in the form of a honeycomb structure and this enables the filtration of the particulates coming from the engine by forcing them through the porous walls of the filter. The SDPF is coated with Zeolite that helps to retain the Diesel Exhaust Fluid (DEF) dosed into the exhaust system thereby helpful for conversion of NOx conversion. Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury. For removing any SCR hydraulic connections carry out below \u201cSCR ROUTINES\u201d by using i-SMART. For additional information refer Diagnosis Manual. \ufeff \u2013 EMPTYING of SCR System
After removal of supply hose, Cover the DEF tank & Dosing Module with dust caps to avoid entry of dust and Contamination of the DEF Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. For additional information refer to Temperature Sensor (T4) - R &R section. ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the Temperature Sensor (T5). For additional information refer to Temperature Sensor (T5) - R &R section. ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the DEF Dosing Module. For additional information refer to DEF Dosing Module - R &R section. ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the Differential Pressure (DPF) Pipes Assembly. For additional information refer to Differential Pressure (DPF) Pipes Assembly - R &R section. ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 15 mm combination and ring spanner, Unscrew exhaust front pipe mounting nuts SDPF end. Using 12 mm socket spanner, Unscrew SDPF front bottom bracket mounting bolt Using 12 mm socket spanner, Unscrew SDPF rear bracket mounting bolt. Using 12 mm socket spanner, Unscrew SDPF mounting bolts cylinder head end. Using 12 mm socket spanner, Unscrew SDPF mounting bolt fire wall end. Using 10 mm socket spanner, Unscrew turbo heat shield mounting bolts. Using 13 mm socket spanner, Loosen Turbocharger and SDPF coupling V Clamp mounting nut. Carefully remove SDPF Assembly from engine compartment. Take at most care not to damage Turbo oil return hose and HVAC pipe lines while take out SDPF from vehicle Position SDPF assembly inside the engine compartment. Install SDPF supporting bracket mounting bolts on the engine head. Position the SDPF over Turbocharger housing and pre-engage the V Clamp over the joint. INITIAL TORQUE 7 Nm FINAL TORQUE 13.5\u00b11 Nm ",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030191.jpg",
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Follow the refitment sequence as instructed in the upcoming steps carefully, false installation can lead to effect the SDPF performance. Always use new V band clamp & Gasket once removed. V Clamp Gasket to be positioned over EATS by aligning the gasket lug with marking on V Clamp as shown in the image V Clamp to be fully opened and put over Turbine Housing before position the SDPF Install DOC bracket mounting bolts on the engine head . Install SDPF bottom front & rear bracket mounting bolts on the crank case. Torque tighten Turbocharger - SDPF Coupling V clamp to the specified torque value. Initial Torque : 7 Nm
Final Torque : 13.5 \u00b1 1 Nm
",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Ensure to fit the clamp in proper position for easy accessing of clamp in subsequent removal. Torque tighten the SDPF supporting bracket bolts to the specified value. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Torque tighten the DOC bracket mounting bolts to the specified value.",
+ "file": null,
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque : 25\u00b13 Nm",
+ "file": null,
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": "Torque tighten the SDPF bottom front & rear bracket mounting bolts to the specified value. Torque : 25\u00b13 Nm Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030038.jpg",
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Install exhaust front flexi pipe mounting nuts. Tighten the nuts to specified torque value. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Refit turbocharger heat shield and install the mounting bolts. Tighten the nuts to specified torque value. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Refit the Differential Pressure (DPF) Pipes Assembly. For additional information refer to Differential Pressure (DPF) Pipes Assembly - R &R section. ",
+ "file": null,
+ "display_order": 72
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Refit the e Temperature Sensor (T4). Refit the e Temperature Sensor (T5). Refit the DEF Dosing Module. Reconnect battery negative cable and torque tighten it to the specified value . Torque :6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 80
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Check and top up the engine coolant if required
2. After refitting DEF Dosing Module carry out below \u201cSCR ROUTINES\u201d by using i- SMART. For additional information refer Diagnosis Manual.
\u2022 Pressure preparation test
\u2022 DEF Leak Test
\u2022 Dosing Module Dry Actuation Test
\u2022 Dosing Module Spray Test
\u2022 DEF static metered dosing test
\u2022 DEF dynamic metered dosing test
\u2022 EMPTYING of SCR System
",
+ "file": null,
+ "display_order": 82
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 347,
+ "sys_id": "THAR.AX-0001-Exhaust & Emission Control",
+ "subsys_id": "THAR.AX-0001-Exhaust & Emission Control-Diesel Exhaust Fuel (DEF)Level Check & Refilling",
+ "systems": "Exhaust & Emission Control",
+ "sub_systems": "Diesel Exhaust Fuel (DEF)Level Check & Refilling",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.1,
+ "rts": null,
+ "mat": "J08-MAT-0240",
+ "cover_image": "/files/W4A030126.jpg",
+ "myid": 1017,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 28,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 46,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 86,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 126,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 165,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 205,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 246,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 285,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 326,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 365,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 406,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Diesel Exhaust Fuel (DEF)Level Check & Refilling-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "Description",
+ "content": "1. Position the vehicle on 2 post lift/ 4 post lift.
Diesel Exhaust Fuel (DEF) - Mahindra MaxiCLEAN Genuine Diesel Exhaust Fluid.20 Liters.Minimum Refill Quantity - 6 Liters.i-SMART diagnostic tester and turn the ignition ON.
2. Launch the i-SMART application.
",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1E030250.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1E030251.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Select Dearborn Electronics India Pvt Ltd. \u2013 Garuda and then click START. Select THAR from the list of vehicles displayed as in following window then select the THAR_ BS6 . Select EMS from the ECU List Select the LIVE DATA tab. In the menu drop down list select DEF Tank level and Temperature and Water Pump Relay and click Proceed . The volume of DEF in the tank is to be read from the label \u201dFiltered DEF in-tank volume\u201d only . Convert the \u201cFiltered DEF in-tank volume\u201d from mL to Litres The Filtered DEF in-tank volume indicates the volume of the DEF left out in the DEF tank. With the tank volume of 20 liters, by doing the following calculation, the DEF Refill quantity can be arrived: DEF Refill Volume = 20 Liters - Filtered DEF in -tank volume. For Example, Filtered DEF in-tank volume = 12560 mL = 12.5 Liters Then DEF Refill Volume = 20 \u2013 12.5 = 7.5 Liters Refill the required quantity of DEF in the tank, follow the below Refill procedure. Select the suitable combination of SKUs of MaxiCLEAN available in stock. Always fill the Diesel Exhaust Fluid (DEF) in ignition OFF condition. Remove the DEF filler cap. Open the Container Pack (Bucket) and fix the filling pipe. The filling pipe supplied with the bucket is to be fitted on the bucket spout. Filling pipe fitment procedure below, Avoid using any funnel or unclean containers for filling. Do not keep container open after use. Fill DEF as required. Maximum Storage capacity is 20 litres. Overfilling DEF more than 20 litres may result in system /component failure. DEF is corrosive against paint and metal surface - Don\u2019t spill DEF on the vehicle, it may damage/ corrode the paint or colour change. If the DEF spills on the metal or plastic or rubber parts, wipe off immediately with a wet cloth or wash it with plain water. This will avoid corrosion. Place DEF filler cap back on DEF filler neck and tighten it moderately by turning it clockwise, then close the DEF filler lid. Close and lock the fuel filler door. Remove the vehicle Key. Turn the ignition ON If Diesel fuel is accidentally filled in the DEF tank, then the following components need to be replaced as the diesel fuel impacts the seals and other components inside the DEF tank. DEF tank along with Supply module Dosing unit pipes and hoses sDPF Assembly sDPF needs to be replaced on further analysis of the vehicle data. Contact your Tekliner for further assistance. Use Genuine DEF MaxiCLEAN always. In case of genuine Diesel Exhaust Fluid (DEF) non-availability, DEF confirming to IS 17042 or ISO 22241 specification only can be used. Overfilling DEF more than 20 litres may result in system /component failure. Don\u2019t expose the DEF or DEF filler container to sun light. By exposing to warm condition or sun light the water gets evaporated from the DEF Solution and results in concentration mismatch or crystallization deposit. The DEF is non toxic and non flammable fluid. DEF is non corrosive to Fabric and humans, but it is recommended to wash immediately on spillage to avoid any stain or allergy. DEF is corrosive against paint and metal surface. Don\u2019t spill DEF on the vehicle, it may damage/ corrode the paint or colour change. If the DEF spills on the metal or plastic or rubber parts, wipe off immediately with a wet cloth or wash it with plain water. This will avoid corrosion. Make sure that no dirt or other foreign matter is allowed to contaminate the DEF. If the DEF is stored in a sealed container for more than a year, before utilizing the DEF perform the following Check the Urea concentration using a refractometer. If it is with in the recommended limit, use the DEF. Check for crystallization deposits. If found discard the DEF. DEF will not deteriorate, if it is stored in sealed container at ambient conditions. It can be used up-to one year. The DEF is available under MaxiCLEAN brand. MaxiCLEAN is available in 10 lit, 6 lit & 2 lit packs. DEF can be filled up to the filler neck, if filled very slowly towards the end. Ensure that the maximum refill quantity is calculated so that the available SKUs are used fully. In the event of requirement of less quantity than the full SKU, use a clean measuring can for calculating the billing amount to the customer. The measuring can should be for the exclusive use of DEF only and should not be used to measure any other fluids like Engine oil or Coolant. MDW/DMS accepts \u201cDecimal\u201d billing. It is always recommended to fill the Maximum qty to maximise the range of vehicle operation. Connect the i-SMART and ensure the Filtered DEF in-tank volume is 20 liters (20000 mL) .
2. If present, then drive the vehicle for 4 to 5 kms.
3. If the warning is still present in the Infotainment System, then connect iSMART and check for any error codes (DTCs\u2019) in \u201cENGINE MANAGEMENT SYSTEM\u201d. Refer the Diagnostic Manual for more details.
",
+ "file": null,
+ "display_order": 45
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 352,
+ "sys_id": "THAR.AX-0001-Exhaust & Emission Control",
+ "subsys_id": "THAR.AX-0001-Exhaust & Emission Control-DOC Post T5 Temperature Sensor",
+ "systems": "Exhaust & Emission Control",
+ "sub_systems": "DOC Post T5 Temperature Sensor",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A030079.jpg",
+ "myid": 1022,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-DOC Post T5 Temperature Sensor-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Heading",
+ "content": "DOC Downstream Temperature Sensor (T5) is located at the bottom side of the oxidation catalyst (DOC). T5 temperature used here is of PTC type. EMS ECU uses signal from T5 mainly forDo not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable Torque :6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON Disconnect temperature sensor (T5) electrical connector. Using 17 mm open end spanner, Loosen temperature sensor T5 mounting on SDPF. Torque : 35\u00b15 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove T5 sensor from routing clip and remove from SDPF. Detach T5 sensor from routing clip and remove it Install in the reverse order of removal. Green colour tape provided on T5 Sensor wiring pigtail and engine wiring harness connector for easy identification while refit and ensure to properly connect the T5 Sensor wiring pigtail connector with engine wiring harness Mismatch connection of wiring connectors may leads to affect the engine performance and occur engine trouble. Check for any external cracks, replace if found any Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury Remove selective diesel particulate filter(SDPF). Remove DPF assembly without removing T4 sensor, T5 sensor mountings and DEF dosing module from SDPF assembly. Using 7 mm socket spanner, Loosen air intake clean hose clip turbo end and detach hose Using 7 mm socket spanner, Loosen turbo outlet hose clip and detach hose . Using 14 mm socket spanner, Unscrew turbocharger oil inlet tube mounting banjo bolt . Torque : 17.5\u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew turbo oil return tube mounting bolts crank case end. Torque : 11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew turbo oil return tube routing bracket mounting bolt Torque :25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect eVGT electrical connector Using 13 mm socket spanner, Unscrew exhaust manifold mounting bolts. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Notice",
+ "content": "Always use new metal gasket onceremoved. check for any leakages. While installing, Molykote to be applied on both sides of stud on exhaust manifold- turbocharger. Torquing to be done immediately after application of molykote sealant. Nuts to be re torque after initial tightening in the same sequence Using 10 mm socket spanner, Unscrew turbo oil outlet pipe mounting bolt from turbocharger. Torque :11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030165.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Check Engine Oil level & Topup the engine oil. Check oil return tube for any external damage, replace if found any. Drain the coolant. For additional information refer to Coolant draining section. Remove pipe EGR module to intake manifold. Disconnect EGR electrical connector. Disconnect EGR cooler bypass actuator electrical connector. Disconnect Vacuum hose EGR module end. Using 12 mm socket spanner, Unscrew engine wiring routing bracket bolt intake manifold end. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew EGR module mounting bolts. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew EGR cooler mounting bolt. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Disconnect EGR cooler inlet and outlet hose quick couplers. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Disconnect coolant temperature sensor electrical connection. Remove EGR assembly from the vehicle. Install in the reverse order of removal. Always use new gasket once removed. Refill the Coolant. For additional information refer to Engine coolant filling and de-aeration Procedure. Check for any external damage, replace if found any. Conditions to Diesel Exhaust Fuel (DEF) Draining & Filling ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030127.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "If vehicle covers less than 10,000 kms in 2 years then replace DEF in 2nd year end. Place the vehicle on a 2/4 post lift. Switch the ignition OFF. Using vehicle key open the fuel filler door. Remove the DEF filler cap. Always fill the Diesel Exhaust Fluid (DEF) in ignition OFF condition. Overfilling DEF more than 20 litres may result in system /component failure. DEF is corrosive against paint and metal surface - Don\u2019t spill DEF on the vehicle, it may damage/ corrode the paint or colour change. If the DEF spills on the metal or plastic or rubber parts, wipe off immediately with a wet cloth or wash it with plain water. This will avoid corrosion. Place DEF filler cap back on DEF filler neck and tighten it moderately by turning it clockwise, then close the DEF filler lid. Close and lock the fuel filler door. Remove the vehicle Key Turn the ignition ON Connect the i-SMART and ensure the \u201cFiltered DEF in-tank volume\u201d is 20 liters (20000 mL). Verify for any warning related to DEF level low in the Infotainment System. If present, then drive the vehicle for 4 to 5 kms. If the warning is still present in the Infotainment System, then connect iSMART and check for any error codes (DTCs\u2019) in \u201cENGINE MANAGEMENT SYSTEM\u201d. Refer the Diagnostic Manual for more details. Use Genuine DEF MaxiCLEAN always. In case of genuine Diesel Exhaust Fluid (DEF) non-availability, DEF confirming to IS 17042 or ISO 22241 specification only can be used. Overfilling DEF more than 20 litres may result in system /component failure Don\u2019t expose the DEF or DEF filler container to sun light. By exposing to warm condition or sun light the water gets evaporated from the DEF Solution and results in concentration mismatch or crystallization deposit. The DEF is non toxic and non flammable fluid. DEF is non corrosive to Fabric and humans, but it is recommended to wash immediately on spillage to avoid any stain or allergy DEF is corrosive against paint and metal surface. Don\u2019t spill DEF on the vehicle, it may damage/ corrode the paint or colour change. If the DEF spills on the metal or plastic or rubber parts, wipe off immediately with a wet cloth or wash it with plain water. This will avoid corrosion Make sure that no dirt or other foreign matter is allowed to contaminate the DEF. If the DEF is stored in a sealed container for more than a year, before utilizing the DEF perform the following Check the Urea concentration using a refractometer. If it is with in the recommended limit, use the DEF Check for crystallization deposits. If found discard the DEF DEF will not deteriorate, if it is stored in sealed container at ambient conditions. It can be used up-to one year ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Notice",
+ "content_type": "Notice",
+ "content": "The DEF is available under MaxiCLEAN brand. MaxiCLEAN is available in 10 lit, 6 lit & 2 lit packs DEF can be filled up to the filler neck, if filled very slowly towards the end Ensure that the maximum refill quantity is calculated so that the available SKUs are used fully In the event of requirement of less quantity than the full SKU, use a clean measuring can for calculating the billing amount to the customer. The measuring can should be for the exclusive use of DEF only and should not be used to measure any other fluids like Engine oil or Coolant MDW/DMS accepts \u201cDecimal\u201d billing It is always recommended to fill the Maximum qty to maximise the range of vehicle operation Using 10 mm socket spanner, Unscrew SDPF heat shield mounting bolts and remove the heat shield. Torque :11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew SDPF heat shield mounting bolt. Torque :25\u00b1 3 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, Unscrew SDPF heat shield top mounting Struds. Torque :11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, Unscrew turbocharger oil inlet tube mounting banjo bolt turbo end.. Torque : 17.5\u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, Unscrew turbocharger oil inlet tube mounting banjo bolt OCFM end Torque : 17.5\u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove turbocharger oil inlet tube.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030186.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Check Engine Oil level & Topup the engine oil. Conditions to Diesel Exhaust Fuel (DEF) Flushing ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "If any contamination or the concentration level of stored DEF not met with the recommended value. For additional information on DEF Concentration Measurement by using Refractometer & Usage guidelines, Refer to DEF Refractometer Session. If alert message of \u201cWrong DEF Detected\u201d display in the infotainment system. If Diesel fuel is accidentally filled in the DEF tank, then the following components need to be replaced as the diesel fuel impacts the seals and other components inside the DEF tank . DEF tank along with Supply module. Dosing unit. pipes and hoses sDPF Assembly sDPF needs to be replaced on further analysis of the vehicle data. Contact your Tekliner for further assistance.
2. Switch the ignition OFF.
3. Using vehicle key open the fuel filler door.
",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030127.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040125.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the DEF filler cap. Using star screw driver, remove DEF tank bottom protection cover scrivets and detach the cover. Remove DEF drain hose quick coupler and drain the DEF. Refit drain hose quick coupler. Fill 2 litres of DEF for flushing and close the DEF filler cap. Always fill the Diesel Exhaust Fluid (DEF) in ignition OFF condition. Remove DEF drain hose quick coupler and drain the 2 Liters of DEF from tank. Refit drain hose quick coupler. Position protection cover and install DEF tank bottom cover scrivets. Fill DEF Maximum Storage capacity 20 litre. Always fill the Diesel Exhaust Fluid (DEF) in ignition OFF condition. Overfilling DEF more than 20 litres may result in system /component failure. DEF is corrosive against paint and metal surface - Don\u2019t spill DEF on the vehicle, it may damage/ corrode the paint or colour change. If the DEF spills on the metal or plastic or rubber parts, wipe off immediately with a wet cloth or wash it with plain water. This will avoid corrosion. Place DEF filler cap back on DEF filler neck and tighten it moderately by turning it clockwise, then close the DEF filler lid. Close and lock the fuel filler door. Remove the vehicle Key. Connect the i-SMART and ensure the Filtered DEF in-tank volume is 20 liters(20000 mL) . Verify for any warning related to DEF level low in the Infotainment System. If present, then drive the vehicle for 4 to 5 kms. If the warning is still present in the Infotainment System, then connect iSMART and check for any error codes (DTCs\u2019) in \u201cENGINE MANAGEMENT SYSTEM\u201d. Refer the Diagnostic Manual for more details. Use Genuine DEF MaxiCLEAN always. In case of genuine Diesel Exhaust Fluid (DEF) non-availability, DEF confirming to IS 17042 or ISO 22241 specification only can be used. Overfilling DEF more than 20 litres may result in system /component failure. Don\u2019t expose the DEF or DEF filler container to sun light. By exposing to warm condition or sun light the water gets evaporated from the DEF Solution and results in concentration mismatch or crystallization deposit The DEF is non toxic and non flammable fluid. DEF is non corrosive to Fabric and humans, but it is recommended to wash immediately on spillage to avoid any stain or allergy. DEF is corrosive against paint and metal surface. Don\u2019t spill DEF on the vehicle, it may damage/ corrode the paint or colour change. If the DEF spills on the metal or plastic or rubber parts, wipe off immediately with a wet cloth or wash it with plain water. This will avoid corrosion. Make sure that no dirt or other foreign matter is allowed to contaminate the DEF. If the DEF is stored in a sealed container for more than a year, before utilizing the DEF perform the following Check the Urea concentration using a refractometer. If it is with in the recommended limit, use the DEF. Check for crystallization deposits. If found discard the DEF DEF will not deteriorate, if it is stored in sealed container at ambient conditions. It can be used up-to one year. The DEF is available under MaxiCLEAN brand. MaxiCLEAN is available in 10 lit, 6 lit & 2 lit packs. DEF can be filled up to the filler neck, if filled very slowly towards the end. Ensure that the maximum refill quantity is calculated so that the available SKUs are used fully. In the event of requirement of less quantity than the full SKU, use a clean measuring can for calculating the billing amount to the customer. The measuring can should be for the exclusive use of DEF only and should not be used to measure any other fluids like Engine oil or Coolant. MDW/DMS accepts \u201cDecimal\u201d billing It is always recommended to fill the Maximum qty to maximise the range of vehicle operation. DEF is a NOx reduction agent. It is recommended to use MaxiCLEAN DEF meeting IS 17042 (or) ISO 22241 specification. It is basically an aqueous urea solution, having a urea content of 32.5% and remaining 67.5% of water. Recommend to check the Urea concentration in the DEF Using Refractometer SCR system is an integral part of the Engine Exhaust System, and any contaminants or impurities in the DEF could cause the SCR system to malfunction or fail. Thus, it is important to maintain quality of the DEF as defined in ISO 22241-1 standard. If the DEF is stored in a sealed container for more than a year, before utilizing the DEF perform the following. 1. Check the Urea concentration Using refractometer. If it is with in the recommended limit, use the DEF.
2. Check for crystallization deposits. If found discard the DEF.
",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1E030402.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Notice",
+ "content": "DEF will not deteriorate, if it is stored in sealed container at ambient conditions. It can be used up-to one year. Press READ button to START the refractometer. Calibration Add 2-3 drops of Distilled water on the prism. Press CAL button for 2 to 3 seconds till see CAL flashing Press CAL button again during CAL flashing to end calibration process - End will be displayed for 2 to 3 seconds on the screen as notification After calibration completes clean and dry the prism using soft tissue paper. Calibration: ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Add 2-3 drops of Distilled water on the prism. Press CAL button for 2 to 3 seconds till see CAL flashing Press CAL button again during CAL flashing to end calibration process - End will be displayed for 2 to 3 seconds on the screen as notification After calibration completes clean and dry the prism using soft tissue paper. DEF Concentration Measurement: ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Collect small quantity of DEF from the DEF Tank. Add 2-3 drops of DEF on the prism Ensure that there are no air bubbles present in the DEF droplets. Press READ button once & wait for about 15 seconds to get Concentration of DEF Ensure that the Scale should be \u201cS 01\u201d. If not, then press the Scale button again till the scale changes to \u201cS 01\u201d DEF concentration will get displayed on the screen The DEF Concentration acceptance range \u2013 31.8 to 33.2 % Post Measurement: ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Completely clean and dry the prism using soft tissue paper. SCR or selective catalytic reduction is an exhaust after-treatment technology to reduce NOx emissions in diesel vehicles. The technology involves the use of Diesel Exhaust Fluid (DEF) which is an aqueous urea solution (AUS32). The DEF is pressurised and injected into the exhaust gases at the SCR catalyst to reduce the NOx at the tail pipe. So in case of any malfunction in the SCR system, DEF not available in the tank or if any other fluid (not meeting AUS32) is used in the DEF tank, the SCR system will not function as intended. The inducement strategy is a legally mandated warning system to alert the driver if the system is not functioning as intended. In the Thar, the inducements are displayed on the Cluster screen. The EMS will enter into a inducement (warning message) when certain emission or functional DTCs are detected. Every inducement always comes with a DTC & the SCR warning lamp in the Cluster. The aim of each inducement is to ensure that the root cause of any malfunction in the SCR system is identified & fixed. So for the inducement to stop the DTC causing the inducement has to be tested again and healed. Inducement will not stop by clearing the DTC using i-SMART For the inducement to stop the DTC will have to be healed, i. e. The root cause identified & then tested. Only when the EMS tests for the DTC again & detects that the DTC is healed inducement stops displaying in the Cluster. If any inducement causing DTC is present in i-SMART, DO NOT CLEAR THE DTC without ensuring that the issue is fixed & tested again. Always generate DTC report in i-SMART at the start of diagnosis of a DTC. There are 3 different inducement messages for Low DEF level, malfunction in DEF dosing system and incorrect DEF present in the system. Each inducement then has 5 levels. At the final inducement (level 5), vehicle will not be allowed to start unless root cause for the inducement (warning message) is fixed. When DEF level in tank fall below pre-defined values, warning lamp turns ON and Alert messages are flashed in five stages in the Cluster. These five warning stages are explained below: If the DEF warning lamp turns on due to the DEF level, refill the DEF tank. Failure to refill may cause the engine start restriction. Overfilling DEF more than 20 litres may result in system /component failure. In absence of DEF level low warning, refilling is not recommended. If SCR system detects quality of DEF inside the tank is not meeting IS 17042 (or) ISO 22241 specification, warning lamp turns ON and Alert messages are flashed in five stages in the Cluster. These four warning stages are explained below: 1. DEF tank along with Supply module
2. Dosing unit
3. pipes and hoses
4. sDPF Assembly
",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "SDPF needs to be replaced on further analysis of the vehicle data. Contact your Tekliner for further assistance. If the DEF warning lamp turns on due to the DEF quality, see contamination/ incorrect fluid for corrective action. Failure to correct may cause the engine start restriction. If SCR system detects any malfunction due to failures in components or tampering, warning lamp turns ON and Alert messages are flashed in five stages in the Cluster. These five stages are explained below: If the DEF warning lamp turns on due to dosing malfunction, refer diagnostic manual for more information. Failure to repair the system may cause the engine start restriction. 1. Driving the vehicle to service center if vehicle is shut off.
2. Testing and healing certain DTCs that may cause DOSING MALFUNCTION or INCORRECT DEF inducement.
",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Refer Diagnostic manual for Inducement Extension Procedure. After extension, the Cluster will display 50 kms and reduce when the vehicle is being driven. Once the distance comes to 0 kms in the Cluster, the extension option can be used again to extend by another 50 kms. The distance can be extended only by 50 kms at a time. Clicking Reset in i-SMART multiple times will not extend the drive distance more than 50 kms. Using 10 mm socket spanner, Unscrew EGR pipe mounting bolts EGR cooler end. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew EGR pipe mounting bolts intake manifold side. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew EGR pipe routing bracket mounting bolts and remove the pipe. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030118.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Always use new metal gasket once removed. Check for any external cracks, replace if found any. The oil filter is located after the oil pump and before the oil starts getting distributed. Any impurity whose size can cause breakdown of lubrication film and cause metal to metal contact are entrapped in the oil filter element\u2019s filtration medium. ground level/ 2 post lift/ 4 post lift and turn engine OFF.
Open the bonnet and lock it in open position using bonnet stay rod.
",
+ "file": null,
+ "display_order": 6
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 27 mm 12 point doublehexagonal socket spanner, Loosen the engine oil filter cap. To access Oil filter cap mounting slightly move the Intercooler hose (without removing) and Carefully remove the damaging the hose. Remove the engine oil filter with cap from engine assembly. Ensure gasket isn\u2019t in casting housing and element assembly should come along with filter cap. Carefully rotate the oil filter element in clockwise direction, pull upward and remove the filter element. Remove the filter element carefully, with no damage to the plastic snaps. Pay attention not to damage the oil bypass valve while removing the oil filter element. Smear a layer of fresh oil on new oil filter O-ring and Position the O-ring on filter cap. Replace the O-ring with new one when replacing the oil filter element. Ensure no damage to O-ring during assembly, with no sharp edges damaging O-ring or element. Ensure to fix the oil bypass valve in proper position on oil filter cap. Place the oil filter in the bowl projection, push the filter inside and rotate the filter in anti-clockwise direction to lock it. Install the element carefully , with no damage to snaps. Position the oil filter cap with filter on the oil cooler surface. Tighten the oil filter cap in clockwise direction and torque tighten cap to the specified value. Torque :25 - 30 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Don\u2019t apply improper torque which leads to damage in threads. Check the engine oil level. Start the engine and check for Oil leakage/ seepage at: Oil pan & crankcase joint. Oil pan drain plug.
Oil filter joint. Recommend to use only the Mahindra genuine oil filter for better engine protection and lubricant life. Make sure for all the subassembly and components going into engine assembly should be clean and away from foreign material. Remove the timing case cover. For additional information refer to Timing Case Cover - R &R; Section. Remove MST 0307ABH0001ST - Flywheel Locking Tool - Eagle mounting bolts and detach it. Position engine front lifting hook and hand tighten the mounting bolts. Using 18 mm socket spanner, unscrew engine mounting bracket nuts (Both RH & LH). Provide engine support beam to support engine. Lift the engine with care, don\u2019t over lift since chances of damaging parts are high Ensure none of the components are effected or damaged during lifting. Using 14 mm combination spanner and socket spanner , unscrew LH engine mounting bracket mounting bolts and remove the LH bracket. Using 6 mm square socket spanner, loosen and remove TDC locking dummy from crankcase. Refit damper pulley and install damper pulley mounting bolt on crankshaft. Lock the crankshaft by Inserting the TDC locking pin (MST\u2013 0312ABH0001ST). Ensure the crankshaft locking tool is seated properly into the slot on crankshaft and ensure the TDC locking pin insert upto Red mark in the pin as shown. Check and ensure the 1st cylinder piston position to TDC. Ensure that correct TDC locking tool is used. TDC locking hole is near crankcase left side below intake manifold (Near Engine LH Mounting bracket). If not able to position the MST in proper position into crankshaft, Slightly rotate damper pulley and align the crankshaft to insert MST:- 0312ABH0001ST Crankshaft Locking Tool - TDC Pin on crankshaft. Install the (MST \u2013 0310ABH0001ST Cam Shaft locking tool) on the front side of cylinder head as the location shown below using appropriate bolts. The Cam shaft 2D Matrix must be on the top side for both Intake and Exhaust camshaft. Crank Sprocket Key must be at 12\u2019O Clock Position. Ensure that locking tool is seated properly on Cam shaft. If the tool is not properly seat on the cam shaft slot then the engine is not in proper timing and follow the below steps for Engine timing adjustment . Using T55 socket spanner, loosen exhaust Cam sprocket mounting bolt. The Exhaust Camshaft Sprocket mounting bolt must be loosened first and then the Intake camshaft Sprocket Mounting bolt to be loosened. Using 15 mm socket spanner, loosen intake CAM sprocket mounting bolt. Loosen (MST\u2013 0310ABH0001ST Cam Shaft locking tool) mounting bolt and adjust cam shaft till MST locking properly at camshaft slot, then tighten MST mounting bolts.
Place the MST203 - Companion Flange Holding Tool into the Primary Chain Intake Cam shaft sprocket as shown and hold the tool in opposite direction of torqueing. Torque tightened the Intake Cam shaftsprocket bolt to 50\u00b12 Nm + 90\u00b0\u00b15\u00b0 . Holding the MST Tool and Torque tightened the Exhaust Cam shaft sprocket bolt after intake sprocket to 50\u00b12 Nm + 80\u00b0\u00b15\u00b0 . MST : 0301BM011ST (cam chain tensioning tool) can be used instead of MST203 - Companion Flange Holding Tool. Using a suitable tool, loosen and remove the MST- 0310ABH0001ST Alignment Tool Camshaft separately. Remove the TDC locking pin. Refit damper pulley and install damper pulley mounting bolt on crankshaft. To reconfirming proper cam and crank timing, Once again Insert TDC locking pin and ensure cam shaft locking tool properly seating on the cam shafts position. Remove the cam shaft locking tool & TDC locking pin after confirmation Apply Loctite 574 , Install the TDC locking dummy on crankcase and torque tighten. Torque : 20\u00b12 Nm ",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Remove the damper pulley. Position the engine LH mounting bracket and install the mounting bolts. torque tighten the bolts to specified value. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Detach the engine support beam from engine and remove support beam from vehicle. Install the engine mounting bracket nuts (Both RH & LH) on engine beds and torque tighten the nuts to specified value. Torque : 110\u00b1 10 Nm. ",
+ "file": null,
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1662.jpg",
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Remove the engine front lifting hook. Refit Flywheel locking tool (MST\u2013 0307ABH0001ST) with suitable mounting bolts on crankcase. Refit the timing case cover. For additional information refer to Timing Case Cover \u2013 R&R; Section. Remove the crankshaft pulley For additional information refer to the Crankshaft Pulley \u2013 R &R; section. Using a suitable tool remove the front end oil seal. Remove the seal from the engine. Install in reverse order of removal. The crankshaft oil seals are one time use, should never be reused. Apply thin layer of oil on the new oil seal lip. Follow the below procedure for front oil seal Installation. Position the front oil seal on the timing cover. Place the front oil seal installer (MST\u20130311DBH0001ST) over the oil seal and tighten the torsional vibration damper pulley bolt. Tighten the torsional vibration damper pulley bolt till the front oil seal is pushed to the timing cover Visually inspect the oil seal for proper seating. Check & Top-up the engine oil. Check and clean the oil seal seating area thoroughly for any damage. Hydro lock or hydrostatic lock is an abnormal condition in internal combustion engine. This occurs when a volume of liquid (Coolant/water or fuel) greater than the volume of the cylinder at its minimum (end of the piston stroke) enters the cylinder. Since liquids are nearly incompressible the piston cannot complete its travel; either the engine stop rotating or a mechanical failure occurs. When an engine is suspected to be hydrostatically locked, regardless of what caused the problem, the following steps should be used DO NOT use starter motor to rotate the engine, severe damage may occur. Inspect air cleaner, air intake system and intake manifold to ensure system is dry and clear of water and foreign material. Disconnect negative battery cable. Place a shop towel around the injectors when removing them from the engine. This will catch any fluid that may possibly be in the cylinder under pressure. With all injectors removed, rotate engine crankshaft. Identify the fluid in the cylinder(s) (i.e., coolant, fuel, oil or other). Make sure all fluid has been removed from the cylinders. Inspect engine for damage (i.e., connecting rods, pistons, valves, etc.) Repair engine or components as necessary to prevent this problem from recurring. Squirt approximately one teaspoon of oil into the cylinders, rotate engine to lubricate the cylinder walls to prevent damage on restart. Drain engine oil and remove oil filter. Install a new oil filter. Fill engine with specified amount of approved oil. Connect negative battery cable. Install all Injectors. Start engine and check for any leaks The oil Sump is the reservoir for the oil and also cover for the crank case. It is secured to the engine block by bolts. A liquid sealant is used to provide an leak proof joint. Drain the engine oil. For additional information refer to engine oil draining procedure section. Remove the stone guard. For additional information refer to Stone Guard \u2013 R &R; Section. For additional information refer to Electric Disconnect Stone Guard \u2013 R &R; Section. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 14 mm ring and 15 mm socket spanner, Unscrew the front cross member mounting bolts and nuts. Torque : 65 \u00b110 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the front cross member from the vehicle Disconnect the front axle electrical connector. Provide jack to support the front axle assembly. Using a 19 mm Socket spanner, loosen and remove the front axle assembly mounting bolts. Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Partially down the front axle assembly . Remove AC compressor belt. For additional information refer to AC compressor belt - R &R; Section. Using a 12 mm socket spanner, loosen and remove the AC compressor bottom mounting bolts. Torque : 23 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the transmission bottom mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the oil sump bottom mounting bolts. Torque : 22.5 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a 8 mm socket spanner, loosen and remove the oil sump bottom mounting bolts. Torque : 11 \u00b1 1.0 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Detach engine oil sump from the vehicle . Install in reverse order of removal Clean the sump and sump seating area on bed plate. Gently apply sealant for engine oil sump. Apply sealant as per recommendation and position the sump on crankcase. Please refer Sealant pattern session for sealant apply pattern. Torque tighten the bolts as per below sequence. Refill the engine oil and check for oil leakage. Check the oil sump for any cracks, damage etc, replace if found any. A glow plug is a heating device used to aid in cold starting. In cold weather, high speed diesel engines can be difficult to start because the mass of the cylinder block and cylinder head absorb the heat of compression, preventing ignition due to the higher surface-to-volume ratio. The glow plug is a pencil-shaped piece of metal with a heating element at the tip. This heating element, when electrified, heats due to its electrical resistance and begins to emit light in the visible spectrum, hence the term glow-plug. The heat generated by the glow plugs is directed into the cylinders and serves to warm the engine block immediately surrounding the cylinders. This aids in reducing the amount of thermal diffusion which will occur when the engine attempts to start. The fuel injector spray pattern then impinges directly upon the hot tip of the glow plug during the injection of fuel at top dead center. This enables the fuel to ignite even when the engine is insufficiently hot for normal operation. This reduces the cranking time needed to start the diesel engine. The glow plugs are controlled by the EMS ECU. The ECU decides the actuation of the glow plugs based on operating conditions, engine temperature and environment temperature. Remove the Intake Manifold. Disconnect the glow plug electrical connector. Using 8 mm deep socket spanner, Carefully loosen and remove the glow plug from the cylinder head. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010678.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "Follow the same procedure for all glow plugs. Install in reverse order of removal. Check for any cracks, damage etc, replace if found any. The oil pump circulates the engine oil to lubricate the components such as bearings, piston and valve. The lower chain drives oil pump to lubricate the engine. This oil pump are integrated with the strainer. The oil strainer is the first stage in the filtration of the lubricant. It filters the coarse particles present in the oil before it enters the oil pump. For additional information refer to Engine Oil Strainer \u2013 R &R Section. Using a 8 mm allen socket spanner, loosen and remove the engine oil pump tensioner mounting bolt. Torque : 25\u00b1 3 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, Remove engine oil pump mounting bolts. Torque : 26 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the engine oil pump from oil pump chain. Carefully remove the engine oil pump. Install in reverse order of removal. Refill the engine oil and check for oil leakage. Inspect the oil pump for any damage. Replace if found. Inspect the oil pump and strainer for any blockage, clean if found. The camshaft controls the valve opening and closing events. It is driven by the crankshaft through a chain connection. The camshaft rotates at half the speed of the crankshaft to maintain proper timing of the four cycle of combustion. The opening and closing of the valves are done by lobes on the camshaft. The timing of the valve depends on the position of the camshaft and shape of the lobes on it. The valve lift is the distance the valve is lifted off its seat when fully opened. This is determined by the height of the CAM lobe. The valve need enough lift to allow air to flow freely into the cylinder and for exhaust gases to flow out of the cylinder, without interfering with piston or binding the spring. The duration is the length of time the CAM lobe keeps the valve open. It is measured in degrees of camshaft rotation and is determined by the shape of the CAM lobe. Camshaft also drives the fuel pump and vacuum pump. Remove the engine top encapsulation cover. Using nose plier, release engine vent hose clip at T Joint and disconnect the hose. Using 10 mm socket spanner, Unscrew degassing tank mounting bolts and partially detach it (Without detaching the hoses). Using 10 mm socket spanner, loosen and remove the engine fead cover mounting bolts. Remove the engine fead cover from engine compartment. Place the MST 0306GAM0006ST - Stretch Fit Belt Removal Tool on damper pulley side as shown in the image. Using 24 mm socket spanner, rotate the damper pulley to clockwise direction then remove the water pump drive belt and MST separately Using 14 mm ring spanner, turn the hexagon knob in the belt tensioner Anti clockwise direction to release the tension. Remove the alternator drive belt. Using 10 mm socket spanner, Unscrew engine wiring harness carrier mounting stud from Cam cover and detach it partially. Disconnect the Injectors electrical connectors from the injectors. Using 17 mm open end spanner, Unscrew High pressure pipe mounting flare nut from common rail end. Using 19 mm open end spanner, unscrew High pressure pipe flare nut from injection pump end. Using 17 mm open end spanner loosen the high pressure pipe flare nuts at common rail side and injector side. While loosening the high pressure pipes at Injector end, hold the injector pipe connector by 13 mm Open end spanner. Remove the high pressure fuel pipes from the engine. Remove injector leak - off pipe lock clip and detach leak off pipes from the injector end. Remove injector leak - off pipe lock clip and detach leak off pipes from the injector end. Remove all 4 Injectors from cylinder head. Injector Bore must be covered with lint sfree cloth/Masking tape to avoid foreign objects entering injector bore/cylinder. Plug the fuel inlet and wiring harness connector slot as soon as injector is removed. Store the injector in a neat tray. Never drop the injectors. Never clean the injector using pressurized water. Disconnect fuel inlet tube quick couplers from fuel injection pump & FCU. All are quick fix connectors, press gently and remove it carefully to avoid seal damages. Using nose plier release fuel return hose spring band clamp and detach hoses from fuel injection pump & FCU. Press the lock and disconnect fuel control unit electrical connector. Using 10 mm socket spanner, Unscrew fuel return line 'T' bracket mounting bolts. Using 12 mm socket spanner, Unscrew Cam box mounting bolts and remove the bolts. Rotate the Cam Box Assembly as direction shown in the image to access fuel high pressure pump mounting bolts. Using T30 socket spanner unscrew fuel high pressure pump mounting bolts and detach pump. Remove Cam box assembly along with FCU from engine. While taking out Cam box, ensure to move the tappet in upward direction by hand. Disconnect T4 temperature sensor electrical connector. Disconnect T5 temperature sensor electrical connector. Detach the vacuum hose routing clips from heat shield. Using 14 mm socket spanner, loosen and remove the heat shield mounting studs from Cam cover. Using 10 mm socket spanner, loosen and remove the heat shield mounting bolt from Cam cover and rear engine hook. Using 12 mm socket spanner, loosen and remove the heat shield mounting bolt from SDPF side. Disconnect the dosing module electrical connector. Disconnect the SDPF Sensor electrical connector. Disconnect the Cam phase sensor electrical connector. Disconnect the common rail electrical connector and wiring harnesses routing clip. Using hose clip plier, Unclip oil separator hose spring band clamp and detach hose. Using 10 mm ring spanner, loosen and remove stud mountings from Cam cover. Using 10 mm socket spanner, loosen and remove Cam cover mounting bolts & studs. Using 8 mm socket spanner, loosen and remove the Cam cover mounting bolts. Detach Cam cover from the engine completely. Using nose plier, Release the spring band clamp and disconnect vacuum hose from vacuum pump side. Using 12 mm socket spanner, Unscrew vacuum pump mounting bolts and remove vacuum pump from engine. Using 14 mm socket spanner, Loosen and remove auto tensioner mounting bolt and remove tensioner Using 14 mm socket spanner, Loosen and remove the drive belt idler mounting bolt and remove idler from the engine. Using 14 mm socket spanner, loosen and remove the starter motor mounting bolts. Lock the flywheel by using MST 0307ABH0001ST - Fly wheel Locking tool. Using 24 mm socket spanner, Unscrew damper pulley mounting bolt and remove damper pulley. Using 12 mm socket spanner, Loosen and remove the engine front cover mounting bolts from the Oil sump. Using 12 mm socket spanner, Loosen and remove the AC compressor top mounting bolt. AC compressor top mounting bolt must be removed, failing to remove the bolt will leads to crack the front cover. Using 14 mm socket spanner, loosen and remove engine front cover mounting bolts from cylinder head. Using 12 mm socket spanner, loosen and remove engine front cover mounting bolts from crank case. Using 12 mm socket spanner, loosen and remove engine front cover mounting bolts. Detach engine front cover from engine. Ensure to cover the engine oil sump open space properly by lint free cloth after removal of Front Cover. Make sure for all the subassembly and components going into engine assembly should be clean and away from foreign material. Remove the flywheel locking tool MST\u20130307ABH0001ST. Position engine front lifting hook and hand tighten the mounting bolts. Using 18 mm socket spanner, unscrew engine mounting bracket nuts (Both RH & LH). Provide engine support beam to support engine. Lift the engine with care, don\u2019t over lift since chances of damaging parts are high. Ensure none of the components are effected or damaged during lifting. Using 14 mm combination spanner and socket spanner , unscrew LH engine mounting bracket mounting bolts and remove the LH bracket. Using 6 mm square socket spanner, loosen and remove TDC locking dummy from crankcase. Refit damper pulley and install damper pulley mounting bolt on crankshaft. Lock the crankshaft by Inserting the TDC locking pin (MST\u2013 0312ABH0001ST). Ensure the crankshaft locking tool is seated properly into the slot on crankshaft and ensure the TDC locking pin insert upto Red mark in the pin as shown. Check and ensure the 1st cylinder piston position to TDC. Ensure that correct TDC locking tool is used. TDC locking hole is near crankcase left side below intake manifold (Near Engine LH Mounting bracket). If not able to position the MST in proper position into crankshaft,Slightly rotate damper pulley and align the crankshaft to insert MST:-0312ABH0001ST Crankshaft Locking Tool - TDC Pin on crankshaft. Install the (MST \u2013 0310ABH0001ST Cam Shaft locking tool) on the front side of cylinder head as the location shown below using appropriate bolts. The Cam shaft 2D Matrix must be on the top side for both Intake and Exhaust camshaft. Crank Sprocket Key must be at 12\u2019O Clock Position. Ensure that locking tool is seated properly on Cam shaft. Remove the damper pulley. Using T55 socket spanner, loosen exhaust Cam sprocket mounting bolt. The Exhaust Camshaft Sprocket mounting bolt must be loosened first and then the Intake camshaft Sprocket Mounting bolt to be loosened. Using 15 mm socket spanner, loosen intake Cam sprocket mounting bolt. Using 10 mm socket spanner loosen, and remove the chain hydraulic tensioner mounting bolts. Using 8 mm Allen key, loosen and remove the chain guide bolt and detach guide. Using 10 mm socket spanner, loosen and remove the chain fixed guider bolts and detach guide. Remove and take out the timing chain with intake Cam sprocket from engine. Using 5 mm Allen key/ Socket, loosen and remove the secondary chain tensioner mounting Allen bolts. Remove the exhaust Cam sprocket mounting bolt. Compress the tensioner and remove the camshaft intake and exhaust drive chain and sprockets along with tensioner. Unscrew Cam Shaft Locking (MST\u20130307ABH0001ST) mounting bolts and remove MST. Using 10 mm socket spanner, Loosen and Remove the Intake Cam shaft rear bearing cap mounting bolts. Remove the rear bearing cap from the cylinder head. Using 8 mm socket spanner, Loosen and Remove Cam shaft front bearing cap mounting bolts. Remove the front bearing cap from the cylinder head. Using 8 mm socket spanner, Loosen and Remove the intake and exhaust CAM shaft bearing cap mounting bolts. Remove the intake and exhaust CAM shaft bearing caps. Remove the Intake and Exhaust CAM shafts from the cylinder head. Check the intake camshaft and the exhaust camshaft for any damage and replace it if necessary. Inspect the camshaft bearing journals for scoring or excessive wear. Inspect the camshaft lobes for scoring or excessive wear. Inspect the threaded bolt holes in the front of the camshaft for damaged threads or debris. Apply a thin layer of engine oil to the mounting parts of the Cam shafts. Install the Intake and Exhaust cam shafts. Line up the timing marks of the intake/exhaust Cam shaft (on the front side) when installing as shown. The Cam shaft 2D Matrix must be on the top side for both Intake and Exhaust camshaft. Crank Sprocket Key must be at 12\u2019O Clock Position. Check and confirm the 1st cylinder piston position at TDC before installation. Apply a thin layer of engine oil on the Cam shafts. Install the Front, Rear & Cam shafts bearing caps. Sealant (Loctite 574- 2mm thickness) to be applied on rear bearing cap as per below pattern. Extra sealant to be wiped off after assembly of rear bearing cap. Install the bearing caps mounting bolts and torque tighten the bolts to specified value as per tightening sequence. Torque for A & B : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 222
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010048.jpg",
+ "display_order": 223
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque for C : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 224
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25246.jpg",
+ "display_order": 225
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install the (MST \u2013 0310ABH0001ST Cam Shaft locking tool) on the front side of cylinder head as the location shown below using appropriate bolts. The Cam shaft 2D Matrix must be on the top side for both Intake and Exhaust camshaft. Crank Sprocket Key must be at 12\u2019O Clock Position. Ensure that locking tool is seated properly on Cam shaft. Assemble the exhaust and intake camshaft sprocket and Cam chain tensioner.Compress the tensioner and insert the suitable locking pins/allen keys on tensioner. Install the camshaft intake and exhaust drive chain and sprockets along with tensioner on cam shafts. Install the secondary tensioner mounting bolts and Torque tighten bolts to specified value. Torque: 11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 239
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Release the tensioner locking pins. Hand tighten the New exhaust Cam sprocket mounting bolt. Ensure to replace New Exhaust Cam shaft bolt while Installation. Before Installation of Primary timing chain, Clean the inner and outer surface of the timing chain and timing cover. Position the primary timing chain along with sprocket on Intake Cam shaft. Align primary chain into primary crank sprocket and engage New Intake camshaft bolt. Ensure to replace New Intake Cam shaft bolt while Installation. Align the timing chain fixed guide on timing chain and install the mounting bolts.torque tighten the bolts to specified value. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 253
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011160.jpg",
+ "display_order": 254
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Align the timing chain guide on timing chain and install the mounting bolt.torque tighten the bolt to specified value. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 257
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Compress the chain hydraulic tensioner and lock the tensioner by using locking pin. Refit the New chain hydraulic tensioner by mounting bolts, torque tighten the bolts to specified value. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 262
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Caution",
+ "content": "Ensure to replace New primary chain hydraulic tensioner while Installation. Follow below Sequence and procedure for Torque tightened the Intake & Exhaust Cam shaft sprocket bolts. Place the MST203 - Companion Flange Holding Tool into the Primary Chain Intake Cam shaft sprocket as shown and hold the tool in opposite direction of torqueing. MST : 0301BM011ST (cam chain tensioning tool) can be used instead of MST203 - Companion Flange Holding Tool. Torque tightened the Intake Cam shaft sprocket bolt to 50\u00b12 Nm + 90\u00b0\u00b15\u00b0. Holding the MST Tool and Torque tightened the Exhaust Cam shaft sprocket bolt after intake sprocket to 50\u00b12 Nm + 80\u00b0\u00b15\u00b0. Intake and exhaust Cam Shaft sprocket mounting bolts should be torque tightened only after installing the chain guides and hydraulic tensioner. Release the chain hydraulic tensioner locking pin. Remove the MST Cam Shaft locking tool. Remove the TDC locking pin. Refit damper pulley and install damper pulley mounting bolt on crankshaft. To reconfirming proper cam and crank timing, Once again Insert TDC locking pin and ensure cam shaft locking tool properly seating on the cam shafts position. Remove the cam shaft locking tool & TDC locking pin after confirmation. Apply Loctite 574 , Install the TDC locking dummy on crankcase and torque tighten. Torque : 20\u00b12 Nm ",
+ "file": null,
+ "display_order": 285
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Remove the damper pulley. Position the engine LH mounting bracket and install the mounting bolts.torque tighten the bolts to specified value. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 290
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Detach the engine support beam from engine and remove support beam from vehicle. Install the engine mounting bracket nuts (Both RH & LH) on engine beds and torque tighten the nuts to specified value. Torque : 110\u00b1 10 Nm. ",
+ "file": null,
+ "display_order": 295
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010986.jpg",
+ "display_order": 296
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Description",
+ "content": "Remove the engine front lifting hook. Refit the flywheel locking tool MST\u2013 0307ABH0001ST. Install MST 0311DBH0002ST \u2013 Engine front cover guide (1 Set) pins on cylinder block. Clean sealant on front cover. Clean sealant & oil between crankcase and front cover mounting surface and ensure sealant not to get inside the oil sump. The thread hole in the front cover at Oil Sump joint to be checked for any sealant present inside. The Sealant must be cleaned completely . Apply the Loctite 5900 (2mm thickness) on the Front cover & Oil sump (Front side) as per below recommended pattern. Use only the recommended sealant, failure to follow the instruction may lead to leakages. Install the front cover to the cylinder block, guiding by guide pins. Remove the front cover installation guide pins. Refit the engine front cover mounting bolts on cylinder block & cylinder head. Visually inspect the oil seal for proper seating. Torque tighten the cover mounting bolts to specified value as per torque tighten sequence. Refit the engine front cover mounting bolts on Oil sump and torque tighten to specified value. Torque : 22.5 \u00b12.5 Nm ",
+ "file": null,
+ "display_order": 323
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "Description",
+ "content": "Refit the AC compressor top mounting bolt and torque tighten to specified value. Torque : 23 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 326
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "Description",
+ "content": "Position the damper pulley, Install the mounting bolt and torque tighten to specified value. Torque : 200\u00b120 Nm + 135\u00b0\u00b15\u00b0 ",
+ "file": null,
+ "display_order": 329
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011161.jpg",
+ "display_order": 330
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "Caution",
+ "content": "Ensure to replace New Damper pulley bolt & spacer while Installation. Remove the flywheel locking tool. Position the starter motor and install the mounting bolts. torque tighten the bolts to specified value. Torque : 44 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 336
+ },
+ {
+ "step_name": "Step-42",
+ "content_type": "Description",
+ "content": "Refit the drive belt idler and install the mounting bolt. torque tighten the bolt to specified value. Torque : 45 \u00b1 3 Nm Refit auto tensioner and install the mounting bolt. torque tighten the bolt to specified value. Torque : 45 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 341
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "Description",
+ "content": "Position the vacuum pump, refit the pump mounting bolts and torque tighten to specified value. Replace the Vacuum Pump \u2018O\u2019 ring with a new one when installing. The slot parts of the vacuum pump are parallel to each other as shown in the figure if the engine chain timing marks are lined up. Fit the slots when assembling Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 346
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010468.jpg",
+ "display_order": 347
+ },
+ {
+ "step_name": "Step-45",
+ "content_type": "Description",
+ "content": "Refit the vacuum hose on pump side. Follow the below Caution points before Install the Cam Cover. Extra sealant to be wiped off after assembly of rear bearing cap. The Sealant at Cam Bearing Area on Cylinder Head and Cover must be cleaned completely. The Oil on the Cylinder Head Cam Cover Joint Face Area must be cleaned before sealant application and cam cover assembly. Apply Sealant (Loctite 5900 - 2mm thickness) on cylinder head as per below pattern before assembling cam cover. Replace the Cam Cover gaskets with a new one when installing. Ensure the New Cam Cover Rubber Gasket is Properly placed in the Cam Cover Groove. The Gasket Profile and cover groove profile must match especially at Intake Camshaft Rear Main Bearing Cap Location. Position the Cam cover with New Gaskets on engine, refit the studs and mounting bolts on the Cam cover. Torque tighten the mounting bolts & studs to specified value as per sequence order. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 363
+ },
+ {
+ "step_name": "Step-48",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25313.jpg",
+ "display_order": 364
+ },
+ {
+ "step_name": "Step-49",
+ "content_type": "Description",
+ "content": "Refit the oil separator hose. Connect the common rail electrical connector and wiring harnesses routing clip. Connect the Cam phase sensor electrical connector. Connect the DPF Sensor electrical connector. Connect the dosing module electrical connector. Position the heat shield and refit the heat shield mounting bolt on DPF side and torque tighten the bolt. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 377
+ },
+ {
+ "step_name": "Step-54",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010920.jpg",
+ "display_order": 378
+ },
+ {
+ "step_name": "Step-55",
+ "content_type": "Description",
+ "content": "Refit the heat shield mounting bolt on Cam cover and rear engine hook and torque tighten the bolts. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 381
+ },
+ {
+ "step_name": "Step-56",
+ "content_type": "Description",
+ "content": "Refit the heat shield mounting studs on Cam cover and torque tighten the studs. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 384
+ },
+ {
+ "step_name": "Step-57",
+ "content_type": "Description",
+ "content": "Attach the vacuum hose on routing clips. Connect T5 temperature sensor electrical connector. Green colour tape provided on T5 Sensor wiring pigtail and engine wiring harness connector side for easy identification while refit and ensure to properly connect the T5 Sensor wiring pigtail connector with engine wiring harness. Mismatch connection of wiring connectors may leads to affect the engine performance and occur engine trouble. Connect T4 temperature sensor electrical connector. Yellow colour tape provided on T4 Sensor wiring pigtail and engine wiring harness connector for easy identification while refit and ensure to properly connect the T4 Sensor wiring pigtail connector with engine wiring harness. Mismatch connection of wiring connectors may leads to affect the engine performance and occur engine trouble. Position the Cam box on Intake cam shaft rear end. While Installing Cam box, ensure to move the tappet in upward direction by hand. Ensure to replace New Cam box gasket during Installation. Before Installation of Cam box mounting bolts, Rotate the Cam Box Assembly as direction shown in the image to install fuel high pressure pump mounting bolts. Position the fuel pump on Cam box and install mounting bolts. Tighten the mounting bolts to the specified torque value. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 405
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040214.jpg",
+ "display_order": 406
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "Notice",
+ "content": "While Installing the pump always replace the Gasket with a new one. While torque tighten the Pump mountings, hold the Cam box Assembly by second technician as shown. Rotate the Cam Box Assembly direction as shown in the image to original position. Install the Cam box mounting bolts. Tighten the bolts to the specified torque value. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 413
+ },
+ {
+ "step_name": "Step-64",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010061.jpg",
+ "display_order": 414
+ },
+ {
+ "step_name": "Step-65",
+ "content_type": "Description",
+ "content": "Install fuel return line 'T' bracket mounting bolts. Tighten the bolts to the specified torque value Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 417
+ },
+ {
+ "step_name": "Step-66",
+ "content_type": "Description",
+ "content": "Refit fuel return hoses and lock it by spring band clamp. Connect fuel inlet tube quick coupler at pump end & FCU. Connect the fuel control unit electrical connector. Position all 4 Injectors and clamps on cylinder head, refit the injector clamp mounting bolts and torque tighten the bolts to specified value. Always replace the injector O\u2013 ring with new one when ever injector is removed. \u2022 Check the Injector Washer condition, replace if in damaged condition. Torque : 32 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 430
+ },
+ {
+ "step_name": "Step-69",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040234.jpg",
+ "display_order": 431
+ },
+ {
+ "step_name": "Step-70",
+ "content_type": "Description",
+ "content": "Connect the Injector electrical connectors. Refit injector leak - off pipe lock clips on the injector end. Position the Fuel HP pipe and tighten the mounting on Common rail end to the specified torque value. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 438
+ },
+ {
+ "step_name": "Step-73",
+ "content_type": "Description",
+ "content": "Position the Fuel HP pipe and tighten the mounting on FIP end to the specified torque value. Torque : 30 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 441
+ },
+ {
+ "step_name": "Step-74",
+ "content_type": "Description",
+ "content": "Refit the engine wiring harness carrier mounting studs on Cam cover and torque tighten the studs. Torque : 8 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 444
+ },
+ {
+ "step_name": "Step-75",
+ "content_type": "Description",
+ "content": "Position the high pressure pipes on common rail side and injector side and torque tighten the mountings to specified value. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 447
+ },
+ {
+ "step_name": "Step-75",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040094.jpg",
+ "display_order": 448
+ },
+ {
+ "step_name": "Step-76",
+ "content_type": "Description",
+ "content": "Position the drive belt and Using 14 mm ring spanner, swing the auto-tensioner in Anti clock-wise direction and install the belt. Place the MST 0306GBH0001ST - Stretch Fit Belt Installation Tool on damper pulley as shown in the image. Using 24 mm socket spanner, rotate the damper pulley in anticlockwise direction. By rotating pulley, belt started getting into pulley groove and once belt installed properly on pulley, then remove the MST and spanner Ensure proper engagement of belt teeth in all the pulley grooves after Installation. Refit the engine fead cover on engine, torque tighten the bolts to specified value. Torque : 11\u00b1 1Nm ",
+ "file": null,
+ "display_order": 460
+ },
+ {
+ "step_name": "Step-80",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011070.jpg",
+ "display_order": 461
+ },
+ {
+ "step_name": "Step-81",
+ "content_type": "Description",
+ "content": "Refit the degassing tank and install the mounting bolts on the bracket. Torque tighten the bolts to specified value. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 464
+ },
+ {
+ "step_name": "Step-82",
+ "content_type": "Description",
+ "content": "Refit the engine vent hose on T connection. Check engine coolant level and top-up. Check engine oil level and top-up if needed. Run the Engine in Idle condition for few minutes, check for oil & coolant leakage and ensure proper functioning of engine. Refit the engine top encapsulation cover. Connect iSmart, Check and clear DTC if any. Drain the engine coolant. For additional information refer to coolant drain Procedure. Remove the OCFM - degassing tank outlet pipe . For additional information refer to OCFM-Degassing Tank Outlet Pipe - R &R.; Recover the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. Using 12 mm socket spanner, Unscrew air cleaUsing a 12 mm socket spanner, loosen and remove the AC compressor suction and discharge pipes mounting nuts from compressor. Torque : 14.0+1.0 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using T45 Torx spanner, loosen and remove the Oil Cooler Mounting torx Bolts. Remove the oil cooler from the engine. Replace New O ring while refitting. Ensure to clean the Engine oil spillages Install in reverse order of removal. Refill the engine oil and check for the oil leakage. Refill the engine coolant and carry-out deaeration procedure. Check and clean the oil cooler thoroughly for any damage. Remove the engine oil sump. Using a 8 mm Allen socket spanner, loosen and remove the engine oil pump tensioner mounting bolt. Torque : 25\u00b1 3 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the starter motor mounting bolts. Torque : 44\u00b15 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using MST\u2013 0307ABH0001ST lock the flywheel. Using a 14 mm socket spanner, loosen and remove the sprocket nut from the sprocket. Torque : 40\u00b15 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the sprocket from the chain and take out from the vehicle. Install in reverse order of removal Ensure to match the Sprocket slot projection to Oil pump shaft slot. Refill the engine oil and check for oil leakage. Inspect the engine oil pump chain for any physical damage. If found replace Using a screw driver, remove the crankshaft rear end oil seal. Install the rear end oil seal by using MST 0302ABH0001ST - Engine Rear End Oil Seal Installer on the crankshaft. Always use new oil seal while installation. Install in reverse order of removal. Check & Top-up the engine oil. Check for any cracks, damage etc, replace if found any. Drain the engine coolant. For additional information refer into engine coolant draining procedure. Remove the water pump pulley. For additional information refer into Water Pump Pulley \u2013 R &R; Section. Detach the wiring routing clip from the water pump. Using a 13 mm socket spanner, Unscrew water pump mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully remove the water pump from the engine. Remove the O ring from the water pump. Install in reverse order of removal. Always replace the O ring new one once removal of water pump. Refill the engine coolant and carry-out de-aeration procedure. Check for coolant seepage and any oil seepage on the engine and transmission. Replace if any traces found. Inspect the water pump for any damage or leakage or noise. Replace if found. Inspect the impeller for any damage, Replace if found. Using 10 mm socket spanner, loosen the battery negative cable mounting nut disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Drain the engine coolant. For additionalinformation refer to engine coolant draining procedure. Recover the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. Drain the power steering oil. For additional information refer to power steering oil draining procedure. Remove the transmission with transfer case. Remove the clean side hose. For additional information refer to Clean Side Hose Assembly - R &R; section. Remove the Hose Turbocharger to Intercooler. For additional information refer to Hose Turbocharger To Intercooler - R &R; section. Remove the Intercooler Outlet Hose. For additional information refer to Intercooler Outlet Hose - R &R; section. Remove the Degassing tank. For additional information refer to Degassing Tank - R &R; section. Disconnect the boost pressure sensor electrical connector. Using a 13 mm Socket Spanner, Unscrew the Intercooler mounting bolts and remove the intercooler. Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020090.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Press and release the dosing module DEF supply quick coupler. Using a 7 mm socket spanner, loosen the coolant hose mounting clamp and detach the coolant inlet hose from Dosing Module end. Using a hose clip piler, release vacuum hose spring band clamp and detach the vacuum hoses from EGR module and vacuum pump end. Detach the vacuum hose from the routing clip and keep aside. Using a 7 mm socket spanner, loosen the radiator outlet hose clamp and detach radiator outlet hose. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using a hose clip plier, release the spring band clamp and detach degassing tank Outlet hose OCFM end. Using a 7 mm socket spanner, loosen the radiator inlet hose clamp and detach radiator inlet hose engine end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Using a hose clip plier, release the spring band clamp and detach the Vent hose pipe end. Using a hose clip plier, release the spring band clamp and detach heater outlet hose heater outlet pipe end. Using a hose clip plier, release the spring band clamp and detach the heater inlet hose from cylinder head side. Using a 13 mm socket spanner, loosen and remove alternator positive cable mounting nut. Torque : 15 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen starter motor positive cable mounting nut and detach cable from starter motor end. Torque : 12\u00b12 Nm ",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": "Using a 8 mm socket spanner, Unscrew starter motor solenoid switch electrical connector. Torque : 2.5\u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Remove AC compressor suction and discharge pipes mounting nuts and detach the pipes. Torque : 14.0+1.0 Nm ",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Disconnect the fuel pipe quick coupler metering unit end. Press and disconnect the quick coupler carefully to avoid seal damages. Using a hose clip plier, unclip the spring band clamp detach fuel return hose from T joint Using a hose clip plier, unclip the spring band clamp detach the fuel line metering unit to return T- Joint hose. Disconnect ECU electrical connector and & routing clip. Using a 10 mm socket spanner, loosen and remove the engine wiring harness carrier mounting struds and detach partially. Disconnect fuel filter electrical connector. Using 15 mm combination spanner, Remove exhaust front pipe mounting nuts SDPF end. Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "Description",
+ "content": "Using 17 mm open end spanner, Remove the power steering pump to steering gear box oil line mounting power steering pump side. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 76
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "Description",
+ "content": "Remove radiator air guide. For additional information refer to Radiator Air Guide - R &R; section. Using a 12 mm socket spanner, loosen and remove the front top cross member mounting bolts. Torque : 25 \u00b1 4.0 Nm ",
+ "file": null,
+ "display_order": 80
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the front top cross member mounting bolts Torque : 10.50 \u00b1 1.5Nm ",
+ "file": null,
+ "display_order": 83
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew degassing tank mounting brackets mounting bolts LH & RH. Torque : 10 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 86
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050043.jpg",
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050044.jpg",
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "Description",
+ "content": "Provide jack support to the engine with the supporting of floor crane. Improper tie-up of the lifting rope chain will cause damage to the vehicle and the persons involved. Using a 19 mm socket spanner, loosen and remove the engine mounting nut from the vehicle. Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 94
+ },
+ {
+ "step_name": "Step-40",
+ "content_type": "Description",
+ "content": "Jack up the crane and take out the engine from the vehicle Improper tie-up of the lifting rope chain will cause damage to the vehicle and the persons involved. Disconnect AC compressor electrical connector. Disconnect engine oil pressure switch electrical connector. Disconnect alternator electrical connector Disconnect EGR unit electrical connectors. Disconnect throttle body electrical connector. Disconnect fuel injection pump electrical connector. Disconnect temperature T4, T5 sensor electrical connectors. Yellow colour tape provided on T4 Sensor wiring pigtail and engine wiring harness connector for easy identification while refit and ensure to properly connect the T4 Sensor wiring pigtail connector with engine wiring harness. Mismatch connection of wiring connectors may leads to affect the engine performance and occur engine trouble. Green colour tape provided on T5 Sensor wiring pigtail and engine wiring harness connector side for easy identification while refit and ensure to properly connect the T5 Sensor wiring pigtail connector with engine wiring harness. Mismatch connection of wiring connectors may leads to affect the engine performance and occur engine trouble. Disconnect EVGT unit electrical connector and routing clip. Disconnect Dosing Module electrical connector Disconnect common rail electrical connector Disconnect coolant temperature sensor electrical connector. Disconnect glow plug electrical connector. Disconnect boost pressure sensor electrical connector Disconnect fuel injector electrical connector. Disconnect differential pressure sensor electrical connector and remove the routing tag from the engine compartment. Disconnect CAM phase sensor electrical connector. Detach the routing clips and remove the wiring harness from the engine assembly Remove the SDPF mounting bolts and Turbo-SDPF Coupling V clamp and detach SDPF. While Installation, Firmly keep the SDPF Assy on th turbo and Take at most care not to damaging SDPF & near by components. Always use new V band clamp & Gasket once removed V Clamp Gasket to be positioned over EATS by aligning the gasket lug with marking on V Clamp as shown in the image. V Clamp to be fully opened and put over Turbine Housing before position the SDPF. Ensure to fit the clamp in proper position for easy accessing of clamp in subsequent removal. Using 12 mm socket spanner loosen and remove clutch cover assembly mounting bolts and remove it. Torque : 25 \u00b1 5.0 Nm (Step Torque : 5,15,25) ",
+ "file": null,
+ "display_order": 146
+ },
+ {
+ "step_name": "Step-59",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011111.jpg",
+ "display_order": 147
+ },
+ {
+ "step_name": "Step-59",
+ "content_type": "Notice",
+ "content": "Install the MST : 0307ABH0001ST \u2013 Flywheel locking tool and lock the flywheel rotation. Insert MST \u2013 0801BUA0001ST \u2013 Master clutch plate assembly, before loosening the clutch cover bolts to prevent clutch plate falling down and getting damage. While Installation, the projected part of clutch disc should come towards transmission side only, fails may result in clutch disc damage. Install in reverse order of removal. Refill the power steering oil. For additional information refer to power steering oil filling procedure. Refit the battery -negative cable Check & Top-up the engine oil. Check for coolant seepage and any oil seepage on the engine and transmission.Replace if any traces found. Check the accessory drive belt for any cracks, damage etc, replace if found any. Check SMF face-out and run-out. Check SMF Surface thermal cracks condition. Check the flywheel ring gear for worn-out or damage, Refer SMF Inspection procedures for more details. Engine Oil \u2013 MAHINDRA 'MAXIMILE ULTRA' Gen-NXT Technology Genuine Engine Fluid Capacity \u2013 6.0 Liters.
Position the Vehicle on level ground and turn engine OFF. Open the bonnet and lock it in open position using bonnet stay rod. Wait for about 10 minutes for oil in circulation to drain down. Pull out the dip stick gauge and wipe it clean with a cloth/paper. Insert the dip stick gauge into the dip stick guide fully till the end. Pull out the dip stick slowly and check for the oil level mark between Maximum and Minimum level - if found below minimum level, top up with recommended oil. Insert the dip stick back and fix properly. Start the engine and check for oil leakage/ seepage at: Oil sump & crankcase joint. Oil sump drain plug. Oil filter joint. Always use MAHINDRA 'MAXIMILE ULTRA'Gen-NXT Technology GENUINE ENGINE Fluid. This is specially developed for your engine\u2019s efficiency. In extreme cases of emergency and non-availability of above oil, we suggest to use 'Maximile Feo' engine oil, take the vehicle to nearest Mahindra Authorised Service centre and replace the oil with 'MAXIMILE ULTRA'. No other brand / grade oil recommended. Remove the air cleaner assembly. Disconnect engine oil pressure switch electrical connector. Using a 24 mm deep socket spanner, loosen and remove engine oil pressure switch from the vehicle. Torque : 17 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010680.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Check engine oil level and Top up engine oil. Refill the engine oil and check for oil leakage. Check oil pressure switch for any cracks, damage etc, replace if found any. The cylinder head gasket failure can be easy to determine. A large stream of white smoke blowing from the exhaust and an overheating engine are sure signs. However, more suitable cylinder head gasket failure signs may be more difficult to diagnose. The engine may experience mysterious coolant loss, or only lose coolant when the engine is driven under heavy load. You may even experience a rough running engine when you first start the vehicle. An initial inspection of cooling system components and a comprehensive test drive may be necessary to confirm the customer's complaint of coolant loss or overheating. Check for the presence of white steam/smoke coming from the exhaust. Steam coming out of the exhaust may smell slightly sweet as the steam gently dissipates into the surrounding air. Another sign that the head gasket may be leaking is the presence of oil in the cooling system. Check for oil residue in the coolant reservoir. It is important to confirm actual engine running temperature and accuracy of the temperature gauge. This can be verified by using a non-contact infrared heat detection gun. It is a non intrusive method used by most repair shops to verify temperature gauge accuracy and actual engine running temperature. Pressurizing the cooling system (to eliminate coolant leaks as being the source of coolant loss), checking for proper operation of the cooling fan, and checking radiator efficiency are important before jumping to the conclusion that the head gasket is defective. Cylinder to Cylinder Leakage Test ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the cylinder compression pressure as already explained. Leakage between cylinders will be result in drop of compression pressure by nearly 50 to 70% in the affected cylinders. Cylinder to Water jacket Leakage Test ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the degassing pressure cap Warm up the engine and allow it to warm up until the engine thermostat opens. If large combustion pressure leak exist, bubbles will be visible in coolant If bubbles are not visible, install a pressure tester and pressurize the cooling circuit. If a cylinder is leaking combustion pressure into the water jackets then the tester\u2019s needle will pulsate with every combustion stroke of the cylinder. This vehicle is equipped with one autotensioner to maintain the accessory drive belt tension for Alternator and Power steering pump drive belt. It is mandatory to maintain belt tension through out the belt life in-order to have maximum efficiency and life. A tensioner is a device that applies a force to create or maintain recommended belt tension. Position the vehicle on ground level/ 2 post lift/ 4 post lift and turn engine OFF. Open the bonnet and lock it in open position using bonnet stay Using a 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially detach it (Without detaching the hoses). Torque : 4.5\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the engine fead cover mounting bolts. Torque : 11 \u00b1 1Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the engine fead cover from engine compartment. Random Cracking Across the Ribs ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010286.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Small yet visible cracks along the length of a rib or ribs. Causes: ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Continuous exposure to high temperatures and the stress of bending around the pulleys leads to cracking. Cracks begin at the rib top and grow to the cord line. As a rule, if cracks appear 1 or 2 cm apart, 80% of the life is gone and the belt should be replaced. Chunk-Out ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010287.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Pieces or chunks of rubber material have come off the belt. When chunk-out has occurred, a belt can fail at any moment. Belt should be replaced immediately Causes: ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Chunk-out can happen when several cracks in one area move parallel to the cord line. Heat, age and stress are the primary contributors. Pilling ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Belt material wears off from the ribs and builds up in the belts grooves. Causes: ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "There are a number of causes, including misalignment, new belt on worn pulleys, lack of tension or a combination of these factors. Gravel Penetration ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W309.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Small pinholes are visible on the backside of the belt. Bumps may be visible and fabric around the holes can be frayed. Causes: ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Granular gravel or pebble gravel is wedged between the belt groove(s) and pulley ridge(s). Damaged Outermost Ribs ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010290.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Sidewalls of the belt may appear glazed or the edge-cord may become frayed and ribs removed. A noticeable noise may result. Causes: ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Pulley misalignment is a common cause of premature belt failure. Misalignment forces the belt to twist while running, causing premature wear. Oil Contamination ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010291.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "The belt surface is flaky, sticky or swollen. Causes: ",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Oil and grease are a rubber compound\u2019s worst enemies, weakening the compound\u2019s bonds and making the belt soft and spongy. Eventually, such a belt will slip, create heat and fail. Abrasion ",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W310.jpg",
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "The backside of the belt appears very shiny or glazed. In advance stages, the fabric or even the cord becomes exposed and gets damaged. Causes: ",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "When in motion, the belt makes contact with the foreign objects in its path such as a flange or bolt. This may be caused by improper belt tension or by belt flutter (vibrations) on longer span lengths between two pulleys. Rib Separation ",
+ "file": null,
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010293.jpg",
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "The belt rib shears off or begins to separate from the belt base. Causes: ",
+ "file": null,
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "The belt is not correctly positioned. One of the belt ribs is placed outside the pulley groove, causing a belt rib to run without a supporting or aligning pulley groove. Uneven Rib Wear ",
+ "file": null,
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010294.jpg",
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Wear that is more severe on one rib than on the others or one rib that exhibits a different wear pattern than the others. A thumping or grinding noise may also be heard. Causes: ",
+ "file": null,
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "A foreign object \u2014 such as a pebble \u2014 in the pulley will cause uneven wear and cut into the belt and break the tensile cords. Broken Belt ",
+ "file": null,
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010295.jpg",
+ "display_order": 72
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "A large foreign object between the belt and pulley can cut into the belt and break the tensile cords. Tensile break may occur but go unnoticed when the belt is forced or pried on during installation. Other possible causes may be severe shock loads or a blocked pulley and/or accessory. Belt Noise ",
+ "file": null,
+ "display_order": 77
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010296.jpg",
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Run the engine and inspect for Chirping, squealing. tapping, ticking or grinding noise coming from the belt. It is recommended to remove & check the drive belts thoroughly if any abnormality noticed Check belt tension as per procedure mentioned below: ",
+ "file": null,
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011102.jpg",
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Turn ON belt tension gauge Select reading mode in hertz (Hz) and hold the probe approximately 5mm distance in front of the belt. Do not touch the probe to the belt, this can damage the probe. Belt tension needs to be checked at the green points shown in illustration. 1. Between Crank pulley & water pump pulley 2. Between water pump pulley & AC Compressor Pulley Tap on the belt near the probe Note the reading, if the reading is within 195 \u2013 228 Hz, belt tension is OK. If the reading is not within the above limit, check & replace the belt if required. Position the vehicle on ground level/ 2 post lift/ 4 post lift and turn engine OFF. Open the bonnet and lock it in open position using bonnet stay rod. Position the vehicle on ground level/ 2 post lift/ 4 post lift and turn engine OFF. Open the bonnet and lock it in open position using bonnet stay rod. Using 10 mm socket spanner, socket spanner, loosen and remove the degassing tank mounting bolts and partially detach it (Without detaching the hoses). Torque : 4.5\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the engine fead cover mounting bolts. Torque : 11 \u00b1 1Nm ",
+ "file": null,
+ "display_order": 99
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the engine fead cover from engine compartment. Random Cracking Across the Ribs ",
+ "file": null,
+ "display_order": 104
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010286.jpg",
+ "display_order": 105
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 106
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Small yet visible cracks along the length of a rib or ribs. Causes: ",
+ "file": null,
+ "display_order": 108
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Continuous exposure to high temperatures and the stress of bending around the pulleys leads to cracking. Cracks begin at the rib top and grow to the cord line. As a rule, if cracks appear 1 or 2 cm apart, 80% of the life is gone and the belt should be replaced. Chunk-Out ",
+ "file": null,
+ "display_order": 110
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010287.jpg",
+ "display_order": 111
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 112
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Pieces or chunks of rubber material have come off the belt. When chunk-out has occurred, a belt can fail at any moment. Belt should be replaced immediately Causes: ",
+ "file": null,
+ "display_order": 114
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Chunk-out can happen when several cracks in one area move parallel to the cord line. Heat, age and stress are the primary contributors. Pilling ",
+ "file": null,
+ "display_order": 116
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010288.jpg",
+ "display_order": 117
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 118
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Belt material wears off from the ribs and builds up in the belts grooves. Causes: ",
+ "file": null,
+ "display_order": 120
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "There are a number of causes, including misalignment, new belt on worn pulleys, lack of tension or a combination of these factors. Gravel Penetration ",
+ "file": null,
+ "display_order": 122
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W309.jpg",
+ "display_order": 123
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 124
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Small pinholes are visible on the backside of the belt. Bumps may be visible and fabric around the holes can be frayed. Causes: ",
+ "file": null,
+ "display_order": 126
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Granular gravel or pebble gravel is wedged between the belt groove(s) and pulley ridge(s). Damaged Outermost Ribs ",
+ "file": null,
+ "display_order": 128
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010290.jpg",
+ "display_order": 129
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 130
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Sidewalls of the belt may appear glazed or the edge-cord may become frayed and ribs removed. A noticeable noise may result. Causes: ",
+ "file": null,
+ "display_order": 132
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Pulley misalignment is a common cause of premature belt failure. Misalignment forces the belt to twist while running, causing premature wear. Oil Contamination ",
+ "file": null,
+ "display_order": 134
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010291.jpg",
+ "display_order": 135
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 136
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "The belt surface is flaky, sticky or swollen. Causes: ",
+ "file": null,
+ "display_order": 138
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Oil and grease are a rubber compound\u2019s worst enemies, weakening the compound\u2019s bonds and making the belt soft and spongy. Eventually, such a belt will slip, create heat and fail. Abrasion ",
+ "file": null,
+ "display_order": 140
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W310.jpg",
+ "display_order": 141
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 142
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "The backside of the belt appears very shiny or glazed. In advance stages, the fabric or even the cord becomes exposed and gets damaged. Causes: ",
+ "file": null,
+ "display_order": 144
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "When in motion, the belt makes contact with the foreign objects in its path such as a flange or bolt. This may be caused by improper belt tension or by belt flutter (vibrations) on longer span lengths between two pulleys. Rib Separation ",
+ "file": null,
+ "display_order": 146
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010293.jpg",
+ "display_order": 147
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 148
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "The belt rib shears off or begins to separate from the belt base. Causes: ",
+ "file": null,
+ "display_order": 150
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "The belt is not correctly positioned. One of the belt ribs is placed outside the pulley groove, causing a belt rib to run without a supporting or aligning pulley groove. Uneven Rib Wear ",
+ "file": null,
+ "display_order": 152
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010294.jpg",
+ "display_order": 153
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 154
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Wear that is more severe on one rib than on the others or one rib that exhibits a different wear pattern than the others. A thumping or grinding noise may also be heard. Causes: ",
+ "file": null,
+ "display_order": 156
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "A foreign object \u2014 such as a pebble \u2014 in the pulley will cause uneven wear and cut into the belt and break the tensile cords. Broken Belt ",
+ "file": null,
+ "display_order": 158
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010295.jpg",
+ "display_order": 159
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 160
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 161
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 162
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "A large foreign object between the belt and pulley can cut into the belt and break the tensile cords. Tensile break may occur but go unnoticed when the belt is forced or pried on during installation. Other possible causes may be severe shock loads or a blocked pulley and/or accessory. Belt Noise ",
+ "file": null,
+ "display_order": 164
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010296.jpg",
+ "display_order": 165
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Heading",
+ "content": "Inspection: ",
+ "file": null,
+ "display_order": 166
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Run the engine and inspect for Chirping, squealing. tapping, ticking or grinding noise coming from the belt. It is recommended to remove & check the drive belts thoroughly if any abnormality noticed Inspect the auto-tensioner carefully for symptoms such as cracked arms, excessive vibration during idle speeds, looseness, noise (clatter or rattling) and sticking or seized operation. These all can be signs that roller needs replacement. Rust bleed and cracks ",
+ "file": null,
+ "display_order": 171
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S2B010321.jpg",
+ "display_order": 172
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 173
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S2B010322.jpg",
+ "display_order": 174
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Rust bleeding between arm and base or dripping from the tensioner. Also, check the tensioner for cracks or damage to arm, housing and bracket. Causes: ",
+ "file": null,
+ "display_order": 176
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Rust bleeding or dripping is a sign of internal component wear. Most common crack damage occurs at tensioner \u201cStops\u201d and mounting bolts. Solution: ",
+ "file": null,
+ "display_order": 178
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Replace the auto-tensioner. Pulley bearing wear ",
+ "file": null,
+ "display_order": 180
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S2B010323.jpg",
+ "display_order": 181
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 182
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "If any abnormality noticed, remove the belt and manually rotate the pulley. If you notice, resistance or roughness, the problem is likely to be pulley bearing wear. Causes: ",
+ "file": null,
+ "display_order": 184
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Defective bearing and/or pulley. Solution: ",
+ "file": null,
+ "display_order": 186
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Replace the complete tensioner. Do not attempt to replace a worn pulley in a used tensioner assembly but always replace the entire tensioner assembly, as part failure will inevitably follow quickly. TENSIONER ASSEMBLY MISALIGNMENT ",
+ "file": null,
+ "display_order": 188
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S2B010324.jpg",
+ "display_order": 189
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 190
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S2B010325.jpg",
+ "display_order": 191
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Abnormal belt tracking on tensioner pulley.. Causes: ",
+ "file": null,
+ "display_order": 193
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Bent or misaligned mounting bracket,improper tensioner installation or corrosion/ contamination between tensioner base and mounting surface. A small amount of contamination results in a large amount of at tensioner pulley Tensioner Noise ",
+ "file": null,
+ "display_order": 195
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 196
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Squeaks and rattles coming from the tensioner. Causes: ",
+ "file": null,
+ "display_order": 198
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Failure of bearings or pivot are will cause excessive noise. Solution: ",
+ "file": null,
+ "display_order": 200
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Replace the tensioner assembly The crankshaft speed sensor is an inductive type sensor. It measures the speed of the trigger wheel mounted on the crankshaft. During engine cranking and running, the EMS ECU receives the output signal from crankshaft speed sensor. Remove the wheel (front LH). Disconnect Engine Speed Sensor electrical connector. By using 8 mm socket spanner, Universal Joint and proper extension rod, Unscrew Engine Speed Sensor mounting bolt and remove it. Torque : 11\u00b11.0 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1560.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "Take sufficient care not to damage the sensor while removing. Ensure correct torque value is given to sensor mounting bolt. Else chances of sensor malfunction is high. Install in reverse order of removal. Inspect the sensor and connector for any physical damage. Replace if found. EMS (Engine Management System) ECU is an electronic control unit which is used to ensure optimal engine performance. It does this by analyzing values or signals from various sensors and other ECU\u2019s and adjusting the actuators accordingly. EMS ECU is mounted on engine compartment LH apron. ECU electrical connector should be disconnected before carrying out any welding activities in the vehicle. Using 10 mm socket spanner, Loosen battery negative terminal mounting nut and disconnect the terminal. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Open the lock and gently pull-out and disconnect EMS ECU electrical connector. Using 10 mm socket spanner remove MS ECU mounting bolts. Torque : 6\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011053.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. For New EMS ECU replacement carry out \u201cComponent Replacement Procedures \u2013 EMS ECU replacement\u201d by using i-SMART. For additional information refer Diagnosis Manual. ECU electrical connector should be disconnected before carrying out any welding activities in the vehicle. Check for any external damage, if found replace. Remove the cylinder head assembly. Place the cylinder head on clean flat work table. Using an appropriate tool, compress and hold the valve spring and then remove the valve spring lock studs. Remove the upper retainer and valve spring. Incase of reusing the same valves spring, make necessary marking according to the respective cylinder. Remove the valve stem seal. The valve should be identified, so that in case the valves are being reused they can be used. Failure to do so may increase the probability of compression leak through the valve after the engine is rebuilt. Check the valve spring lock for any internal and external damage. 2. Check the valve spring height. Check the valve guide bore diameter. Check the valve guide for any damages. Check the valve for any damages. Using a micrometer measures the diameter of the valve stems. If the measurements are not to specification, install a new valve. Check the valves for bend - especially if the engine has suffered water entry into combustion chamber. Clean the cylinder head assembly thoroughly, if any cracks or damages are found replace the cylinder head. Check the Cylinder Head for external damages. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. Check the valve seat area for leakages. Check the Cylinder Head bottom face for distortion. Check the cylinder head flatness, if any misalignment or bend found replace the cylinder head assembly. Check the cylinder head for warpage. Check the length of the Cylinder Head bolts. Using a micrometer measure the diameter at 90\u00b0 intervals to determine if the journals are out-of-round. Measure at two different points on the journal to determine if there is any tapering. Check the camshaft for any damage and replace it if necessary. Do not dis-assemble the HLLA, as it is not a serviceable component. Incase of a failure of a HLLA, replace the complete assembly. Camshaft Surface Inspection ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1563.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": " 1. Inspect the camshaft lobes for pitting or damage in the active area. Minor pitting is acceptable outside the active area. ",
+ "file": null,
+ "display_order": 40
+ }
+ ]
+ },
+ {
+ "procedure_name": "Assembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using suitable tool refit new valve stem seal Never use old valve stem seal, always use a new one. Insert the respective valve spring and top retainer. Using a suitable tool, compress the valve spring carefully insert the locking pins and lock it properly. Install the cylinder head assembly. Clean the cylinder head assembly thoroughly, if any cracks or damages are found replace the cylinder head. Replace the cylinder head gasket with a new one. Failure to follow this will lead to compression failure. The cylinder head mounting bolts cannot be reused. Always use new bolts during installation. Start the engine. Run at idle for 5 minutes. Observe for leaks. Drive the vehicle at 50% of the maximum speed in each gear for about 10 to 30 kms each (Approx.) Hand over the vehicle to customer to drive with speed limitation for 2000 kms. Do not run the engine without load for hours for bedding in. This process only harms the engine Running the engine without load cause ring fluttering and damage to rings as well as liners. Running the engine at idle for prolonged time has serious consequences on major engine components. Engine Oil \u2013 MAHINDRA 'MAXIMILE ULTRA' Gen-NXT Technology Genuine Engine Fluid. Capacity \u2013 6.0 Liters.
Position the vehicle on ground level/ 2 post lift/ 4 post lift and turn engine OFF.
Open the bonnet and lock it in open position using bonnet stay rod.
",
+ "file": null,
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Draining Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the engine top encapsulation cover. Remove the engine oil filler cap. Using 22 mm ring/ socket spanner, Unscrew engine oil drain plug located under the oil sump. Torque value: 33\u00b12 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Allow the entire oil to get drained. Place a tray under the drain plug to collect the oil. Refit the drain plug with a new copper washer and tighten the drain plug to specific torque. Torque : 33\u00b1 2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Always replace the copper washer with a new one. Fill fresh recommended oil to specified quantity. Refit the engine oil filler cap. Refit the engine encapsulation cover. Pull out the dip stick gauge and wipe it clean with a cloth/paper. Insert the dip stick gauge into the dip stick guide fully till the end. Pull out the dip stick slowly and check for the oil level mark between Maximum and Minimum level - if found below minimum level, top up with recommended oil. Insert the dip stick back and fix properly. Always use MAHINDRA 'MAXIMILE ULTRA'Gen-NXT Technology GENUINE ENGINE Fluid. This is specially developed for your engine\u2019s efficiency. In extreme cases of emergency and non-availability of above oil, we suggest to use 'Maximile Feo' engine oil, take the vehicle to nearest Mahindra Authorised Service centre and replace the oil with 'MAXIMILE ULTRA'. No other brand / grade oil recommended. The engine oil becomes hot and has to be cooled to increase its life and performance. Heat is transferred from oil to coolant in the oil filter module. The oil cooler and filtration (OCFM) module consists of oil cooler, oil filter, thermostat and coolant pipes. Drain the coolant. For additional information refer to coolant drain Procedure. Remove the turbocharger with exhaust manifold. For additional information refer to the turbocharger with exhaust manifold - R &R.; Remove the AC/water pump belt. For additional information refer to AC/water pump belt - R &R.; Using a 14 mm socket spanner, loosen and remove the OCFM to turbo oil inlet banjo bolt. Torque : 17.5+2.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the EGR cooler inlet pipe routing bracket mounting bolt from the OCFM . Torque :11\u00b11 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew EGR cooler outlet pipe mounting bolt at OCFM end. Torque :11\u00b11 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the turbo oil return pipe routing bracket bolt. Torque :25\u00b13 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 7 mm socket spanner, loosen and remove the radiator outlet hose clamp OCFM pipe end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the degassing to OCFM pipe mounting bolt. Torque :11\u00b11 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the wiring harness routing bracket bolts from the water pump and OCFM. Torque :11\u00b11 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1570.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque : 10\u00b11 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the OCFM mounting bolts from engine. Torque :25\u00b13 Nm ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Caution",
+ "content": "Replace New rubber gasket while refitting Remove OCFM from the vehicle Using a 10 mm socket spanner, Unscrew water pump pulley mounting bolts and remove pulley from water pump. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Notice",
+ "content": "Using a suitable tool hold the pulley then remove the water pump pulley. Using a 13 mm socket spanner, Unscrew water pump mounting bolts and remove the water pump from the OCFM. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010267.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Refill the engine oil and check for the oil leakage. Refill the engine coolant and carry-out de-aeration procedure. Check the OCFM for any external cracks, replace if found any. This vehicle is equipped with one autotensioner to maintain the accessory drive belt tension for Alternator and Power steering pump drive belt. It is mandatory to maintain belt tension through out the belt life in-order to have maximum efficiency and life. A tensioner is a device that applies a force to create or maintain recommended belt tension. Position the vehicle on ground level/ 2 post lift/ 4 post lift and turn engine OFF. Open the bonnet and lock it in open position using bonnet stay rod Using 10 mm socket spanner, Unscrew degassing tank mounting bolts and partially detach it (Without detaching the hoses). Torque : 4.5\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen and remove the engine fead cover mounting bolts. Torque : 11 \u00b1 1Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the engine fead cover from engine compartment Place the MST 0306GAM0006ST - Stretch Fit Belt Removal Tool on damper pulley side as shown in the image. Using a 24 mm socket spanner, rotate the damper pulley to clockwise direction then remove the water pump drive belt and MST separately Place the MST 0306GBH0001ST - Stretch Fit Belt Installation Tool on damper pulley as shown in the image. Using a 24 mm socket spanner, rotate the damper pulley in anticlockwise direction. By rotating pulley, belt started getting into pulley groove and once belt installed properly on pulley, then remove the MSTand spanner Ensure proper engagement of belt teeth in all the pulley grooves after Installation. Check the Belt tension. Refer Belt Tension Checking Procedure session. Refit the engine fead cover on engine compartment, torque tighten the bolts to specified value Torque : 11\u00b1 1Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011070.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit the degassing tank mounting bolts on the bracket and Torque tighten the bolts to specified value. Torque : 4.5\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Refit the new auto-tensioner assembly . Torque tighten the mounting bolt to specified value. Torque : 45 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010933.jpg",
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 14 mm ring spanner, swing the auto-tensioner in counter clock-wise direction and install the belt. Refit AC Compressor /Water Pump Stretch Fit Belt. For additional information refer to Accessory Drive Belt (AC Compressor /Water Pump) \u2013 Replace section. Check belt tension as per procedure mentioned below: ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011102.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Run the engine for few minutes. Turn ON belt tension gauge. Select reading mode in hertz (Hz) and hold the probe approximately 5mm distance in front of the belt. Do not touch the probe to the belt, this can damage the probe Belt tension needs to be checked at the green points shown in illustration. Between Crank pulley & water pump pulley Between water pump pulley & AC Compressor Pulley Tap on the belt near the probe Note the reading, if the reading is within 195 \u2013 228 Hz, belt tension is OK. Position the vehicle on ground level/ 2 post lift/ 4 post lift and turn engine OFF. Open the bonnet and lock it in open position using bonnet stay rod. Remove AC Compressor /Water Pump Stretch Fit Belt. For additional information refer to Accessory Drive Belt (AC Compressor /Water Pump) \u2013 Replace section. Using 14 mm ring spanner, turn the hexagon knob in the belt tensioner Anti clockwise direction to release the tension. Using 14 mm socket spanner, remove the alternator/power steering auto tensioner mounting bolt and remove the tensioner. The cylinder compression test is performed to determine the compression pressure of individual cylinders. The test is performed in two stages. 1. Dry Test. 2. Wet Test The results of the cylinder compression test can be utilized to diagnose several engine malfunctions. Before carrying out the compression test ensures that the battery is in good working condition. Otherwise the indicated pressures may not be valid for diagnostic purpose Check engine oil level and add oil if necessary. Drive the vehicle until engine reaches normal operating temperature. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Spray 10 to 20 ml of engine oil inside the bore through the injector port with the help of an oil can. Fit the dummy injector and connect it with the compression gauge. Disconnect the cam phase sensor and crank shaft sensor (for safety) electrical connector. Crank the engine. Note the maximum value the gauge indicates. Repeat the procedure for all the other cylinders. Tabulate the results. Refer to the specification for the value. Compare both the dry and the wet values with the specifications. The wet test values should always be higher than the dry test values. If the reading does not change during wet test this can hint towards compression leakage from cylinder head or through the valves. If the wet and dry test values vary considerably between cylinders then the piston rings can be suspected. Remove the engine top encapsulation cover. Using nose plier, release engine vent hose clip at T Joint and disconnect the hose. Using 10 mm socket spanner, Unscrew degassing tank mounting bolts and partially detach it (Without detaching the hoses). Using 10 mm socket spanner, loosen and remove the engine fead cover mounting bolts. Remove the engine fead cover from engine compartment. Place the MST 0306GAM0006ST -Stretch Fit Belt Removal Tool on damper pulley side as shown in the image. Using 24 mm socket spanner, rotate the damper pulley to clockwise direction then remove the water pump drive belt and MST separately. Using 14 mm ring spanner, turn the hexagon knob in the belt tensioner Anticlockwise direction to release the tension. Remove the alternator drive belt. Using 10 mm socket spanner, Unscrew engine wiring harness carrier mounting stud from Cam cover and detach it partially. Disconnect the Injectors electrical connectors from the injectors. Using 17 mm open end spanner,Unscrew High pressure pipe mounting flare nut from common rail end. Using 19 mm open end spanner,unscrew High pressure pipe flare nut from injection pump end. Using 17 mm open end spanner loosen the high pressure pipe flare nuts at common rail side and injector side. While loosening the high pressure pipes at Injector end, hold the injector pipe connector by 13 mm Open end spanner. Remove the high pressure fuel pipes from the engine. Remove injector leak - off pipe lock clip and detach leak off pipes from the injector end. Using 8 mm Allen socket spanner, Unscrew the injector clamp mounting bolts. Remove all 4 Injectors from cylinder head. Injector Bore must be covered with lint free cloth/Masking tape to avoid foreign objects entering injector bore/cylinder. Plug the fuel inlet and wiring harness connector slot as soon as injector is removed Store the injector in a neat tray. Never drop the injectors. Never clean the injector using pressurized water. Disconnect fuel inlet tube quick couplers from fuel injection pump & FCU. All are quick fix connectors, press gently and remove it carefully to avoid seal damages. Using nose plier release fuel return hose spring band clamp and detach hoses from fuel injection pump & FCU. Press the lock and disconnect fuel control unit electrical connector. Using 10 mm socket spanner, Unscrew fuel return line 'T' bracket mounting bolts. Using 12 mm socket spanner, Unscrew Cam box mounting bolts and remove the bolts. Rotate the Cam Box Assembly as direction shown in the image to access fuel high pressure pump mounting bolts. Using T30 socket spanner unscrew fuel high pressure pump mounting bolts and detach pump. Remove Cam box assembly along with FCU from engine. While taking out Cam box, ensure to move the tappet in upward direction by hand. Disconnect T4 temperature sensor electrical connector. Disconnect T5 temperature sensor electrical connector. Detach the vacuum hose routing clips from heat shield. Using 14 mm socket spanner, loosen and remove the heat shield mounting studs from Cam cover. Using 10 mm socket spanner, loosen and remove the heat shield mounting bolt from Cam cover and rear engine hook. Using 12 mm socket spanner, loosen and remove the heat shield mounting bolt from SDPF side. Disconnect the dosing module electrical connector. Disconnect the dosing module electrical connector. Disconnect the Cam phase sensor electrical connector. Disconnect the common rail electrical connector and wiring harnesses routing clip. Using hose clip plier, Unclip oil separator hose spring band clamp and detach hose. Using 10 mm ring spanner, loosen and remove stud mountings from Cam cover. Using 10 mm socket spanner, loosen and remove Cam cover mounting bolts & studs. Using 8 mm socket spanner, loosen and remove the Cam cover mounting bolts. . Detach Cam cover from the engine completely. Using nose plier, Release the spring band clamp and disconnect vacuum hose from vacuum pump side. Using 12 mm socket spanner, Unscrew vacuum pump mounting bolts and remove vacuum pump from engine. Using 14 mm socket spanner, Loosen and remove auto tensioner mounting bolt and remove tensioner Using 14 mm socket spanner, Loosen and remove the drive belt idler mounting bolt and remove idler from the engine. Using 14 mm socket spanner, loosen and remove the starter motor mounting bolts. Lock the flywheel by using MST0307ABH0001ST - Fly wheel Locking tool. Using 24 mm socket spanner, Unscrew damper pulley mounting bolt and remove damper pulley. Using 12 mm socket spanner, Loosen and remove the engine front cover mounting bolts from the Oil sump. Using 12 mm socket spanner, Loosen and remove the AC compressor top mounting bolt. AC compressor top mounting bolt must be removed, failing to remove the bolt will leads to crack the front cover Using 14 mm socket spanner, loosen and remove engine front cover mounting bolts from cylinder head. Using 12 mm socket spanner, loosen and remove engine front cover mounting bolts from crank case. Using 12 mm socket spanner, loosen and remove engine front cover mounting bolts. ach engine front cover from engine. Ensure to cover the engine oil sump open space properly by lint free cloth after removal of Front Cover. Make sure for all the subassembly and components going into engine assembly should be clean and away from foreign material. Remove the flywheel locking tool MST\u2013 0307ABH0001ST. Position engine front lifting hook and hand tighten the mounting bolts. Using 18 mm socket spanner, unscrew engine mounting bracket nuts (Both RH & LH). Provide engine support beam to support engine. Lift the engine with care, don\u2019t over lift since chances of damaging parts are high. Ensure none of the components are effected or damaged during lifting. Using 14 mm combination spanner and socket spanner , unscrew LH engine mounting bracket mounting bolts and remove the LH bracket. Using 6 mm square socket spanner, loosen and remove TDC locking dummy from crankcase. Refit damper pulley and install damper pulley mounting bolt on crankshaft. Lock the crankshaft by Inserting the TDC locking pin (MST\u2013 0312ABH0001ST). Ensure the crankshaft locking tool is seated properly into the slot on crankshaft and ensure the TDC locking pin insert upto Red mark in the Check and ensure the 1st cylinder piston position to TDC. Ensure that correct TDC locking tool is used. TDC locking hole is near crankcase left side below intake manifold (Near Engine LH Mounting bracket). If not able to position the MST in proper position into crankshaft, Slightly rotate damper pulley and align the crankshaft to insert MST:- 0312ABH0001ST Crankshaft Locking Tool - TDC Pin on crankshaft. Install the (MST \u2013 0310ABH0001ST Cam Shaft locking tool) on the front side of cylinder head as the location shown below using appropriate bolts. The Cam shaft 2D Matrix must be on the top side for both Intake and Exhaust camshaft. Crank Sprocket Key must be at 12\u2019O Clock Position. Ensure that locking tool is seated properly on Cam shaft. Remove the damper pulley. Using T55 socket spanner, loosen exhaust Cam sprocket mounting bolt. The Exhaust Camshaft Sprocket mounting bolt must be loosened first and then the Intake camshaft Sprocket Mounting bolt to be loosened. Using 15 mm socket spanner, loosen intake Cam sprocket mounting bolt. Using 10 mm socket spanner, loosen and remove the chain hydraulic tensioner mounting bolts. Using 8 mm Allen key, loosen and remove the chain guide bolt and detach guide. Using 10 mm socket spanner, loosen and remove the chain fixed guider bolts and detach guide. Remove and take out the timing chain with intake Cam sprocket from engine. Using 5 mm Allen key/ Socket, loosen and remove the secondary chain tensioner mounting Allen bolts. Remove the exhaust Cam sprocket mounting bolt. Compress the tensioner and remove the camshaft intake and exhaust drive chain and sprockets along with tensioner. Unscrew Cam Shaft Locking (MST\u2013 0307ABH0001ST) mounting bolts and remove MST. Using 10 mm socket spanner, Loosen and Remove the Intake Cam shaft rear bearing cap mounting bolts. Remove the rear bearing cap from the cylinder head. Using 8 mm socket spanner, Loosen and Remove Cam shaft front bearing cap mounting bolts. Remove the front bearing cap from the cylinder head. Using 8 mm socket spanner, Loosen and Remove the intake Cam shaft bearing cap mounting bolts. Remove the intake Cam shaft bearing caps. Remove the Intake Cam shaft from the cylinder head. Apply a thin layer of engine oil to the mounting parts of the Intake Cam shaft. Install the New Intake Cam shaft. Line up the timing marks of the intake/ exhaust Cam shaft (on the front side) when installing as shown. The Cam shaft 2D Matrix must be on the top side for both Intake and Exhaust camshaft. Crank Sprocket Key must be at 12\u2019O Clock Position. Check and confirm the 1st cylinder piston position at TDC before installation. Apply a thin layer of engine oil on the Intake Cam shaft. Install the Front, Rear & Intake Cam shaft bearing caps. Sealant (Loctite 574 - 2mm thickness) to be applied on rear bearing cap as er below pattern. Extra sealant to be wiped off after assembly of rear bearing cap. Install the bearing caps mounting bolts and torque tighten the bolts to specified value as per tightening sequence. Tightening Sequence ",
+ "file": null,
+ "display_order": 220
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010048.jpg",
+ "display_order": 221
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque for A & B : 11\u00b11 Nm Torque for C : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 222
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20758.jpg",
+ "display_order": 223
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install the (MST \u2013 0310ABH0001ST Cam Shaft locking tool) on the front side of cylinder head as the location shown below using appropriate bolts. The Cam shaft 2D Matrix must be on he top side for both Intake and Exhaust camshaft. Crank Sprocket Key must be at 12\u2019O Clock Position. Ensure that locking tool is seated properly on Cam shaft. Assemble the exhaust compress the tensioner and insert the suitable locking pins/allen keys on tensioner. Install the camshaft intake and exhaust drive chain and sprockets along with tensioner on cam shafts. Install the secondary tensioner mounting bolts and Torque tighten bolts to specified value. Torque: 11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 237
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Release the tensioner locking pins. Hand tighten the New exhaust Cam sprocket mounting bolt. nsure to replace New Exhaust Cam shaft bolt while Installation. Before Installation of Primary timing chain, Clean the inner and outer surface of the timing chain and timing cover. Position the primary timing chain along with sprocket on Intake Cam shaft. Align primary chain into primary crank sprocket and engage New Intake camshaft bolt. Ensure to replace New Intake Cam shaft bolt while Installation. Align the timing chain fixed guide on timing chain and install the mounting bolts. torque tighten the bolts to specified value. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 251
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011160.jpg",
+ "display_order": 252
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Align the timing chain guide on timing chain and install the mounting bolt. torque tighten the bolt to specified value. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 255
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Compress the chain hydraulic tensioner and lock the tensioner by using locking pin. Refit the New chain hydraulic tensioner by mounting bolts, torque tighten the bolts to specified value. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 260
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Caution",
+ "content": "Ensure to replace New primary chain hydraulic tensioner while Installation. Follow below Sequence and procedure for Torque tightened the Intake & Exhaust Cam shaft sprocket bolts. Place the MST203 - Companion Flange Holding Tool into the Primary Chain Intake Cam shaft sprocket as shown and hold the tool in opposite direction of torqueing. Torque tightened the Intake Cam shaft sprocket bolt to 50\u00b12 Nm + 90\u00b0\u00b15\u00b0 . Holding the MST Tool and Torque tightened the Exhaust Cam shaft sprocket bolt after intake sprocket to 50\u00b12 Nm + 80\u00b0\u00b15\u00b0 . MST : 0301BM011ST (cam chain tensioning tool) can be used instead of MST203 - Companion Flange Holding Tool. Intake and exhaust Cam Shaft sprocket mounting bolts should be torque tightened only after installing the chain guides and hydraulic tensioner. Release the chain hydraulic tensioner locking pin. Remove the MST Cam Shaft locking tool. Remove the MST Cam Shaft locking tool. Refit damper pulley and install damper pulley mounting bolt on crankshaft. To reconfirming proper cam and crank timing, Once again Insert TDC locking pin and ensure cam shaft locking tool properly seating on the cam shafts position. Remove the cam shaft locking tool & TDC locking pin after confirmation. Apply Loctite 574 , Install the TDC locking dummy on crankcase and torque tighten. Torque : 20\u00b12 Nm ",
+ "file": null,
+ "display_order": 283
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Remove the damper pulley. Position the engine LH mounting bracket and install the mounting bolts. torque tighten the bolts to specified value. Torque :45\u00b15 Nm ",
+ "file": null,
+ "display_order": 288
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Detach the engine support beam from engine and remove support beam from vehicle. Install the engine mounting bracket nuts (Both RH & LH) on engine beds and torque tighten the nuts to specified value. Torque : 110\u00b1 10 Nm. Remove the engine front lifting hook. Refit the flywheel locking tool MST\u20130307ABH0001ST. Install MST 0311DBH0002ST \u2013 Engine front cover guide (1 Set) pins on cylinder block. Clean sealant on front cover Clean sealant & oil between crankcase and front cover mounting surface and ensure sealant not to get inside the oil sump. The thread hole in the front cover at Oil Sump joint to be checked for any sealant present inside. The Sealant must be cleaned completely . Apply the Loctite 5900 ( 2mm thickness) on the Front cover & Oil sump (Front side) as per below recommended pattern. Use only the recommended sealant,failure to follow the instruction may lead to leakages. Install the front cover to the cylinder block, guiding by guide pins. Remove the front cover installation guide pins. Refit the engine front cover mounting bolts on cylinder block & cylinder head. Visually inspect the oil seal for proper seating. Torque tighten the cover mounting bolts to specified value as per torque tighten sequence. Refit the engine front cover mounting bolts on Oil sump and torque tighten to specified value. Torque : 22.5 \u00b12.5 Nm ",
+ "file": null,
+ "display_order": 321
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "Description",
+ "content": "Refit the AC compressor top mounting bolt and torque tighten to specified value. Torque : 23 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 324
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "Description",
+ "content": "Position the damper pulley, Install the mounting bolt and torque tighten to specified value. Torque : 23 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 327
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011161.jpg",
+ "display_order": 328
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "Caution",
+ "content": "Ensure to replace New Damper pulley bolt & spacer while Installation. Remove the flywheel locking tool. Position the starter motor and install the mounting bolts. torque tighten the bolts to specified value. Torque : 44 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 334
+ },
+ {
+ "step_name": "Step-42",
+ "content_type": "Description",
+ "content": "Refit the drive belt idler and install the mounting bolt. torque tighten the bolt to specified value. Torque : 45 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 337
+ },
+ {
+ "step_name": "Step-43",
+ "content_type": "Description",
+ "content": "Refit auto tensioner and install the mounting bolt. torque tighten the bolt to specified value. Torque : 45 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 340
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "Description",
+ "content": "Position the vacuum pump, refit the pump mounting bolts and torque tighten to specified value. Replace the Vacuum Pump \u2018O\u2019 ring with a new one when installing. The slot parts of the vacuum pump are parallel to each other as shown in the figure if the engine chain timing marks are lined up. Fit the slots when assembling. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 345
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1629.jpg",
+ "display_order": 346
+ },
+ {
+ "step_name": "Step-45",
+ "content_type": "Description",
+ "content": "Refit the vacuum hose on pump side. Follow the below Caution points before Install the Cam Cover. Extra sealant to be wiped off after assembly of rear bearing cap. The Sealant at Cam Bearing Area on Cylinder Head and Cover must be cleaned completely The Oil on the Cylinder Head Cam Cover Joint Face Area must be cleaned before sealant application and cam cover assembly. Apply Sealant (Loctite 5900 - 2mm thickness) on cylinder head as per below pattern before assembling cam cover. Replace the Cam Cover gaskets with a new one when installing \u2022 Ensure the New Cam Cover Rubber Gasket is Properly placed in the Cam Cover Groove. The Gasket Profile and cover groove profile must match especially at Intake Camshaft Rear Main Bearing Cap Location. Position the Cam cover with New Gaskets on engine, refit the studs and mounting bolts on the Cam cover. Torque tighten the mounting bolts & studs to specified value as per sequence order. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 362
+ },
+ {
+ "step_name": "Step-48",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20824.jpg",
+ "display_order": 363
+ },
+ {
+ "step_name": "Step-49",
+ "content_type": "Description",
+ "content": "Refit the oil separator hose. Connect the common rail electrical connector and wiring harnesses routing clip. Connect the Cam phase sensor electrical connector. Connect the DPF Sensor electrical connector. Connect the dosing module electrical connector. Position the heat shield and refit the heat shield mounting bolt on DPF side and torque tighten the bolt. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 376
+ },
+ {
+ "step_name": "Step-54",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010920.jpg",
+ "display_order": 377
+ },
+ {
+ "step_name": "Step-55",
+ "content_type": "Description",
+ "content": "Refit the heat shield mounting bolt on Cam cover and rear engine hook and torque tighten the bolts. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 380
+ },
+ {
+ "step_name": "Step-56",
+ "content_type": "Description",
+ "content": "Refit the heat shield mounting studs on Cam cover and torque tighten the studs. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 383
+ },
+ {
+ "step_name": "Step-57",
+ "content_type": "Description",
+ "content": "Attach the vacuum hose on routing clips. Connect T5 temperature sensor electrical connector. Green colour tape provided on T5 Sensor wiring pigtail and engine wiring harness connector side for easy identification while refit and ensure to properly connect the T5 Sensor wiring pigtail connector with engine wiring harness. Mismatch connection of wiring connectors may leads to affect the engine performance and occur engine trouble. Connect T4 temperature sensor electrical connector. Yellow colour tape provided on T4 Sensor wiring pigtail and engine wiring harness connector for easy identification while refit and ensure to properly connect the T4 Sensor wiring pigtail connector with engine wiring harness. Mismatch connection of wiring connectors may leads to affect the engine performance and occur engine trouble. Position the Cam box on Intake cam shaft rear end. While Installing Cam box, ensure to move the tappet in upward direction by hand. Ensure to replace New Cam box gasket during Installation. Before Installation of Cam box mounting bolts, Rotate the Cam Box Assembly as direction shown in the image to install fuel high pressure pump mounting bolts. Position the fuel pump on Cam box and install mounting bolts. Tighten the mounting bolts to the specified torque value. While Installing the pump always replace the Gasket with a new one. While torque tighten the Pump mountings, hold the Cam box Assembly by second technician as shown. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 406
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1644.jpg",
+ "display_order": 407
+ },
+ {
+ "step_name": "Step-63",
+ "content_type": "Description",
+ "content": "Rotate the Cam Box Assembly direction as shown in the image to original position. Install the Cam box mounting bolts.Tighten the bolts to the specified torque value. Tightening Sequence ",
+ "file": null,
+ "display_order": 412
+ },
+ {
+ "step_name": "Step-64",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010061.jpg",
+ "display_order": 413
+ },
+ {
+ "step_name": "Step-64",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 414
+ },
+ {
+ "step_name": "Step-65",
+ "content_type": "Description",
+ "content": "Install fuel return line 'T' bracket mounting bolts. Tighten the bolts to the specified torque value Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 417
+ },
+ {
+ "step_name": "Step-66",
+ "content_type": "Description",
+ "content": "Refit fuel return hoses and lock it by spring band clamp. Connect fuel inlet tube quick coupler at pump end & FCU. Connect the fuel control unit electrical connector. Position all 4 Injectors and clamps on ylinder head, refit the injector clamp mounting bolts and torque tighten the bolts to specified value. Always replace the injector O\u2013 ring with new one when ever injector is removed. Check the Injector Washer condition,replace if in damaged condition. Torque : 32 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 430
+ },
+ {
+ "step_name": "Step-69",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040234.jpg",
+ "display_order": 431
+ },
+ {
+ "step_name": "Step-70",
+ "content_type": "Description",
+ "content": "Connect the Injector electrical connectors. Refit injector leak - off pipe lock clips on the injector end. Position the Fuel HP pipe and tighten the mounting on Common rail end to the specified torque value. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 438
+ },
+ {
+ "step_name": "Step-73",
+ "content_type": "Description",
+ "content": "Position the Fuel HP pipe and tighten the mounting on FIP end to the specified torque value. Torque : 30 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 441
+ },
+ {
+ "step_name": "Step-74",
+ "content_type": "Description",
+ "content": "Refit the engine wiring harness carrier mounting studs on Cam cover and torque tighten the studs. Torque : 8 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 444
+ },
+ {
+ "step_name": "Step-75",
+ "content_type": "Description",
+ "content": "Position the high pressure pipes on common rail side and injector side and torque tighten the mountings to specified value. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 447
+ },
+ {
+ "step_name": "Step-75",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040094.jpg",
+ "display_order": 448
+ },
+ {
+ "step_name": "Step-76",
+ "content_type": "Description",
+ "content": "Position the drive belt and Using 14 mm ring spanner, swing the auto-tensioner in Anti clock-wise direction and install the belt. Place the MST 0306GBH0001ST - Stretch Fit Belt Installation Tool on damper pulley as shown in the image. Using 24 mm socket spanner, rotate the damper pulley in anticlockwise direction. By rotating pulley, belt started getting into pulley groove and once belt installed properly on pulley, then remove the MST and spanner Ensure proper engagement of belt teeth in all the pulley grooves after Installation. Refit the engine fead cover on engine, torque tighten the bolts to specified value. Torque : 11\u00b1 1Nm ",
+ "file": null,
+ "display_order": 460
+ },
+ {
+ "step_name": "Step-80",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1647.jpg",
+ "display_order": 461
+ },
+ {
+ "step_name": "Step-81",
+ "content_type": "Description",
+ "content": "Refit the degassing tank and install the mounting bolts on the bracket. Torque tighten he bolts to specified value. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 464
+ },
+ {
+ "step_name": "Step-82",
+ "content_type": "Description",
+ "content": "Refit the engine vent hose on T onnection. Check engine coolant level and top-up. Check engine oil level and top-up if needed. Run the Engine in Idle condition for few minutes, check for oil & coolant leakage and ensure proper functioning of engine. Refit the engine top encapsulation cover. Connect iSmart, Check and clear DTC if any. The cylinder head contains valves, fuel injectors, camshafts, glow plugs, vacuum pump, intake manifold, exhaust manifold and Fuel pump. In the diesel engine cylinder head performs several functions. It provide as the top seal for the cylinders bore. The cylinder head even consists of ports which are used to allow air in to the combustion chamber and allows the exhaust gases to move out. The cylinder is made by gravity casting and integrated with water jacket. The cylinder oil passage is drilled and sealed by Expansion plug or steel ball. The Camshafts bearing cap is also made by casting and installed on the cylinder head. Remove the turbocharger with exhaust manifold. Remove the intake manifold. Remove the HLA assembly. For additional information refer to the HLA assemblies \u2013 R &R; section. Using a 12 mm ring spanner, loosen and remove common rail mounting bolts. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the CAM shaft lower bearing caps from cylinder head. Disconnect the electrical connectors from the glow plug. Using a 8 mm deep socket spanner, loosen and remove the glow plugs from the cylinder head. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 19 mm socket spanner, loosen and remove the coolant temperature sensor. Torque : 20 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the heater inlet pipe mounting bolt and detach from cylinder head. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the engine rear hanging hook mounting bolts. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a 17 mm socket spanner, loosen and remove the cylinder head mounting bolts. Torque : 90\u00b110 Nm + 2x90\u00b0\u00b15\u00b0 ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Remove the cylinder head from engine. Using a 6 mm Allen spanner, loosen and remove engine coolant vent pipe mounting banjo bolt Install in reverse order of removal. Always replace the mounting bolts New ones while installing head assembly. Replace the cylinder head gasket with a new one. Failure to follow this will lead to compression failure. When fitting the cylinder head with it fitted to the glow plug, be careful not to damage the glow plug, since the broken pieces may enter inside the cylinder and damage the engine if the glow plug is exposed to an impact, which results in breakage of it. Refill the power steering oil. For additional information refer to power steering oil filling procedure. Refill the engine coolant and carry-out de-aeration procedure. For additional information refer to the engine coolant and carry-out de-aeration procedure Check & Top-up the engine oil. Check for coolant seepage and any oil seepage on the engine and transmission. Replace if any traces found. Clean the cylinder head assemblies thoroughly, replace it if any cracks or damages are found. Check the Cylinder Head for external damages. Check the cylinder head height and if not meeting the specified value, replace the cylinder head assembly. Check the Cylinder Head bottom face for distortion. Using 10 mm Allen key, loosen and remove rear axle filler plug. Using 10 mm Allen key, remove rear axle drain plug and drain the entire oil. Wait till the entire oil get drained. Place a tray beneath the rear axle for collecting the oil while draining. Using 13 mm and 16 mm ring and open end spanners unscrew rear propeller shaft mounting bolts and nuts rear axle end. Torque : 65 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "By using Special tool MST 203\u2013Companion Flange Holding Tool, hold the companion flange and Using 32 mm deep socket spanner loosen and remove the companion flange mounting nut Remove the companion flange using mallet. If companion flange shows wear in the area of seal contact, it should be replaced. Remove the pinion oil seal by using screw driver. Ensure not to damage the oil seal mating surface while remove the Oil seal.
2. Inspect t the companion flange for any damage. Replace if found.
",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using MST 0502AUA0004ST Rear Axle Pinion Oil Seal Installer, Place and Press New oil seal uniformly on banjo gear carrier housing. Apply a light coat of oil to the lip of oil seal before installation. Install the dust cap into the companion flange. Install the companion flange on the banjo housing and Install the new mounting nut with washer. Always use new flange mounting nut once it removed. Hold the companion flange Using MST203 Companion Flange Holding Tool and torque tighten the companion flange mounting nut. Tighten nut to Initial torque as 270 Nm Measure the Pinion Rotational Torque (PTTR), It should be within 2.5 - 3.5Nm. If measured Pinion Rotational Torque (PTTR) not within 2.5 - 3.5 Nm, Then tighten nut to incremental torque from 270 Nm onwards to 330 Nm until specified PTTR (Pinion torque to rotate) is achieved. Measure and ensure the Final Pinion Rotational Torque (PTTR), It should be within 2.5 - 3.5 Nm. PTTR SPEC : 2.5 to 3.5 Nm Attach the propeller shaft to the rear axle with mounting nuts, torque tighten it to the specified value. Torque : 65 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refit the drain plug and torque tighten tospecified value. Clean the drain plug and differential housing with a clean cloth before refitting. Torque : 47 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Refill specified quantity of recommended differential oil into differential assembly Never reuse drained oil. Always use recommended oil only. Never mix different types of oil and use. Clean filler plug area properly using acloth before filling the oil. Check the oil level and ensure its up to the level. Ensure that the oil level is up to lower most point of the filler plug. Refit the filler plug back and torque tighten to mounting plug specified value. Clean the filler plug with a clean cloth before refitting. Torque : 29 \u00b1 5Nm ",
+ "file": null,
+ "display_order": 57
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 116,
+ "sys_id": "THAR.AX-0001-Rear Axle",
+ "subsys_id": "THAR.AX-0001-Rear Axle-Rear Axle Inboard Oil Seal",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Axle Inboard Oil Seal",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W358.jpg",
+ "myid": 1236,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Rear Axle Inboard Oil Seal-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W358.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20131.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20132.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-0001,1013,1233",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 0502CAA0012ST \u2014Puller Oil Seal Pinion /Flange Inbord-X ,remove the inboard oil seal. Refit in the reverse order of removal. Use a MST (0502BUA0001ST \u2014 Rear Axle Shaft Inboard Oil Seal Installer, during Installation. Check differential oil level, top up the oil if required. Carry out Parking Brake Adjustment. Certain rear axle and driveline trouble symptoms are also common to the engine, transmission, tyres and other parts of the vehicle. For this reason be sure that the cause of the trouble is in the rear axle before adjusting, repairing or replacing any of the axle parts. Basic characteristics in a rear axle are more difficult to diagnose and repair than mechanical failures. Slight axle noise heard only at certain speed or under particular conditions must be considered normal. Axle noise tend to peak or be more pronounced at particular speeds and the noise is in no way a sign of the trouble in the vehicle. Where noise is present in objectionable form (Loud and/ or at all speeds) the first effort should be to isolate the noise. Isolation of noise in any one unit requires care and experience and an attempt to eliminate a slight noise may baffle even the most experienced mechanic/ technician. The most important characteristic of the gear noise is that it is usually sensitive to accelerator position. E.g. noise audible under drive condition will often disappear under coast condition (i.e. driving in neutral with the clutch released and engine running) at the same vehicle speed and vice versa. Axle gear noise whine will always occur at the same road speed and throttle setting i.e. drive or coast (i. e. driving in neutral with the clutch released and engine running). Gear whine is usually a fairly high pitched pure tone as opposed to a low-pitched rumble caused by a spalled bearing. Some noises, which can be confused with axle gear whine, are: - 1. Whine from an engine component; this will always occur at the same engine speed irrespective of which transmission gear is used. 2. Whine from an indirect transmission gear (e. g. 5th gear on some vehicles produces a whine comparable with axle whine) however this will disappear when the direct transmission ratio is selected. 3. Whine from tyres or wind noise from a rack or aerial. These noise generally occur over a very broad speed range and do not change with driving mode i. e. drive or coast (i.e. driving in neutral with the clutch released and engine running). Occurs in direct transmission ratio (4th gear). Changes with throttle/ accelerator variations (drive and coast) (i.e. driving in neutral with the clutch released and engine running). Always occur at the same road speed and not engine speed. Occurs over a limited vehicle speed. (This can vary over a wide band should the axle be in extremely bad condition.). Bearing noise is inclined to be less throttle sensitive than gear noise and frequently occurs over a wide speed range. Bad cases of faulty bearings can, in fact be detected from walking speed, building up in pitch as speed increases and is not directly affected by changing from drive to coast (i. e., driving in neutral with the clutch released and engine running) and vice versa.
2. Differential bearing noise is usually similar to in pitch to wheel bearing noise but is not affected by the swerve check referred to previously.
3. Pinion bearing noise is normally at a higher pitch than wheel or differential bearings and is often slightly sensitive to throttle position, although not to the same extent as gear noise.
",
+ "file": null,
+ "display_order": 6
+ }
+ ]
+ },
+ {
+ "procedure_name": "Other Noise",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "1. A further condition, which can exist, is due to a worn bearing that allows the gear set to move out of its correct mesh cause gear noise. This condition is usually throttle sensitive, with the noise frequently disappearing on a \u201cdrive\u201d condition. Any amount of or end play in either the pinion bearings or differential carrier bearings are detrimental to the gears and bearings and will cause axle noise.
2. A high spot sometimes occur on either the ring gear or the drive pinion; this shows up as a ticking or light knocking noise over a restricted range of throttle position. The frequency of the noise will indicate whether the high spot is on the pinion (drive shaft frequency) or on the ring gear. The severity of the noise indicates the size of the defect. A light \u201ctick\u201d is seldom detrimental and usually occurs in new axle and will normally disappears once the axle has been run in.
3. Louder noise usually indicates a more serious defect and a knock occurring in an axle which was previously free from this type of noise must always be investigated.
",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16402.pdf",
+ "display_order": 8
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 115,
+ "sys_id": "THAR.AX-0001-Rear Axle",
+ "subsys_id": "THAR.AX-0001-Rear Axle-Rear Axle Shaft Oil Seal Outer & Wheel Bearing",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Axle Shaft Oil Seal Outer & Wheel Bearing",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A140066.jpg",
+ "myid": 1235,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Rear Axle Shaft Oil Seal Outer & Wheel Bearing-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140066.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20121.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20122.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the rear axle shaft RH. Using circlip plier, remove the toner wheel circlip. By using hydraulic press, remove toner wheel along with Rear bearing carrier assembly. Take sufficient care not to damage the toner ring while removing. Remove the bearing from Rear bearing carrier. Replace the toner ring and bearing assembly once removed. Using a suitable tool, Remove the oil seal from Rear bearing carrier. Replace the outboard oil seal once removed. Refit in the reverse order of removal. Check differential oil level, top up the oil if required. Carry out Parking Brake Adjustment. Remove rear brake drum LH and RH. For additional information refer to Rear brake drum LH and RH \u2013 R &R; section. Detach the hand brake cable from brake shoe. Remove the hand brake cable lock clip and detach the hand brake cable from backplate. Using 11 mm open end spanner, Loosen brake bundy tube flare nut wheel cylinder end. Torque : 16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 17 mm socket spanner, loosen and remove axle shaft mounting nuts. Torque : 35 \u2013 50 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using MST 0505AAA0001ST puller rear axle shaft banjo remove rear axle shaft, dust shield with brake liner assembly from vehicle. To avoid the back plate falling down,using a plastic tag tie it with any other fixed member before the shaft is pulled out. Clean sealant on the axle housing flange, Back Plate and apply new sealant on the housing. Apply Locktite Sealant 5060 during Installation and Ensure that sealer bead is on the inside of screw holes as shown above. Bead must be 3 to 6mm high and 3 to 6mm wide. Refit in the reverse order of removal. Check differential oil level, top up the oil if required. Carry out Parking Brake Adjustment.
2. Inspect the toner ring for any damage.
3. Inspect the rear wheel bearing for any damage.
4. Inspect the back plate for any damage.
",
+ "file": null,
+ "display_order": 26
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 110,
+ "sys_id": "THAR.AX-0001-Rear Axle",
+ "subsys_id": "THAR.AX-0001-Rear Axle-Rear Axle Oil - Replace",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Axle Oil - Replace",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.18,
+ "rts": null,
+ "mat": "J08-MAT-0340",
+ "cover_image": "/files/W4A140026.jpg",
+ "myid": 1230,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 23,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 47,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 108,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 148,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 186,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 227,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 267,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 286,
+ "kilometers_applicable": 1
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+ "kilometer_name": "80,000",
+ "kilometer_IDX": 347,
+ "kilometers_applicable": 0
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+ "kilometer_name": "90,000",
+ "kilometer_IDX": 386,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 427,
+ "kilometers_applicable": 0
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Rear Axle Oil - Replace-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "RearAxleOil \u2013Mahindra MAXIMILEELITE NewGenerationGenuineDifferentialFluid. , Capacity\u20132.0 Litres. Rear Axle Oil \u2013 Mahindra 'MAXIMILE ELITE' New Generation Genuine Differential Fluid. Capacity \u2013 2.0 Litres. using 10 mm allen key, loosen and remove rear axle filler plug. Using 10 mm allen key, remove rear axle drain plug and drain the entire oil. Wait till the entire oil get drained. Place a tray beneath the rear axle for collecting the oil while draining. Refit the drain plug and torque tighten to specified value. Clean the drain plug and differential housing with a clean cloth before refitting. Torque:47\u00b17 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refill specified quantity of recommended differential oil into differential assembly Never reuse drained oil. Always use recommended oil only. Never mix different types of oil and use. Clean filler plug area properly using a cloth before filling the oil. Check the oil level and ensure its up to thelevel. Ensure that the oil level is up to lower mostpointofthefillerplug. Refit the filler plug back and torque tightentomountingplugspecifiedvalue. Clean the filler plug with a clean cloth beforerefitting. Torque:29\u00b15 Nm ",
+ "file": null,
+ "display_order": 24
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 118,
+ "sys_id": "THAR.AX-0001-Rear Axle",
+ "subsys_id": "THAR.AX-0001-Rear Axle-Rear Axle Carrier Assembly Overhaul",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Axle Carrier Assembly Overhaul",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A140074.jpg",
+ "myid": 1238,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Rear Axle Carrier Assembly Overhaul-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Removal & Installation Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/VST-0076_Rear Axle Differential Overhaul.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/53595.pdf",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Disassembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the Rear axle oil. For additional information refer to Rear axle oil draining procedure. Remove the Rear Axle Carrier Assembly. Mount the Rear Axle carrier assembly on a suitable stand. Liquid sealant is used to seal carrier section with banjo beam. Clean the sealant on the carrier facing Using a 17 mm socket spanner, loosen and remove the bearing cap mounting bolts and then remove the bearing caps. Using a Mallet, tap and detach the bearing caps. Identification marks are punched on bearing cap; this is to ensure correct bearing cap is installed on correct side. Ensure correct bearing caps used While reassembly. Pry out differential case from carrier with help of (MST 0502AAA0001ST - Tommy Bars) as shown in the illustration. Remove the shims from both the sides of differential case. Backlash shims are not to be interchanged during assembly If Backlash shims are damaged, replace with new shims during assembly. There is no identification provided on the shim, Needs to be measured by micro meter. Remove the bearing caps from both the ends. Mount the (MST 0502AUA0013ST - R Axle Diff Case Bearing Puller Adapter) and (MST 0502AUA0012ST - Axle Bearing Puller) on side bearing cone as steps shown below. Remove the side bearing cone by tightening the screw rod using 24 mm ring spanner and remove the bearing cone from the differential case. Hold the top plate using 36 mm open end spanner while tightening. It is always preferred to replace side bearings, but one can confirm free rolling of bearings and reuse if they are defect free. Similarly remove ring gear other side bearing cone as steps shown below. Using 14 mm socket spanner remove the ring gear mounting bolts. Ring gear mounting bolts are opposite threaded. Loosen in clock wise direction. Tap ring gear with a mallet to free it from case If required and remove. Follow Steps 15 to 18 to remove Side Gears & Pinion Mate Gears for Open Differential. Using MST 0502AUA0033ST - Front Axle Diff Case Pin Remover &Installer; and hammer remove the differential gear locking pin. Using hammer and punch, Remove the differential shaft from differential case as shown in illustration. To remove side gears and pinion mate gears, rotate the side gears, this will allow the pinion mate gears to turn to opening of the case. To remove side gears and pinion mate gears, rotate the side gears, this will allow the pinion mate gears to turn to opening of the case. Check the differential gear condition, any damage replaces it Inspect cross pin for excessive wear, replace it if necessary Always replace differential pinion gears and side gear both along with washer as a complete set. Do not mix new gears with old gears, as this may cause uneven wear and short gear life. Position the carrier assembly on the suitable stand to facing the companion flange side. Hold the companion flange using (MST 203\u2013 Companion Flange Holding Tool) and Using 32 mm deep socket spanner loosen and remove the companion flange mounting nut. Using mallet tap and remove the companion flange, washer and dust cup. If companion flange shows wear in the area of seal contact, it should bereplaced. Using a mallet, tap the pinion assembly and remove the pinion assembly from the differential housing. Fit a nut of pinion before tapping to avoid thread damage. Hold the pinion with hand to avoid falling. Gear teeth have sharp edges. Handle gears carefully to avoid injury. . Remove the collapsible Washer. Discard collapsible spacer. New one is required to be used during assembly. Assemble (MST 0502AUA0014ST - R Axle Pinion Inner Bearing Puller Adapter) and (MST 0502AUA0012ST - Axle Bearing Puller) as shown in the illustration. Tighten the screw rod using 24 mm ring spanner to remove the pinion inner bearing. Hold the top plate using 36 mm open end spanner while tightening. Remove the pinion head bearing & remove the shims from the pinion. Collect shims and keep them togetherg. Replace shims if found damaged. Remove the pinion oil seal by using screw driver. Ensure not to damage the oil seal mating surface while remove the Oil seal. Gently pull-out and remove the pinion outer bearing. Using suitable punch and hammer remove the outer bearing cap. Using suitable punch and hammer remove the inner bearing cap. Ring gear and pinion is supplied as a set. They are matched with each other during manufacture. Matching numbers on both pinion and ring gear are etched for verification. Refer Fig. A or Fig. B for more details. If a new gear set is used, verify numbers on pinion and ring for matching before proceeding with assembly. Standard mounting distance from center line of ring gear to back face of pinion is 109.525 mm. This dimension is controlled by selecting shims, which are positioned between the inner pinion bearing and pinion shoulder. Best running position of gear set is achieved by proper shim selection. On the bottom face of pinion, a number is etched. It can be a plus (+) number, a minus (-) number or Zero (0). Required pinion shim selection is achieved with help of this number. Pinion offset always in thou (1 thou = 0.0254 mm). Fig. A shows ring and pinion etched with inch identification. Fig. B shows ring and pinion etched with metric identification If no offset on pinion face then assume it zero. If no offset on pinion face then assume it zero. Position the rear axle housing on a suitable stand. Position the (MST 0502AUA0016ST -Rear Axle Pinion Height Master Block) over the inner bearing cup seating area as shown. Position the (MST 0502AUA0016ST -Rear Axle Pinion Height Master Block)/b <> over the inner bearing cup seating area as shown. Using feeler gauge measure the distance between the MST\u2019s as shown and the value assumed as \u2018A\u2019 . For example consider the value obtained as 1.51 mm. Convert the obtained value in \u201cmm\u201d into \u201cThou\u201d (1.51x39 = 59 Thou). Now see the etched value on pinion, the value assumed as \u2018B\u2019 (For example consider the offset value as +4) Now to get the final shim size, the formula is Shim thickness (In Thou) = A \u2013 (+B or \u2013 B).i.e, (59 \u2013 4 = 55 Thau) Convert the Thou value to mm ( 55 x 0.0254 = 1.40 mm) , which is the final shim thickness required. Mount the pinion positioning shim pack on pinion Select shim pack based on Pinion Shim Selection Procedure to position the pinion at correct mounting distance as per value etched on pinion stem for best running position Position the pinion inner bearing on pinion & press the bearing by using (MST 0502AUA0017ST - R Axle Pinion Inner Brg Press Dolly) . Insert a new collapsible spacer Collapsible spacer should rest in between pinion inner and outer bearing and it can be fitted in any direction. Always use new collapsible spacer,never use old one Install the Inner bearing cup by using (MST 0502AUA0018ST - Pinion Inner bearing cup installer) and (MST 0707BBA0003ST - Universal mandrel) on banjo gear carrier housing. Install the Outer bearing cup by using (MST 0502AUA0019ST - Pinion outer bearing cup installer) and (MST 0707BBA0003ST - Universal mandrel) on banjo gear carrier housing. Install the pinion on the axle banjo housing and provide a support for pinion in the bottom. Using (MST 0502AUA0017ST - R Axle Pinion Inner Brg Press Dolly) and hammer press the pinion outer bearing. Place oil slinger on pinion outer bearing cone Place and Press oil seal on banjo gear carrier housing using (MST 0502AUA0004ST - Rear Axle Pinion Oil Seal Installer) Apply a light coat of oil to the lip of oil seal . Install the dust cap into the companion flange. Install the companion flange on the banjo housing.. Install the companion flange mounting nut. Hold the companion flange using (MST203 - Companion Flange Holding Tool) and torque tighten the companion flange mounting nut. Tighten nut to Initial torque as 270 Nm Measure the Pinion Rotational Torque (PTTR), It should be within 2.5 - 3.5 Nm. If measured Pinion Rotational Torque (PTTR) not within 2.5 - 3.5 Nm, Then tighten nut to incremental torque from 270 Nm onwards to 330 Nm until specified PTTR (Pinion torque to rotate) is achieved. Excessive care must be taken during bearing preload torque adjustment. Do not over tighten, loosen and then retighten nut. Do not exceed specified bearing preload torque. Measure and ensure the Final Pinion Rotational Torque (PTTR), It should be within 2.5 - 3.5 Nm. (PTTR SPEC : 2.5 to 3.5 Nm) If preload torque is exceeded, a new collapsible spacer must be installed and torquing sequence as above to be repeated. Follow Steps 17 to 20 to Install Side Gears & Pinion Mate Gears for Open Differential. Assemble both side gears and thrust washers, hold them in place with one hand and then assemble the pinion mate gears with thrust washer to hold the side gears in place. An easy way to assemble the side gears and pinion mate gears is to have all parts lubricated before assembly. Rotate the side gears until the holes of the spherical washers and pinion mate gears line up with the holes in the case by the help of engaging the splines of axle shaft to side gears. When both the cross bore hole matched and insert the differential shaft.. Use a drift to line holes of the gears up with case. Assemble differential shaft and pull out drift. Be sure vertical lock pin hole is lined up with that of the case, and that pinion mate washers are in place and lined up with gear and case Align the differential shaft hole, insert the lock pin and fix using (0502AUA0033ST - Differential gear lock pin removal tool) and hammer. Assemble ring gear to the differential case using mounting bolts. Tighten the bolts to specified Torque Value in recommended sequence.. Torque : 90 - 105 Nm ",
+ "file": null,
+ "display_order": 180
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140174.jpg",
+ "display_order": 181
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Notice",
+ "content": "Always use new ring gear bolts. Ring gear mounting bolts have LH threads. While Installation torque in anti-clocking direction Assemble (MST 0502AUA0020ST - Rear Axle Dummy Bearing) on to differential case Place differential case assembly into housing. Push the differential case assembly towards the pinion side and insert the shims pack on the LH side (Back to ring gear) and Insert the shims pack on the RH side (Teeth side). Remove the shims (6 Thou) from LH Side and add to RH Side for backlash tolerance. Install dial gauge and locate tip of indicator on the surface of one of the ring gear teeth and measure the backlash at three equally spaced points (Each 120 degree rotation space), confirm the Backlash tolerance is (0.15 to 0.25 mm) Fix the Dial Gauge on Housing, Set the Dial Indicator 0 on Ring gear teeth as shown. Hold the pinion flange at the bottom side. Rotate the ring gear by using ring spanner & measure the backlash. Backlash variation at three points should not more than 30% . These corrections are made by switching shims from one side of differential case to other High backlash is corrected by moving ring gear closer to pinion (Move Shims from RH to LH). Low backlash is corrected by moving ring gear away from pinion (Move Shims from LH to RH). Remove dial gauge and take out diff case & remove the dummy differential bearings. Press bearing on Differential case assembly by using (MST 0502AUA0021ST - R Axle Diff Case Brgs Pressing tool). Repeat the same procedure for installation of bearing on other side. Install the Differential bearing caps on both the sides. Install differential case assembly into carrier with the help of mallet. Carelessness while installing differential case assembly may result in injury.. Install the shims on both the sides of differential case Backlash shims are not to be interchanged during assembly. If Backlash shims are damaged, replace with new shims during assembly Assemble bearing caps using mounting bolts. Ensure correct fitment of caps by matching letters on caps and carrier on either side. Tight the bearing cap bolts to specified value. Torque : 90 - 110 Nm ",
+ "file": null,
+ "display_order": 220
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "Description",
+ "content": "Install dial gauge and locate tip of indicator on the surface of one of the ring gear teeth and measure the ring gear and pinion backlash at three equally spaced points (Each 120 degree rotation space),confirm the Backlash tolerance is (0.15 to 0.25 mm). Fix the Dial Gauge on Housing, Set the Dial Indicator 0 on Ring gear teeth as shown. Hold the pinion flange at the bottom side. Rotate the ring gear by using ring spanner & measure the backlash. Backlash variation at three points should not more than 30% . These corrections are made by switching shims from one side of differential case to other. High backlash is corrected by moving ring gear closer to pinion (Move Shims from RH to LH). Low backlash is corrected by moving ring gear away from pinion (Move Shims from LH to RH). If backlash is as per specification, check ring gear and pinion tooth contact pattern. If backlash is as per specification, check ring gear and pinion tooth contact pattern as below. Apply Locktite RTV Sealant 5060 to flat surface of banjo beam Flat face of the carrier assembly and flat surface of the banjo beam must be free of any oil film or foreign material. Ensure that sealer bead is on the inside of bolt holes. Bead must be 3 to 6 mm high and 3 to 6 mm wide. Refit the Differential Carrier Assembly. For additional information refer to Differential carrier assembly R &R; section. Fill the differential fluid. For additional information refer to Differential fluid filling procedure. Remove the Rear Axle Shaft Assembly LH . Remove the Rear Axle Shaft Assembly RH. Using 14 mm socket spanner, Unscrew rear propeller shaft mounting bolts and detach propeller rear end and properly hang the shaft. Torque : 65 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrewgear carrier to banjo housing mounting bolts. Torque : 35 - 50 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 17 mm socket spanner, Unscrew rear stabilizer bar bracket mounting bolts and detach the bracket partially. Torque tightening should be done without load and with the tyres on level ground. Ensure to add washer only for bottom mounting of stabilizer bar. Torque : 70 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 5 mm allen key, hold the rear stabilizer bar link bottom mounting then using a 18 ring spanner, loosen and remove the top mounting nut from stabilizer bar. Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140038.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on levelground. Remove the rear axle gear carrier from vehicle. Clean the sealant on the gear carrier Refit in the reverse order of removal. Apply Locktite Sealant 5060 during Installation and Ensure that sealer bead is on the inside of screw holes and pattern as shown below Bead must be 3 to 6 mm high and 3 to 6 mm wide. Refill the rear axle oil.
2. Check the axle case for yield, deformation or cracks, replace if necessary.
",
+ "file": null,
+ "display_order": 36
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 114,
+ "sys_id": "THAR.AX-0001-Rear Axle",
+ "subsys_id": "THAR.AX-0001-Rear Axle-Rear Toner Wheel",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Toner Wheel",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A140048.jpg",
+ "myid": 1234,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Rear Toner Wheel-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140048.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20114.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20115.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the rear axle shaft assembly. Using circlip plier, remove the toner wheel circlip. By using hydraulic press, remove toner wheel along with Rear bearing carrier assembly & dust shield. Take sufficient care not to damage the toner ring while removing. Replace the toner ring and bearing once removed. Refit in the reverse order of removal. Check differential oil level, top up the oil if required. Carry out Parking Brake Adjustment. Foradditional information refer to Parking Brake Adjustment Section.
2. Inspect the Rear bearing carrier assembly for any damage, Replace if necessary.
",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 111,
+ "sys_id": "THAR.AX-0001-Rear Axle",
+ "subsys_id": "THAR.AX-0001-Rear Axle-Rear Axle Assembly",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Axle Assembly",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A140025.jpg",
+ "myid": 1231,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Rear Axle Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140025.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20011.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20012.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove rear brake drum LH and RH. For additional information refer to Rear brake drum LH and RH \u2013 R &R; section. Detach the hand brake cable both the sides(LH&RH;)from brake shoes. Remove the hand brake cable lock clips from both the sides (LH & RH) and detach the hand brake cables from back plate. Remove the hand brake holding spring on the axle from LH & RH side. Remove the bundy tube rear hose to LH wheel. For additional information refer to Bundy Tube Rear Hose to LH Wheel - R &R; section. Remove the bundy tube rear hose to RH wheel. Remove the flexible hose LH & RH side locking from the axle. Using a 10mm socket spanner,Unscrew wheel speed sensor mounting bolts and detach the sensors. Torque:9\u00b11Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140015.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Provide a jack to support the rear axle assembly. Remove the rear propeller shaft. For additional information refer to Rear Propeller Shaft - R &R; section. Remove the stabilizer bar rear. For additional information refer to Stabilizer Bar Rear-R &Rsection.; Using a 24 mm socket spanner, loosen and remove the upper link mounting bolt/nut. Torque : 230 \u00b1 20 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170029.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 21mm ring spanner. Torque tightening should be done without load and with the tyres on level ground. Using a 24 mm socket spanner, loosen and remove the lower arm mounting bolt/nut. While loosening the nut, hold the bolt using 21mm ring spanner. Torque tightening should be done without load and with the tyres on level ground. Torque:230\u00b120Nm ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using a 17 mm socket spanners, loosen and remove the both rear shock absorbers bottom side mounting bolts and nuts. Torquevalue:110\u00b111Nm , Torque Wrench Type - Open end Torque Wrench ",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. While loosening the nut, hold the bolt using15mmringspanner. Remove the rear coil spring and pad securelyfromvehicle. Pay attention while Installation Locking lug to be matched with hole on Rear Coil spring dome bracket of Chassis. Yellow coloured PU sleeve should be on chassis side while assembling the coil spring ashown in illustration. Carefully remove the rear axle assembly from vehicle. Refit in the reverse order of removal. Check differential oil level,top up the oil if required. All Suspension Torque tightening should be done without load and with the tyres on level ground.
2. Check the axle case for yield,deformation or cracks,replace if necessary.
3. Inspect rear axle for any oil leakage,seepage.
",
+ "file": null,
+ "display_order": 56
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 42,
+ "sys_id": "THAR.AX-0001-en-SM-Starting System",
+ "system_name": "Starting System",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1006,
+ "active_status": true,
+ "Assets": [
+ {
+ "systemdisplayorder": 14,
+ "system_asset": "/files/Security.mp4",
+ "active_status": true
+ }
+ ],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 44,
+ "sys_id": "THAR.AX-0001-Starting System",
+ "subsys_id": "THAR.AX-0001-Starting System-Ignition Switch",
+ "systems": "Starting System",
+ "sub_systems": "Ignition Switch",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A090001.jpg",
+ "myid": 1126,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Ignition Switch-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The ignition key barrel consists of ignition switch and steering lock. It is located on the steering column. The ignition barrel when switched ON by the mechanical key,switches the power supply to all controllers. Using a 10 mm combination spanner,loosen battery negative cable mounting nut and disconnect cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Remove Combination switch. Disconnect the ignition switch electrical connection. Using a Small sizzle and hammer, hit and remove the key barrel screws. Use new screw while installing key barrel. Remove the Ignition key with ICU from the vehicle. Using a star screw driver, loosen and remove the ICU mounting screws then remove the ICU from the key barrel. Insert the key and turn the key into AC position. Cut the micro switch routing tag and detach the connector holding clip from the ICU. Install in reverse order of removal. Always use new mounting bolts while installing the Ignition Switch Assembly clamping unit.
2. Inspect ICU for crack or damage. Replace if found any.
",
+ "file": null,
+ "display_order": 27
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 45,
+ "sys_id": "THAR.AX-0001-Starting System",
+ "subsys_id": "THAR.AX-0001-Starting System-Starting Relay Check",
+ "systems": "Starting System",
+ "sub_systems": "Starting Relay Check",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A090048.jpg",
+ "myid": 1127,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Starting Relay Check-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The starter relay is an electromechanical device that switches battery current to the starter solenoid when the ignition switch is turned to the Start position. The starter relay is made of two separate circuits.Give 12 volt supply to pin number 86 and earth pin number 85. Once supply is given sound can be noticed which indicated control circuit is perfect. If sound is not noticed, replace the relay. Using multi-meter, check continuity between pin number 30 & 87. (Power given to pin number 86 and earth given to pin number 85). If continuity is there, which indicates that the power circuit is perfect. If Continuity is not there then replace the relay. Using multi-meter, check for continuity between pin numbers 30 and 87 (No power given to pin number 86 and no earth given to pin number 85). If continuity is there which indicates power circuit is NOT OK (Short internally). Replace the relay. If continuity is not there, Relay is OK. This test can only be performed with starter motor removed from vehicle. Remove Starter Motor from vehicle. Disconnect wire from solenoid field coil terminal. Check for continuity between solenoid terminal and solenoid field coil terminal with a continuity tester. There should be continuity. If OK, go to Step 4. If not OK, replace faultystarter motor. Check for continuity between solenoid terminal and solenoid case. There should be continuity. If not OK, replace faulty starter motor. The cranking voltage test measures the voltage available for ignition while the starting motor cranks the engine. Turn off the ignition, connect a voltmeter across the battery and crank the engine. Note the voltage reading. If the starting motor cranks normally and the voltmeter reads 9 volts or higher, cranking voltage is normal. Slow cranking with the voltage above 9 volts indicates high resistance in the motor circuit or starting motor. Low cranking speed and low voltage may indicate a discharger battery. If the battery is charger, look for trouble in the starter motor or engine. Using a 10 mm combination spanner,loosen battery negative cable mounting nut and disconnect cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON,Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Remove Combination switch. Disconnect the ignition switch electrical connection. Using a star screw driver, loosen and remove ICU mounting screws then remove ICU from the key barrel. Install in reverse order of removal. Check and ensure both the front wheels for straight ahead position while fitting the steering wheel and also after fitting. Carefully install the clock spring without damaging the locks. When installing the DAB, make sure that all electrical connectors are fixed in proper position. When installing the driver airbag into steering wheel, make sure the horn pad buttons are fixed properly and correct position.
2. Inspect ICU connector for any damage or loose connection. Rectify if found.
",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 47,
+ "sys_id": "THAR.AX-0001-Starting System",
+ "subsys_id": "THAR.AX-0001-Starting System-Voltage Drop Test",
+ "systems": "Starting System",
+ "sub_systems": "Voltage Drop Test",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A090033.jpg",
+ "myid": 1129,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Voltage Drop Test-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The following operation will require a voltmeter accurate to 1/10 (0.10) volt. The battery should be fully-charged. Engage the parking brake. Position the gearshift selector lever in the neutral position and lock the clutch pedal in the fully depressed position. Verify that all lamps and accessories are turned off. In-order to avoid the engine from starting, remove the starter relay. Connect the positive lead of the voltmeter to the battery negative terminal post and then connect the negative lead of the voltmeter to the battery negative cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery negative cable terminal clamp and the battery negative terminal post. Connect the positive lead of the voltmeter to the battery positive terminal post. Connect the negative lead of the voltmeter to the battery positive cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery positive cable terminal clamp and the battery positive terminal post. Connect the voltmeter to measure between the battery positive cable terminal clamp and the starter solenoid terminal stud.Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt. Clean and tighten the battery positive cable eyelet terminal connection at the starter solenoid terminal stud. Repeat the test. If the reading is still above 0.2 volt,replace the faulty battery positive cable. Connect the voltmeter to measure between the battery negative cable terminal clamp and ground on the transmission. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery negative cable eyelet terminal connection to the engine block. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery negative cable. The starting motor is a device that converts electric energy into mechanical energy to generate rotational power, and transfers the energy required for starting the engine initially with this power. The starter motor is composed of three parts, which are: The solenoid, which moves the starter pinion by means of a fork and at the same time closes the power circuit to feed the electric motor. The direct current electric motor, which cranks the engine. The fork and pinion assembly, which makes the connection between the starter motor and the ring gear on the flywheel. Using a 10 mm combination spanner,loosen battery negative cable mounting nut and disconnect cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Using a 13 mm socket spanner, loosen and remove the battery positive cable mounting nut on starter motor end. Torque : 12\u00b12 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 8 mm socket spanner, loosen and remove the starter motor solenoid switch mounting nut on starter motor end. Torque : 2.5\u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen and remove the starter motor mounting bolts and remove starter motor from vehicle. Torque : 44\u00b15 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090046.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.
2. Check the starter motor external crack or damage. Replace if found any.
3. Check the starter motor internal gear crack or damage. Replace if found any.
",
+ "file": null,
+ "display_order": 21
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 223,
+ "sys_id": "THAR.AX-0001-en-SM-Instrument Panel",
+ "system_name": "Instrument Panel",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1020,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 228,
+ "sys_id": "THAR.AX-0001-Instrument Panel",
+ "subsys_id": "THAR.AX-0001-Instrument Panel-IP Top Cover Assembly LH",
+ "systems": "Instrument Panel",
+ "sub_systems": "IP Top Cover Assembly LH",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A220020.jpg",
+ "myid": 1345,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-IP Top Cover Assembly LH-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220020.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5571.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5572.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080024.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON,Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Glove Box Assembly. Remove the IP grab handle cover. Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220024.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting screws. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220025.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle. Partially detach the door edge beading and using a trim removal tool, remove the IP LH side cover. By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt. Torque : 8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220066.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220077.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector. Take out the IP LH side top cover with Passenger air bag from the IP. Using a 10 mm ring spanner, loosen and remove the air bag mounting bolt from IP top cover. Torque :4.5\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210047.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210048.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Expand the PAB module holder both sides using screw driver and detach the PAB separately from IP top cover. Using a star screw driver, Unscrew LH side AC vent mounting screws. Carefully release the vent locking clips from the cover and detach the vent. Check for any external damages or damaged locking clips, Replace if necessary. Inspect the PAB module for any damage. Replace if found any. Inspect the PAB module connector for any damage. Inspect the PAB module trim for any damage. Remove the Combination Switch. Remove the A Pillar Upper Trim LHS & RHS. Remove the Glove Box Assembly. Partially detach the door edge beading and using a trim Removal tool, Remove the IP side trim RH side. Using star screw driver, Unscrew Driver side top cover mounting screw and remove the cover. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220072.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew the cluster mounting screws. Torque : 2 \u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220071.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Partially Detach Cluster and disconnect the electrical connector. Remove the Instrument Cluster. Remove the Floor Console Assembly. For additional information refer to Floor Console Assembly \u2013 R &R; Section. partially detach the switch bang assembly and remove electric connector to take out from the vehicle. Detach the USB Docking station bezel and disconnect the electrical connectors. Disconnect Driver switch bank electrical connector. Remove the IP grab handle cover. Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts. Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220024.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting bolts. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220025.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle. Partially detach the door edge beading and using a trim removal tool , remove the IP side trim LH side. By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt. Torque : 8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220066.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220077.jpg",
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector. Disconnect speaker electrical connectors from both the sides. Using a trim removal tool Detach the infotainment trims. Using a star screw driver, Unscrew the infotainment mounting screws. Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220086.jpg",
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Partially detach infotainment and disconnect the electrical connectors.",
+ "file": null,
+ "display_order": 72
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290007.jpg",
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Remove the infotainment from Instrument panel. Using 10 mm socket spanner, Unscrew instrument panel mounting bolts. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 84
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220096.jpg",
+ "display_order": 85
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "Description",
+ "content": "Carefully remove the instrument panel from vehicle. Install in the reverse order of removal. Check for any external damages or damaged locking clips, Replace if necessary. Using trim removal tool remove the cluster bezel. Using a trim removal tool, remove the IP panel assembly driver side. Partially detach the door edge beading and using a trim removal tool, remove the IP RH side cover. Using star screw driver, Unscrew driver side IP cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220019.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the driver side IP cover. Using star screw driver, Unscrew AC vent mounting screws. Remove the RH side AC vent. Carefully release the vent locking clips from the cover and detach the vent. Install in the reverse order of removal. check for any external damages or damaged locking clips, Replace if necessary. Remove the Instrument Panel Assembly. Using a star screw driver, Unscrew the Instrument Panel AC & defroster Duct mounting screws and remove the ducts. Using a star screw driver, Unscrew IP driver switch bank mounting screws. Torque : 1.5 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270121.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the Driver Switch bank from Instrument Panel Using a star screw driver, Unscrew IP centre air vent mounting screws. Remove the Centre Air Vents from Instrument Panel. Install in the reverse order of removal. check for any external damages or damaged locking clips, Replace if necessary. Using trim removal tool remove the cluster bezel. Using a trim removal tool, remove the IP panel assembly driver side. Partially detach the door edge beading and using a trim removal tool, remove the IP RH side cover. Using star screw driver, Unscrew driver side IP cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220019.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the driver side IP cover. Using star screw driver, Unscrew AC vent mounting screws. Remove the IP AC Vent RH. Carefully release the vent locking clips from the cover and detach the vent. Install in the reverse order of removal. check for any external damages or damaged locking clips, Replace if necessary. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W322.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220007.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console LH screvits and detach the panel from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220036.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220037.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Loosen and Remove Gear Knob and Transfer case shifter knobs.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220044.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the gear shifter cover with trim.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the rummier mat from the cup holder.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110306.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "For AT Variants top trim removal follow (Steps 6\u2013 11) : Remove the 4WD selection knob by rotating it in anti-clock wise direction. Pull and fold the gear shifter boot from gear shifter bezel. Partially detach the bezel from the console. Excessive pull may leads to damage of the electrical connector. ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110135.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Disconnect the AT gaiter electrical connector from the bezel. Carefully remove the bezel trim from the TGS lever. Handle bezel assembly carefully to prevent it from damage or scratches. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220050.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220049.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew floor console LH and RH side mounting screws.",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220043.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Remove the bottle holder rubber mat.",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220046.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew floor console mounting bolts.",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220051.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220052.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew floor console LH and RH side mounting bolts.",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220053.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Lift the floor console and disconnect the floor console electrical connector.",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220055.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Remove the floor console from vehicle. Remove the power window switch assembly from floor console. Install in the reverse order of removal. Check floor console assembly for any damage, replace if found any. Remove the Instrument Panel Assembly. Install in the reverse order of removal. Check the glove box for damage, replace if necessary. Using a 10 mm socket spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Glove Box Assembly. Remove the IP grab handle cover. Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts. Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220024.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting screws. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220025.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle. Partially detach the door edge beading and using a trim removal tool, remove the IP LH side cover. By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt. Torque : 8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220066.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220077.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector. Take out the IP LH side top cover with Passenger air bag from the IP. Using a star screw driver, Unscrew LH side AC vent mounting screws. Remove the IP AC Vent LH. Carefully release the vent locking clips from the cover and detach the vent. Check for any external damages or damaged locking clips, Replace if necessary. The tachometer indicates the real-time engine speed in thousands of RPM(revolutions per minute). Each division is 500 RPM. Operating the engine at very high RPM may lead to excessive engine wear and low fuel economy. Maintain steady engine speed below 2500 RPM and do not accelerate or decelerate abruptly. Do not over-accelerate the engine during idling, this can cause severe engine damage and would be treated as abuse of the engine which is not covered by warranty The speedometer indicates the real time road surface speed of the vehicle in kilometers per hour. The vehicle speedometer is affected by size of the tyres used. If the size of the tyres are changed from those fitted at the factory, the speedometer might not display the correct road surface speed and distance travelled Using trim removal tool, remove the cluster bezel mounting clips and remove the cluster bezel. Using trim removal tool, remove the IP side trim. Using star screw driver, Unscrew IP cover mounting screw and detach the IP cover using trim removal too. Using star screw driver, Unscrew instrument cluster mounting screw. Torque : 2 \u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W123.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect cluster electrical connector and remove instrument cluster. Check for any damage or crack, replace if found. Disconnect the TMC electrical connector then detach from the routing clips. Using 13 mm open end spanner, loosen and remove the TMC to EHCU Primary & Secondary bundy tubes from TMC side flare nuts. Torque :16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using hose clip plier, release brake fluid reservoir tank to clutch TMC hose clip then detach the hose. Using 12 mm combination spanner, Unscrew TMC mounting nuts and remove the TMC assembly from the brake booster. Torque : 16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130187.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Check and top up the brake fluid, If required. Carry-out the brake bleeding procedure. For additional information refer to Brake bleeding procedure. Check for master cylinder external damage, if found replace. Remove the front brake pad assembly. For additional information refer to front brake pad assembly \u2013 R &R; section. Using 14 mm socket spanner, loosen and remove the brake hose banjo bolt then detach the brake hose. Torque :24 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Replace the banjo bolt washers with new ones always while installation, else brake fluid leakage may happen. Using 19 mm socket spanner, loosen and remove the caliper assembly mounting bolts. Torque : 95 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the caliper assembly from the vehicle. Install in the reverse order of removal. Check and top up the brake fluid, If required. Carry-out the brake bleeding procedure. For additional information refer to Brake bleeding procedure. Inspect the caliper for any physical damage. Replace if found any. Carefully refit the rubber seal. Clean all the internal parts thoroughly with fresh brake fluid or alcohol. Do not use mineral oil like kerosene, petrol, diesel etc. If the piston does not move smoothly, remove it and examine the sealing ring for correct seating in its groove. Fit the other end of the piston boot on to the caliper housing Refit the front caliper assembly. Using 13 mm open end spanners, loosen and remove the TMC to primary and secondary bundy tubes flare nuts on EHCU side. Torque :16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 11 and 13 mm open end spanners, loosen and remove the EHCU to FL,FR,RL, RR output bundy tubes flare nuts on EHCU side. Torque : 16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Carefully detach the bundy pipe without any bend. if the bundy tube bends, Constant pressure will not be maintained. Disconnect the EHCU electrical connector. Using 12 mm socket spanner, Unscrew air cleaner housing mounting bolts to partially detach and keep aside. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanners, Unscrew EHCU mounting bolts and remove the EHCU assembly with EHCU mounting bracket. Torque : 23 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner , Unscrew EHCU mounting nuts from the bracket. Torque : 8 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130196.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "After removing the bundy tubes from EHCU, seal each port of ECHU with dummy plugs to avoid dust entry. Do not give any impact to hydraulic unit and take at most care not to allow dust to enter the hydraulic unit. Do not place hydraulic unit on its side or upside down. Handling it in inappropriate way will affect its original performance. Take sufficient care while installation and ensure correct bundy is connected to the specified inlet port. Use colour code for identification. Install in the reverse order of removal. Check and top up the brake fluid, If required. Carry-out the brake bleeding procedure. For additional information refer to Brake bleeding procedure. Check the EHCU for any external damage, if found replace. Using trim removal tool, remove the IP panel trim driver side. Using Nose plier, remove the R-clip and the clevis pin from the pedal shank. Using 12 mm socket spanner, loosen and remove the pedal box top mounting bolt. Torque :25 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the pedal box mounting nuts then remove the brake pedal box assembly. Torque :25\u00b15.0 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W40180003.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the brake pedal assembly for any physical damage. Replace if found any. Disconnect battery negative connector. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Disconnect the wheel speed senor electrical connector. Detach the wheel speed sensor cable from the routing clips. Using 10 mm socket spanner, loosen and remove the wheel speed sensor mounting bolt then remove the sensor. Torque :9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130035.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the sensor for any physical damage. Replace if found any. Inspect the sensor for foreign particles segregation. Clean if found. Inspect the sensor connector for any damage. Remove the floor console assembly. Using 10 mm open end spanner, loosen and remove the parking brake adjusting nut. Detach the parking brake cable from parking brake lever. Disconnect the parking brake switch electrical connector. Using 12 mm socket spanner, Unscrew parking brake lever assembly mounting nuts. Torque :25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the parking brake switch from parking brake lever assembly. Install in the reverse order of removal. For additional information refer to Parking brake adjustment section. ",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the park brake lever for any physical damage. Replace if found any. Remove the front caliper assembly. Blow dry compressed air into the caliper gradually through the inlet port connected to banjo bolt, to gradually move the piston out of the caliper. Remove the piston from the caliper housing. Remove the dust cover from the caliper housing. Remove the rubber seal from the groove in the caliper housing. Piston Outer surface should be free from nicks, score or rust and should feel smooth to touch. Do not use emery paper on piston surface, Replace if found any. Caliper Housing bores should be free from score, pitting, and corrosion, Replace if found any. Carefully refit the rubber seal. Clean all the internal parts thoroughly with fresh brake fluid or alcohol. Do not use mineral oil like kerosene, petrol, diesel etc. If the piston does not move smoothly, remove it and examine the sealing ring for correct seating in its groove. Fit the other end of the piston boot on to the caliper housing. Refit the front caliper assembly. Press the lock and disconnect the electrical connector from the brake switch. Place the brake pedal in release position. Turn the brake switch in anti-clock wise direction to get the brake switch free from adjuster lock. Insert the brake switch (A) in adjuster (B) till the switch plunger get completely pressed against brake pedal (at this point switch body will rest on brake pedal). Ensure no play between adjuster and the mounting bracket . Replace the adjuster if play is observed. While replacing new Switch with adjuster - Adjuster is to be snapped on mounting bracket. Ensure no play between the adjuster and mounting. Rotate the brake switch in clock wise direction till the switch gets locked. After locking the switch, the gap between the switch body and brake pedal will set to 1\u00b10.15mm. Connect the brake switch electrical connector. It is connected to brakes booster push rod. Brake pedal switch is mounted on the brake pedal. When the brake pedal is depressed by the driver based on brake pedal travel, brake pedal ratio and vacuum assist booster ratio, hydraulic pressure is generated in the master cylinder. Also brake switch gets released to activate brake lamps/stop lamps and high mount stop lamp at the rear of the vehicle. Disconnect the brake switch electrical connector. Rotate the brake switch in anti-clockwise direction and remove the brake switch. Install in the reverse order of removal. Carry out brake switch adjustment setting. Inspect the brake switch for any damage. Replace if required. Inspect the connector for any damage. Check proper fitment of connector. Brake Fluid - Mahindra 'Maximile DOT 4' Genuine brake fluid. Capacity - 1.75 Liters (Including bleeding quantity). Entire bleeding operation should be done with engine ON condition. In case of fluid reservoir or brake fluid replacement, bleeding of brake circuit is required. Always use recommended fluid and do not mix different brand fluids. Always use fresh and clean fluid from a sealed container. Do not pump the brake pedal at any time while bleeding (i. e. when the bleeding screw is opened). Air in the system will be further compressed into small bubbles and distributed throughout the hydraulic system and will result in additional bleeding operations. Do not reuse the drained fluid. Fluid level in the reservoir must be at MAX level at the start of bleeding and should be checked after bleeding each brake circuit and top up as required. 2 post lift/ 4 post lift.
2. Open the bonnet and lock it in open position using bonnet stay rod.
",
+ "file": null,
+ "display_order": 7
+ }
+ ]
+ },
+ {
+ "procedure_name": "Draining Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Open brake fluid reservoir cap. Pull-out the bleeding nipple dust cap from both front & Rear (RH and LH) bleeding nipple. Connect a transparent tube into rear LH side bleeding nipple and using a 9 mm ring spanner, loosen the brake fluid nipple then allow the brake fluid to drain. Press the brake pedal gently to drain the fluid completely. Collect the brake fluid in the container and tighten the brake fluid nipple then detach the hose from bleeder nipple. Connect a transparent tube into rear RH side bleeding nipple and using a 9 mm ring spanner, loosen the brake fluid nipple then allow the brake fluid to drain. Press the brake pedal gently to drain the fluid completely. Collect the brake fluid in the container and tighten the brake fluid nipple then detach the hose from bleeder nipple. Connect a transparent tube into front LH side bleeding nipple and using a 8 mm ring spanner, loosen the brake fluid nipple then allow the brake fluid to drain out completely. Press the brake pedal gently to drain the fluid completely. Collect the brake fluid in the container and tighten the brake fluid nipple then detach the hose from bleeder nipple. Connect a transparent tube into front RH side bleeding nipple and using a 8 mm ring spanner, loosen the brake fluid nipple then allow the brake fluid to drain. Press the brake pedal gently to drain the fluid completely. Collect the brake fluid in the container and tighten the brake fluid nipple then detach the hose from bleeder nipple. Hand tighten all the bleeding nipples. Fill recommended brake fluid up to \u201cMAX\u201d mark on the brake fluid reservoir. Press and release brake pedal gently several times, so that brake fluid will get circulated throughout the circuit. 1. Manual bleeding.
2. Bleeding the EHCU with the use of diagnostic Tool.
3. Final manual bleeding.
",
+ "file": null,
+ "display_order": 49
+ }
+ ]
+ },
+ {
+ "procedure_name": "Manual Bleeding",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "During the bleeding process, it has to be ensured that the fluid level in the reservoir does not drop below minimum. Refer the below illustration for the bleeding sequence. Manual Bleeding Procedure ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130236.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Connect a transparent tube into Rear LH side bleeding nipple and insert the other end of tube in a transparent container. Ensure other end of tube is submerged in liquid, else chances for air entry is high. Always use transparent tube for better visibility of air bubbles. Press and release the brake pedal 3 - 4 times gently to the full stroke and hold the pedal in depressed condition. Ensure proper quantity of brake fluid in the reservoir throughout the bleeding procedure. Using a 9 mm ring spanner, loosen the brake fluid nipple and allow the brake fluid to drain. Air bubbles will escape from brake circuit to container through transparent pipe and the bubbles will be clearly visible. Tighten the bleeder screw as soon as there is no air bubbles visible in the transparent tube. Continue procedure steps 2 - 4 till there is no air bubbles visible in the transparent tube. Remove the transparent tube and firmly tighten the brake fluid nipple. Follow steps from 1\u2013 6 for Rear RH side brake. Refit the bleeding nipple dust cap on both REAR RH and LH bleeding nipples. Connect a transparent tube into Front LH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Ensure other end of tube is submerged in liquid, else chances for air entry is high. Always use transparent tube for better visibility of air bubbles. Press and release the brake pedal 3 - 4times gently to the full stroke and hold the pedal in depressed condition. Ensure proper quantity of brake fluid in the reservoir throughout the bleeding procedure. Using a 8 mm ring spanner, loosen the brake fluid nipple and allow the brake fluid to drain. Air bubbles will escape from brake circuit to container through transparent pipe and the bubbles will be clearly visible. Tighten the bleeder screw as soon as there is no air bubbles visible in the transparent tube. Continue procedure Steps 10 \u2013 12 till there is no air bubbles visible in the transparent tube. Remove the transparent tube and firmly tighten the brake fluid nipple. Follow steps from 9 \u2013 14 for Front RH side brake. Refit the bleeding nipple dust cap on both Front RH and LH brake bleeding nipples. Maintain recommended brake fluid up to MAX mark on the brake fluid reservoir. Refit the brake fluid reservoir cap. Connect i-SMART diagnostic tester and turn the ignition \u201cON\u201d . During the tool-bleeding process, ensure that the fluid level in the reservoir does not drop below minimum. Launch i-SMART Select ABS ECU and Navigate to Write Data . Routine screen will appear. Click on \u201cROUTINE SELECTION\u201d drop down list and select \u201cREPAIR BLEEDING\u201d . Click on \u201cSTART ROUTINE\u201d to initiate the tool bleeding. Ensure the fluid level in brake fluid reservoir is at \u201cMAX\u201d mark. Connect a transparent tube into rear LH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Loosen and open the rear LH bleeding screw and then press \u201cOK\u201d button Click on \u201cYES\u201d button to proceed for \u201cBleeding phase I\u201d. Ensure other end of tube is submerged in liquid, else chances for air entry is high. After pressing \u201cYES\u201d button, Press and hold the brake pedal for 3 seconds and then release for 0.5 seconds. Continue above procedure till \u201cBleeding phase I \u201d ends Connect a transparent tube into front LH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Loosen and open the front LH bleeding screw and then press \u201cOK\u201d button. Click on \u201cYES\u201d button to proceed for \u201cBleeding phase II\u201d. Ensure other end of tube is submerged in liquid, else chances for air entry is high. After pressing \u201cYES\u201d button, Press and hold the brake pedal for 3 seconds and then release for 0.5 seconds. Continue above procedure till \u201cBleeding phase II \u201d ends. Close the front LH bleeding nipple once the above mentioned pop up window appears. Connect a transparent tube into front RH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Loosen and open the Front RH bleeding screw and then press \u201cOK\u201d button. Ensure other end of tube is submerged in liquid, else chances for air entry is high. Click on \u201cYES\u201d button to proceed for \u201cBleeding phase III\u201d. After pressing \u201cYES\u201d button, Press and hold the brake pedal for 3 seconds and then release for 0.5 seconds. Continue above procedure till \u201cBleeding phase IV\u201d ends. In bleeding phase IV\u201d, pump motor switches ON and OFF in a pre defined intervals. While pump motor is ON, brake pedal pulsations can be felt along with the motor operating sound. Connect a transparent tube into Rear RH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Loosen and open the Rear RH bleeding screw and then press \u201cOK\u201d button. Ensure other end of tube is submerged in liquid, else chances for air entry is high. Click on \u201cYES\u201d button to proceed for \u201cBleeding phase IV\u201d. After pressing \u201cYES\u201d button, Press and hold the brake pedal for 3 seconds and then release for 0.5 seconds. Continue above procedure till \u201cBleeding phase IV\u201d ends. In bleeding phase IV, pump motor switches ON and OFF in a pre defined intervals. While pump motor is ON, brake pedal pulsations can be felt along with the motor operating sound. Once again carry-out mechanical bleeding. For additional information refer to Manual bleeding section . Check brake pedal for sponginess. If found spongy, repeat the entire procedure of bleeding. Check and ensure there is no leakage from pipes and joints. Do not spill brake fluid on the vehicle, it may damage the paint, if the brake fluid does contact the paint, wash it off immediately with water. Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. The fluid reservoir cap/ container should not be opened with dirty hands. Avoid direct water spray on reservoir while washing engine compartment. If Maximile DOT 4 Brake fluid is not used and in emergency conditions, use brake Fluid Meeting SAE J1703 FMVSS NO.116 DOT 4 OR IS 8654 TYPE-2 Specification and change it at 30,000 kms or 2 years whichever is earlier. During the bleeding operation ensure the container and pipe used is of transparent for better visual. At all times during the bleeding process, it has to be ensured that the fluid level in the reservoir does not drop below minimum. Brake and Clutch Fluid: - Mahindra Maximile DOT 4 Genuine Brake fluid. Brake and Clutch Fluid: - 1.75 Liters .
2. Open the bonnet and lock it in open position using bonnet stay rod.
",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "1. Check Brake fluid reservoir fluid level, if found less than MIN mark, top up to MAX mark.
2. Check the reservoir for leakage and check the level of fluid, if found less top up till MAX mark.
3. Always maintain fluid level at MAX mark on reservoir
",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130134.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Brake Fluid Leakages",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for brake fluid leakage at master cylinder primary & secondary bundy tubes. Check for brake fluid leakage at EHCU primary, secondary and outlets bundy tubes. Check for brake fluid leakage or seepage from front LH/RH flexible hose. Check for brake fluid leakage or seepage from EHCU front bundy tubes to front LH/RH flexible hose joints. Check for brake fluid leakage at front bleeding nipple (both LH & RH side). Check for brake fluid leakage or seepage from front and rear bundy tube joints shown in illustration. Check for brake fluid leakage or seepage from rear brakes bundy tubes (Both LH & RH side) to rear RH/LH flexible hoses joints. Check for brake fluid leakage or seepage from rear both LH/RH wheel cylinder joints. Check for brake fluid leakage or seepage from rear both LH/RH wheel cylinder bleeding nipples. Use recommended fluid & do not mix different brand fluids. In case fluid reservoir replaced, brake and clutch system needs bleeding. Brake/Clutch fluid level & leak check to be done at every service interval (Excludes fluid replacement intervals). Use the same brand fluid for top up; do not top up brake fluid from used and unsealed brake fluid container. The brake/clutch fluid reservoir cap container should not be opened with dirty. Avoid direct water spray on reservoir while washing engine compartment. Always use Mahindra Maximile DOT 4 genuine brake fluid. Using trim removal tool, remove the IP panel trim driver side. Using Nose plier, remove the R-clip and the clevis pin from the pedal shank. Using 12 mm socket spanner, loosen and remove the pedal box top mounting bolt. Torque :25 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the pedal box mounting nuts then remove the brake pedal box assembly. Torque :25\u00b15.0 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130330.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the brake pedal assembly for any physical damage. Replace if found any. Using a 21 mm wheel spanner, remove wheel mounting nuts and then remove the front wheel. For vehicles with Alloy wheels,measuring can be done without removing the wheels. Insert the Brake pad gauge between caliper housing and edge of brake pad backing plate and contact Tip of tool housing (A) on rotor machined surface as shown. Brake pad gauge should be in perpendicular to rotor surface while measuring. Rotate Knurled ring (D) of rear measuring barrel in same direction to view quick reference color pattern (C) and find actual brake pad thickness (In mm). If Measured pad thickness is 1 mm or less, it has to be replaced. New pad thickness: 11.35 mm. Useful Pad thickness: 10.35 mm. Wear Limits: ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Follow the Step 2 to 7 for measuring thickness of Inboard Brake Pad. 30mm. 28 mm. Refit the front wheel back with the help of mounting nuts and torque tighten it to specified torque value. Follow the above procedure for front other side wheel brake pad and disc inspection. Remove and inspect the brake pads if the vehicle is reported for the following concerns. 1. Brake Shudder.
2. Brake Noise.
3. Brake Squeal and any other brake related concerns.
If any one pad is worn out (inboard /outboard) then replace both the pads. If pads on one wheel only are worn, even then replace the other wheels also. Rotate the disc and make sure it is free to rotate. If it is not free to rotate, inspect and rectify. The Pads in the Pad kit should be replace on the respective caliper i.e. assemble < RH > marked pads on RH Caliper and < LH > marked pads on LH Caliper. Never polish pad lining with sandpaper. If lining is polished with sandpaper, hard particles of sandpaper will be deposited in lining and may damage disc. When pad lining requires correction, replace it with a new one. After assembly of pads, apply brake pedal 5 - 6 times in static condition in order to make the pads align properly. It is recommended to apply light braking during the road test and avoid heavy and continuous braking during the initial 200kms of run or until the new pads are performing satisfactorily. Never lubricate the pad seating areas as this may lead to jamming. Always ensure that the anti rattle pad clips (small low abutment clip \u2013 sLAC) are replaced whenever the pads are replaced. Always ensure the grease (Wolfracote) between clip & carrier whenever the sLAC clips are removed/replaced. Don\u2019t overload or pull the retraction loop during pad assembling. Don\u2019t use deformed clips & don\u2019t damage the clips during pad insertion. Remove the primary bundy tube. For additional information refer Primary Bundy Tube \u2013 R &R; section. Remove the secondary bundy tube. For additional information refer Secondary Bundy Tuber \u2013 R &R; section. Using hose clip plier detach the vacuum hose clip and remove hose from the brake booster. Disconnect the brake booster electrical connector and detach from the routing clips. Using hose clip plier, release the brake fluid reservoir tank to clutch TMC hose clip then detach the hose. Using cutting plier, remove the R-clip then remove the clevis pin. Using 12 mm socket spanner, Unscrew brake booster mounting nuts and remove the brake booster with TMC. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130024.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Carry out brake switch adjustment setting. Check and top up the brake fluid, If required. Carry-out the brake bleeding procedure. For additional information refer to Brake bleeding procedure. Check for the booster diaphragm if found check & replace the assembly. Disconnect battery negative terminal. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Disconnect the wheel speed senor electrical connector. Detach the wheel speed sensor cable from the routing clips. Using 10 mm socket spanner, loosen and remove the wheel speed sensor mounting bolt then remove the sensor. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130227.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the sensor for any physical damage. Replace if found any. Inspect the sensor for foreign particles segregation. Clean if found. Inspect the sensor connector for any damage. Using a 21 mm wheel spanner, Loosen and remove the rear LH wheel. Using a star screw driver, Loosen and remove drum mounting screw. Clean the brakes by blowing compressed air. Check the wheel cylinder for oil leakage. (It is recommended to check the oil seepage from wheel cylinder by lifting the dust boots.) Check the brake lining for wear/cracks. Measure the brake lining thickness by using Vernier caliper. The minimum usable thickness of the rear brake liner is 4.6 mm. Replace when thickness falls Minimum thickness of lining below 1 mm. The brake shoe must be replaced before the rib starts touching the drum. Measure the wear of the brake lining at the maximum worn out place. Place the drum in its position and install the mounting screw. Refit the LH wheel and torque tighten the nuts to specified value. Whenever the brake shoes are replaced, replace both RH & LH assemblies as a set to prevent car from pulling to one side when braking. If there is significant difference in the thickness of the liner on the left and right sides, check parking brake operation/ wheel cylinders piston for free movement. Parking Brake Operation \u2013 Check & Adjust ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130296.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Apply and release the parking brake 5 times to condition the cables for normal use and Put the parking brake lever into the released position. Check both the rear wheels for free rotation. Position the parking brake lever at 5th notch position . Check both the rear wheels for free rotation, if the wheels are rotate then tighten the adjusting nut 14 mm till the rear wheels can no longer be rotated using hands. Apply and release the parking brake 5 times. Set the parking brake lever into the released position. The rear wheels must be able to turn freely. If not, loosen the adjusting nut gradually until the wheel can turn freely. Brake pads convert the kinetic energy of the car to thermal energy by friction. Two brake pads are contained in the brake caliper with their friction surfaces facing the brake disc which are pressed together against the rotating disc to slow/stop the vehicle. Using 21 mm wheel spanner remove mounting nuts and remove the front RH wheel. Remove front caliper lower mounting bolt using 12 mm socket spanner. Lift the caliper upwards as shown in the illustration. Pull the Brake Pad outwards upto pad contact with clip as shown in the illustration. Twist the pad in anti clock wise direction, lift the pad upwards and remove the pad. Follow Step 4 & 5 for remove another pad. While inserting the pads between the carrier and disc care should be taken that the friction material should be towards the disc. Rotate the disc and make sure it is free to rotate. If it is not free to rotate, inspect andrectify. Before inserting the pads ensure that caliper is returned fully to its position. (Push the caliper inside if necessary). Never polish pad lining with sandpaper. If lining is polished with sandpaper, hard particles of sandpaper will be deposited in lining and may damage disc. When pad lining requires correction, replace it with a new one. While fitting the guide pin ensure that the straight portion of the pin matches with the ear of the calliper body. The Pads in the Pad kit should be replace on the respective caliper i.e. assemble RH marked pads on RH Caliper and LH marked pads on LH Caliper. If the pads are to be reused make sure they are assembled back in the same position as they were when removed i.e., inboard pad on to the piston side and outboard pad to the wheel side. This is possible only when at the time of removal these pads are marked for their positions and kept aside. Never lubricate the pad seating areas as it may lead to jamming. After assembly of pads, apply brake pedal 5 - 6 times in static condition in order to make the pads align properly. It is recommended to apply light braking during the road test and avoid heavy and continuous braking during the initial 200 kms of run or until the new pads are performing satisfactorily. Never lubricate the pad seating areas as this may lead to jamming. Always ensure that the anti rattle pad clips (small low abutment clip \u2013 sLAC) are replaced whenever the pads are replaced. Always ensure the grease (Wolfracote) between clip & carrier whenever the sLAC clips are removed/replaced. Ensure that the sLAC clips are placed properly and fitted in correct direction in the caliper bracket as shown in the illustration. Ensure that the sLAC clips are replaced/swapped diagonally as shown in the illustration. Ensure that no damage or no deformation of retraction loop in the sLAC clips before fitment. Don\u2019t overload or pull the retraction loop during pad assembling. Don\u2019t use deformed clips & don\u2019t damage the clips during pad insertion. Ensure the proper fitment of all the small low abutment clip (sLAC) . Replace sLAC clips with a new one if found any damage or crack. Refit the brake pad by pushing the pad inside the clips in angled approach as shown in the illustration. Rotate the pad in clockwise direction to vertical position and push the pad inside to caliper. Ensure pad touching the clip retraction. Move the caliper downwards and bring back to its original position. For easy movement, pull the caliper outwards a bit and move it down. Chances for piston seal damage is high, so take adequate precaution while moving the caliper downwards. If the pads are changed with a new one, push both the pistons inside before moving the caliper downwards. Refit the caliper bottom mounting bolt and torque tighten to specified torque value. Ensure the sliding pins are greased well, whenever removed or replaced. Torque : 31 \u2013 38 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit the front RH wheel back with the help of mounting nuts and torque tighten it to specified torque value. Torque : 140\u00b110 Nm ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Follow the same procedure for front LH brake pad and caliper inspection. If any one pad is worn out (inboard /outboard) then replace both the pads. If pads on one wheel only are worn, even then replace the other wheels also. Using 21 mm wheel spanner, Loosen and remove the rear LH wheel. Using star screw driver, Loosen and remove drum mounting screw. Using flat screw driver, slide the parking brake retaining lever and Using plier, remove the parking brake cable. Disconnect the parking brake cable connection from the liner assembly. Using plier, remove the liner spring holder. Gently expand and remove the liner assembly carefully. Remove the auto-adjuster and adjuster lever. Using flat end screw driver detach the top shoe return spring and the bottom shoe return spring and remove the liners. Align the shoes and fit bottom return spring. Refit the auto-adjuster and auto-adjuster lever. Refit the top shoe return spring. Refit the liner kit assembly. Refit the liner spring holder. Using plier slide the parking brake retainer lever & fix the parking cable. Refit the brake drum with the help of mounting screw. Refit the LH wheel and torque tighten the nuts to specified value. Whenever the brake shoes are replaced, replace both RH & LH assemblies as a set to prevent car from pulling to one side when braking. If there is significant difference in the thickness of the liner on the left and right sides, check parking brake operation/ wheel cylinders piston for free movement. Remove Brake Shoes. For additional information refer to brake shoe \u2013 R &R; section. Remove the hand brake cable lock clip and detach the hand brake cable from back plate. Using 11 mm open end spanner, Loosen brake bundy tube flare nut wheel cylinder end. Torque : 16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew Wheel cylinder mounting bolts and remove the cylinder. Using 17 mm socket spanner, loosen and remove axle shaft mounting nuts. Torque : 90 \u2013 100 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using MST (0505AAA0001ST puller rear axle shaft banjo) remove rear axle shaft, dust shield with brake liner assembly from vehicle.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130361.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Notice",
+ "content": "To avoid the back plate falling down, using a plastic tag tie it with any other fixed member before the shaft is pulled out. Clean sealant on the axle housing flange, Back Plate and apply new sealant on the housing. Apply Locktite Sealant 5060 during Installation and Ensure that sealer bead is on the inside of screw holes as shown above Bead must be 3 to 6 mm high and 3 to 6 mm wide. Remove Back plate from vehicle. Install in the reverse order of removal. Check and top up the brake fluid, If required. Carry-out the brake bleeding procedure. For additional information refer to Brake bleeding procedure. Check the brake back plate any external damage & also check the brake back plate usable thickness, if required replace. Remove front wheel. For additional information refer to Front wheel \u2013 R &R; section. Remove the Front stabilizer bar assembly. For additional information refer to Front Stabilizer Bar \u2013 R&R; section. Using 24 mm socket spanner, loosen and remove the front lower control arm mounting nuts on chassis. While loosening the nut, hold the bolt using 24 mm ring spanner. Torque tightening should be done without load and with the tyres on level ground. Torque value: 250 \u00b1 20 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 19 mm socket spanner, loosen and remove strut fork mounting bolt. Torque tightening should be done without load and with the tyres on level ground. Ensure to insert the washer before Install the bolt. Torque : 120 \u00b1 12 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a cutting plier, remove the cotter pin from the ball joint Never reuse the split pin, always replace with a new one. Using a 24 mm socket spanner, loosen and remove lower arm ball joint mounting nut. Torque : 130 \u2013 150 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Using a 22 mm socket spanner, loosen and remove knuckle bracket mounting bolts,remove the knuckle lower half. Torque value: 140 \u00b1 10 Nm Torque Wrench Type - Open end Torque Wrench ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Using a hammer, tap strut fork and release it from lower arm. Remove the lower control arm mounting bolts from the vehicle frame. Torque value: 250 \u00b1 20 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the lower control arm from the vehicle Install in reverse order of removal. Pay attention while Installation. Torque tightening should be done without load and with the tyres on level ground. LH and RH identification sticker available on part for orientation. Camber and caster bolt marking position required at center. Camber and caster bolt should be fitted in the direction of Arrow shown in illustration. Inspect the lower control arm for any external damage or bent, if found replace. Inspect the lower control arm ball joint and bushes for any damage. Place the Pan hard on suitable base block. Place the suitable dolly on the Pan hard bush One end. Using a hydraulic press or hammer remove the Pan hard bush one end. Place the Pan hard other end on base block and place the dolly on Pan hard bush. Using a hydraulic press or hammer remove the Pan hard bush other end. Place the Pan hard one end on base block and place the bush installer MST:0401BAA0043ST).on the bush. Using a hydraulic press or hammer, Install the Pan hard bush One end. Panhard bush should be fitted in center of panhard and ensure to maintain equal distance on both side of panhard as shown. Dimensions are in mm. Place the Pan hard other end on base block and place the bush installer (MST:0401BAA0043ST).on the bush. Using a hydraulic press or hammer, Install the Pan hard bush other end. Remove the Front Lower Control Arm. Place the base block (MST:0401BAA0033ST) and place the collar support (MST: 0401BAA0037ST) . on the base block. Place the upper arm one end on the base block. Place the upper arm bush remover (MST: 0401BAA0040ST) on the bottom bush. Place the Pin cage (MST:0401BAA0041ST) & the support cage (MST: 0401BAA0013ST) as shown. Using a hydraulic press remove the upper arm one side (bottom) bush. Place the upper arm other end on the base block (MST: 0401BAA0033ST) and collar support (MST: 0401BAA0037ST) . Place the upper arm bush remover (MST: 0401BAA0040ST) on the bush. Place the upper arm dummy bush (MST:0401BAA0042ST) on the upper side bush seating hole. Place the upper arm pin cage (MST:0401BAA0041ST) & the support cage (MST:0401BAA0013ST) as shown. Using a hydraulic press remove the other side bush. Place the Upper arm on the base block (MST: 0401BAA0033ST) & collar support (MST: 0401BAA0037ST) and place the bush over the upper arm. Place the bush installer (MST:0401BAA0043ST) on the bush. Using a hydraulic press, Install the upper arm one side bush. Place the Upper arm other side on the base block (MST: 0401BAA0033ST) & collar support (MST: 0401BAA0037ST) and place the bush over the upper arm. Place the bush installer (MST:0401BAA0043ST) .on the bush. Using a hydraulic press, Install the upper arm bush. Refit the Front Upper Control Arm. Using a 24 mm socket spanner, loosen the mounting bolt and nut in the chassis end then remove nut from the link. Torque : 230 \u00b1 20 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 21 mm ring spanner. Torque tightening should be done without load and with the tyres on level ground. Torque Wrench Type - Open end Torque Wrench for LH chassis & axle ends. Using a 24 mm socket spanner, loosen and remove the link mounting nut from the axle end. Torque : 230 \u00b1 20 Nm Torque Wrench Type - Open end Torque Wrench for LH chassis & axle ends ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 21 mm ring spanner. Torque tightening should be done without load and with the tyres on level ground. Using a appropriate jack support slightly lift the rear axle. Using a 17 mm socket spanners, loosen and remove the both rear shock absorbers bottom side mounting bolts and nuts. Torque value : 110\u00b111 Nm Torque Wrench Type - Open end Torque Wrench ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. While loosening the nut, hold the bolt using 15 mm ring spanner. Remove the respective side coil spring. Jack up the rear axle slightly. Remove the rear upper link chassis end mounting bolt then remove the front and rear upper link from the vehicle. Pay attention while Installation Bolt should be fitted in the direction of Arrow shown in illustration
2. Inspect the upper link bushes for any damage, crack or material deterioration. Replace the bushes if found any.
",
+ "file": null,
+ "display_order": 30
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 145,
+ "sys_id": "THAR.AX-0001-Suspension",
+ "subsys_id": "THAR.AX-0001-Suspension-Rear Lower Link Bushes Overhaul",
+ "systems": "Suspension",
+ "sub_systems": "Rear Lower Link Bushes Overhaul",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170276.jpg",
+ "myid": 1263,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Rear Lower Link Bushes Overhaul-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/VST-0074_Rear Suspension Rear lower Link Bushes Removal & Installation.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Rear Lower Link. Place the base block (MST:0401BAA0033ST) & place the Rear Lower and Upper Link Coller (MST :0401BDD0001ST) . Place the Lower link one end on the base block. Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) on the lower link one end bush. Using a hydraulic press, remove the lower link one end bush. Place the Lower link other end on the base block. Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) on the lower link other end bush. Using a hydraulic press, remove the lower link other end bush. Place the Lower link one end on then base block and place the bush over the lower link. (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170258.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "While Installation ensure to maintain Bush Void at 45\u00b0 angle as shown. Ensure to Install the Bush with Void end should be fitted in Chassis end on vehicle. Place the Lower link other end on the base block and place the bush over the lower link. Place the Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press. Refit the Rear Lower Link. Remove front wheel. For additional information refer to Front wheel \u2013 R &R; section. Using a 13 mm socket spanner , loosen and remove the brake hose routing bracket mounting nut. Using a 19 mm socket spanner , loosen and remove the strut fork mounting bolt at lower arm end and detach it. Torque : 120 \u00b1 12 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Using hammer, tap strut fork graduall and release strut fork from lower arm. Using a 17 mm ring spanner, loosen and remove the strut top mounting nuts from chassis. Torque value: 40 \u00b1 5Nm Torque Wrench Type - Open end Torque Wrench ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Detach Wheel speed sensor routing clips from upper control arm. Using 14 mm socket spanner and 18 mm open end spanner, unscrew upper arm bolt and nut and detach partially. Torque value: 97\u00b1 10 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170137.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Remove front strut assembly from front suspension. LH and RH identification sticker available on part for orientation. Using a 17 mm socket spanner and 19mm open end spanner, loosen the fork ounting bolt and nut and remove fork from strut assembly. Install in reverse order of removal.
2. Check for oil leakage from the shock absorber.
",
+ "file": null,
+ "display_order": 32
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 146,
+ "sys_id": "THAR.AX-0001-Suspension",
+ "subsys_id": "THAR.AX-0001-Suspension-Rear Upper Link Bushes Overhaul",
+ "systems": "Suspension",
+ "sub_systems": "Rear Upper Link Bushes Overhaul",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170276.jpg",
+ "myid": 1264,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Rear Upper Link Bushes Overhaul-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/VST-0073_Rear Suspension Rear upper Link Bushes Removal & Installation.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Rear Upper Link. Place the base block (MST:0401BAA0033ST) & Place the Rear Lower and Upper Link Coller (MST : 0401BDD0001ST) . Place the upper link one end on the base block. Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) on the lower link one end bush. Place the upper link other end on the base block. Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) on the upper link other end bush and Using a hydraulic press, remove the bush. Place the upper link one end on then base block and place the bush over the upper link. Place the bush & Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press While Installation ensure to maintain Bush Void at 90\u00b0 angle as shown. Place the upper link other end on the base block and place the bush over the upper link. Place the bush & Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press. Refit the Rear Upper Link. Using a appropriate jack support and slightly lift the rear axle. Using a 24 mm deep socket spanner,loosen and remove the pan hard rod mounting nut and bolt from chassis side. Torque : 230\u00b1 20 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt with the help of 21 mm deep socket. Torque tightening should be done without load and with the tyres on level ground. Using a 21 mm socket spanner, loosen and remove the pan hard rod mounting bolt from axle side. Torque : 230\u00b1 20 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Remove pan hard rod separately. Yellow color all round marking added on Pan hard rod to identify chassis end. Install in reverse order of removal. After installation of pan hard rod remove the jack support. Pay attention while Installation. Bolt should be fitted in the direction of Arrow shown in illustration. While Installation, ensure to refit the Anti Rotation Bracket in the axle end bold side. Preliminary Activities/Conditions ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": " 1. Position the Vehicle on 4 post lift. ",
+ "file": null,
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Front Suspension Bushes Inspection procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "1. Check lower control arm front and rear bush condition (both LH & RH) for wear & tear, cracks & shift. Replace if necessary.
2. Check upper control arm front and rear bush condition (both LH & RH) for wear & tear, cracks & shift. Replace if necessary.
3. Check the ball joint boots for damage, cracks, replace if necessary.
4. Check shock absorber bushes, shock absorber dust boot, stabilizer bar bushes, stabilizer bar link boots, bump stop for wear & tear, cracks and shift, replace if necessary.
",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170083.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Rear Suspension Bushes Inspection Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "1. Check the lower link, pan hard rod, Upper link, stabilizer bar and stabilizer bar links bushes for any damage/crack or deterioration. Replace the bushes if found any.
2. Check shock absorber bushes, dust boot & bump stop for wear, crack and shift.
",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170082.jpg",
+ "display_order": 7
+ }
+ ]
+ },
+ {
+ "procedure_name": "Suspension Arms & Links \u2013 Inspect",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Preliminary Activities/Conditions ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " 1. Position the Vehicle on 4 post lift. ",
+ "file": null,
+ "display_order": 9
+ }
+ ]
+ },
+ {
+ "procedure_name": "Front Suspension Lower Control Arm",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " 1. Inspect front suspension lower control arm for any bend, damage or crack. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170070.jpg",
+ "display_order": 11
+ }
+ ]
+ },
+ {
+ "procedure_name": "Front Suspension Upper Control Arm",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " 1. Inspect front suspension upper control arm for any bend, damage or crack. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170071.jpg",
+ "display_order": 13
+ }
+ ]
+ },
+ {
+ "procedure_name": "Front Suspension Stabilizer Bar",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " 1. Inspect front suspension stabilizer bar for any bend, twisting, damage or crack. ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170064.jpg",
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Rear Suspension Lower Link",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " 1. Inspect rear suspension lower link for any bend, damage or crack. ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170055.jpg",
+ "display_order": 17
+ }
+ ]
+ },
+ {
+ "procedure_name": "Rear Suspension Upper Link",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " 1. Inspect rear suspension upper link for any bend, twisting, damage or crack. ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170065.jpg",
+ "display_order": 19
+ }
+ ]
+ },
+ {
+ "procedure_name": "Rear Suspension Panhard Rod",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " 1. Inspect rear suspension panhard rod for any bend, twisting, damage or crack. ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170068.jpg",
+ "display_order": 21
+ }
+ ]
+ },
+ {
+ "procedure_name": "Rear Suspension Stabilizer Bar",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " 1. Inspect rear suspension stabilizer bar for any bend, twisting, damage or crack. ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170072.jpg",
+ "display_order": 23
+ }
+ ]
+ },
+ {
+ "procedure_name": "Front/Rear Stabilizer Bar Links",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " 1. Inspect front & rear suspension stabilizer bar link for any bend, twisting, damage or crack. ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170061.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "While tightening the link & torquing ensure that wheels are resting on the ground/ 4post lift. If it is not done, the ride quality will get adversely affected. Remove the Front Lower Control Arm. Place the base block (MST:0401BAA0033ST) and place the Front Lower Arm Big End Bush Collar (MST: 0401BBB0001ST) . on the base block. Place the Lower arm big bush end over the fixture. Place the LCA big bush remover (MST: 0401BAA0038ST) and Front Lower Arm Bushs Support tool (MST: 0401BBB0002ST) on the big end bush. Place the Pin cage (MST:0401BAA0019ST) & the support cage (MST:0401BAA0013ST) as shown. Using a hydraulic press, remove the lower arm big end bush. Place the LCA small bush end on the base block (MST: 0401BAA0033ST) and LCA small bush collar support (MST : 0401BAA0036ST) . Place the Lower arm small bush end over the fixture. Place the LCA small bush remover (MST: 0401BAA0039ST) & Front Lower Arm Bushs Support tool (MST :0401BBB0002ST) over the lower arm bush. Place the dummy bush (MST:0401BAA0016ST) on the big end bush seating hole. Place the Pin cage (MST:0401BAA0019ST) & support cage (MST:0401BAA0013ST) as shown. Using a hydraulic press, remove the LCA small bush. Place the lower arm on the base block (MST: 0401BAA0033ST) . Place the bigger end bush on the lower arm & place the bush installer (MST: 0401BAA0044ST) on the bush. Lower arm big end bush has Void profile and While Installation ensure to maintain Bush Void at appropriate angle as shown. Using a hydraulic press, Install the lower arm big end bush. Place the lower arm small end on the base block (MST: 0401BAA0033ST) Place the lower arm small end bush & the installer (MST: 0401BAA0045ST) . Using a hydraulic press, Install the lower arm small end bush. Refit the Lower Upper Control Arm. Support the rear axle using the appropriate hydraulic jack. Using a 17 mm socket spanners, loosen and remove the both rear shock absorbers bottom side mounting bolts and nuts. Torque value : 110\u00b111 Nm Torque Wrench Type - Open end Torque Wrench ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. While loosening the nut, hold the bolt using 15 mm ring spanner. Remove the rear coil spring and pad securely from vehicle. Install in reverse order of removal. Pay attention while Installation. Locking lug to be matched with hole on Rear Coil spring dome bracket of Chassis. Yellow coloured PU sleeve should be on chassis side while assembling the coil spring ashown in illustration.
2. Inspect the coil spring pad for any damage. Replace if found.
",
+ "file": null,
+ "display_order": 21
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 149,
+ "sys_id": "THAR.AX-0001-Suspension",
+ "subsys_id": "THAR.AX-0001-Suspension-Troubleshoot - Suspension",
+ "systems": "Suspension",
+ "sub_systems": "Troubleshoot - Suspension",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1466,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Troubleshoot - Suspension-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/6064.pdf",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Components Inspection and action table",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/6065.pdf",
+ "display_order": 2
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 141,
+ "sys_id": "THAR.AX-0001-Suspension",
+ "subsys_id": "THAR.AX-0001-Suspension-Assembly Front Strut Overhaul",
+ "systems": "Suspension",
+ "sub_systems": "Assembly Front Strut Overhaul",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170158.jpg",
+ "myid": 1259,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Assembly Front Strut Overhaul-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Disassembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Front strut assembly. Using a spring compressor compress the strut coil spring. Ensure that the spring compressor is tightened with the spring, else expansion of the spring cause severe injury. Using a 6 mm open end spanner hold the shock absorber & using a 16 mm ring spanner remove the mounting nut. Remove the shock absorber washer & bush. Remove the bracket coil spring guide assembly. Remove the coil spring seat. Remove the compressed coil spring. Remove the shock absorber bush. Remove the bump stopper cap. Remove the shock absorber dust seal. Remove the front bump stopper. Remove the shock absorber.
2. Inspect the dust seal for damage, if found replace.
3. Check the bush condition, if worn out please replace.
",
+ "file": null,
+ "display_order": 28
+ }
+ ]
+ },
+ {
+ "procedure_name": "Assembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Install the front bump stopper on the shock absorber. Install the shock absorber dust seal. Install the bump stopper cap. Install the shock absorber bush. Install the compressed spring. Install the coil spring seat. Install the coil spring bracket. Install the shock absorber washer & bush. Install the mounting nut. Install the top mounting nut. Torque tighten the nut to specified value. Torque : 40 \u2013 45 Nm Torque Wrench Type - Open end Torque wrench ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the spring compressor tool. Remove front wheel. For additional information refer to Front wheel \u2013 R &R; section. Never reuse the split pin, always replace with a new one. Using a 24 mm socket spanner, loosen and remove the upper control arm ball joint nut. Torque : 90 \u2013 110 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Detach the wheel speed sensor routing clips from the upper control arm. Using a 18 mm ring spanner, hold the mounting nut & using an 14 mm socket spanner loosen the bolt, remove the bolts & nuts. Torque : 97 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Detach and remove the upper control arm. Install in reverse order of removal. Pay attention while Installation. Bolt should be fitted in the direction of Arrow marks shown in illustration. Inspect the upper control arm for any external damage or bent, if found replace. Remove the rear shock absorber. Place the rear shock absorber one end on the suitable base block. Place the suitable dolly on the rear shock absorber. Using a hydraulic press or hammer remove the rear shock absorber bush. Place the rear shock absorber one end on then base block and place the bush over the rear shock absorber. Refit the rear shock absorber, Support the rear axle using the appropriate hydraulic jack and lift the vehicle to compress the coil springs. Using a 17 mm socket spanners, loosen and remove the bottom mounting bolts and nuts of rear shock absorbers from the rear axle. Torque value : 110\u00b111 Nm Torque Wrench Type - Open end Torque Wrench ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. While loosening the nut, hold the bolt using 15 mm ring spanner. Using a 14 mm socket spanner, loosen and remove the top mounting bolts of both rear shock absorbers from the chassis. Torque value : 65\u00b110Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Remove the shock absorber from the vehicle. Install in reverse order of removal. Pay attention while Installation. Bolt should be fitted in the direction of Arrow shown in illustration. Ensure the arrow on Rear Shock absorber should be on rear side of vehicle.
2. Inspect the shock absorber bushes for any damage.
",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 132,
+ "sys_id": "THAR.AX-0001-Suspension",
+ "subsys_id": "THAR.AX-0001-Suspension-Wheel Alignment",
+ "systems": "Suspension",
+ "sub_systems": "Wheel Alignment",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.6,
+ "rts": null,
+ "mat": "J08-MAT-0510",
+ "cover_image": "/files/W4A170079.jpg",
+ "myid": 1250,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 21,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 56,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 107,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 146,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 175,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 225,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 266,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 295,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 346,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 384,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 417,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0001-Wheel Alignment-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Wheel alignment (adjustment of Camber, Caster and Toe) is part of standard automobile maintenance that consists of adjusting the angles of the wheels so that they are set to the specification. The purpose of these adjustments is to reduce tyre wear, and to ensure that vehicle travel is straight and true (without pulling to one side). Wheel alignment consists of adjusting the angles of the wheels so that they are perpendicular to the ground and parallel to each other. The purpose of these adjustments is maximum tyre life and a vehicle that tracks straight and true when driving along a straight and level road. The symptoms of a vehicle that is out of alignment are: Uneven or rapid tyre wear, Pulling or drifting away from a straight line, Wandering on a straight level road, Spokes of the steering wheel off to one side while driving on a straight and level road. Before doing wheel alignment, ensure front and rear tyre pressure are as per specifications.Vehicle to be run for some distance before starting the wheel alignment. This will settle the load on each tyre. Ensure that the turn table & roller plate move freely to avoid suspension block & no rocking of turn tables. Check for any damage of the rims or bushes & suspension joints/ wheel end for play. Ensure that the front turntables & rear plates are at the same level. Do the setting of steering wheel for Straight Ahead Position (SAP) and lock the steering column rotation. Refer the wheel alignment specification chart for the front Suspension. Refer decision tree for wheel alignment: Wheel Alignment Sequence Run Out Compensation ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U3A130002.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "If above sequence is not followed, it will lead to incorrect wheel alignment even though individual adjustments are done correctly. Park the vehicle on 4 post wheel alignment equipment to do the run-out compensation. Refer wheel alignment equipment manufacturer's guide lines while doing run-out compensation. Steering Straight Ahead Position Setting ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "1. Keep the wheels on turntables of the wheel alignment machine.
2. Rotate the steering wheel to LHS lock position.
3. From LHS lock position, rotate steering wheel to RHS Lock position.
4. Count the number of turns of steering wheel from LHS to RHS lock position.
5. From RHS lock position, rotate steering wheel exactly half the number of turns towards LHS.
6. Lock the steering wheel.
7. If the steering straight ahead does not match the wheel straight ahead, then adjust the OBJ of the desired side.
8. Ensure that the silent bushes in the front suspension are in satisfactory condition.
9. Ensure that the front suspension fasteners are tightened to specified torque.
10. Ensure that there is no play in steering linkages and suspension ball joints.
11. Follow instruction manual of wheel aligning system manufacturer.
",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Heading",
+ "content": "Wheel Alignment - Check & Adjust Specification for Wheel Alignment Front Suspension ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20183.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Wheel alignment consists of adjusting the angles of the wheels so that they are parallel to each other and perpendicular to the ground, thus maximizing tyre life and ensures straight and true tracking along a straight and level road. Front Suspension Steering Angle Parameters ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20184.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Wheel alignment procedure to be done in vehicle unladen condition only Do wheel alignment only according to manufacturer's specifications. Front tyre should have uniform wear and inflated to recommended pressure. Ensure that hub play is correct. Ensure that the front suspension fasteners are tightened to specified torque. Ensure that there is no play in steering linkages and suspension ball joints. Camber is defined as the inward or outward tilt of the top of the wheel as viewed from the front. While adjusting camber angle vehicle should be unladen and nobody should sit inside. The camber values should be within: 0\u2070 \u00b1 0.2\u2070. The difference between two wheels should be within: 0\u2070\u00b1 0.4\u2070. Using a 24 mm socket spanner, loosen the camber bolt locking nut. While loosening hold the bolt with the help of a 24 mm ring spanner. To adjust camber angle, rotate the camber bolt using 24 mm ring/socket spanner, to clockwise or anti clockwise direction. Clockwise rotation will reduce the camber angle and anti-clockwise rotation will increase the camber angle. After adjusting camber angle tighten the camber bolt locking nut and recheck the camber angle. The angle between the vertical line and king pin, which fixes the steering knuckle and front axle, (steering column which connects the top and bottom ball joints in the independent axle type) when viewed the tyres from the side is called caster angle. While adjusting caster angle vehicle should be unladen. The values should be within: 4.2\u00b0 \u00b10.4\u00b0. The difference between two wheels should be within: 0\u00b0 \u00b1 0.4\u00b0 Adjust caster bolt until red zone becomes green. (Only if wheel alignment is out of specs). Using a 24 mm socket spanner, loosen the caster bolt locking nut. While loosening the nut, hold the bolt using 24 mm ring spanner. To adjust castor angle, rotate the caster bolt to clockwise or anti clockwise direction using 24 mm socket spanner. Clockwise rotation will decrease the caster angle and anti-clockwise rotation will increase the caster angle. Toe is the difference of measured distances between the front ends of the tyres (A) and the rear ends of the tyres (B) along the same axle when viewed the wheels from the top. Front Toe In to be adjusted individually on LH and RH side tie rod ends. The values should be within: 4.2\u00b0 \u00b10.4\u00b0. Front Total toe between two wheels should be within: 0.23\u2070 \u00b1 0.1\u2070. Using a 19 mm open end spanner, hold tie rod end first and then loosen tie rod end lock nut with the help of 19 mm open end spanner. Using a 14 mm open end spanner, Toe-in is adjusted by varying the length of tie rods. While adjusting toe-in, adjust the length of both the tie rods by rotating them in the same direction such that their lengths remain equal at all times. Perform steering angle sensor (SAS) calibration if steering wheel is removed and adjusted during straight ahead position setting and procedure as below. After adjusting the length of tie rods, recheck toe in and then hold tie rod end with 19 mm open end spanner and then tightening locknut with 19 mm open end spanner. Ensure the Steering Wheel is at center and the front wheels are straight. Connect the i-SMART diagnostic tester and turn the ignition ON . Launch i-SMART Select ABS ECU and Navigate to Write Data . Select the WRITE DATA tab. Click on \u201cROUTINE SELECTION\u201d drop down list and select \u201cSteering Angle Sensor Calibration\u201d . Click on \u201cSTART ROUTINE\u201d to initiate the SAS Calibration. Ensure the Steering Wheel is at center and the front wheels are straight. The following pop up window appears once the SAS Calibration completed. Press \u201cOK\u201d button to complete SAS Calibration through i-SMART. Refer wheel alignment equipment manufacturer's guide lines for wheel turning angle check. Ride height is to be measured from wheel arch center (Bottom Surface) to ground for both front and rear in unladen condition. Front ride height : Front wheel arch center (Bottom Surface) to ground.
2. Rear ride height : Rear wheel arch center (Bottom Surface) to ground.
",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "R16 SF 6S - Rim Size 16, Side Facing 6 Seater R16 FF 4S - Rim Size 16, Front Facing 4 Seater R18 FF 4S - Rim Size 18, Front Facing 4 Seater Correct Wheel alignment values. Recommended Tyre pressure. DEF tank filled full. Fuel tank filled 90%. Spare Wheel mounted. Correct tyre pressure. Coil spring damage. Loosened suspension mounting bolts. Rubber bushes of UCA and LCA. Position the vehicle on a 2 post lift and Raise the vehicle. Prior to inspect the ball joint, inspect the wheel bearings for any play. Check 1 On Vehicle. Inspect the ball joint for relative movement by, grasp the top and bottom of the wheel and rock it in and out along the wheel\u2019s vertical axis. Observe any relative movement between the wheel knuckle and ball joints. Ensure wheel nuts/bolts are not in loosen condition while checking, as that may cause movement when rocking the wheel. If relative movement play is little or no play then the ball joint is in good condition. If relative movement play that seems excessive or noises, then Visual check the ball joints. Any noises or play heard towards the top are most likely indicative of a problem with the upper ball joint, while, any play or noise coming from the bottom of the wheel are probably indicative of a problem with the lower ball joint. Check 2 (On Vehicle) ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Take a pry bar and place it between the lower control arm and the steering knuckle, the two parts that are connected together by the ball joint and attempt to pry them apart. Loose ball joints will have an excessive amount of play and movement when you pry on them, may even make knocking or clicking sounds. Check 3 On Vehicle \u2013 Visual Inspection ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170172.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Inspect the ball joints for any signs of rust, damage to the dust boot, grease leakage, or other potential problems that may indicate a need for replacement. Check the looseness of ball joints in Control arms. Remove the Ball joints from Vehicle. Refer Respective Ball Joints R&R; Section. Check 4 Off Vehicle ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Check the ball joint for free rotational torque by rotate the ball pin through the periphery of ball joint cup for checking the movement. Replace the ball joint only if movement is found jerky during rotation. Check the Axial lift by holding the ball Joint and lifting the ball pin in upward direction. If the play was observed more than 0.5 mm replace the ball joint. Lift the ball pin by one hand & hold the lower end of ball joint grounded by other hand. Refer the procedure given below for SAP setting ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "1. Keep the wheels on turntables of the wheel alignment machine.
2. Rotate the steering wheel to LHS lock position.
3. From LHS lock position, rotate steering wheel to RHS Lock position.
4. Count the number of turns of steering wheel from LHS to RHS lock position.
5. From RHS lock position, rotate steering wheel exactly half the number of turns towards LHS.
6. Lock the steering wheel.
7. If the steering straight ahead does not match the wheel straight ahead, then adjust the OBJ of the desired side.
",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Ensure that the silent bushes in the front suspension are in satisfactory condition. Ensure that the front suspension fasteners are tightened to specified torque. Ensure that there is no play in steering linkages and suspension ball joints. Follow instruction manual of wheel aligning system manufacturer. Using a 24 mm socket spanner loosen and remove the rear lower link front and rear mounting nuts and bolts. Torque value: 230 \u00b1 20 Nm Torque Wrench Type - Open end Torque Wrench for LH chassis side ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 21 mm ring spanner. Torque tightening should be done without load and with the tyres on level ground. Remove the rear lower link from the vehicle. Install in reverse order of removal. Pay attention while Installation. Bolt should be fitted in the direction of Arrow shown in illustration. Remove the Front Door Trim. For additional information refer to Front Door Trim R &R; section. Using 10 mm socket spanner, unscrew glass channel mounting nuts and detach the run channel beading from the channel and take out the channel from door. Torque :5\u00b11 Nm ",
+ "file": "",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": "Disconnect the door latch electrical connector. Detach the mounting link from latch to exterior door handle. Detach link from the handle lever. Using a 5 mm Allen key, Unscrew the latch to door mounting Allen screws. Torque : 7 Nm ",
+ "file": "",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": "Remove the front door latch assembly separately. Install in the reverse order of removal. Inspect the latch assembly for any damage, replace if found. Inspect the linkages for any damage or bend. Open the bonnet and lock it using bonnet stay rod. Using a star screw driver, loosen and remove both side front splash shield mounting screw rivets. Remove both front splash shields from vehicle. Using a 10 mm socket spanner, loosen and remove the front stone guard front mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen and remove the rear stone guard rear mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the stone guard mounting screw rivets. Remove the stone guard from the vehicle. Disconnect the fog lamp electrical connectors LH & RH sides. Pull and remove the front bumper top panel trim clips and remove the panel. Using a 10 mm socket spanner, Unscrew front bumper mounting nuts. Torque : 4.0\u00b10.5Nm ",
+ "file": "/files/W4A290004.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, Unscrew front bumper bottom mounting bolts. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew front bumper top side mounting bolts. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front bumper top centre mounting screw rivets. Remove the front bumper assembly from the vehicle. Using a 13 mm socket spanner, Unscrew front bumper center bracket mounting bolts and remove the front bumper center mounting bracket. Torque : 10.0\u00b11 Nm ",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the front grill mounting screw rivets. Using a star screw driver, loosen and remove the bottom side front grill mounting screw rivets. Using a 10 mm socket spanner, loosen and remove the front grill mounting bolts. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Remove the front grill assembly from the vehicle. Using a 10 mm socket spanner, Unscrew hood catcher mounting nuts both the sides. Torque : 7 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380105.jpg",
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Remove the hood catchers from the vehicle. Install in the reverse order of removal. Inspect the hood catcher for any damages. Replace if found any. Remove the Front Door Window Glass. For additional information refer to Front Door Window Glass R &R; section. Disconnect the front door window glass motor electrical connector. Using a 10 mm socket spanner, loosen and remove the front door window glass mechanism to door mounting nuts. Torque : 10.50 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the front door window glass mechanism separately. Install in the reverse order of removal. Inspect the glass for any damage. Replace if found. Inspect the regulator for any damages, Replace if found any. Remove the Tail Door Trim. For additional information refer to Tail Door Trim R &R; section. Using a star screw drive, unscrew tail door handle top mounting screw and remove the cover. Carefully pull and detach the outer door handle from tail door. Using a star screw driver, unscrew handle inside support mounting screw from the tail gate. Torque : 1.3 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal. Inspect the rear door exterior handle for any damages. Replace if found any. Pull out the bonnet latch cable and open the bonnet. Lock it using bonnet stay rod. Disconnect cable guide and link from latch. Detach cable from routing clips. Press the lock and pull lever to detach bonnet cable lever with cable and take out the cable from the vehicle. Install in the reverse order of removal. Inspect the bonnet cable for any damage, replace if found. Remove Tail Door Trim. For additional information refer to Tail Door Trim \u2013 R &R; section. For Softtop Variants, , Remove the Tail Door Inner Handle. For additional information refer to Tail Door Inner Handle - R &R; Section. Disconnect tail door latch electrical connector. Disconnect latch lever from the key lock and handle. Using a 5mm allen key, unscrew the tail door latch mounting screw. Torque : 7 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully detach tail door latch. Inspect the latch assembly for any damage, replace if found. Remove the Front Door Window Glass Regulator LH. Using a T20 torx socket spanner, unscrew the regulator motor mounting screws. Torque : 2.5 to 3 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380081.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the glass for any damage. Replace if found. Inspect the regulator for any damages, Replace if found any. Remove the Intercooler Assembly. For additional information refer to Intercooler Assembly \u2013 R &R; section. Disconnect cable guide and link from latch. Using a 10 mm socket spanner, unscrew bonnet latch mounting nuts. Torque : 10.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the bonnet latch from hood. Install in the reverse order of removal. While Installation, hand tighten the latch mounting nuts first and align the latch in appropriate position. And ensure smooth locking of latch in holding bracket , finally torque tighten the mounting nuts. Inspect the bonnet latch for any damage, replace if found. Remove Front LH wheel Hub.
For additional information refer to Front Stabilizer Bar \u2014 R&R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front LH wheel speed sensor mounting bolt and remove the sensor. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the wheel speed sensor routing clips from the upper control arm. Using cutting plier, remove upper arm ball joint cotter pin. Never reuse the cotter pin, always replace with a new one. Using 24 mm socket spanner, unscrew upper arm ball joint mounting nut. Torque : 90 \u2013 110 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Using suitable lever, partially detach the knuckle and remove the drive shaft. Pull the drive shaft downwards and remove it. Install in the reverse order of removal. Drain the front differential oil.For additional information refer to Front differential oil draining and filling procedure. Remove Front LH wheel Hub. For additional information refer to Front LH wheel Hub \u2014 R&R section. Remove Front Stabilizer Bar.For additional information refer to Front Stabilizer Bar \u2014 R&R section. Using 10 mm socket spanner, Unscrew front RH wheel speed sensor mounting bolt and remove the sensor. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the wheel speed sensor from routing bracket. Using cutting plier, remove upper arm ball joint cotter pin. Never reuse the cotter pin, always replace with a new one. Using 24 mm socket spanner, unscrew upper ball joint mounting nut. Torque : 90 \u2013 110 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Remove E-Disconnect stone guard.For additional information refer to E-Disconnect stone guard \u2013 R&R section. Disconnect E \u2013 Disconnect electric connector. Provide a jack to support front axle. Using 19 mm socket spanner, unscrew front axle mounting bolts and partially down the axle. Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150037.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using suitable lever partially detach the knuckle and remove the drive shaft. Pull the drive shaft downwards and remove it. Install in the reverse order of removal. Refill the front axle oil upto Max level.For additional information refer to Front differential oil draining and filling procedure. Move the joint up, down, left, right, and in axial direction. Check for any rough movement or significant looseness. Check the drive shaft boot for cracks or other damage, and for grease leakage. If damaged, disassemble the drive shaft to verify the damage, repair or replace if necessary. Check the splines for wear and tear. Remove Front LH drive shaft. Using MST 0502AUA0002ST Front Axle Shaft Inboard Oil Seal Puller, remove the Oil seal from the housing. Replace the Inboard Oil Seal once removed. For additional information refer to E-Disconnect stone guard \u2013 R&R section. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect E \u2013 Disconnect electric connector. Using 10 mm socket spanner, Unscrew electric disconnect housing mounting bolts and Carefully remove the E-Disconnect Housing with Fork . Torque : 17\u00b12 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150265.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using circlip plier remove the intermediate shaft circlip from housing. Tool should not damage the splines on the axle shaft this affects disconnect operation. Pull out the axle shaft from wheel end side of e-disconnect housing. Using MST 0502AUA0008ST Front Axle Tube Needle Bearing Puller, remove the Needle bearing from e-disconnect housing LH side. By using MST 0502AUA0007ST - F Axle Tube Needle Bearing Dolly, Install the LH Side needle bearing In the disconnect housing. Clean and Insert the axle shaft through wheel end side of the disconnect housing. Align the shifter sleeve on the intermediate shift through disconnect housing window and Install the circlip on the axle shaft with the help of circlip tool. Ensure there should not be excessive play between two shafts this affects the disconnect . Install the new cover gasket while locating in the dowel on the disconnect housing. Ensure to use New Gasket while Installation. Ensure the cleanliness of disconnect housing cover face and cover resting face. Do not bent the wrap the Gasket while installing. Gasket orientation is fixed by dowel on the disconnect housing hence it will fit in one direction only . Bent or warped cover gasket may lead to leak during running. Locate the disconnect cover on the dowel and install the bolts. Tighten the mounting bolts to specified torque value. Ensure to use New bolts while Installation. Apply locktite sealant on the bolts while installing, this avoid the leakthrough cover. Torque : 17\u00b12 Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Connect e-Disconnect electrical connector. For additional information refer to E-Disconnect stone guard \u2013 R&R section. ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, refit the Oil seal on the housing. Refit Front LH drive shaft. Inspect the Front axle Tube Needle Bearing for any damage, Replace if necessary Remove Front LH drive shaft. Using MST 0502AUA0002ST Front Axle Shaft Inboard Oil Seal Puller, remove the Oil seal from the housing. Replace the Inboard Oil Seal once removed. Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, refit the Oil seal on the housing. Refit Front LH drive shaft. Inspect the axle shaft Inboard Oil Seal for any damage, Replace if necessary. Remove Front RH drive shaft. Position the Special tool support piece inside the axle housing and using MST 0502AUA0002ST Front Axle Shaft Inboard Oil Seal Puller, remove the Oil seal from the housing. Replace the Inboard Oil Seal once removed. Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, refit the Oil seal on the housing. Refit Front RH drive shaft. Inspect the axle shaft Inboard Oil Seal for any damage, Replace if necessary. For additional information refer to E-Disconnect stone guard \u2013 R&R section. ",
+ "file": "",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Disconnect E \u2013 Disconnect electric connector. ",
+ "file": "",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A150016.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Provide a jack to support front axle. ",
+ "file": "",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A150037.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using 19 mm socket spanner, unscrew front axle mounting bolts and partially remove the axle downwards. ",
+ "file": "",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A150038.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Torque Value",
+ "content": "Torque : 90 \u00b1 10 Nm ",
+ "file": "",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Partially detach the knuckle and remove the drive shaft by using a suitable lever. ",
+ "file": "",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A150039.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Pull the drive shaft downwards and remove it. ",
+ "file": "",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A150040.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Remove the front axle assembly from Vehicle. ",
+ "file": "",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A150043.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. ",
+ "file": "",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Refill the front axle oil upto Max level. For additional information refer to Front differential oil draining and filling procedure.",
+ "file": "",
+ "display_order": 39
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " 1. Check the axle shaft for straightness, cracks, damage, wear or distortion, replace it if necessary. 2. Check the axle case for yield, deformation or cracks, replace if necessary. 3. Inspect front axle for any oil leakage, seepage. ",
+ "file": "",
+ "display_order": 40
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 108,
+ "sys_id": "THAR.LX-0004-Front Axle",
+ "subsys_id": "THAR.LX-0004-Front Axle-Front Axle Overhual",
+ "systems": "Front Axle",
+ "sub_systems": "Front Axle Overhual",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1227,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Front Axle Overhual-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Disassembly and Assembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16224.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16225.pdf",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Disassembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the Front Differential Oil. For additional information refer to Front differential oil draining and filling procedure. Remove the Front Axle Assembly. Mount the Front Axle Assembly on a suitable stand. Using 15 mm socket spanner, Unscrew front axle RH bracket mounting bolts and remove the RH bracket. Using 13 mm socket spanner, Unscrew differential assembly cover bolts and remove the cover. Clean the sealant on cover & banjo housing. Liquid sealant is used to seal cover with banjo beam. Scrap the sealant and clean the cover and banjo surfaces. Using 10 mm socket spanner, Unscrew e-disconnect cover assembly mounting bolts and remove the cover with shifter fork & motor. Using 10 mm socket spanner, Unscrew e-disconnect motor mounting bolts and remove the e-disconnect motor. Hit the shift shaft on suitable block and remove the shift shaft, shaft fork & spring from the disconnect cover. Using MST 0502AUA0002ST - Front Axle Shaft Inboard Oil Seal Puller, remove housing LH Oil seal. Replace the Inboard Oil Seal once removed. Position the Special tool support piece inside the axle housing and using MST 0502AUA0002ST Front Axle Shaft Inboard Oil Seal Puller, remove the RH Oil seal from the housing. Using circlip plier remove the intermediate shaft circlip from housing. Tool should not damage the splines on the axle shaft this affects disconnect operation. Pull out the axle shaft from wheel end side of e-disconnect housing. Remove the shifter shaft thrust washers from e-disconnect housing. Remove the shifter sleeve from e-disconnect housing. Using MST 0502AUA0008ST Front Axle Tube Needle Bearing Puller, Needle bearing from e-disconnect housing LH side. Remove LH Side differential shaft from the housing wheel end side. Using 16 mm socket spanner, Remove the Differential bearing caps mounting bolts. Remove the Differential bearing caps. Identification marks are punched on bearing cap; this is to ensure correct bearing cap is installed on correct side. Ensure correct bearing caps used While reassembly. Mount MST 0502AUA0030ST Front Axle Expander on carrier and Spread carrier by rotating nut on expander. Do not spread more than 0.5 mm. Using MST 0502AAA0001ST - Tommy Bars-X, Pry out differential case from carrier. Remove the expander from housing. Mount the MST 0502AUA0023ST \u2014 Front Axle Diff Case Bearing Puller Adapter and Using MST 0502AUA0012ST \u2014 Axle Bearing Puller on side bearing cone and remove the bearing from differential case assembly. Identify shims and side bearings on both sides, they are not to be interchanged during assembly. Similarly remove ring gear other side bearing cone by using MST 0502AUA0023ST \u2014 Front Axle Diff Case Bearing Puller Adapter and MST 0502AUA0012ST \u2014Axle Bearing Puller. Identify shims and side bearings on both sides, they are not to be interchanged during assembly. Using 17 mm socket spanner, Remove the ring gear mounting bolts and remove the ring gear. If require tap ring gear by mallet to remove the ring gear. By Using MST 0502AUA0033ST \u2014 Front Axle Diff Case Pin Remover & Installer and hammer, remove the roll pin retaining the cross shaft. Using suitable punch & hammer, remove the cross pin from case. To remove side gears and pinion mate gears, rotate the side gears, this will allow the pinion mate gears to turn to opening of the case. Remove pinion mate gears and spherical washers behind the gears. Lift out the side gears and thrust washers. Using MST 203 - Wrench Universal Joint Flange Holding tool hold the companion flange and remove the pinion nut and washer using 30 mm socket spanner from the differential housing. Using mallet tap and remove the companion flange along with dust cover. If not able to remove the companion flange tapping by mallet, use suitable 2 Jaw puller for removal. If companion flange shows wear in the area of seal contact, it should be replaced. Using a mallet, tap the pinion assembly and remove the pinion assembly from the differential housing. Make a centre punch and tap at top of the pinion assembly by using a mallet. Hold the pinion with hand to avoid falling. Gear teeth have sharp edges. Handle gears carefully to avoid injury Discard collapsible washer. Remove the Pinion Oil seal By using Screw driver/ Oil Seal Puller. Remove the slinger and outer bearing. Turn Carrier and Using MST 0502AUA0028ST Front Axle Pinion Inner Bearing Cone Remove Adapter and MST 0502AUA0032ST Front Axle Universal Handle, Remove the Inner Pinion bearing cone. Turn Carrier and Using MST 0502AUA0029ST \u2014 Front Axle Pinion outer Bearing Cone Remove Adapter and MST 0502AUA0032ST \u2014 Front Axle Universal Handle, Remove the outer Pinion bearing cone. Using the MST 0502AUA0022ST Front Axle Pinion Inner Bearing Puller Adapter and MST 0502AUA0012ST Axle Bearing Puller, Remove the Pinion Inner Bearing. Take out the pinion shims from the pinion. Using MST 0502AUA0006ST Front Axle Tube Cyl Roller Bearing Puller, Remove the Cylindrical roller bearing from disconnect housing. If replacement of one gear is required, then both side gears, pinion mate gears and washers have to be replaced. Always replace gears as a complete set, do not mix new gears with old gears, as this may cause uneven wear and short gear life. Ring gear and pinion is supplied as a set. They are matched with each other during service. Matching numbers on both pinion and ring gear are etched for verification. Refer illustration shown below for more clarity. If a new gear set is used, verify numbers on pinion and ring for matching before proceeding with assembly. Standard mounting distance from centre line of ring gear to back face of pinion is 103.5 \u00b1 0.1mm. This dimension is controlled by selecting shims, which are positioned between the inner pinion bearing cone and pinion gear. Best running position of gear set is achieved by proper shim selection. This dimension for front live axle will be different. On the bottom face of pinion, a number is etched. It can be a plus (+) number, a minus (-) number or Zero (0). Required pinion shim selection is achieved with help of this number. If alphabet 'm' appears on pinion face shim, selection has to be done in mm (Metric). If alphabet 'm' does not appear on pinion face, shim selection has to be done in inches (English). Shims with different thicknesses are available for selection. Use tables shown below for selecting correct thickness of shims either for addition or for subtraction from old shim pack. Ring and pinion etched with inch identification. Refer Table A. Ring and pinion etched with metric identification. Refer Table B. Observe the marking on pinion. If \u2018m\u2019 is found etched on the face, refer table B. If not refer table A. Pinion Position shims selection can be done using MST\u2019s Pinion Height Master Block & Pinion Height Setting Gauge, in the absence of removed Ring/Pinion gear or Old shim not available. Position the MST 0502AUA0010ST - Front Axle Pinion Height Master Block on the pinion inner bearing setting area. Fix the dial gauge on MST 0502AUA0009ST Front Axle Pinion Height Setting Gauge and set dial gauge to zero reading on surface plate. Place the MST 0502AUA0009ST Front Axle Pinion Height Setting Gauge with Dial gauge on differential housing as shown. Rock the MST 0502AUA0009ST Front Axle Pinion Height Setting Gauge and load the Dial gauge on MST 0502AUA0010ST - Front Axle Pinion Height Master Block and measure the reading on Dial Gauge (X mm). Say X mm for example which is measured by using special tool - 0.79 mm (i.e X = 0.79 mm) Convert mm to thau, i.e (0.79*39) = 31 Thau Then see the Pinion off set i.e (+ 2) Thou (For example) Final shim size = 31 - 2 = 29 Thau Convert to mm = 29*0.0254 = 0.74 mm If Pinion offset is Positive (+), then subtract the pinion offset value. If Pinion offset is Negative (-), then add the pinion offset value. Using MST 0502AUA0026ST Front Axle Pinion Inner Bearing Cone Press Dolly and MST 0502AUA0032ST Front Axle Universal Handle, refit the pinion inner bearing cone into carrier housing. Using MST 0502AUA0027ST - Front Axle Pinion Outer Bearing Cone Press Dolly and MST 0502AUA0032ST - Front Axle Universal Handle, refit pinion outer bearing cone into carrier housing. Place shims selected as per Shim Selection procedure on pinion gear. Using MST 0502AUA0025ST Front Axle Pinion Inner Bearing Press Dolly, Install pinion inner bearing cone. Take care to avoid damaging the pinion teeth while installing the bearing. Place the Pinion outer Bearing cone and slinger into housing. Using MST - 0502AUA0031ST Front Axle Pinion Oil Seal Installer, Install the New pinion seal into housing. Ensure to replace New Oil seal while Install. Apply a light coat of oil to the lip of oil seal. Install a new collapsible spacer into pinion shaft. Collapsible spacer should rest on bearing inner race and pinion shoulder and it can be fitted in any one direction. Assemble the Pinion into differential housing. Install the end yoke, washer and new pinion mounting nut. Hold the end yoke using (MST203 - Companion Flange Holding Tool) and torque tighten the mounting nut. Tighten nut to Initial torque as 217 Nm. Measure the Pinion Rotational Torque (PTTR), It should be within 17 \u2013 34 Kgf\u2013cm (1.7 to 3.3 Nm). If measured Pinion Rotational Torque (PTTR) not within (1.7 to 3.3 Nm), Then tighten nut to incremental torque from 217 Nm onwards to 678 Nm until specified PTTR ( Pinion torque to rotate) is achieved. Excessive care must be taken during bearing preload torque adjustment. Do not over tighten, loosen and then retighten nut. Do not exceed specified bearing preload torque . Measure and ensure the Final Pinion Rotational Torque (PTTR), It should be within 17 \u2013 34 Kgf\u2013cm (1.7 - 3.3 Nm). PTTR SPEC : 17 \u2013 34 Kgf\u2013 cm (1.7 to 3.3Nm). If preload torque is exceeded, a new collapsible spacer must be installed and torquing sequence as above to be repeated. If only oil seal needs to be changed, measure rotating torque of pinion with the help torque measuring tool. In this case use new collapsible spacer and keep same rotational torque of pinion as before. Apply grease to new side gear thrust washers and hubs of side gears. Assemble both side gears. Apply grease to new pinion mate spherical washers, and pinion mate gears. Assemble pinion mate gears. Assemble both side gears and thrust washers, hold them in place with one hand and then assemble the pinion mate gears with thrust washer to hold the side gears in place. An easy way to assemble the side gears and pinion mate gears is to have all parts lubricated before assembly. Always replace gears as a complete set. Do not mix new gears with old gears, as this may cause uneven wear and shorter gear life. Rotate the side gears until the holes of the spherical washers and pinion mate gears line up with the holes in the case by the help of engaging the splines of axle shaft to side gears. When both the cross bore hole matched and insert the differential shaft. Use MST 0502AUA0033ST Front Axle Differential Case Pin Remover and Installer to line holes of the gears up with case. Assemble differential shaft and pull out MST. Be sure vertical lock pin hole is lined up with that of the case, and that pinion mate washers are in place and lined up with gear and case. Align the differential shaft hole, insert the lock pin and fix using (0502AUA0033ST - Differential gear lock pin removal tool) and hammer. Always replace with new Lock pin while Installation. When roll pin bottoms out, stake (peen) metal of case over pin in two places, 180 degrees apart. Assemble MST 0502AUA0011ST Front Axle Dummy Bearings on to differential case as shown in the illustration. Assemble the differential case with Dummy Bearings on housing (Without Ring Gear). Mount the magnetic dial indicator with magnetic base, locate its tip on that surface of case. Force differential assembly to the extreme in the direction towards indicator, With force still applied set indicator to 0.00. Force differential assembly to the extreme end in opposite direction. Repeat above steps until the same reading is obtained, Record reading in the format given as' A'. Remove dummy bearing and keep aside. Assemble ring gear to the differential case using mounting bolts. Tighten the bolts to specified torque value in recommended sequence. Torque : 95 - 122 Nm ",
+ "file": null,
+ "display_order": 208
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Notice",
+ "content": "Always use new ring gear bolts. Assemble MST 0502AUA0011ST Front Axle Dummy Bearings on differential case as shown in the illustration. Position differential assembly into housing and Mount the magnetic base dial indicator on housing and locate the tip of indicator on the surface of one of the ring gear screws. Force differential case assembly away from pinion gear. With force still applied set indicator to zero. Force differential case assembly and ring gear to mesh with pinion gear. Rock the ring gear to allow teeth to mesh, Repeat to obtain the reading and continue the procedure until the same reading is obtained. Record reading in the format given as' B'. Remove dial indicator and dummy differential bearings from differential housing. Calculate the Ring Gear Backlash & Differential Bearing Preload shims based on below calculation. Install the selected shim pack in between side bearing and carrier assembly. Using MST 0502AUA0024ST Front Axle Differential Case Bearing Dolly, Install side bearing cone on hub of differential assembly. It is always preferred to replace side bearings once pulled out. But one can confirm free rolling of bearings and reuse it, if they are defect free. Install the selected shim pack in between other side bearing and carrier assembly. Using MST 0502AUA0024ST Front Axle Differential Case Bearing Dolly, Install other side bearing cone on hub of differential assembly. It is always preferred to replace side bearings once pulled out. But one can confirm free rolling of bearings and reuse it, if they are defect free. Install spreader and dial indicator and expand the carrier. Never expand the differential housing over 0.5 mm to avoid distortion. Remove dial indicator from the differential housing. Install differential case assembly into carrier with the help of mallet. Ensure differential case shim is behind the bearing cap. Carelessness while installing differential case assembly may result in injury. Position the bearing caps and install the mounting bolts and torque tighten the bolts to specified torque. Torque : 47 - 68 Nm ",
+ "file": null,
+ "display_order": 243
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "Notice",
+ "content": "Ensure correct fitment of caps by matching letters on caps and carrier on either side. Remove the expander from differential housing. Check ring gear and pinion backlash at three equally spaced points with dial indicator. Backlash tolerance is 0.13 to 0.20mm and should not vary more than 0.08 mm between the three points checked . Fix the Dial Gauge on Housing, Set the Dial Indicator 0 on Ring gear teeth as shown. Hold the pinion flange at the bottom side. Rotate the ring gear by using ring spanner & measure the backlash. High backlash is corrected by moving ring gear closer to pinion. Low backlash is corrected by moving ring gear away from pinion. These corrections are made by switching shims from one side of differential case to other. If backlash is as per specification, check ring gear and pinion tooth contact pattern. Interpretation of Contact Pattern ",
+ "file": null,
+ "display_order": 252
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/front axle overhaul.PNG",
+ "display_order": 253
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "Description",
+ "content": "The TOE of the gear is the portion of the tooth surface at the end towards the centre. The HEEL of the gear tooth is the portion of the tooth surface at the outer end. The TOP LAND of a gear tooth is the surface of the top of the tooth. Every gear has a characteristic pattern. Measure and ensure the Final Total Torque To Rotate (TTTR) at pinion nut, It should be within 28 - 51 Kgf-cm (2.8 - 5 Nm). TTTR SPEC : 28 - 51 Kgf-cm (2.8 - 5 Nm). Using MST 0502AUA0005ST Front Axle Tube Cyl Roller Bearing Dolly, Install the RH housing cylindrical roller bearing through the oil seal bore In the housing. Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, Install the RH side housing Oil seal. Clean the intermediate shaft and insert the shims in intermediate shaft. Push intermediate shaft in same way the direction used during removal. Install the synthetic bush in the bore of axle shaft with the help of light nylon mallet. Press force must not so high which may damage the bush during pressing. Insert the thrust washers in the sequence opposite to removal in the disconnect housing. Shaft End Play Checking ",
+ "file": null,
+ "display_order": 282
+ },
+ {
+ "step_name": "Step-47",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150129.jpg",
+ "display_order": 283
+ },
+ {
+ "step_name": "Step-47",
+ "content_type": "Description",
+ "content": "Insert the axle shaft through wheel end side of the disconnect housing. Install the circlip on the axle shaft with the help of circlip pressing tool. Check end play with dial gauge at the axle shaft end. End play should be 0.025 to 0.1 mm. End play can be adjusted by adding/deleting shims from the intermediate shaft. After adjusting end play, remove the circlip & axle shaft from the housing. Install the shifter sleeve on the intermediate shift through disconnect housing window while aligning with the splines on it. shift splines and shifter sleeve must be free from foreign particles and burr. Insert the axle shaft through wheel end side of the disconnect housing. Install the circlip on the axle shaft with the help of circlip pressing tool. Ensure there should not be excessive play between two shafts this affects the disconnect . Insert the spring and shaft fork through the disconnect cover window while aligning the spring into bore in the cover and sitting in the slit of shift fork. Insert the shaft shift fork in the opposite way of removal ensuring that it passing through shift fork as well as spring. Orientation of the shift fork is important and it should be in same way while was removing. Ensure old spring is discarded and to use spring during installation. Ensure cleanliness of the disconnect housing cover, shift fork shaft , shift fork and spring. Press the shaft shift fork in the bore by hand. Install the new cover gasket while locating in the dowel on the disconnect housing. Ensure to use New Gasket while Installation. Ensure the cleanliness of disconnect housing cover face and cover resting face. Do not bent the wrap the Gasket while installing. Gasket orientation is fixed by dowel on the disconnect housing hence it will fit in one direction only . Bent or warped cover gasket may lead to leak during running. Locate the disconnect cover on the dowel and install the bolts. Tighten the mounting bolts to specified torque value. Torque : 17\u00b12 Nm ",
+ "file": null,
+ "display_order": 312
+ },
+ {
+ "step_name": "Step-54",
+ "content_type": "Notice",
+ "content": "Ensure to use New bolts while Installation. Apply locktite sealant on the bolts while installing, this avoid the leak through cover. Install the electrical motor on the cover assembly and tighten the screw with specified torque. Torque : 12.5\u00b13.5 Nm ",
+ "file": null,
+ "display_order": 316
+ },
+ {
+ "step_name": "Step-55",
+ "content_type": "Notice",
+ "content": "Ensure that the 'O' ring on the electrical motor is not cracked or damaged if so replace the 'O' ring as new one. By using MST 0502AUA0007ST - F Axle Tube Needle Bearing Dolly, Install the LH Side needle bearing In the disconnect housing. By using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, Install the housing LH side Oil seal. Apply the uniform sealant bid along the carrier cover face and avoiding the bolt holes as far as possible. Use Anabond A-676 or 3M sealant on the cover plate. Ensure the cleanliness of the carrier cover face before Installation. Install the carrier cover plate and locate it on the cover plate mounting studs on the carrier Install cover plate bolts and tighten them to specified torque value. Torque : 38 - 45 Nm ",
+ "file": null,
+ "display_order": 332
+ },
+ {
+ "step_name": "Step-60",
+ "content_type": "Notice",
+ "content": "Discard the old bolts and Use new bolts for cover plate mounting as the bolts are coming with sealant patch on it and during sealant patch wears off. Reusing cover bolts may leads to leakage from cover bolts sides. Refill the front axle oil upto Max level. For additional information refer to Front differential oil draining and filling procedure. Remove E-Disconnect motor. Using 10 mm socket spanner, Unscrew electric disconnect housing mounting bolts Torque : 17\u00b12 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Carefully remove the E-Disconnect Housing with Fork . Refit in the reverse order of removal. While Installation Apply Locktite sealant on the E-Disconnect Housing bolts to avoid the leak through cover. Check the e-disconnect housing with fork for any damage, Replace if necessary.
",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1012,1224",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step 2",
+ "content_type": "Description",
+ "content": "Disconnect E \u2013 Disconnect electric connector. Using 10 mm socket spanner, unscrew E \u2013 Disconnect motor mounting bolts. Torque : 12.5\u00b13.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step 4",
+ "content_type": "Description",
+ "content": "Carefully remove the E-Disconnect motor. Refit in the reverse order of removal. While Installation ensure to replace the New O Ring for E \u2013 Disconnect motor. Torque : 90 \u2013 110 Nm ",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the E-Disconnect motor, connector for any damage, Replace if necessary. Position the vehicle on 2 post lift/ 4 post lift. Differential Oil Front Replace - Procedure Front Axle Oil \u2013 Mahindra 'MAXIMILE ELITE' New Generation Genuine Differential Fluid , Capacity \u2013 1.25 Litres. Using 10 mm square bit spanner, loosen and remove front axle filler plug. Using 10 mm square bit spanner, loosen and remove front axle drain plug and drain the entire oil. Wait till the entire oil get drained. Place a tray beneath the front axle for collecting the oil while draining. Refit the drain plug and torque tighten to specified value. Clean the drain plug and differential housing with a clean cloth before refitting. Torque : 34 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refill specified quantity of recommended differential oil into differential assembly. Never reuse drained oil. Always use recommended oil only. Never mix different types of oil and use. Clean filler plug area properly using a cloth before filling the oil. Check the oil level and ensure its up to the level. Ensure that the oil level is up to lower most point of the filler plug. Refit the filler plug back and torque tighten to specified value. Clean the filler plug with a clean cloth before refitting. Torque : 34 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Recommend to use only Mahindra 'MAXIMILE Elite' new generation genuine differential fluid. In case of non availability of 'Maximile' brand, other brands meeting API GL5, SAE 80W-90 specification can be used as second preference and oil change period should be reduced as 20,000 km.
2. Visually inspect the front axle for any noticeable signs of mechanical damage.
3. If an obvious cause is found during the inspection, correct the same before proceeding to the next step.
4. If the cause is not found visually during the inspection, refer to the troubleshooting chart.
5. Check for oil level and condition.
",
+ "file": null,
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Mechanical",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "1. Check for any oil leakage in the differential assembly, gasket and axle shaft oil seal.
2. Check for any noise in the bearing, pinion gear, crown wheel and planet gears.
",
+ "file": null,
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Refer below chart for various symptoms causes and there remedial actions of system",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16394.pdf",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Noise when the vehicle is coasting",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16395.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Intermittent Noise",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16396.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Noise when the vehicle is turning",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Noise when the vehicle is coasting.png",
+ "display_order": 6
+ }
+ ]
+ },
+ {
+ "procedure_name": "Constant Noise",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Constant Noise.png",
+ "display_order": 7
+ }
+ ]
+ },
+ {
+ "procedure_name": "Vibration",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Vibration.png",
+ "display_order": 8
+ }
+ ]
+ },
+ {
+ "procedure_name": "Oil leakage from Differential carrier leakage",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Oil leakage from Differential carrier leakage.png",
+ "display_order": 9
+ }
+ ]
+ },
+ {
+ "procedure_name": "Axle case oil leakage",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Axle case oil leakage.png",
+ "display_order": 10
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 65,
+ "sys_id": "THAR.LX-0004-en-SM-Manual Transmission",
+ "system_name": "Manual Transmission",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1008,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 75,
+ "sys_id": "THAR.LX-0004-Manual Transmission",
+ "subsys_id": "THAR.LX-0004-Manual Transmission-Clutch Housing And Input Shaft Oil Seal",
+ "systems": "Manual Transmission",
+ "sub_systems": "Clutch Housing And Input Shaft Oil Seal",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A110018.jpg",
+ "myid": 1156,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Clutch Housing And Input Shaft Oil Seal-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110018.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Clutch Housing and Input Shaft Oil Seal.png",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Clutch Housing and Input Shaft Oil Seal2.png",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the Transmission fluid. For additional information refer to Transmission fluid Drain & Filling Section.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Clutch Concentric Slave Cylinder. Using a 14 mm socket spanner remove the clutch housing mounting bolts and then gently tap using plastic mallet & remove clutch housing. Using a screw driver/suitable oil seal remover, remove the input shaft oil seal from clutch housing. Install the input gear oil seal on the clutch housing by using MST - 0703BBA0001ST - Clutch Housing Oil Seal Installer. Check for correct seating of oil seal on clutch housing. Apply Loctite 5188 on front housing. Install the clutch housing. Refit the clutch housing with the help of mounting bolts torque tighten the bolts to specified value. Torque : 30 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit the Clutch Concentric Slave Cylinder. Refill the Transmission fluid. Check for any external cracks, if found replace. Check the oil seal for deformation, if found replace. Front housing is used to provide support for mounting transmission shafts with the help of bearings. It is mounted in between clutch housing and Intermediate plate. Using a 22 mm ring spanner, loosen and remove the neutral sensor. Remove the rear housing assembly. Using a snap ring removal tool/ flat end screw driver, remove the input shaft snap ring from the front housing. Using a snap ring removal tool/ flat end screw driver, remove the counter shaft snap ring from the front housing. Using open end spanner, detach the front housing from the intermediate plate. Remove the front housing assembly. Apply loctite 5188 on the front housing in intermediate plate side. Install the front housing assembly. Use 3 nos. of 17 mm dummy bolts (Appox. length of 40 mm) to tighten the front housing to ensure proper sealant application. Ensure to fix the dowels before tighten the front housing. Using a snap ring, removal tool/ screw driver install the counter shaft snap ring. Using a snap ring, install the input shaft snap ring. Refit the Clutch housing assembly. Refit the Rear housing assembly. Install the neutral sensor. Torque tighten the nut to specified value. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 37
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 70,
+ "sys_id": "THAR.LX-0004-Manual Transmission",
+ "subsys_id": "THAR.LX-0004-Manual Transmission-Transmission With Transfer Case",
+ "systems": "Manual Transmission",
+ "sub_systems": "Transmission With Transfer Case",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A110001.jpg",
+ "myid": 1151,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Transmission With Transfer Case-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110001.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Transmission with Transfer Case.png",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Transmission with Transfer Case1.png",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the battery negative terminal. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON For additional information refer to Rear Propeller Shaft R&R Session. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 8 mm socket spanner, loosen and remove the front propeller shaft mounting C clamp bolts from the transfer case. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the cross pin and detach the Shifter cable from the shifter control housing on transmission. Using a 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the Selector cable from the Shifter Control Housing ball pin. Detach the Selector cable & Shifter cable abutments from the cable brackets on transmission by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Using a 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the transfer case cable from the transfer case ball pins. Detach the transfer case cable abutment from the cable bracket on transmission by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Disconnect the GNS sensor & transfer case switch electrical connection. Disconnect the reverse switch electrical connection. Disconnect the transmission wiring routing clips. Disconnect the clutch bundy tube connection from clutch slave cylinder. Using a 14 mm socket spanner, loosen and remove the starter motor mounting bolts then keep aside the starter motor. Torque: 44 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the transmission housing mounting bolts. Torque: 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Provide a jack to support the transmission. Using a 12 mm socket spanner, loosen and remove the transmission bed mounting bolts from transmission. Torque :25\u00b15 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using 14mm, 15mm socket and ring spanners, unscrew transmission cross member mounting bolts, nuts and detach it. Torque: 65 \u00b110.0 Nm ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Lower the jack and remove the transmission along with the transfer case. Install in reverse order of removal. For additional information refer to clutch fluid Refilling and bleeding procedure. ",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A1103931ddac5.jpg",
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Notice",
+ "content": "While refit Cables, Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Move the shifter cable quick adjuster outer cover in forward direction and unlock the QA clip in transmission end. Position the shifter control housing in Neutral Position on transmission. Ensure the Selector cable is properly fitted on Shifter Control Housing ball pin on transmission. Ensure the selector cable & shifter cable abutments are properly fitted on transmission cable brackets. Remove the gear shifter lever knob with spring and 4WD selection knob. Using trim removal tool, remove the Gear selection rod cover with trim. Ensure the selector cable & shifter cable abutments are properly fitted on shifter lever bracket Inside passenger cabin. Move the selector cable quick adjuster outer cover in forward direction and unlock the QA clip. Insert the Neutral lock Special tool to shifter housing hole and lock the tool C profile to shifter lever as shown for ensuring selector & shifter arm in neutral position. After Inserting the Neutral lock special tool, Shifter lever should not move in any direction. In this Condition press the selector cable QA clip as shown to lock it fully and release the quick adjuster outer cover. Ensure the proper locking by confirming/ hearing the click noise while install. Ensure the shifter cable end is properly fitted on the shifter lever ball pin inside passenger cabin. Ensure Transmission is in Neutral at transmission end. In this condition press the shifter cable QA clip towards arrow mark as shown to lock it fully and release the cable quick adjuster outer cover. Ensure the proper locking by confirming/ hearing the click noise while install. After adjustment remove the special tool from shifter lever. Refit the Gear selection rod cover with trim. Refit the gear shifter level knob with spring and 4WD selection knob. Inspect the shifter lever smooth shifting & gear engagement to all the gear range. Remove the Transfer Case. Using a screw driver, remove the rear end oil seal from the Rear housing. Position the rear end oil seal along with 0703BBA0002ST - Transmission Rear Housing Oil Seal Installer & install the oil seal using a mallet. Remove the Transmission with Transfer case. Pull the clutch bleeder lock and detach the bleeder from CSC. Using a 12 mm socket spanner, loosen and remove the CSC mounting bolts. Torque: 25 \u00b1 3.5 Nm ( Step UP Torque \u2013 5, 15 , 25) ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 15 mm socket spanner/ combination spanner, loosen and remove the transfer case mounting nuts then detach the transfer case from the transmission. Torque: 45 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110017.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Remove the Shifter Control Housing. By Using 5 mm thin Punch & hammer, remove the Select lever guide locking pin and detach the guide. Take out the control housing boot from the shift lever assembly. By using 3 mm Allen key, remove the Plug to access shift lever ball assembly locking pin. By Using 5 mm thin Punch and hammer, remove the shift lever ball assembly locking pin by accessing thru plug hole. Remove the Shift lever assembly from the housing and remove the shift lever ball assembly as shown in the Illustration . Remove the other side boot from the shift control housing. By using screw driver, remove the seal from the housing (One Side). By using screw driver, remove the seal from the housing (Other Side). By using M 8 flange headed bolt and 8 mm punch, remove the bush from the housing (One Side). Position the M8 flange headed bolt on bush as shown above & hit the bolt by using punch and mallet. By using M 8 flange headed bolt and 8 mm punch, remove the bush from the housing (Other Side). Position the M8 flange headed bolt on bush as shown above & hit the bolt by using punch and mallet. By using screw driver, remove the select lever circlip. By screw drive, hit the select lever shift pivot and remove the shaft. Detach select lever from the housing. By using 15 mm ring/open end spanner, remove the breather from the housing. By using 15 mm ring/open end spanner, refit the breather on the housing. Position the select lever on housing and insert the select lever shaft on lever. Refit the select lever circlip on select lever by using nose plier. Position the bush on housing (One side) and Install by using M8 flange headed bolt, 8 mm punch & mallet as shown illustration. After Installation,Ensure bush face parallel to housing bore face as shown. Install the Oil seal by gently press by using hand or suitable dolly. Position the bush on housing (Other side) and Install by using M8 flange headed bolt, 8 mm punch & mallet as shown illustration. After Installation, Ensure bush face parallel to housing bore face as shown. Install the Oil seal by gently press by using hand or suitable dolly (Other side). Refit the one side boot on shifter control housing. Insert the shift lever assembly on housing and insert the Shift lever ball assembly to the shift lever assembly (As direction shown). Align the Ball Assembly and shift lever shaft hole and Install the locking pin by using 5 mm punch and hammer. Install the Plug on housing. Insert the other side control housing boot to the shift lever. Insert the lever guide on shift lever. Install the select lever guide locking pin by using 5 mm punch and hammer. Refit the Shifter Control Housing. Remove the Floor Console. Using a MST 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the Selector cable & Shifter cable from the shift lever ball pins. Detach the Selector cable & Shifter cable abutments from the shifter bracket by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Using a 13 mm socket spanner, loosen and remove the gear shifter lever assembly mounting nuts. Remove the gear shifter lever assembly from the vehicle. Position the gear shifter lever assembly on the vehicle. Refit the gear shifter lever assembly mounting nuts and torque tighten the nuts to specified value. Torque: 21\u00b13 NM ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Refit the Selector cable & Shifter cable abutments on shift lever bracket. Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Refit the Selector cable & Shifter cable on shift lever. Carry out Gear Cable Setting. New Shifter Lever Assembly supplied with Gear shifter Neutral position tool, ensure to remove the tool from shifter housing after Gear cable setting. Support the transmission using jack. Using a 18 mm socket spanner, loosen and remove the transmission bed mount nuts. Torque: 110 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 14 mm & 15 mm socket/ring spanner, loosen and remove the cross member mounting bolts & nuts then remove the transmission cross member. Torque: 65\u00b1 10 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the transmission bed mounting bolts then remove the transmission bed mount from the vehicle.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110021.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque: 25\u00b15 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110085.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Detach the Shifter cable abutment from the cable bracket on transmission by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Using a 12 mm socket spanner, loosen and remove the shifter cable bracket mounting bolts and remove the bracket. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the GNS electrical connection and detach the wiring routing clip. Using a 22 mm open end spanner, loosen & remove the Gear Neutral Sensor. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. While Install cable, Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Check for any external damage, if found please replace. Remove the Air Cleaner Assembly. Remove the Floor Console. Using a 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the Selector cable & Shifter cable from the shift lever ball pins. Detach the Selector cable & Shifter cable abutments from the shifter bracket by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Remove the cross pin and detach the Shifter cable from the shifter control housing on transmission. Using a 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the Selector cable from the Shifter Control Housing ball pins. Detach the Selector cable & Shifter cable abutments from the cable brackets on transmission by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Using a 10 mm socket spanner, loosen and remove the shifter & selector cable grommet mounting bolts. Detach the shifter and selector cable from routing clips & take out from the vehicle. Routing the shifter and selector cable to the vehicle and position the cables on routing clips. While routing the cable ensure to insert Selector cable in the left side of the Gear shifter lever and shifter cable in the right side. Select & Shift cable should not cross each other. Refit the shifter & selector cable grommet mounting bolts and torque tighten the bolts. Torque: 13\u00b1 2 Nm ",
+ "file": "/files/W4A110381.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Caution",
+ "content": "Ensure the cable grommet should get assemble from outside the cabin. Refit the selector cable & shifter cable abutments on transmission cable brackets. Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Attach the Shifter cable on shifter control housing on transmission and refit the cross pin on Shifter control housing. Attach the Selector cable on Shifter Control Housing ball pins by hand. Refit the selector cable & shifter cable abutments on shift lever bracket inside passenger cabin. Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Attach the Selector cable end on Shifter lever ball pin by hand. Refit the shifter cable end on Shifter lever ball pin by hand. Carry out Gear Cable Setting. Refit the Air Cleaner Assembly. Inspect the gear shift & select cables for any damage. Replace if found any. Rear housing is used to protect rear parts of transmission components from external environment. It is used to hold the Shifter Control Housing assembly & detent block. Drain the transmission oil. Using a 12 mm socket spanner, remove the gear control housing mounting bolts and then gently detach and remove the gear control housing assembly. Yellow colored bolts are fitted with dowel inside, this bolts should be removed & refit first. Using a T30 torx spanner, remove the torx bolt from the shift block actuator. Using a 22 mm socket spanner, remove the reverse switch. Using a 12 mm socket spanner, remove the idler shaft front mounting bolt & using a 13 mm socket spanner remove the bottom idler shaft bolt. Using a 12 mm socket spanner, loosen and remove the selector bracket mounting bolts. Using a 12 mm socket spanner, loosen and remove the shifter bracket mounting bolts. Using a 14 mm socket spanner, remove the rear housing bolts from the front housing side. Ensure and take more care on not to breakage the front housing sealant while removing rear housing bolts from the front housing side. Using a 14 mm socket spanner/Open end spanner, remove the rear housing mounting bolts. Turn the shift block actuator & release from the spring support. By using screw driver, release the rear housing dowels and using open end spanner detach the rear housing. Release the dowels from the rear housing and ensure not to remove fully from the housing and it leads to touch the dowels on center housing projection as shown. Use the open end spanner on both the side simultaneously. Lift the rear housing assembly along with the shift block actuator. Remove the rear housing assembly and take out shift block actuator from housing. Using a screw driver/suitable oil seal remover, remove the rear end oil seal from the Rear housing. Using a 12 mm socket spanner, remove the H plate mounting bolts & the H plate assembly from the Rear housing. Using hydraulic press, remove both the detents by pressing from outside to inside. Check for any external oil leakage. Rectify if found. Using suitable tool and hydraulic press, fit the detent (press from outside to inside) Position the rear end oil seal along with 0703BBA0002ST - Transmission Rear Housing Oil Seal Installer & install the oil seal using a mallet. Check for the rear end oil seal correct seating. Refit the H plate mounting bolts & torque tighten the bolts to specified value. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Apply loctite 5188 on Intermediate plate and insert the rear housing assembly. Install the shift block actuator while installing the rear housing. Insert the rear housing mounting bolts, torque tighten the bolts specified value. Torque : 30\u00b15 Nm ",
+ "file": null,
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Insert the rear housing mounting bolt from front housing side and torque tighten the bolts to specified value. Torque : 30\u00b15 Nm ",
+ "file": null,
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110122.jpg",
+ "display_order": 72
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Refit the reverse light switch, torque tighten the switch to specified value. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Insert the front & the bottom idler shaft mounting bolts, torque tighten the bolts to specified value. Torque : Idler Shaft Bolts - 30\u00b15 Nm ",
+ "file": "/files/W4A110120.jpg",
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Refit the shifter bracket with mounting bolts , torque tighten them to the specified value. Torque: 20.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Refit the selector bracket with mounting bolts , torque tighten them to the specified value. Torque: 20.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 85
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Position the shift block actuator, apply Loctite 262 & insert the torx bolt and torque tighten the bolt to specified value. Torque : 10 - 15 Nm ",
+ "file": null,
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110323.jpg",
+ "display_order": 89
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Apply 5188 loctite on the rear housing to fit gear control housing. Refit the gear control housing & the mounting bolts. torque tighten the bolts to specified value. Yellow colored bolts are fitted with dowel inside, this bolts should be refit first. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 97
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 68,
+ "sys_id": "THAR.LX-0004-Manual Transmission",
+ "subsys_id": "THAR.LX-0004-Manual Transmission-Shifter Control Housing",
+ "systems": "Manual Transmission",
+ "sub_systems": "Shifter Control Housing",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A110075.jpg",
+ "myid": 1149,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Shifter Control Housing-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Shifter Control Housing is for gear selecting and shifting. It is connecting element between gear shift lever and shift rail through Shifter & Selector cables. Remove the Transmission with Transfer case. Using a 12 mm socket spanner, remove the gear control housing mounting bolts and then gently detach and remove the gear control housing assembly. Position the shifter lever in Natural Position on transmission. Yellow colored bolts are fitted with dowel inside, this bolts should be removed & refit first. While Installation, Apply sealant LOCTITE 5188 on the rear housing shifter control housing seating area. Install in reverse order of removal, before installation apply the sealant if required. Top up the transmission oil. Inspect the shift control housing for any damage. Replace if found any. Using a 12 mm socket spanner, remove the gear control housing mounting bolts and then gently detach and remove the gear control housing assembly. Yellow colored bolts are fitted with dowel inside, this bolts should be removed & refit first. Using a T30 torx spanner, remove the torx bolt from the shift block actuator. Using a 22 mm socket spanner, remove the reverse switch. Using a 22 mm open end spanner, remove the neutral sensor. Using a 12 mm socket spanner,remove the idler shaft front mounting bolt & using a 13 mm socket spanner, remove the bottom idler shaft bolt. Using a 14 mm socket spanner, remove the rear housing bolts from the front housing side. Using a 14 mm socket spanner/Open end spanner, remove the rear housing mounting bolts. Turn the shift block actuator & release from the spring support. By using screw driver, release the rear housing dowels and using open end spanner, detach the rear housing. Release the dowels from the rear housing and ensure not to remove fully from the housing and it leads to touch the dowels on center housing projection as shown. Use the open end spanner on both the side simultaneously. Lift the rear housing assembly along with the shift block actuator. Remove the rear housing assembly and take out shift block actuator from housing. Using a screw driver/suitable oil seal remover, remove the rear end oil seal from the Rear housing. Using a 12 mm socket spanner remove the H plate mounting bolts & the H plate assembly from the Rear housing. Using hydraulic press, remove both the detents by pressing from outside to inside. Remove the idler gear, shaft & the plastic support assembly. Remove washer, idler gear & needle roller bearing from shaft. Remove main shift rod & the washers on both sides. Ensure Gear in neutral position. Using a 14 mm socket spanner remove the counter shaft lock bolt in clock wise direction. The bolt is reverse threaded, hence rotate in clockwise for removing. Using a MST 0703AD2720H116 \u2013 Lock Nut Dolly, loosen the output shaft lock nut. Using a bearing puller (SKF TMMR 120F), remove the counter shaft rear DGBB (Double Grove Ball Bearing). Use Counter shaft dummy bolt for support bearing puller. Using a puller (SKF TMMR 350F), remove the reverse driven gear, washer & CRB (Cylinder Roller Bearing) from output shaft. Remove reverse synchro ring and remove the reverse driven gear needle bearing & remove the bush. Remove reverse synchro stud and reverse fork & rail shift assembly along with reverse synchro sleeve from output shaft. Using a puller (SKF TMMR 350F) remove the reverse synchro hub from output shaft. Using a puller (SKF TMMR 120F), remove the reverse drive gear, thrust washer & 5th drive gear from counter shaft. Remove the 5th drive gear NRB (Needle Roller Bearing) and 6th synchro ring. Using a suitable puller (SKF TMMR 350F) remove the 5th driven gear & bush from output shaft. Remove the 5th & 6 th synchro studs and remove the 5th & 6 th synchro sleeve along with fork & rail shift. Using a puller (SKF TMMR 120F) remove 5th drive gear bush, 5th & 6th synchro hub, synchro ring & 6th drive gear from counter shaft. Remove the 6th drive gear NRB. Using 14 mm socket spanner, remove the clutch housing bolts. Gently tap using plastic mallet & remove clutch housing. Using a screw driver/suitable oil seal remover, remove the input shaft oil seal from clutch housing. Using a snap ring removal tool/ flat end screw driver, remove the input shaft snap ring from the front housing. Using a snap ring removal tool/ flat end screw driver, remove the counter shaft snap ring from the front housing. Using open end spanner, detach the front housing from the intermediate plate. Using a roll punch & hammer, remove the pin spring dowel from the 1st & 2nd shifter fork & rail assembly. Using a roll punch & hammer, remove the pin spring dowel from the 3rd & 4th shifter fork & remove fork rail assembly from intermediate plate. By using snap ring removal tool, expand the output shaft snap ring and release the output shaft from intermediate plate. Using a mallet tap and remove the intermediate plate. Remove the counter shaft assembly. Remove the output shaft assembly from the input shaft assembly. Remove the pilot bearing & Synchro ring from input shaft. Using a circlip plier, remove the circlip from input shaft. By Using a puller (SKF TMBS 150E ) remove the DGBB from input shaft. Using a circlip plier, remove the circlip from counter shaft front end. By using a puller (SKF TMBS 150E) remove the DGBB from counter shaft front end. By using a puller (SKF TMMR 160F) remove the DGBB, 6th drive gear bush & thrust washer from counter shaft rear end. Using a puller (SKF TMBS 150E) remove the 1st driven gear, 2 nd driven gear, 1st & 2 nd synchro pack along with output shaft DGBB & 6th driven gear Engage puller legs in the 2nd driven gear. Remove in the sequence of 6th driven gear, output shaft DGBB, 1st driven gear with bush, 1st driven gear NRB, 1st & 2nd synchro pack, 2nd driven gear. Remove the 2 nd driven gear NRB. Using a circlip plier remove the circlip from the output shaft. Remove the 3rd & 4th synchro studs & sleeve. Using puller (SKF TMMR 350F) remove the 3rd & 4th synchro hub & the 3rd driven gear assembly. Remove the 3rd driven gear NRB. Shift Control Components ",
+ "file": null,
+ "display_order": 145
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110195.jpg",
+ "display_order": 146
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check contact and sliding surfaces of shifter fork & rails for wear, scratches, projections and other damage. Gear Components ",
+ "file": null,
+ "display_order": 148
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110196.jpg",
+ "display_order": 149
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Check shafts for cracks, wear and bend. Check gears for excessive wear, chips and cracks. Synchronizers ",
+ "file": null,
+ "display_order": 152
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110198.jpg",
+ "display_order": 153
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Check spline portion of coupling sleeves, synchronizer hubs, and gears for wear, chips, and racks. Check ring for cracks and deformation. Check struts for wear and deformation. Bearings ",
+ "file": null,
+ "display_order": 155
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110199.jpg",
+ "display_order": 156
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Make sure all bearings roll freely and are free from noise, cracks, pitting or wear. Remove the gear shifter level knob with spring and 4WD selection knob. Using trim removal tool, remove the Gear selection rod cover with trim. Using a screw driver , loosen and remove the gear selection rod cover mounting screw and detach boot from trim. Install in reverse order of removal. Transmission Oil \u2013 Replace ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Transmission Oil - replace.mp4",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Transmission Oil \u2013 MAHINDRA \u201cMAXIMILE SYNTEC F2\u201d New Generation Genuine Transmission Fluid. Capacity \u2013 2.25 Litres. Position the vehicle on a 2 post /4 post lift Using a 8 mm square bit spanner, loosen and remove the filler plug. Using a 8 mm square bit spanner, loosen and remove the drain plug & allow the oil to drain out completely. Place a tray or drain oil collecting bin under the drain plug to collect the oil. Install the drain plug. Torque tighten the drain plug to specified value. Always replace the drain plug washer with a new one. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Fill recommended oil using an oil filling machine or by clean transparent pipe attached to the mechanical hand pump. Ensure that the oil level is up to lower most point of the filler plug. Refit the filler plug. Torque tighten the filler plug to specified value. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Recommend to use only Mahindra 'MAXIMILE SYNTEC F2' new generation genuine transmission fluid. In case of genuine oil non-availability, manual transmission oil meeting API GL-4 SAE 80W-90 specification is suggested. This alternate oil or other brand may not provide equivalent performance of recommended genuine oil. Drain Interval should be reduced as 20,000 km. Never mix two different oils. For additional information refer to Roof Speaker - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Roof Tweeter LH & RH. For additional information refer to Roof Tweeter - R&R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240016.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240018.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a trim removal tool pull out center bow trim and disconnect roof lamp electrical connector.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290057.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the sound bar electrical connector.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290058.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew sound bar mounting bolts.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W349.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290059.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Detach the Wiring Harness from routing and remove from the sound bar assembly.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the Wiring Harness for any physical damage. Replace if found.Inspect the connector for any damage.",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 300,
+ "sys_id": "THAR.LX-0004-Infotainment Assembly",
+ "subsys_id": "THAR.LX-0004-Infotainment Assembly-MIC",
+ "systems": "Infotainment Assembly",
+ "sub_systems": "MIC",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A290008.jpg",
+ "myid": 1418,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-MIC-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290008.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/15689.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/15690.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Driver Sun Visor. For additional information refer to Driver Sun Visor - R&R Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Co-Driver Sun Visor. For additional information refer to Co-Driver Sun Visor - R&R Section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280010.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280011.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using Torx screw driver, Unscrew Centre bow trim mounting screw and detach the bow trim. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 5 \u00b1 0.5 Nm",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280012.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the MIC electrical.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280013.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280009.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the MIC from Centre bow trim.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the MIC unit for any damage.
Remove the clutch pedal box assembly. For additional information refer to Clutch Pedal box Assembly - R &R; section. Loosen the sensor lock nut with the help of 13 mm open end spanner. Insert a 2 mm spacer in the gap between magnetic holder and sensor body. Using a 12 mm open end spanner, adjust the magnetic holder till it touches the surface of spacer, thus maintain 2 \u00b10.5 mm gap between sensor body and magnetic holder. Tighten the sensor lock nut. For additional information refer to Clutch Pedal box Assembly - R &R section . ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1007,1143",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "After completing the clutch sensor setting, connect i-SMART and navigate to THAR \u2013 THAR_BS6. Select \u201cEMS\u201d in the ECU List. Click on \u201cLIVE DATA\u201d and select \u201cDriveability\u201d. Release the clutch pedal fully, the value of clutch status should be \u201c64\u201d. Press the clutch pedal to 10%, the value of clutch status should be \u201c65\u201d. Press the clutch pedal fully, the value of clutch status should be \u201c81\u201d If the clutch status value is not changing according to different clutch pedal position, re-adjust the clutch sensor. Check the hose joint at reservoir and clutch master cylinder (CMC) inlet hose connection for any leak and proper fitment. Check clutch master cylinder bundy tube connection for any leak and proper fitment. Check clutch bundy tube connection to concentric slave cylinder and bleeding nipple for any leak.
\u2022 In case fluid reservoir replaced, brake and clutch system needs bleeding.
\u2022 Use the same brand fluid for top up; do not top up brake fluid from used and unsealed brake fluid container.
\u2022 The Brake fluid reservoir cap/ container should not be opened with dirty hands.
\u2022 Avoid direct water spray on reservoir while washing engine compartment.
\u2022 Always use Mahindra \"Maximile DOT 4\" genuine Brake fluid.
\u2022 If Maximile DOT 4 brake fluid is not available and in emergency conditions, use Brake Fluid Meeting SAE J1703 FMVSS NO.116 DOT 4 OR IS 8654 TYPE-2 Specification. Change it at 30,000 km or 2 years whichever is earlier.
",
+ "file": null,
+ "display_order": 10
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 63,
+ "sys_id": "THAR.LX-0004-Clutch",
+ "subsys_id": "THAR.LX-0004-Clutch-Troubleshoot - Clutch",
+ "systems": "Clutch",
+ "sub_systems": "Troubleshoot - Clutch",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1458,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Troubleshoot - Clutch-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Trouble Shooting",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Unless the cause of a clutch problem is extremely obvious, accurate problem diagnosis will require a road test to confirm whether the problem exists or not. During the road test, drive the vehicle at normal operating speeds, shift the gears and observe the clutch action. If chatter, grab, slip or improper release is experienced, check clutch free pedal play, clutch fluid leakages, also do clutch bleeding, if the problem still persists, then remove & inspect the suspected parts. However if problem is noise or hard shift then the problem may not be in clutch only but also with the transmission or the drive-line If any obvious cause is found, correct the same before proceeding to the next step. If the clutch slip is suspected then drive the vehicle in 1st or 2nd gear at the top speed(corresponding to the gear). Keeping the accelerator fully pressed; slowly apply the brake with your left feet. If the engine stalls then the clutch is not slipping. To find out the actual root cause of the problem, the failed parts needs to be examined. Fluid contamination is the most frequent cause of clutch malfunction. Oil, water on the clutch contact surface will cause faulty operation viz. slip, grab, and judder. During inspection check if any parts in the clutch are coated with oil or water splash from road. Oil contamination indicates a leak at either engine rear oil seal or transmission input shaft. The oil leaks from either of these areas will normally coat the housing interior or clutch cover or flywheel. Heat buildup due to slippage between the clutch plate and the flywheel or the pressure plate can result into the leaked oil literally getting baked. Visually this will result in a glazed residue varying from amber to black. Roads splash contamination will mean that the dirt water is entering the clutch housing either due to loosen bolt or torn rubber boot. To find out the actual root cause of the problem, the failed parts needs to be examined. The clutch housing has to be aligned with the engine so that the input shaft is aligned with the crankshaft. Absence of this alignment results in clutch noise, incomplete release of the clutch plate. It can normally be judged by uneven wear of the finger and pilot bearing. In severe case it can also damage the spline of the input shaft and clutch hubs well as the clutch splines The clutch component i.e. the clutch plate, flywheel and the pressure plate have to be aligned with the crankshaft and the transmission input shaft. Misalignment caused by run outs/ warpage will cause clutch to grab judder as well as improper release (also manifesting as hard gearshift).. Normally the clutch housing misalignment is a result of Incorrect seating on the engine/transmission Missing alignment dowel holes. Loose or missing mounting bolt. Mounting surfaces that are damaged/ not parallel A noisy gearshift operation especially in 1st and 2nd gear can be due to clutch not getting disengaged completely. To check, turn the engine OFF, shift the gear lever to 1st or 2nd gearand then jack up the rear axle till both the wheels gets lifted enough from the ground Now press the clutch pedal completely and start the engine, the wheels should not be spinning after that slowly release the pedal till it has moved about 10 mm, the wheel should still not be spinning. If some spinning is noticed then it indicates improper lift of the pressure plate Do clutch bleeding and, then check for the pressure plate lift. To check the clutch housing misalignment bell housing run out will also need to be checked. If the clutch slip is suspected then drive the vehicle in 1st or 2nd gear at the top speed(corresponding to the gear). Keeping the accelerator fully pressed; slowly apply the brake with your left feet. If the engine stalls then the clutch is not slipping. For additional information refer to Transmission Assembly With Transfer Case \u2013 R &R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Put the dust cap/cotton cloth in CSC nozzle port during clutch or transmission service. Pull the locking clip outwards using a small flat end screw driver and disconnect concentric slave cylinder upper part of bleeder. using a 12mm socket spanner remove concentric slave cylinder mounting bolts. Torque : 25\u00b13.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove concentric slave cylinder assembly. Install in the reverse order of removal. Carry-out clutch circuit bleeding. For additional information refer to Clutch Fluid Air Bleeding Procedure. Inspect clutch slave cylinder for any leakages. Check the clutch slave cylinder Axial movement (Up & down) & bearing rotational movement (Right & left) for any abnormality. Inspect clutch slave cylinder boot condition for any damages. Inspect clutch slave cylinder mountings for any damages. Assemble the extension shaft and flat head to the push rod (Push end) of the Push & pull gauge. Switch OFF the Push & Pull gauge and adjust the gauge dial to zero. Now switch ON the gauge. Ensure engine is in running condition at idle speed Position the push & pull gauge at the centre of the clutch pedal pad with gauge\u2019s flat surface touching the pedal pad surface in parallel Push the gauge by holding the gauge at the sides (as shown the figure) till the pedal moves down, stop before the pedal hits the bottom stopper Note the peak values on the push & pull gauge during the clutch pedal travel. Repeat the procedure for another 2 times and record the peak values. The average of the three values would be the pedal effort in Kgf. New clutch assembly 9 -12 Kgf (88 -118N). The maximum allowable clutch pedal effort is 17 Kgf (167N) Max. The flywheel run out needs to be checked whenever misalignment is suspected. Flywheel run out should not exceed 0.40 mm. To measure the run out, mount the base of the magnetic dial gauge on the block and then locate the dial gauge\u2019s needle on the outer surface of the flywheel and rotate the flywheel. Some of the common reasons for excessive run out are - Heat warpage. Improper machining. Incorrect bolt tightening. Foreign material on crankshaft flange or flywheel. Improper seating on crankshaft. If the flywheel has been removed for resurfacing or replacing the pilot bearing then while fitting it back ensure that: No dirt and grease present on the mounting face (it can cause cocking & run out). The flywheel bolts have been replaced. Torque tightened as per sequence and perform angular torquing as per the specifications. Absence of any of the above mentioned activities, may result in bolt loosening causing flywheel run out. The pilot bearing is mounted in the crankshaft and supports and locates the input shaft of the transmission. Use of a rolling bearing in place of the conventional bush, reduces the rolling resistance. However it should be noted that because of the bearing, it gives less leeway during assembly procedure. Remove the clutch pressure plate & disc . For additional information refer to Clutch Pressure Plate & Disc - R&R; section. Using a MST 543 - Extractor flywheel bearing, remove the Flywheel Pilot Bearing. Refit the Flywheel Pilot Bearing by using MST 0312CBH0001ST - Flywheel Pilot Bearing Installer. Refit the clutch pressure plate & disc . For additional information refer to Clutch Pressure Plate & Disc - R&R; section . Inspect the pilot bearing for any damage, crack. Replace if found any. For additional information refer to Clutch Pressure Plate & Disc - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Lock the flywheel using MST 0307ABH0001ST \u2013 Flywheel Locking Tool. Using 19 mm socket spanner, remove flywheel mounting bolts and detach the flywheel 50\u00b13 Nm + 60\u00b0\u00b11. Remove the flywheel assembly. Install in the reverse order of removal. Always replace flywheel mounting bolts with new one before installation. Tighten the flywheel as per sequence and torque tighten the bolts to specified value. 50\u00b13 Nm + 60\u00b0\u00b11\u00b0. Refill the clutch fluid and Carry-out clutch bleeding procedure. For additional information refer to Carry-out clutch bleeding procedure. Check Flywheel face-out and run-out. Check Flywheel Surface Thermal Cracks Condition. Check the flywheel ring gear for worn-out or damage For additional information refer to the transmission assembly with transfer case \u2013 R &R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Lock the flywheel using MST 0307ABH0001ST \u2013Flywheel Locking Tool. Using a 12 mm socket spanner, loosen and remove clutch cover assembly mounting bolts. Insert MST 0801BUA0001ST \u2013 Clutch Disc Aligner Tool, before loosening the clutch cover bolts to prevent clutch plate falling down and getting damage. Torque : 25 \u00b1 5Nm. ",
+ "file": "/files/W4A100085.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the clutch cover assembly along with the clutch disc. Detach the clutch disc from clutch cover assembly. Install in the reverse order of removal. While Installation, the projected part of clutch plate should come towards transmission side only, false installation can lead to clutch plate damage. While Installation, Using MST 0801BUA0001ST \u2013 Clutch Disc Aligner Tool, align the clutch cover assembly and clutch disc and fix the clutch cover assembly with the help of mounting bolts. Carry-out clutch circuit bleeding. Check for abnormal wear in finger, pressure plate. Check pressure plate face-out and run-out. Check thickness of clutch plate, replace if found below MIN value. For additional information refer to Clutch Pedal Assembly - R &R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step 1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1007,1135",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket and ring spanner loosen and remove the Clutch Pedal Pivot Shaft nut and bolt. Remove the pedal pivot bolt and remove the pedal shank from the clutch pedal box. Using a nose plier, pull-down the double torsion Spring downwards and detach from pedal box and then gently pullout spring. Install in the reverse order of removal. Check return spring for proper stiffness. Check the Clutch Pedal Shank & Return Spring for any damage, crack. Replace if found any. Using a flat end screw driver pull the bleeder lock and pull-out the clutch bundy tube upward from bleeder to drain the clutch fluid. Keep a tray beneath, pull-out the clutch bundy tube and collect the drained fluid in the tray. Press the clutch pedal gently for draining the entire fluid. Collect the fluid drained in a tray. Avoid spilling on floor. Drain the complete brake fluid. Connect the bundy tube back and press locking clip to lock the bundy tube. Ensure the bundy tube connected back and locking clip locked the bundy tube in its position. Fill recommended brake fluid up to MAX mark on brake fluid reservoir Press and release the clutch pedal gently to full stroke a few times for the fluid to enter completely in the circuit. Remove bleeder plug cap from clutch operating slave cylinder pipe. Attach a vinyl tube to bleeder plug and insert the other end into container. Ensure that the other end of the tube is fully immersed in the bottle having clean clutch /brake fluid. If the bleeding operation is done without connecting a tube and in the open air then the chance of air trapped in the system is high. Ensure that the other end of the tube is fully immersed in the bottle having clean brake fluid. Press and release the clutch pedal 3-4 times slowly to the full stroke and hold the pedal in depressed condition. Using 11 mm open end spanner, rotate the bleeder screw by 90 degree in anticlockwise rotation and allow all the air bubbles to escape into the container. Bleeding plug to be in opened condition during bleeding process only. Remaining time it should be in closed position. Fluid starts flowing through the transparent tube into the container. Tighten the bleeder screw as soon as there is no air bubbles visible in the transparent tube. Repeat this operation until there are no more air bubbles in hydraulic line. Ensure sufficient fluid level in reservoir throughout the bleeding procedure. Remove the transparent tube. Then attach bleeder plug cap. Check fluid level in reservoir, maintain brake fluid at MAX level mark. Close the reservoir cap back and tight properly. Check and ensure proper working of clutch. Ensure to check any leakage in the bundy tube connector & bleeding plug cap, if leak found ensure to fit properly the bundy tube connector & bleeding plug cap. If pedal sponginess is present do the entire bleeding procedure again. Check clutch pedal for sponginess. If found spongy, repeat the entire procedure of bleeding Check and ensure there is no leakage from pipes and joints. Do not spill brake fluid on the vehicle, it may damage the paint, if the brake fluid does contact the paint, wash it off immediately with water. Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. At all times during the bleeding process, it has to be ensured that the fluid level in the reservoir does not drop below minimum. The brake fluid reservoir cap should not be opened with dirty hands. Avoid direct water spray on reservoir while washing engine compartment. During the bleeding operation ensure the container and pipe used is of transparent for better visual. If Maximile DOT 4 brake fluid is not available and in emergency conditions, use Brake Fluid Meeting SAE J1703 FMVSS NO.116 DOT 4 OR IS 8654 TYPE-2 Specification. Change it at 30,000 km or 2 years whichever is earlier. At all times during the bleeding process, it has to be ensured that the fluid level in the reservoir does not drop below minimum. The clutch master cylinder push rod is connected to clutch pedal. The clutch master cylinder converts driver's foot effort to hydraulic pressure and transmits the pressure to the slave cylinder through clutch bundy tube. For additional information refer to Clutch Pedal box Assembly - R &R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1007,1136",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Detach clutch master cylinder(CMC) fluid inlet hose CMC end. Pull the lock clip upwards and detach clutch high pressure pipe CMC end. Carefully remove the clutch master cylinder. Install in the reverse order of removal. Carry-out clutch circuit air bleeding. For additional information refer to Clutch Fluid Air Bleeding Procedure. Inspect the clutch high pressure tube for any damage. Replace if found Inspect the Clutch Master Cylinder for any damage, crack. Cleck the fluid level in clutch fluid reservoir Fluid Level Low \u2013 Check the Fluid Leakage in Lines, Bleeder or CSC. Fix the leaks or replace the part/s. Then perform clutch bleeding and check the pedal condition Fluid Level is Ok Check the Clutch Pedal to Clutch Master Cylinder Link for damage Not Ok \u2013 Replace the Clutch master Cylinder and perform Bleeding OK Check Clutch master cylinder operation for internal leak Checking procedure \u2013 Disconnect the CMC outlet Hose CMC side, then hold the output with figure. Press the clutch pedal and feel the fluid get compress and experience the pressure, Not Ok \u2013 Replace CMC, CMC output pressure as per specification Check the Clutch Disc or Pressure plate condition, Clutch Disc & Cover Inspection Procedure , Clutch pressure plate Spring damage or clutch disc burn \u2013 Replace the Set and check the clutch pedal condition Using a star screw driver, loosen and remove the front splash shield mounting screw rivets from both the sides of vehicle. Remove the front splash shield both the sides from vehicle Using a 10 mm socket spanner, loosen and remove the front stone guard front mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250064.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen and remove the rear stone guard rear mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250033.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the stone guard mounting screw rivets. Remove the stone guard from the vehicle. Disconnect the fog lamp electrical connectors LH & RH sides. Pull and remove the front bumper winch cover clips and remove the panel. Using 10 mm socket spanner, Unscrew front bumper mounting nuts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290005.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscre front bumper bottom mounting bolts. Torque 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290006.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front bumper top side mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290007.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front bumper top centre mounting screw rivets. Remove the front bumper assembly from the vehicle. Install in the reverse order of removal. Inspect the front bumper assembly for any crack or damage. Replace if found. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Disconnect EMS ECU connector with routing clip. Disconnect engine oil pressure switch electrical connector with routing clip. Disconnect e-VGT electrical connector. Disconnect T4 temperature sensor electrical connector. Disconnect T5 temperature sensor electrical connectors. Disconnect Dosing Module electrical connectors. Disconnect DPF sensor electrical connector. Disconnect fuel metering Unit electrical connector. Disconnect fuel injector electrical connectors.(4NOS) Disconnect CAM phase sensor electrical connector. Disconnect Common rail pressure sensor electrical connector. Disconnect coolant temperature sensor electrical connector. Disconnect Glow Plug inter-connector Disconnect throttle valve actuator electrical connector. Disconnect engine speed sensor electrical connector. Disconnect alternator telltale electrical connector. Disconnect EGR module electrical connectors. Using 8mm socket spanner unscrew starter motor solenoid electrical connector. Torque : 2.5\u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A03C016.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A03C017.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Disconnect reverse switch electrical connector. Disconnect GNS electrical connector. Disconnect transfercase switch electrical connector Detach Engine WH on intake manifold side. Using a 10 mm socket spanner unscrew wiring carrier mounting nuts. Disconnect fuel filter electrical connector. Disconnect engine compartment to Engine WH inter-connectors (2NOS) and routing clips(2NOS). Disconnect MAP sensor electrical connector. Detach engine wiring harness from engine compartment. Install in the reverse order of removal. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Torque tighten the earth mounting nuts to specified values. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Remove HVAC Control Panel (Manual). Carefully pull the Telltale Bank from inside. Disconnect the Telltale Bank electrical connectors and 12 volt electric connector and remove the Assy from IP. Using star screw driver remove Telltale bank mounting screws. Torque : 1.5 \u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220131.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the telltale bank. Install in the reverse order of removal. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the telltale bank for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Using 10 mm socket spanner, Unscrew fuse box mounting bolts. Using 10 mm socket spanner, Unscrew fuse box mounting bolts. Torque : 4 .0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A05C046.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the RH side door to IP interconnector and holding clip. Disconnect engine compartment to IP RH side inter-connector and holding clips. Disconnect the MBFM electrical connectors. Using 10 mm socket spanner, Unscrew ground cable mounting nuts and detach the connectors. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A05C003.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Disconnect the ignition key barrel electrical connectors. Disconnect the HVAC assembly electrical connectors. Disconnect LH door electrical connector. Disconnect the IP to Roof wiring harness inter-connector. Disconnect LH side IP to engine interconnectors with holding clip. Using 10 mm socket spanner, Unscrew earth cable mounting nuts. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220111.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Remove the IP wiring routing clips from CCB. For additional information refer to Front LH Scuff Plate \u2013 R&R Section. ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1034,1439",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240037.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Detach the LH B pillar partially. Disconnect the Pre tensioner electrical connectors LH side. Disconnect the LH seat electrical connector and routing clips. Disconnect the Airbag ECU electrical connector. Using a 10 mm socket spanner, Unscrew earth cable mounting nut and disconnect the cable. Disconnect the parking brake switch electrical connector. For additional information refer to Front RH Scuff Plate \u2013 R&R section. ",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370043.jpg",
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Detach the RHS B pillar partially. Disconnect the Pre tensioner electrical connectors RH side. Disconnect the floor console inside wiring Harness routing clips. Disconnect the RH seat electrical connector and routing clips. Remove the wiring harness from vehicle. Install in the reverse order of removal. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness Torque tighten the earth mounting nuts to specified values. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Remove the Intake Manifold. Disconnect the interconnection glow plug to engine C 435 M connector. Disconnect the glow plug-1 C 39 connector. Disconnect the glow plug-2 C 38 connector. Disconnect the glow plug-3 C 37 connector. Disconnect the glow plug-4 C 36 connector. Remove the wiring harness from the engine compartment. Install in the reverse order of removal. Refit the Intake Manifold. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Remove A Pillar Upper Trim LH. Disconnect speaker electrical pigtail inter-connector. Detach MIC wire from routing. Detach roof wiring harness from routing clips. Disconnect IP to roof WH inter-connector and holding clip with routing clips. Remove IP TOP Cover with PAB Assembly LH. Detach WH routing clip and from vehicle. Install in the reverse order of removal Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Service Reminder Indicator Reset Procedure ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "In the instrument cluster, the service reminder alert will start popping up in the cluster screen at 200 kms before the actual kilometers at which the service is due. This will continue at every ignition cycle. It is necessary to reset the service reminder once the service is rendered to the vehicle. If not reset, the service alert will continue to pop up at every ignition cycle, till it is reset by using recommended procedures. Press the OK button on Driver side switch bank and simultaneously turn the ignition ON. Release the OK button within 5 seconds after ignition on. Check and ensure that the service reminder alert is OFF in the cluster. The above procedure would reset the Service Reminder Alert till the next scheduled maintenance. Service reminder alert is provided with the intent of reminding the customer about a pending service visit hence, perform this SOP only after the vehicle has actually undergone servicing. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Disconnect the MBFM electrical connectors. Detach the IP wiring harness holding clip from MBFM bracket. Using 10 mm socket spanner, Unscrew MBFM bracket mounting bolts from BIW and remove MBFM with bracket from the vehicle. Torque : 6.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370060.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370057.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew MBFM mounting bolts from the bracket and detach the MBFM. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the MBFM and bracket for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Using star screw driver, Unscrew the DEF tank bottom protection cover mounting screws and remove the cover. Disconnect the reduction agent temp sensor C 535 connector. Disconnect the magnetic coil & reduction agent surge pump C 276 connector. Disconnect the chassis C 707 M interconnector. Remove the Wiring Harness from routing clips and detach from the DEF tank. Install in the reverse order of removal. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Disconnect the HFM sensor C 19 connector. For additional information refer to Spash shield \u2013 R&R section. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C045.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect EMS ECU connector with routing clip. Using 10 mm socket spanner remove earth cable mount nut and a routing clip. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C046.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove LH Side marker lamp connector with a routing clip. Disconnect LH side turn lamp electrical connector. Disconnect LH DRL connector and detach grow mat to take out connector. Disconnect LH Head lamp and levelling motor(HLLD) electrical connectors. Disconnect Horn electrical Connectors (2Nos) and 3 routing clip. Disconnect Electrical fan electrical connector. Disconnect LH Crash sensor electrical connector. Disconnect fog lamp electrical connector routing clips. Disconnect ambient temperature sensor electrical connector. Using 10 mm socket spanner, Unscrew engine compartment fuse box mounting bolts. Torque : 10\u00b11 Nm ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370065.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using 8 mm socket spanner remove fuse box positive cable mounting nut and disconnect from battery fuse connection. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370017.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Disconnect engine compartment to engine wiring harness inter-connector. Detach WH routing clips from fire wall. Using 10 mm socket spanner unscrew earth cable mounting nut from fire wall and detach cable. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C005.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Disconnect NOx Sensor electrical connector. Remove Air Cleaner Assembly. Using 10 mm combination spanner Remove LH fender ground mounting nut and detach it. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C003.jpg",
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Disconnect brake fluid level sensor electrical connector. Disconnect ABS ECU electrical connector. Disconnect HVAC triple pressure switch electrical connector. Disconnect EWP electrical connector and routing clip. Disconnect RH Crash sensor electrical connector. For additional information refer to Splash Shield Front RH - R&R section. ",
+ "file": null,
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C009.jpg",
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Description",
+ "content": "Disconnect RH fog lamp electrical connector routing clips. Disconnect RH head lamp electrical connector. Disconnect RH head lamp levelling motor(HLLD) electrical connector. Disconnect RH side marker lamp electrical connector with a routing clip. Disconnect Front RH indicator and DRL connector and detach grow mat to take out connector. cxc Using 10 mm socket spanner unscrew earth cable mounting nut from RH fender and detach cable. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370030.jpg",
+ "display_order": 80
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370029.jpg",
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "Description",
+ "content": "Detach WH routing clips from fender. Disconnect engine compartment to IP electrical connectors. Disconnect accelerator pedal electrical connector. Disconnect brake switch electrical connector with a routing clip. Disconnect clutch sensor electrical connector. Detach WH routing clips and take out wiring. Detach WH from inside to outside . Remove the scuttle Grill. Disconnect Wiper motor electrical connector and a routing clip. Disconnect IP to Engine compartment wiring harness inter-connectors. Disconnect engine compartment to chassis WH inter-connector. Disconnect washer tank electrical connector. Using 12 mm socket spanner remove fuel filter mounting bolts and partially detach it. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 110
+ },
+ {
+ "step_name": "Step-48",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A3700077b0936.jpg",
+ "display_order": 111
+ },
+ {
+ "step_name": "Step-48",
+ "content_type": "Description",
+ "content": "Detach Engine compartment Wiring Harness from engine compartment. Install in the reverse order of removal. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Torque tighten the earth mounting nuts to specified values. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. For additional information refer to edisconnect stone guard - R&R section. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A16C005.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the Front RH wheel speed sensor C 361 connector. Detach wiring harness routing clips on front cross member. Disconnect the e-disconnect motor C 231 connector. Disconnect the front LH wheel speed sensor C 360 connector. Detach wiring harness routing clips on chassis. Disconnect engine compartment WH to Chassis WH inter-connector. Detach routing clips on chassis LH side. Disconnect the chassis to FDM C 485 F inter-connector. Disconnect the rear LH wheel speed sensor C 362 connector. Detach routing clips on chassis rear LH side . Disconnect the chassis to bumper C 434 F inter-connector. Disconnect the DEF pigtail C 707 F inter-connector. . Detach rear chassis routing clips. Disconnect the rear RH Wheel Speed Sensor C363 connector. Detach routing clips on chassis rear RH side. For additional information refer to Rear LH Tail Lamp Assembly \u2013 R&R section. ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A16C014.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner unscrew LH tail lamp earth cable mounting nut and detach it. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A37001362d0d3.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370015.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Detach routing clip and grow mate. For additional information refer to Rear RH Tail Lamp Assembly \u2013 R&R section. ",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A16C015.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner unscrew RH tail lamp earth cable mounting nut and detach it. Disconnect the tail lamp RH C 153 connector. Disconnect the tail lamp LH C 154 connector. Disconnect the chassis to tail gate-2 C 708 F inter- connector. Disconnect the chassis to tailgate-3 C 709 F inter-connector. Remove the chassis wiring harness from vehicle. Install in the reverse order of removal. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Torque tighten the earth mounting nuts to specified values. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Remove the HVAC Control Panel. Open the glove box and remove the glove box by detaching the lock. Remove the Driver side IP panel assembly. Disconnect the HVAC control panel C 720 connector. Disconnect the intake actuator C 722 connector. Disconnect the blower motor C 721 connector. Disconnect the blower resistor C 723 connector. Disconnect the thermo amplifier C 724 connector. Disconnect the HVAC unit C 117 M connector. Disconnect the blower switch C 720A connector. Using 10 mm socket spanner, loosen and disconnect the HVAC ground G 2 connector. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Remove the wiring harness separately. Install in the reverse order of removal. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Torque tighten the earth mounting nuts to specified values. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Remove the sensor from the routing slot. Take out the sensor and disconnect the electrical connector. Install in the reverse order of removal. Inspect the ambient temperature sensor for any external damage, If any replace it. Using a star screw driver, Unscrew hard top quarter glass frame mounting screws from the rear window. Pull - out the glass beading from Quarter Glass. Carefully push from inside to outside and remove the rear window from the vehicle. Install in the reverse order of removal. While Installation always replace with New frame mounting screws. Inspect the hard top quarter glass for any damage/crack etc. Replace if found any. Inspect the hard top quarter glass mounting fasteners for any damage. Replace the fasteners if required. Remove the hard top assembly. Inspect the Hard-Top windshield upper frame Seal and replace if needed when the seal loses its softness or if found any damages. Follow the below steps for replacement of Hard-Top windshield upper frame Seal Remove the X-mas tree clips by trim remover from over the roof rail outer frame. Then pull the seal by manually, due to this seal has fixed with two-way pasting tape. Clean the surface by digresses cloth. Peel the sticker label sheet from the new Seal, then paste on the roof rail outer frame followed by press the X-mas tree clips. The Seal must be replaced along with X-mas tree clips, when the seal loses its softness or if found any damages, don't reused the X-mas tree clips. This seal is for preventing the water leakage and wind noise only. Seal coming with Two-way pasting tape. Install in the reverse order of removal. Remove the centre roof bow trim. Open the top cover and Using a 14 mm socket spanner, loosen and remove the seat belt upper mounting bolt. Torque :38 \u00b16 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A210069.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A210071.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the upper trim from vehicle. Install in the reverse order of removal. Inspect the B-pillar upper trim for any damage/crack/cut etc. Replace if found any. Inspect the B-pillar upper trim fasteners for any damage. Replace the fasteners if found any damage. Remove Side window RH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Remove Side window LH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Unzip the tail gate window, detach the tail gate bar locking from rear RH & LH belt rails remove the tailgate window. Unhook the \u2018C\u2019 pillar cover from rear RH & LH belt rails and fold the cover at top of the soft top. Using a T30 socket spanner, loosen and remove the belt rear rail Mounting bolts and remove the belt rail from the vehicle Follow the same procedure for LH side. Using a T30 socket spanner, loosen and remove the belt center rail Mounting bolts and remove the belt rail from the vehicle. Follow the same procedure for LH side. Torque : 5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/convertible2.PNG",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using T30 socket spanner, loosen and remove the belt vertical rail mounting bolts and remove the belt rail from the vehicle. Follow the same procedure for LH side. Torque : 5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W354.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the belt corner rail from the vehicle.. Follow the same procedure for LH side. Torque : 5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/convertible3.PNG",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using T30 socket spanner, loosen and remove the belt door rail mounting bolts and remove the belt rail from the vehicle. Follow the same procedure for LH side. Torque : 5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/convertible4.PNG",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/convertible5.PNG",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/convertible6.PNG",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/convertible7.PNG",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the Seal/rail for any damage/crack/cut etc. Replace if found any. Remove the Hardtop Assembly. Remove the Seal from the vehicle. Install in the reverse order of removal. Inspect the Front Lateral trim for any damage/crack/cut etc. Replace if found any. Inspect the Front Lateral trim mounting legs for crack/bend etc. Using a trim removal tool pull out center bow trim and disconnect roof lamp electrical connector. Remove the centre bow trim from the vehicle. Remove the roof lamp from bow trim. Install in the reverse order of removal. Inspect the trim for any damage/crack/cut etc. Replace it if found. Remove the B Pillar Upper Trim. Using a 10 mm socket spanner unscrew Grab handle mounting bolts. Torque : 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A240065.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A240066.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner unscrew front lateral trim mounting bolt. Torque : 2 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the Front lateral trim. Install in the reverse order of removal. Inspect the Front Lateral trim for any damage/crack/cut etc. Replace if found any. Inspect the Front Lateral trim mounting legs for crack/bend etc. Using a T40 Torx Socket spanner unscrew centre bow trim mounting screws. Torque : 5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A240011.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a trim removal tool carefully detach the trim and remove electrical connector. Detach the MIC carefully from the trim. install in the reverse order of removal. Inspect the trim for any damage/crack/cut etc. Replace it if found . Remove Front Roof Bow Trim. Remove Front Lateral Trim. Using a 10 mm socket spanner unscrew A pillar trim mounting bolt. Torque : 2 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A240032.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the A pillar upper trim from vehicle. Install in the reverse order of removal. Inspect the A-pillar upper trim for any damage/crack/cut etc. Replace if found any. Inspect the A-pillar upper trim mounting legs for crack/bend etc. When the engine is stopped and the ignition switched off, the battery feeds accessories which are directly connected to battery, such as alarms, clock, radio code and certain computers that operate continuously. Dark currents are considered normal if they do not exceed a few tens of milli amperes. If the value is more than that, one or more permanent electrical component is drawing too much current. They can be isolated by withdrawing the fuses one by one until the faulty circuit is identified. A multi-meter is the best tool for these measurements. A current clamp cannot accurately measure currents of less than 1 A. The measurement must be taken at the battery itself. Turn all accessories OFF. Switch OFF the ignition and remove the key. Close all doors and windows. Wait for minimum 3 Minutes and then do the checking procedure. In multi-meter, current selection should be in milliampere. Set the current measuring range of the ammeter to 10 A. Disconnect the negative terminal from the battery. Connect the positive terminal of multimeter (Red probe) with the negative terminal removed from the battery and connect the negative terminal of multimeter (black probe) with negative pole of the battery. Read the value in multi-meter. (For MT Variants \u2013 7 mA (Max) & for AT Variants \u2013 12 mA (Max)) , check for any:.An alternator consists of two main components rotor and stator. The rotor is connected directly to the Over running Alternator Pulley (OAP). The drive belt drives the pulley by taking power from engine, which in turn spins the rotor. The stator is mounted to body of the alternator and remains stationary. The rotor is an electromagnet which rotates past the stator windings, and thus the rotor induces an alternating current in the stator. The induced current is proportional to the energizing current of the electromagnet. Alternating current cannot be used to recharge the battery, so it must be converted to direct current before use. The voltage regulator incorporated in the alternator adjusts the electricity produced to the requirements of the battery and the vehicle. If the alternator output voltage is too low, the regulator increases the energizing current in the rotor windings. If the output voltage is too high, the regulator decreases the energizing current in the rotor windings. Voltage regulator ensures the alternator voltage upper limit to 14.0 V. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Using 10 mm socket spanner, Unscrew degassing tank mounting bolts and partially detach the degassing tank and keep aside. (Without detaching the hoses). Torque : 4.5\u00b10.5 Nm. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen and remove the engine fead cover mounting bolts. Torque : 11 \u00b1 1Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the engine fead cover from engine compartment. Using 14 mm ring spanner, turn the hexagon knob in the belt tensioner Anti clockwise direction to release the tension and detach the accessory belt. Using 14 mm socket spanner, loosen and remove the auto tensioner mounting bolt then remove the auto tensioner to access the alternator mounting. Torque : 45\u00b13 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect the alternator electrical connector. Remove alternator positive cable cover. Using 13 mm socket spanner, loosen and remove the alternator positive cable nut. Torque : 15 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 12 mm socket and ring spanner, Remove the alternator top mounting bolt and nut. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the alternator bottom mounting bolt and nut. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080014.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Carefully remove the alternator from engine compartment. Install in reverse order of removal. Check alternator pulley for any damage. Check free play of alternator pulley. Check alternator drive belt for any damage. If found replace with a new one. Hydrometer is a float-type device used to determine the State-of-Charge by measuring the specific gravity of the electrolyte in each cell. It is an accurate way of determining a battery's state of charge and weak or dead cells. Wear suitable eye protectors (goggles). With the help of a flat end screw driver, remove the vent caps or covers from the battery. Squeeze the hydrometer bulb and insert the pickup tube into the cell close to the battery positive terminal. Slowly release the bulb to draw in only enough electrolyte to cause the float to rise. Do not remove the tube from the battery. Read the specific gravity indicated on the float. Be sure the float is drifting free, and does not contact with sides of the barrel. Read the hydrometer at eye level. Disregard the slight curvature of liquid on the float. Note the reading for all the cells. The difference in specific gravity readings should not be more than 0.05. The specific gravity for fully charged battery is as follows: . AMARON - 1.270 \u00b1 0.010 at 27\u00b0C. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "Specific gravity readings ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080030.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "By measuring the specific gravity of the electrolyte, you can identify whether the battery is fully charged, requires charging, or must be replaced. Specific gravity varies with the temperature. If the electrolyte temperature is substantially above 27\u00b0 C add seven points (0.007) to the observed specific gravity reading for every 10\u00b0 C by which the actual temperature is above 27\u00b0 C. Deduct seven points per 10\u00b0 C where the observed reading is below 27\u00b0 C to obtain the temperature corrected reading at 27\u00b0 C. Inspect battery electrolyte specific gravity whenever required.
2. Open the bonnet and lock it in open position using bonnet stay rod.
",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Battery Health - Inspect",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080023.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Health Testing",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Connect the MDX - 650P battery tester to battery terminals connecting probes on the battery posts respectively. When you start a new test, the last test results in memory are overwritten. Remember to record or print the results if you need to retain them. Press the Enter button and confirm the BATTERY LOCATION by selecting the \u201cIN VEHICLE\u201d in the tester using navigation button Up or Down. . Press the Enter button and confirm the POST TYPE by selecting the \u201cTOP POST\u201d in the tester using navigation button Up or Down . Press the Enter button and confirm the APPLICATION by selecting the \u201cAUTOMOTIVE\u201d in the tester using navigation button Up or Down . Press the Enter button and confirm the BATTERY TYPE by selecting the \u201cREGULAR FLOODED\u201d in the tester using navigation button Up or Down . Press the Enter button and confirm the BATTERY STANDARD by selecting the \u201cJIS\u201d in the tester using navigation button Up or Down . Press the Enter button and get the recommended JIS Number value by pressing button Up or Down . Press the Enter button and perform the TESTING. Once the TESTING done, the initial battery result will be display. Press the PRINT button to get the hard copy print out. Disconnect the battery tester probes from battery terminals. Follow the below table for Battery Testing test results condition and remedial action: ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/batteryhealthcheckup12.png",
+ "display_order": 28
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 40,
+ "sys_id": "THAR.LX-0004-Charging System",
+ "subsys_id": "THAR.LX-0004-Charging System-Charging System Technical Spec",
+ "systems": "Charging System",
+ "sub_systems": "Charging System Technical Spec",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1122,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Charging System Technical Spec-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Battery Specifications",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/6042.png",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 38,
+ "sys_id": "THAR.LX-0004-Charging System",
+ "subsys_id": "THAR.LX-0004-Charging System-Checking Electrolyte Level",
+ "systems": "Charging System",
+ "sub_systems": "Checking Electrolyte Level",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A080023.jpg",
+ "myid": 1120,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Checking Electrolyte Level-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080023.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step 1",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step 2",
+ "content_type": "Description",
+ "content": "Check the electrolyte level. Add distilled water to all the cells which require water. Ensure the electrolyte level between MIN and MAX marks. Refit the vent plugs properly. Topping up should be done with distilled water only. . Never use normal water or mineral water to top battery electrolyte. . Vent holes should be clear. . Clean the terminals. . Tighten terminals to specified torques. Check battery electrolyte level whenever required. Do battery electrolyte level inspection when required. Verify the customers concern. Visually inspect the charging system for any noticeable signs of mechanical or electrical damage. If any obvious cause is found, correct the same before proceeding to the next step. Digital voltmeter checks the battery\u2019s open circuit voltage. Analogue meters do not show accurate readings and should be avoided. Turn ON the head lamp high beam for 30 seconds to remove any surface charge. Turn OFF the head lamp, disconnect the battery and connect the digital voltmeter across the battery terminals. Note the readings in the voltmeter. A fully charged battery will have an open-circuit voltage based on below table value. Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. . Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. , Before disconnecting the battery, check for the audible sound of EWP ON. Using 10 mm socket spanner, loosen battery positive cable mounting nut and disconnect the cable. Torque : 6 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, loosen and remove the battery holding clamp mounting nuts. Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the battery from the vehicle. Install in reverse order of removal.
2. Check for any cracked or broken cables/connections, and replace the cables if necessary.
3. Check for corrosion on terminals and dirt/acid on the battery case top. Clean the terminals and the battery case top with mixture of water and baking soda. A battery wire brush tool can also be used to clear heavy corrosion on the terminals. Prevent further corrosion by applying petroleum jelly to the outside of the terminals.
",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 218,
+ "sys_id": "THAR.LX-0004-en-SM-Restraint System",
+ "system_name": "Restraint System",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1019,
+ "active_status": true,
+ "Assets": [
+ {
+ "systemdisplayorder": 16,
+ "system_asset": "/files/Safety.mp4",
+ "active_status": true
+ }
+ ],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 219,
+ "sys_id": "THAR.LX-0004-Restraint System",
+ "subsys_id": "THAR.LX-0004-Restraint System-Passenger Airbag Module",
+ "systems": "Restraint System",
+ "sub_systems": "Passenger Airbag Module",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A210035.jpg",
+ "myid": 1336,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Passenger Airbag Module-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210035.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210045.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The Passenger Airbag Module is a bag within the module inflates to protect the passenger in the event of a collision severe enough to deploy the system and located on LH side of Instrument panel, above the glove box and its functioning is controlled by the airbag ECU. , Within the passenger airbag module is a squib which, when given the correct current by the airbag ECU, inflates the airbag by initiating a chemical reaction. In deployment, the airbag inflates within a fraction of a second and then deflates at a controlled rate as the passenger body regions; typically head and chest interact with airbag. Vents in the airbag control its deflation. Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Before disconnecting the battery, check for the audible sound of EWP ON Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Glove Box Assembly. Remove the IP grab handle cover. Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts. Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220024.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting screws. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220025.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle. Partially detach the door edge beading and using a trim removal tool, remove the IP LH side cover. By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt. Torque : 8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220066.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220077.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector. Take out the IP LH side top cover with Passenger air bag from the IP. Using a 10 mm ring spanner, loosen and remove the air bag mounting bolt from IP top cover. Torque :4.5\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210047.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210048.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Expand the PAB module holder both sides using screw driver and detach the PAB separately from IP top cover. Install in the reverse order of removal. Inspect the PAB module for any damage. Replace if found any. Inspect the PAB module connector for any damage. Inspect the PAB module trim for any damage. The Airbag ECU is installed on the floor panel under the floor console. It deploys the proper Airbag according to the signals from the impact sensors. This ECU communicates with other ECU\u2019s through CAN directly. Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Before disconnecting the battery, check for the audible sound of EWP ON Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Front console assembly. For additional information refer to Front Console Assembly R &R section. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Screenshot 2023-03-24 130741.png",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver remove the Airbag ECU Cover screw from airbag ECU. Disconnect the SRS/ Airbag ECU electrical connectors. Using a 10 mm socket spanner, loosen the SRS/ Airbag ECU mounting nuts on the floor panel. Torque :8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210053.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210054.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the SRS/ Airbag ECU from the body. Install in the reverse order of removal. Inspect the airbag ECU for any damage, replace if found any. Inspect the airbag ECU connectors for any damage. Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Before disconnecting the battery, check for the audible sound of EWP ON Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250193.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front splash shield lower mounting screws. Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts. Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield. Disconnect the front Crash sensor electrical connector. Using a 10 mm socket spanner, loosen and remove the front Crash sensor mounting bolt from the vehicle. Torque :8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210058.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the front crash sensor from the vehicle. Install in the reverse order of removal. Inspect the front crash sensor for any damage. Replace if found. The driver airbag module is located in the steering wheel and its function is controlled by the airbag ECU. A bag within the module inflates to protect the driver in the event of a collision severe enough to deploy the system. , The driver airbag module connects to the steering column wiring harness via a rotary coupler called as clock spring. Within the driver airbag module there is a squib which, when given the correct current by the airbag ECU, inflates the airbag by initiating a chemical reaction. In deployment, the airbag inflates within a fraction of a second and then deflate at a controlled rate as the driver body regions; typically head and chest interact with airbag. Vents in the airbag control its deflation Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Before disconnecting the battery, check for the audible sound of EWP ON Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Steering Column Shrouds. Turn the steering wheel to 90\u00b0 counter clockwise direction from the steering wheel straight position and using a screw driver press the RHS DAB lock then release the lock. DAB locks are made up of plastic, ensure to press the locks softly by screwdriver. Turn the steering wheel to 90\u00b0 clockwise direction from the steering wheel straight position and using a screw driver press the LHS DAB lock then release the lock. DAB locks are made up of plastic, ensure to press the locks softly by screwdriver. Gently pull-out the DAB module from the steering wheel. Using a small flat end screw driver release the lock of the DAB electrical connector, then disconnect the DAB and horn electrical connectors. While refit ensure wires are routed out of the snapping zones to avoid damage. Remove the DAB module separately. Install in the reverse order of removal. Inspect the DAB module for any physical damage. Replace if found any Inspect the DAB connector for any damage. Precautions to be followed: ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040221.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " Whenever an injector or ECU need to be replaced, the new injector\u2019s IQA code need to be written in to the ECU, using i-FLASH/ i-SMART. IQA code is engrave on the top of the injector. It is a 6 character alphanumeric code. Connect the transparent pipe to the drain plug outlet of the fuel filter assembly Using a Nose plier, rotate drain plug anticlockwise till the water starts flowing from the tube. Drain plug requires hand tight only; do not use any tool and avoid over tightening. Do not over tight the drain plug Rotate drain plug in clockwise directio to stop the flow as soon as water gets over and fuel flow starts. Tighten the drain plug. Start the engine and check for any leaks. Remove the engine top encapsulation cover. Using 10 mm socket spanner, Unscrew engine wiring harness carrier mounting stud from Cam cover and detach it partially. Press the lock and disconnect fuel control unit electrical connector. Using 17 mm open end spanner, Unscrew High pressure pipe mounting flare nut from common rail end. Using 19 mm open end spanner, unscrew High pressure pipe flare nut from injection pump end. Press the lock and disconnect fuel control unit inlet and outlet pipes. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Using nose plier release fuel return hose spring band clamp and detach hoses from fuel injection pump & FCU. Using 10 mm socket spanner, Unscrew fuel return line 'T' bracket mounting bolts. Using 12 mm socket spanner, Unscrew Cam box mounting bolts and remove the bolts. Rotate the Cam Box Assembly as direction shown in the image to access fuel high pressure pump mounting bolts. Using T30 socket spanner unscrew fuel high pressure pump mounting bolts and detach pump. Remove Cam box assembly along with FCU from engine. While taking out Cam box, ensure to move the tappet in upward direction by hand. Using 5 mm Allen socket spanner unscrew tappet roller guide bolt. Remove roller tappet from the cam box housing. Using 12 mm socket spanner Unscrew Fuel Control Unit mounting bolts and separate the CAM Box. Inspect the CAM box for any damage. Replace if found any. Refit Fuel Control Unit and install the mounting bolts. Tighten the bolts to specified torque value. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refit the roller tappet and install the guide bolt. Tighten the bolt to specified torque value. Torque : 20\u00b12 Nm ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011182.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Insert the roller tappet in correct orientation so that the locking pin will seat properly in the slot Position the Cam box on Intake cam shaft rear end. While Installing Cam box, ensure to move the tappet in upward direction by hand. Ensure to replace New Cam box gasket during Installation. Before Installation of Cam box mounting bolts, Rotate the Cam Box Assembly as direction shown in the image to install fuel high pressure pump mounting bolts. Position the fuel pump on Cam box and install mounting bolts. Tighten the mounting bolts to the specified torque value. While Installing the pump always replace the Gasket with a new one. While torque tighten the Pump mountings, hold the Cam box Assembly by second technician asshown. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011138.jpg",
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Rotate the Cam Box Assembly direction as shown in the image to original position. Install the Cam box mounting bolts.Tighten the bolts to the specified torque value. Torque : 25 \u00b1 3 Nm , Torque : 25 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010061.jpg",
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Heading",
+ "content": "Tightening Sequence ",
+ "file": null,
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install fuel return line 'T' bracket mounting bolts. Tighten the bolts to the specified torque value. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Refit fuel return hoses and lock it by spring band clamp. Connect fuel inlet tube quick coupler at pump end & FCU. Position the Fuel HP pipe and tighten the mounting on Common rail end to the specified torque value. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Position the Fuel HP pipe and tighten the mounting on FIP end to the specified torque value. Torque : 30 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 85
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Refit the engine wiring harness carrier mounting studs on Cam cover and torque tighten the studs. Torque : 8 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Connect the fuel control unit electrical connector. Refit the engine top encapsulation cover. Other observations ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "No error codes registered. In the live data the status of torque limitation, synchronization status and the state of staring system are correct If HP pipe is removed at the rail end then fuel can be observed. Parts Required ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Test tube with graduations, capacity 30 to 75 ml (Quantity : 04 Nos). Engine tube connection injection, Part Number : 9350042680, Length 310 mm (Quantity : 04 Nos.). The ID of the tube is important hence use only the part number specified. Remove engine top encapsulation cover from engine. Blow air around the injectors to remove the dust. Remove injector leak-off hose clips and then gently pullout and remove leak-off hose from injectors. Keep the removed leak-off pipe behind injectors. Do not remove overflow tube connection from the fuel return line \u2018T\u2019 joint. Insert the hose firmly in each injector and insert the other end in test tubes as shown in illustration below. (Use rubber band to hold the test tubes in stand). Images are only for representation. Actual image for this vehicle may vary. Start engine and keep it in idle. Collect fuel in test tube for one minute. Stop the engine, ignore first reading.Empty the test tubes & reconnect. If any test tube gets filled during the test, \u201cSTOP\u201d the test and replace that cylinder injector. Start engine & repeat test for exactly one minute. Observe the quantity of leakage fuel corresponding to each injector. If the leakage quantity of any injector is higher than 3 times the minimum of any three injector, then that injector is faulty. Replace the injector. Crank the engine for 30 seconds, the faulty injector's will show leakage quantity more than 3 times the minimum of any four injector Replace the defective injector's. Repeat the test with new replaced injector & confirm the resolution of for starting problem. Images shown is just for representation. The fuel tank is a reservoir for the fuel and incorporates the Fuel delivery module inside. Disconnect the fuel tank electrical connector and remove the FDM pigtail from the fuel tank. Remove the Fuel tank heat Shield mounting clamp from the tank. Using screw driver, loosen and remove the Fuel tank Bracket mounting clips from the tank. Remove the fuel supply and return hose quick coupler from the fuel delivery module. Remove the fuel supply and return hose from the fuel tank. Drain the fuel from the fuel tank and refill the fuel in new tank Install in the reverse order of removal. Always replace the O ring with a new one once FDM removed. Ensure the FDM top flange extension should be matched with the arrow mark on the fuel tank shell as shown in the above illustration. Using a suitable metal shaft and hammer, tap the FDM lock ring to get properly lock. Check the fuel tank for any damage and replace it if necessary. Check the tank ventilation hose for clog/debris. Check for free movement of float assembly without any restriction. This high pressure fuel line connects High pressure pump with common rail and supplies compressed high pressure fluid to common rail. Remove the engine top encapsulation cover. Using 10 mm socket spanner, Remove engine WH carrier mounting nuts and detach partially. Torque : 8 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 17 mm open end spanner loosen the mounting nut from the common rail. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 19 mm open end spanner, Unscrew fuel injection pump mounting. Torque : 30 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the high pressure pipe. Install in the reverse order of removal. Inspect the high pressure fuel pipes for any damage. Replace if found any. Inspect the high pressure fuel pipes for leakage, rectify if found. Fuel System Low Pressure Circuit Test Gauge. ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040231.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Fuel System Low Pressure Circuit Test Gauge tool kit is used to diagnose Fuel System Low pressure circuit related concerns only. Without removing FDM Assembly or Fuel Tank assembly from vehicle, we can able to check the Fuel Delivery Module supply pressure. Any blockages/ choke or air entrapment in Fuel line low pressure circuit can be diagnosed by using this Kit. Park the vehicle on level work bay Open the bonnet and lock it in open position using bonnet stay rod Press the lock and disconnect fuel control unit electrical connector. Using 10 mm socket spanner, Unscrew engine wiring harness carrier mounting stud from Cam cover and detach it partially. Using 17 mm open end spanner, Unscrew High pressure pipe mounting flare nut from common rail end Using 19 mm open end spanner, unscrew High pressure pipe flare nut from injection pump end. Disconnect fuel inlet tube quick couplers from fuel injection pump & FCU. All are quick fix connectors, press gently and remove it carefully to avoid seal damages. Using nose plier release fuel return hose spring band clamp and detach hoses from fuel injection pump & FCU. Using 10 mm socket spanner, Unscrew fuel return line 'T' bracket mounting bolts. Using 12 mm socket spanner, Unscrew Cam box mounting bolts and remove the bolts. Rotate the Cam Box Assembly as direction shown in the image to access fuel high pressure pump mounting bolts. Using T30 socket spanner unscrew fuel high pressure pump mounting bolts and detach pump. Remove Cam box assembly along with FCU from engine. While taking out Cam box, ensure to move the tappet in upward direction by hand. Inspect the FIP for any physical damage. Replace if found Position the Cam box on Intake cam shaft rear end. While Installing Cam box, ensure to move the tappet in upward direction by hand. Check the condition of Cam box gasket during Installation and replace if it damaged Before Installation of Cam box mounting bolts, Rotate the Cam Box Assembly as direction shown in the image to install fuel high pressure pump mounting bolts. Position the fuel pump on Cam box and install mounting bolts. Tighten the mounting bolts to the specified torque value. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040214.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "While Installing the pump always replace the Gasket with a new one. While torque tighten the Pump mountings, hold the Cam box Assembly by second technician as shown. Rotate the Cam Box Assembly direction as shown in the image to original position. Tightening Sequence ",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install the Cam box mounting bolts.Tighten the bolts to the specified torque value.",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm , Torque : 25 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install fuel return line 'T' bracket mounting bolts. Tighten the bolts to the specified torque value.",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040206.jpg",
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refit fuel return hoses and lock it by spring band clamp. Connect fuel inlet tube quick coupler at pump end & FCU. Position the Fuel HP pipe and tighten the mounting on Common rail end to the specified torque value. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Position the Fuel HP pipe and tighten the mounting on FIP end to the specified torque value. Refit the engine wiring harness carrier mounting studs on Cam cover and torque tighten the studs. Torque : 8 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Connect the fuel control unit electrical connector. Refit the engine top encapsulation cover. The injector uses electronically controlled solenoid actuation for precise control of injection. The solenoid injectors can inject very small quantities of fuel. The injection can be split into pilot, main and post injection. Or without pilot, post and only main injection. Each fuel injector is mounted directly above the piston within the cylinder head and is connected to the fuel rail by rigid steel lines that can withstand the high fuel pressure. The actuation of injectors is done by EMS ECU. Remove the Injectors 3rd & 4th HP Pipes. Using a 10 mm socket spanner, loosen and remove the engine WH carrier mounting nuts and detach partially. Torque : 8 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 17 mm open end spanner, loosen and remove the HPP pump to common rail at rail end. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 19 mm open end spanner , loosen and remove the HPP pump to common rail at pump end. Torque : 30 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove injector leak-off pipe lock clip and detach leak off pipes from the injector end. Disconnect Injectors 3rd & 4th electrical connectors from the injectors. Using 8 mm Allen socket spanner, loosen and remove the injector clamp mounting bolt. Torque : 32 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the Injectors 3rd & 4th from cylinder head. Injector Bore must be covered with lint free cloth/Masking tape to avoid foreign objects entering injector bore/ cylinder. Plug the fuel inlet and wiring harness connector slot as soon as injector is removed. Store the injector in a neat tray. Never drop the injectors. Never clean the injector using pressurized water. Install in reverse order of removal. Always replace the injector lower copper washer and O\u2013 ring with new ones when ever injector is removed For New Injector replacement carry out Component Replacement Procedures Injector replacement by using i-SMART. For additional information refer Diagnosis Manual. Check for any cracks, damage etc, replace if found any Fuel control unit consists of a solenoid valve which controls the amount of fuel entering the PF pump according to the instruction from EMS ECU and thus regulates the optimum fuel pressure desired for various engine conditions. Remove the engine top encapsulation cover Press the lock and disconnect fuel control unit electrical connector Press the lock and disconnect fuel control unit inlet and outlet pipes. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Using hose clamp plier, Release metering unit fuel return hose clamp and disconnect hose. Using 12 mm socket spanner Unscrew Fuel Control Unit mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove fuel control unit assembly from vehicle Install in the reverse order of removal. Inspect Fuel Control Unit for any physical damage, replace if found any. . Inspect fuel pipes for any damage. Replace if found any. For additional information refer to the splash shield rear wheel LH (Rear)- R &R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using hose clip plier release the hose clip from the fuel filler neck Disconnect the fuel vent hose quick coupler from fuel filler neck. Using vehicle key open the fuel lid Rotate the fuel cap anti-clockwise to remove from the fuel filler neck. Using 10 mm socket spanner, Unscrew fuel filler neck mounting nuts. Torque : 5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040124.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Gently pull out the fuel filler neck from the vehicle. Install in the reverse order of removal. Inspect the filler neck for any damage. Replace if found any Check the mounting clips for any damage. Replace the clips if found damaged. Fuel Delivery Module delivers the fuel to the low pressure line and to measure the fuel level in the tank. Fuel delivery module consists : ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040184.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "1. Float assembly for fuel level status.
2. An electric motor with inbuild reservoir for pumping the fluid.
",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The entire fuel delivery module is immersed in fluid and the electric motor is lubricated by fuel itself. Remove the fuel tank assembly. Disconnect the pig tail electrical connector. Using screw driver, loosen and Remove the Fuel tank heat Shield mounting clamp from the tank. Press the lock and disconnect the fuel supply line and return line pipe from the fuel delivery module and remove the hoses from the fuel tank. Using suitable metal shaft and hammer, tap the FDM lock ring and remove the lock ring from FDM unit. Remove fuel delivery module and O ring from the tank Install in the reverse order of removal. Always replace the O ring with a new one once FDM removed. Ensure the FDM top flange extension should be matched with the arrow mark on the fuel tank shell as shown in the above illustration Using a suitable metal shaft and hammer, tap the FDM lock ring to get properly lock. Inspect fuel delivery module for any damage. Inspect the float assembly for any damage. The common fuel rail is a high pressure accumulator in which the fuel from high pressure PF Pump is accumulated and is maintained at required pressure. This pressure sensor is fitted on the fuel rail and gives a close loop control of the rail pressure. Fuel is maintained at a high pressure in the fuel rail depending on requirement of the engine. Press the lock and disconnect the rail pressure sensor electrical connector. Using 17 mm open end spanner, loosen and remove the HPP pump to common rail at rail end. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 17 mm open end spanner loosen the high pressure pipe flare nuts at common rail side and injector side. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040094.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "While loosening the high pressure pipes at Injector end, hold the injector pipe connector by 13 mm Open end spanner. Using 12 mm socket spanner, loosen and remove common rail mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the common rail from the vehicle. Install in the reverse order of removal. Inspect the common rail for any damage. Replace if found. Inspect the connector for any damage. Inspect the rail pressure sensor for any damage. The fuel filter filters impurities that may be present in the fuel. The fuel system operates under high pressure which makes it absolutely essential for the fuel to be dust free and moisture free. The fuel filter also has the water separator which filters the moisture that may have crept into the fuel. The high pressure pump in the fuel system operates at high speeds and fine clearance which needs the diesel to be dust free and also be free of moisture at the same time. Since the diesel itself lubricates the PF Pump, If water content is present in fuel, the fuel looses its lubrication property and thus PF Pump and injectors will get damaged. Also the moisture content may lead to formation of rust on the pump elements. This makes it advisable not to use diesel with additives which may cause damage to the PF Pump. Press the lock and disconnect the electrical connector from the fuel filter Press the lock and disconnect fuel filter supply line from the fuel filter All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Press the lock and disconnect fuel filter return line from the fuel filter. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Using 12 mm socket spanner loosen and remove the fuel filter assembly mounting bolts from the vehicle. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the filter from the vehicle Install in the reverse order of removal. Check and ensure proper fitment of fuel lines, any leakage can lead to fire. Inspect the fuel filter assembly for any physical damage, replace if found. Inspect the fuel lines and connectors for any damage. Replace if damaged The fuel tank is a reservoir for the fuel and incorporates the Fuel delivery module inside. Disconnect the fuel tank electrical connector Remove the fuel supply and return hose quick coupler from tank side. Detach the vent hose to fuel tank quick fix coupler. Using hose clip plier remove the fuel filler hose clip then remove the fuel filler hose. Using hydraulic jack support tank to remove from the vehicle Using 14 mm socket spanner, loosen and remove the fuel tank mounting bolts and nut. Torque : 50\u00b15 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using Supported hydraulic jack lower the fuel tank from the vehicle . Install in the reverse order of removal. Check the fuel tank for any damage and replace it if necessary. Check the tank ventilation hose for clog/debris. Fuel Delivery Module delivers the fuel to the low pressure line and to measure the fuel level in the tank. Fuel delivery module consists : ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "1. Float assembly for fuel level status.
2. An electric motor with inbuild reservoir for pumping the fluid.
",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The entire fuel delivery module is immersed in fluid and the electric motor is lubricated by fuel itself. Remove the Fuel Delivery Module Assembly. Press the level sensor towards swirl pot center with moderate strength and unlock the sensor from the clip of the holder Then move the level sensor in upward direction with moderate strength towards swirl pot center from the holder and remove the sensor assembly from the FDM. Detach the wiring from the FDM housing. By Using suitable pin take out the wiring pins from sensor. Pressing the both sided snap-on tabs of the cable connector through the opening of the housing and cover carefully and simultaneously pull out the wire connectors from float unit. Prior to the Installation, both the wiring connector snap-on tabs have to be bent back to the right position as shown below (By using Knife or suitable tool) Plug the wiring connectors pins on the New sensor housing at appropriate place with moderate force Ensure to Plug the wiring connectors pins on the New sensor housing at appropriate slots based on wiring colour as shown. The firm snap-on of the wire connectors is to be examined by a moderate pulling examination. Attach the wiring on FDM housing Lock the sensor on the mount & refit the sensor assembly on the FDM. Refit the Fuel Delivery Module Assembly. Check for free movement of float assembly without any restriction. Inspect the float assembly for proper working condition. Check for any damage in float assembly, If any damage found replace it. The fuel filter filters impurities that may be present in the fuel. The fuel system operates under high pressure which makes it absolutely essential for the fuel to be dust free and moisture free. The fuel filter also has the water separator which filters the moisture that may have crept into the fuel. The high pressure pump in the fuel system operates at high speeds and fine clearance which needs the diesel to be dust free and also be free of moisture at the same time. Since the diesel itself lubricates the PF Pump, If water content is present in fuel, the fuel looses its lubrication property and thus PF Pump and injectors will get damaged. Also the moisture content may lead to formation of rust on the pump elements. This makes it advisable not to use diesel with additives which may cause damage to the PF Pump. Park the vehicle on level work bay Open the bonnet and lock it in open position using bonnet stay rod Press the lock and disconnect the electrical connector from the fuel filter. Ensure that the fuel is drained from filter assembly before the fuel filter element is removed. Do not hold fuel filter body part and avoid damage to the fuel filter body. Disconnect the fuel supply pipe by disconnecting the quick coupler. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Disconnect the fuel return pipe by disconnecting the quick coupler. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Using a 12 mm socket spanner, loosen and remove the fuel filter assembly mounting bolts. Remove the filter from the vehicle. Use two approx. 2\u2013 3 inches long size M12 bolts and nuts to hold fuel filter assembly in a bench vice as shown in illustration. Using a 36 mm ring/socket spanner, rotate the fuel filter bottom cover in anticlockwise direction and loosen. Remove the fuel filter body. Take out the filter element from the fuel filter housing. Remove the O-ring from the fuel filter housing. Assemble the new O-ring back on to filter housing, which is supplied along with new filter element. Ensure little oil is smeared on to the surface of O-ring before assembly on to head. Insert the filter element correctly into housing as shown in illustration. Press the filter element by gentle push into the head. Refit the fuel filter element into the fuel filter housing. Assemble filter element on to head in the direction shown. Ensure open end of filter element goes inside first. Tighten the filter body using 36 mm size socket spanner to specified torque value. Do not over tighten beyond 25\u00b15 Nm. This may cause damage to the bowl and Head. Is it recommended to tight the fuel filter using torque wrench. Remove the filter assembly from the wise. Refit the fuel filter assembly and install the mounting bolts. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Reconnect the fuel filter fuel return line quick coupler. All are quick fix connectors, press gently and refit it carefully; avoid seal damages. Check and ensure proper fitment of fuel lines, any leakage can lead to fire. Reconnect the fuel filter fuel supply pipe quick coupler. All are quick fix connectors, press gently and refit it carefully; avoid seal damages. Check and ensure proper fitment of fuel lines, any leakage can lead to fire. Reconnect the fuel filter electrical connector. Always use recommended filter element only. Before removing the fuel filter, open the fuel tank cap to release the pressure from the tank and fuel lines. Fuel filter cartridge needs to be replaced earlier in case of repeat water in fuel warning in cluster even after the water is drained from the system. The injector uses electronically controlled solenoid actuation for precise control of injection. The solenoid injectors can inject very small quantities of fuel. The injection can be split into pilot, main and post injection. Or without pilot, post and only main injection. Each fuel injector is mounted directly above the piston within the cylinder head and is connected to the fuel rail by rigid steel lines that can withstand the high fuel pressure. The actuation of injectors is done by EMS ECU. Remove the Injectors 1st & 2nd HP Pipes. Remove injector leak - off pipe lock clip and detach leak off pipes from the injector end. Disconnect the Injectors 1st & 2nd electrical connectors from the injectors. Using socket spanner 10 mm, Unscrew engine WH carrier mounting nuts and detach the carrier partially. Torque : 8 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 8 mm Allen socket spanner, Unscrew the injector clamp mounting bolt. Torque : 32 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the Injectors 1st & 2nd from cylinder head. Injector Bore must be covered with lint free cloth/Masking tape to avoid foreign objects entering injector bore/ cylinder. Plug the fuel inlet and wiring harness connector slot as soon as injector is removed. Store the injector in a neat tray . Never drop the injectors. Never clean the injector using pressurized water. Install in reverse order of removal. Always replace the injector lower copper washer and O\u2013 ring with new ones when ever injector is removed. For New Injector replacement carry out \u201cComponent Replacement Procedures \u2013Injector replacement\u201d by using i-SMART. For additional information refer Diagnosis Manual. Check for any cracks, damage etc, replace if found any. This high pressure fuel lines connects common rail with injectors and thus supplies high pressure fluid to injectors. Remove the engine top encapsulation cover. Using 17 mm open end spanner loosen the high pressure pipe flare nuts at common rail side and injector side. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040094.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "While loosening the high pressure pipes at Injector end, hold the injector pipe connector by 13 mm Open end spanner. Remove the high pressure fuel pipes from the vehicle. Install in the reverse order of removal. Inspect the high pressure fuel pipes for any damage. Replace if found any Inspect the high pressure fuel pipes for leakage, rectify if found. Remove the wheel. For additional information refer to Wheel \u2013 R &R; Section. Remove the tyre from the rim. Using a T10 Socket Spanner, loosen and remove the TPMS sensor mounting screw and detach the sensor. The TPMS and Valve cannot be replaced separately. These can be replaceable as assembly. The valve must be positioned just left of the start position to avoid sensor damage. Do not touch the sensor with the tyre tool. Starting to mount the tyre from the valve location is a wrong fitment. The fixing tool/ stem may hit the sensor and damage it. Start from the opposite direction. By using suitable TPMS removal/Installer tool, remove the valve from the rim. Install in the reverse order of removal. Ensure that the TPMS Sensor is not damaged while removing the tyre. Check the tyre inner surface for cuts and punctures. TPMS Manual Learning is the process by which the identities of 5 sensors installed inside the tyres are learnt & programmed in to the memory of receiver module. It should be mandatory to performe on any of the following conditions or operations done. Any of the old TPMS sensors are damaged & sensors are replaced. Any of the tyre among 5 tyres are replaced. If any of the tyres or set of tyres are shuffled or swapped in position. If tyres rotation operation is performed. If observed that the alert indications in TPMS screen are not correlating with respect to their actual position in vehicle. Once the manual learning is initiated the sensors inside the tires needs to triggered by leaking the air from each tire one at a time and should be completed within 90 secs post to each event for learning all 5 tires. Do not perform Manual learning process at the same time on two vehicles with in the radius of 20 meters. Any of the tyre among 5 tyres are replaced. If any of the tyres or set of tyres are shuffled or swapped in position. It is mandatory that manual learning of tyres should follow the sequence of \u2018front left tyre position, front right tyre, rear right tyre, rear left tyre and spare tyre\u2019. It is required to ensure the tires are having pressure > 32 psi & < 36 psi before initiating the manual learning process. Post to manual learning all tire should be filled with recommended tyre pressure value . At any point of time during the learning process if learning takes more than 90 secs of time for each tire position then the system shall exit the learning mode and show the Learning not successful screen. At a time, only one tyre can be swapped with the spare wheel and then follow the learning procedure. Press the Scroll Up arrow button on Driver side switch bank and simultaneously turn the ignition ON. Wait for cluster\u2019s tachometer & speedometer self-check rotation and then release the arrow button. Identifying weather the learning is initiated. Infotainment will show popped out screen TPMS Learning screen. TPMS telltale in cluster shall keep blinking. Three vehicle siren chirps will be heard. If failed to enter in to manual learning mode Try initiating the manual learning once again. Check if reverse gear is engaged, if engaged disengage it. Check MBFM, Infotainment & Cluster software versions. Check if variant coding is done in all three. Check if Scroll Up arrow button on Driver side switch bank button is working fine. TPMS learning procedure must be done in the below sequence: 1. Front left tyre 2. Front right tyre 3. Rear right tyre 4. Rear left tyre 5. Spare tyre Start leaking the air from front left tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If front left tyre is learned 1 siren chirp sound is heard and FL tyre shows learned in infotainment system. Start leaking the air from front right tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If front right tyre is learned 1 siren chirp sound is heard and FR tyre shows learned in infotainment system. Start leaking the air from rear right tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If rear right tyre is learned 1 siren chirp sound is heard and RR tyre shows learned in infotainment system. Start leaking the air from rear left tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If Rear left tyre is learned 1 siren chirp sound is heard and RL tyre shows learned in infotainment system. Start leaking the air from the spare wheel tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If spare tyre is also learned then 1 siren chirp sound is heard and ALL tyres show learned at respective tyre positions and \u2018All tyres Learned successfully\u2019 in the center of the screen. At any point of time during the learning process, if learning takes more than 90 seconds of time for each tyre position then the system shall exit the learning mode and show the \u201cLearning not successful\u201d screen. After tyre rotation or TPMS sensor replacement, TPMS must be learnt,otherwise the system will show TPMS malfunction indicator. TPMS learning need to be carried out whenever : 1. Tyre rotation happens. 2. 2 or more wheels are swapped. 3. TPMS sensor is replaced. 4. MBFM is replaced. The TPMS should not be used as a tyre pressure gauge while adjusting vehicle tyre pressure. No two vehicles should be done with manual learning process at a time in same location with in radius of 20 meters. Post to manual learning all tire should be filled with recommended tyre pressure value. Mechanical ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Check for any oil leakage in the transfer case. Check the yoke, flange and drive gear for any damage. Check for loose mounting bolts. Remove the gear shifter level knob and 4WD selection knob by rotating them in anticlock wise direction. Using trim removal tool, remove the gear selection rod cover with trim. For AT Variants top trim removal follow (Steps 3 - 8) : \ufeff
",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110269.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Pull and fold the gear shifter boot from gear shifter bezel. Partially detach the bezel from the console. Excessive pull may leads to damage of the electrical connector. Disconnect the AT gaiter electrical connector from the bezel. Carefully remove the bezel trim from the TGS lever. Handle bezel assembly carefully to prevent it from damage or scratches. Using trim removal tool, carefully remove the floor console top trim with transfer case shifter boot. Detach the transfer case cable abutment from the shifter bracket by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Using 13 mm socket spanner unscrew transfercase shifter lever assembly mounting nuts. Take out the shifter and tilt the lever assembly gear shifter lever side to remove the TC shifter cable 'R' clip. Detach the TC shifter cable from shifter assembly. Remove the transfer case shifter from the vehicle. Inspect the transfer case shifter for any damage. Replace if found any. Position the transfer case cable on shift lever bracket. Position the transfer case shifter lever at 2H position. Ensure that the transfer case link should be in 2H position on transfer case (Extreme Rear end position from front of the vehicle). Refit the transfer case cable abutments on shift lever bracket. Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Refit the shifter lever assembly mounting nuts. Tighten the mounting nuts to specified torque value. Torque : 22.51\u00b14 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120007.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120048.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from '2H' to other range. If Shifting not smooth Carry-out Transfer Cable setting. For AT Variants top trim Installation follow (Steps 8 \u2013 12) : , Refit the floor console top trim with transfer case shifter boot. Connect the AT gaiter electrical connector with the bezel. Handle bezel assembly carefully to prevent it from damage or scratches. Unfold the gear shifter boot and refit the boot with gear shifter bezel. Refit the 4WD selection knob by rotating it in clock wise direction Refit the Manual transmission gear selection rod cover with trim. Refit gear shifter level knob and 4WD selection knob by rotating them in clock wise direction. Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from 'N' to other range Inspect that engine can be started with shift lever only 'N' or 'P', but not in other range (For AT variants) Inspect that indicating lamp can be turned on correctly in PRND positions (For AT variants). Remove the Air Cleaner Assembly. Using MST 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the transfer case shifter cable from the transfer case ball pins. Detach the transfer case cable abutment from the cable bracket on transmission by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Using 10 mm socket spanner unscrew shifter cable grommet mounting bolts on fire wall. Remove the gear shifter level knob and 4WD selection knob by rotating them in anticlock wise direction. Using trim removal tool, remove the gear selection rod cover with trim. For AT Variants top trim removal follow (Steps 7 \u2013 12) : Remove the 4WD selection knob by rotating it in anti-clock wise direction. Pull and fold the gear shifter boot from gear shifter bezel. Partially detach the bezel from the console. Excessive pull may leads to damage of the electrical connector. Disconnect the AT gaiter electrical connector from the bezel. Carefully remove the bezel trim from the TGS lever. Handle bezel assembly carefully to prevent it from damage or scratches. Using trim removal tool, carefully remove the floor console top trim with transfer case shifter boot. Remove the floor console side trim mounting screw rivet and remove the trim both sides. Detach the transfer case cable abutment from the shifter bracket by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Detach the transfer case cable from the cable bracket routing clamp. Using nose plier, remove cable cross pin from the transfer case shifter and detach shifter cable. Keep the Transfercase shifter in 4L position while remove R Clip. Detach the cable from lever and take out from vehicle. Keep the Transfercase shifter in 2H position while remove the cable. Inspect the transfer case for any damage. Replace if found any. Position and route the cable inside the vehicle. Move shifter to 2H position and attach the cable with the shifter lever. Keep the Transfercase shifter in 2H position while refit the cable. Refit shifter cable R clip with the transfer case shifter cable. Keep the Transfercase shifter in 4L position while refit R Clip. Attach the transfer case cable abutment with the shifter bracket by pressing locking clip. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Attach the transfer case cable with the cable bracket routing clamp. Refit the floor console side trim and install the mounting screw rivet. Refit the gear selection rod cover with trim. Refit gear shifter level knob and 4WD selection knob by rotating them in clock wise direction. For AT Variants top trim Installationfollow (Steps 9 \u2013 13) : , Refit the floor console top trim with transfer case shifter boot. Connect the AT gaiter electrical connector with the bezel. Refit the bezel trim with shifter bezel. Handle bezel assembly carefully to prevent it from damage or scratches. Unfold the gear shifter boot and refit the boot with gear shifter bezel. Refit the 4WD selection knob by rotating it in clock wise direction. Refit shifter cable grommet and install the mounting bolts on fire wall. Ensure the cable grommet should get assemble from outside of the cabin. Torque :10 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120013.jpg",
+ "display_order": 89
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Position the transfer case lever at 2H position on transfer case (Extreme Rear end position from front of the vehicle). Refit the transfer case cable abutments on transmission cable brackets. Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. For adjust cable length, move the cable quick adjuster outer cover in forward direction and unlock the QA clip. Adjust the cable length to fix the cable on link ball pin. After adjusting the length, position the quick adjuster body on link ball pin. Once quick adjuster body snap on ball pin, press the QA clip towards arrow mark shown to lock it fully and release the cable quick adjuster outer cover. Ensure the proper locking by confirming/ hearing the click noise while install. Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from '2H' to other range.
",
+ "file": "",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4C110041.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Torque Value",
+ "content": "Torque : 45 \u00b1 5.0 Nm ",
+ "file": "",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner unscrew transfer case rear facing bottom mounting bolt. ",
+ "file": "",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4C110042.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Torque Value",
+ "content": "Torque : 45 \u00b1 5.0 Nm ",
+ "file": "",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 12 mm ring spanner unscrew transfer case rear facing top mounting bolt. ",
+ "file": "",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4C110043.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Torque Value",
+ "content": "Torque : 45 \u00b1 5.0 Nm ",
+ "file": "",
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A110029.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Remove the transfer case from the vehicle. ",
+ "file": "",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A110393.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. ",
+ "file": "",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Notice",
+ "content": "While Installation of transfer case cable abutments on transmission cable brackets, Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. ",
+ "file": "",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A120013.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "After Installation of Transfer Case Assembly on vehicle, Carry-out below cable setting Procedure. *Ensure that the transfer case link should be in 2H position on transfer case (Extreme Rear end position from front of the vehicle). ",
+ "file": "",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A120014.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "For adjust cable length, move the cable quick adjuster outer cover in forward direction and unlock the QA clip. ",
+ "file": "",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A120047.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Adjust the cable length to fix the cable on link ball pin. After adjusting the length position the quick adjuster body on link ball pin. ",
+ "file": "",
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A120046.jpg",
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Once quick adjuster body snap on ball pin, press the QA clip towards arrow mark shown to lock it fully and release the cable quick adjuster outer cover. ",
+ "file": "",
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Notice",
+ "content": "Ensure the proper locking by confirming/ hearing the click noise while install. ",
+ "file": "",
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A120007.jpg",
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A120048.jpg",
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from '2H' to other range. ",
+ "file": "",
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Check transfer case oil level & top up if required. ",
+ "file": "",
+ "display_order": 61
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the transfer case for any damage. Replace if found any. ",
+ "file": "",
+ "display_order": 62
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 91,
+ "sys_id": "THAR.LX-0004-Transfer Case",
+ "subsys_id": "THAR.LX-0004-Transfer Case-Transfer Case Overhual",
+ "systems": "Transfer Case",
+ "sub_systems": "Transfer Case Overhual",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1212,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Transfer Case Overhual-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Dis-assembly and Assembly Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/VST-0077_Transfer Case Overhaul.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4692.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4693.pdf",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Dis-assembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the Transfer case fluid. For additional information refer to Transfer case fluid Drain & Filling Section. Remove the Transfer case from the vehicle. Position the transfer case on the suitable Wooden/ Nylon blocks. Ensure the oil is drained prior to disassembly of the transfer case. Using a Special tool MST 203 Companion Flange Holding Tool, hold the transfer rear flange. Using a 30 mm socket spanner, loosen and remove rear flange center nut. Torque Value : 340 - 370 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120066.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120131.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120132.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120067.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a magnetic stick, take out flange washer and remove seal from transfer case rear flange. Ensure the use New washer & Seal while installation. Using a mallet, remove the transfer case rear flange. Use suitable 2 Jaw puller to remove the flange, In case of flange not able to remove by mallet. Using a 10 mm square bit spanner, remove the transfer case draining & filling oil plugs from the cover. Using a 15 mm socket spanner remove the assembly cover mounting bolts and remove the mounting bolts & identification tag. Separate the front assembly cover and the rear case assembly To avoid damage of the metal surface, apply limited force to the bosses on the cover and the transfer case while breaking the sealant bond. Using a flat end screw driver, remove transfer case Rear output shaft oil seal from the cover. Remove the Spacer from the cover. Separate the return spring from the front assembly cover by pulling them outwards. Using flat screw driver& circlip plier, remove the ball bearing snap ring. Rotate the cover and by using MST 0707BBA0003ST - Universal Mandtral remove the ball bearing from the cover. By using suitable Internal puller, pull out the needle bearing from the cover. Care must be taken not to damage the metal surface while removing the needle bearing. Position the transfer case casing and remove the shift collar hub from the output shaft. Remove the 2W-4W lock up assembly and lock up fork together from output shaft and separate lock up fork from the 2W-4W lock up assembly. To dismantle 2W-4W lockup assembly, remove snap ring, lock up hub return spring from lock up collar. Using a circlip plier & flat screw driver, remove the snap ring from the output shaft and remove the spacer. Remove the drive chain with sprocket and drive sprocket from the output shaft. Separate the drive chain, driven sprocket and drive sprocket. Remove the magnet from the slot in the case. Remove the coupler from the case. Remove the output shaft and the gear rotor (Gearotor) pump from the case. Rotate and align the guide pin of the shaft to the slot on the pump body and Separate the gear rotor pump and strainer assembly from the output shaft. By using nose plier, remove the hose clip and remove the hose from pump and remove the strainer. Remove the rail shaft assembly from the case. Remove the reduction hub and the reduction fork from the case. Separate the reduction hub and the reduction fork. Remove the two shift fork facings from the shift fork assembly (if required). Using a Special tool MST 203 Companion Flange Holding Tool, hold the transfer case output shaft yoke. Using a 30 mm socket spanner, loosen and remove rear output shaft yoke center nut. Torque Value : 340 - 370 Nm ",
+ "file": null,
+ "display_order": 94
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120142.jpg",
+ "display_order": 95
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120143.jpg",
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "Description",
+ "content": "Using a magnetic stick & flat screw drive , take out flange washer and remove seal from transfer case output shaft yoke. Ensure the use New washer & Seal while installation. Using a mallet, remove the transfer case rear flange. Use suitable 2 Jaw puller to remove the flange, In case of flange not able to remove by mallet. Remove the lower output shaft from the casing. Using a 15 mm socket spanner, remove the adapter assembly, input shaft and carrier assembly bolts. Take out the adapter assembly with input shaft and carrier assembly. Using an outer circlip plier, Expanding the long ends snap ring unlock the bearing lock circlip and remove the input shaft and carrier assembly. Remove snap ring and oil seal from adapter assembly. Remove the input shaft bearing retaining ring. Remove the bearing by hitting input shaft by mallet and remove the thrust washer from input shaft. Remove the ASM Carrier from the input shaft. Remove the sun gear snap ring from ASM Carrier. Remove the thrust plate & sun gear from ASM Carrier. By using suitable Internal puller, remove the copper bush from the input shaft. By using suitable Internal puller, remove the needle bearing from the input shaft. By using 17 mm Open end spanner, remove the Breather (For MT variants located at Adapter plate & for AT variants at Adapter case assembly). By using 13 mm socket spanner, remove the hexagonal nut of the shift shaft. By using T25 torx spanner, remove the transfer case and shift cam torx screws. By using flat end screw driver & mallet, remove the clip ring and pull out shift shaft & lever. Remove shift lever from shift shaft. By using flat end screw driver, remove the \u2018o\u2019 ring from shift shaft. Remove 4L assist spring and roller, shifter cam. Remove plunger and spring from the transfer case. By using 24 mm ring spanner, remove 4WD indicator switch from the transfer case (If required). By using flat end screw driver, remove the oil seal from the assembly case. By using flat end screw driver, remove the retaining ring from the assembly case. By using MST 0707BBA0003ST \u2014 Universal Mandtral remove the ball bearing from the case. By using cutting plier, remove the dowel pin from transfer case. Do not remove the ring gear shown in the below figure from the case. Using a cleaning solvent, clean the old oil and dirt deposits. Before cleaning, check the magnet for the presence of metal particles which indicate internal chipping of the transfer case. After cleaning dry the parts with low pressure (20 psi maximum) compressed air. Lubricate the ball bearings and needle bearing with Transfer Case oil. Protect lubricated bearings from dust. Visually check all the parts for damage. Referring to normal gear tooth face, specifically inspect the uneven wear and chips of gear tooth. Replace or repair if necessary. Always replace the hose coupling, O-ring , oil seal and flange/Yoke Nut with new parts. Insert dowel pins to the ring gear casing. Use respective Special tools for Bearings & Oil Seal Installation. Do not directly use hammer/mallet for Installation. Lubricate oil seals, O-rings, bushings and matching metal parts before assembly (with Transfer Case oil). Lubricate the ball bearings and needle bearing with Transfer Case oil. Protect lubricated bearings from dust. Dropping of heavy/large objects will damage the part and cause personal injury. Press the ball bearing to the front casing by using MST\u2019s (0707AUA0005ST - Trasfer case Case Covers Ball Bearing Pressing tool) & (0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer). Check the ball bearing for functionality prior to installation. Using a snap ring removal tool/screw driver install the retainer ring to the front casing. Install the new output oil seal into the case by using MST\u2019s (0707BBA0001STTransfer Case Output Shafts Oil Seal Installer) & (0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer). Install new \u2018O\u2019 ring on the shift shaft and lubricate it. Refit the shift shaft in to the shift lever. Position spring and plunger in the hole of the transfer case. Ensure spring and plunger are properly seated in the hole of the transfer case and not to unseat plunger while Install Cam assembly. Partially Insert star splined end of the shift shaft into the transfer case. Position shift cam into transfer case with flat end of cam approximately parallel with front face of case (as shown in the picture). Install 4L assist spring roller in groove of shift cam and Install other end to slot of transfer case. Pressing cam against plunger and compressing spring align splines in cam and on shift shaft and press shaft fully into cam and Install clip ring in groove near inside end of shift shaft. Refit the transfer case and shift cam torx screws by using screwdriver. Torque Value : 7 \u2013 8 Nm ",
+ "file": null,
+ "display_order": 212
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Notice",
+ "content": "Make sure that shift shaft is fully engaged so that second screw end enters groove in shaft. Refit the hexagonal nut of the shift shaft, Torque tighten mounting nut to specified value. Torque Value : 41 \u2013 48 Nm ",
+ "file": null,
+ "display_order": 216
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120178.jpg",
+ "display_order": 217
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Install 4WD indicator switch to transfer case. Torque Value : 34 \u2013 48 Nm ",
+ "file": null,
+ "display_order": 219
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120180.jpg",
+ "display_order": 220
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120179.jpg",
+ "display_order": 221
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Press the needle bearing into the input shaft by using MST\u2019s (0707AUA0004ST - T Case Input Shaft NRB Pressing tool & 0707BBA0003ST - Universal Mandtral - Oil Seal/ Bearing Installer). Press the new sleeve bearing into the input shaft by using MST\u2019s (0707AUA0003ST - T Case Input Shaft Sleeve Pressing tool & 0707BBA0003ST - Universal Mandtral - Oil Seal/ Bearing Installer. Install the sun gear & thrust plate on ASM Carrier. Install the sun gear snap ring on ASM Carrier. Refit the input shaft to the carrier assembly by matching the splines. Install the thrust washer onto the input shaft. Position and press the bearing onto the input shaft by using a MST 0707AUA0002ST - T Case Input Shaft Ball Brg Pressing tool. Install the retaining ring on the input shaft assembly by using circlip plier. Install snap ring by making sure that snap ring is correctly install in the groove. Using a circlip plier expand the snap ring and insert the carrier assembly with input shaft to the adapter case and release the snap ring. Ensure that carrier assembly with input shaft position properly to the adapter case and snap ring seated properly to hold the assembly. Install the oil seal on carrier assembly body by using a MST\u2019s For MT Variants : 0707BBA0002ST - Transfer Case Input Shaft Oil Seal Installer - MT For AT Variants : 0707BAJ0001ST \u2014 Transfer Case Input Shaft Oil Seal Installer - AT and 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Apply a 1.6 mm bead of Loctite RTV598 sealant on the mounting face for the transfer case. Refit the carrier assembly to the case and using a 16 mm socket spanner, tighten the mounting nuts to specified torque. Torque Value : 34 \u00b1 6 Nm ",
+ "file": null,
+ "display_order": 263
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120204.jpg",
+ "display_order": 264
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Refit the breather nipple. Torque Value : 5 \u2013 8 Nm ",
+ "file": null,
+ "display_order": 266
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120205.jpg",
+ "display_order": 267
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120206.jpg",
+ "display_order": 268
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Description",
+ "content": "Position the output shaft in the transfer case. Position the output shaft in transfer case, and install the end yoke assembly, seal, washer and the lock nut. Using a Special tool MST 203 Companion Flange Holding Tool, tighten the front flange mounting lock nut to specified torque. Torque Value : 340 - 370 Nm ",
+ "file": null,
+ "display_order": 279
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120216.jpg",
+ "display_order": 280
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "Description",
+ "content": "Install the two forks facing on the reduction shift fork assembly. Install the reduction hub in to the fork. Refit the reduction hub and reduction shift fork into the planet carrier. Slide roller of fork in to the cam groove. Insert shift rail in reduction fork bore, to match with case bore. Align rotor slot of the pump and slot of the pump body in line. Align the slide the pump assembly on output shaft over pump pin. Align the guide pin of the shaft to the slot on the pump body and slide the pump assembly onto the output shaft over pump pin. Assemble the strainer and hose to the gear rotor pump. Install the output shaft and gear rotor pump assembly into the reduction hub housing by matching the splines. Couple strainer with case and insert the magnet into the transfer case slot. Install the drive chain onto the sprockets. Position the drive sprocket to the rear output shaft end and driven sprocket to the front output shaft end. Holding each sprocket with the drive chain tight and parallel with the transfer case, install the drive chain assembly to the output shaft. Rotate the driven sprocket slightly to engage splines on the front output shaft. Install the spacer to the front output shaft. Install the snap ring into the groove of the front output shaft. Install the lockup hub and return spring to the lockup collar and insert the snap ring. Install new facings to the fork. Engage the lockup fork in the groove in 2WD-4WD lockup assembly and slide this assembly down over output shaft and rail shaft. Install shift collar engaging splines on output shaft and in 2WD-4WD lockup assembly. Position the cover with the open end facing up on the table. Position the end of the needle bearing with the identification mark and up the press into the cover by using a MST\u2019s (0707AUA0006ST \u2014 T Case Rear Cover NRB Pressing tool & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer). Press the ball bearing into cover by using MST\u2019s (0707AUA0005ST \u2014 T Case Covers Ball Brg Pressing tool & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer). Install snap ring over the ball bearing into cover by using screw driver or circlip plier. Install the return spring over rail shaft in the transfer case. Position the cover with the open end facing down on the table. Install the spacer over output shaft spline in the cover assembly. Press the new oil seal into the cover assembly by using MST\u2019s (0707BBA0001ST \u2013 Transfer Case Output Shafts Oil Seal Installer & 0707BBA0003ST \u2013 Universal Mandtral - Oil Seal/ Bearing Installer). Apply 1.6 mm bead of Loctite RTV598 to the transfer case mounting surface. Position and align the transfer case with cover. Do not use excessive force. Follow the below steps while Installing the cover into the transfer case Align the cover holes with the transfer case dowel pins. Align the cover bearing with output shaft. Align the cover blind hole with rail shaft and make sure that return spring is not cocked. Do not apply excessive force while Installation. Refit the front and rear housing cover mounting bolts along with identification tag and torque tighten the bolts to specified value. Torque Value : 34 \u00b1 6 Nm ",
+ "file": null,
+ "display_order": 369
+ },
+ {
+ "step_name": "Step-61",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120274.jpg",
+ "display_order": 370
+ },
+ {
+ "step_name": "Step-61",
+ "content_type": "Description",
+ "content": "Install the two oil plugs to the cover, torque tighten the nuts to specified value. Torque Value : 34 \u00b1 6 Nm ",
+ "file": null,
+ "display_order": 372
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120275.jpg",
+ "display_order": 373
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120276.jpg",
+ "display_order": 374
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120277.jpg",
+ "display_order": 375
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120278.jpg",
+ "display_order": 376
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "Description",
+ "content": "Install the flange,seal, washer and lock nut to the output shaft. Do not fully tighten the bolts at this stage. Using a Special tool MST 203 Companion Flange Holding Tool, hold the transfer case output shaft yoke and torque tighten the nut to specified value. Refit the Transfer case on the vehicle. Refill the Transfer case fluid. For additional information refer to Transfer case fluid Drain & Filling Section. Position the transfer case shifter lever at 2H position. Ensure the transfer case cable abutment is properly fitted on shifter bracket. Ensure the transfer case cable abutment is properly fitted on transmission cable bracket. Using a 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the transfer case cable from the transfer case ball pins. Ensure that the transfer case link should be in 2H position on transfer case (Extreme Rear end position from front of the vehicle). For adjust cable length, move the cable quick adjuster outer cover in forward direction and unlock the QA clip. Adjust the cable length to fix the cable on link ball pin. After adjusting the length, position the quick adjuster body on link ball pin. Once quick adjuster body snap on ball pin, press the QA clip towards arrow mark shown to lock it fully and release the cable quick adjuster outer cover. Ensure the proper locking by confirming/ hearing the click noise while install. Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from 2H to other range. Transfer case Oil \u2013 MAHINDRA MAXIMILE POWER STEERING FLUID Genuine Power Steering Fluid Capacity \u2013 1.2 Litres. Using a 10 mm square bit spanner,remove the oil filling plug from the transfer case. Place a tray beneath the drain plug for collecting the oil while draining. Using a 10 mm square bit spanner, loosen and remove the drain plug. Collect the drained oil in a suitable container. Refit the drain plug. Torque tighten the drain plug to specified value. Torque : 34\u00b16 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110414.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110412.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Fill recommended transfer case fluid with the help of a mechanical pump through filler plug. Ensure that the oil level by insert the 8 mm allen key and check the oil level mark. Refit the filler plug and torque tighten the filler plug to specified torque value. Torque : 34\u00b16 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Recommend to use only MAHINDRA MAXIMILE POWER STEERING FLUID Genuine Power Steering Fluid. In case of non-availability of Genuine fluid, SHELL MAKE SPIRAX S3 ATF MD3 can be used. In emergency conditions, fluid meeting DEXRON III specification can be used and oil change interval should be at every 40000 km. It is a structure of a pipe, which carries air into the combustion chamber in an engine. The primary function of the intake manifold is to evenly distribute the air to each intake port in the cylinder head. Even distribution is important to optimize the efficiency and performance of the engine. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the terminal. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Remove the throttle assembly. Remove the alternator assembly. Remove the EGR module assembly. Using a 10 mm socket spanner, Unscrew NVH cover mounting bracket mounting bolt. Using a 10 mm socket spanner, Unscrew wiring routing bracket mounting bolt from manifold end. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020080.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew dipstick routing bracket mounting bolt. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020115.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 8 mm socket spanner, Unscrew boost temperature sensor mounting bolt and remove it. Torque : 6 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020081.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, Unscrew intake manifold mounting bolts from cylinder block. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020112.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the intake manifold carefully from the engine. Replace the gaskets to the intake manifold whenever removed from the engine. Install in the reverse order of removal. Check the intake manifold for the external damage. If any damage found replace it. The boost downstream temperature sensor is used to monitor the intake air temperature at the intercooler outlet. The sensor is an NTC type sensor. EMS ECU uses signal from this sensor for Air-intake system control & flow rate modelling. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the terminal. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Disconnect the boost pressure sensor electrical connector. Using 10 mm Socket Spanner, Unscrew Boost pressure sensor mounting bolt. Torque : 2.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020089.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the boost pressure sensor. Install in the reverse order of removal. Check for any external cracks or damage, replace if found any. Using 10 mm socket spanner, Loosen battery negative terminal mounting nut and disconnect the terminal. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Using 7 mm socket spanner, Loosen the intercooler inlet hose clip and disconnect the hose intercooler end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020036.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner, Loosen the intercooler outlet hose clip and disconnect the hose intercooler end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020113.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, remove boost pressure sensor mounting bolt and detach it. Torque : 2.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020114.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect the boost pressure sensor electrical connector. Using 10 mm socket spanner, Unscrew degassing tank mounting bolts and partially detach it. Torque : 4.5\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020034.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 13 mm Socket Spanner, Unscrew the Intercooler mounting bolts. Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020090.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020037.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Carefully remove the intercooler from vehicle. Install in the reverse order of removal. Check for the external damage. If found replace it. Check for any oil seepage ,if found please inspect the turbocharger for any oil leakage. Inspect intercooler hoses for any damage. Replace if found any. Inspect intercooler rubber Isolators for any damage. Replace if found any. The air filter housing is made up of two parts. The bottom housing and top housing with the air filter element sandwiched in between. Air is drawn through the dirty side intake duct into the bottom housing. It gets filtered and passes on via top housing, throttle valve into the intake manifold. Using 10 mm socket spanner, Loosen battery negative terminal mounting nut and disconnect the terminal. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Using 7 mm socket spanner, Loosen the intercooler inlet hose clip and disconnect the hose intercooler end. Torque : 6.5 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Ensure the sensor is stored in a dust free area Using 12 mm socket spanner, Unscrew air cleaner assembly mounting bolts from BIW. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020118.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully take out the air cleaner assembly and air intake dirty duct. Using a 5 mm allen key, loosen and remove the dirty side duct mounting bolts from the air cleaner assembly then separate the air cleaner assembly. Install in the reverse order of removal. Check the air cleaner housing for the external damage. If any damage found replace it. The air cleaner element is Non woven +Pleated Media type (Dry Type). Filtration happens in two stages. Coarser particles are filtered in first stage by foam media and fine particles are filtered by Paper media in second stage. The dust and other fine particles which are sucked inside along with air gets trapped in the air cleaner while passing through the filter element. The air filter element should be inspected and replaced from time to time, when driving under the following conditions: Unpaved road. Dusty air-polluted road. Long-term driving in rainy weather. Using 5 mm allen key, Unscrew air cleaner dirty duct mounting screws and lift the top housing. Gently take out the air cleaner element from the housing. Clean the inner side of the air cleaner housing using a lint free cloth. Refit the New air filter element gently inside the air cleaner housing. During Installation ensure to keep foam side of the filter element in the bottom side. Ensure dust should not fall inside the clean hose area while fitting. Always use recommended genuine air filter element. Do not tap or hit the filter element. Position the air cleaner assembly top cover and refit the mounting screws. Torque : 10 Nm ",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 338,
+ "sys_id": "THAR.LX-0004-Air Intake",
+ "subsys_id": "THAR.LX-0004-Air Intake-Intake Manifold Sensor",
+ "systems": "Air Intake",
+ "sub_systems": "Intake Manifold Sensor",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A020125.jpg",
+ "myid": 1007,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Intake Manifold Sensor-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020125.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Intake manifold pressure sensor is mounted located at the plenum of the intake manifold. This sensor continuously monitors the variation in intake air pressure. EMS ECU uses this information for fuel correction, EGR control & turbocharger pressure control. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the terminal. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Remove the engine top encapsulation cover. Disconnect boost temperature sensor electrical connector. Using a 8 mm socket spanner, loosen and remove the boost temperature sensor mounting bolt. Torque : 6 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020089.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully remove the sensor from intake manifold. Install in the reverse order of removal. Check for any external cracks, replace if found any. The throttle body is used to control the air flow rate to the engine. The valve actuation in the throttle body depends upon the engine speed and torque demand from driver and is controlled by EMS Using a 10 mm socket spanner, loosen and remove the battery negative terminal Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Remove the engine top encapsulation cover. Disconnect the throttle valve electrical connector. Using a 7 mm socket spanner, loosen intercooler outlet hose clip from throttle valve end. Torque : 6.5 \u00b1 0.6Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020060.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew the throttle body assembly mounting bolts. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020091.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully remove throttle body from intake manifold. Install in the reverse order of removal. Check for any external cracks, replace if found any. The HFM sensor is used to find out the mass flow rate of air entering into fuel injection internal combustion engine. The air mass information is necessary for the ECU to balance and deliver the correct fuel quantity to the engine. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the terminal. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Disconnect the HFM sensor electrical connector. Using a 7 mm socket spanner, loosen the hose clip and detach hose from HFM sensor. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020030.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the HFM sensor mounting bolts. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020031.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020032.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the HFM sensor from the air cleaner assembly. Install in the reverse order of removal. Check for any external cracks, replace if found any. Check for the obstruction of the air flow, if found please replace. The air cleaner element is Non woven +Pleated Media type (Dry Type). Filtration happens in two stages. Coarser particles are filtered in first stage by foam media and fine particles are filtered by Paper media in second stage. The dust and other fine particles which are sucked inside along with air gets trapped in the air cleaner while passing through the filter element. Don\u2019t tap or hit the filter element. The air filter element should be inspected and replaced from time to time, when driving under the following conditions: Unpaved road. Dusty air-polluted road. Long-term driving in rainy weather. Using a 5 mm allen key, Unscrew air cleaner top housing mounting allen screws and lift the top housing. Gently take out the air cleaner element from the housing. Clean the inner side of the air cleaner housing using a lint free cloth. Blow the compressed air from the top clean side of filter element. Blow the compress air from the top clean side of filter element (From Paper side). Do not blow the air from bottom dirty side (Foam side). While cleaning, ensure the air pressure should be less than 2 bar. Clean the inner side of the air cleaner housing using a lint free cloth. Gently insert the air cleaner element inside the air cleaner housing. During Installation ensure to keep foam side of the filter element in the bottom side Ensure dust should not fall inside the clean hose area while fitting. Ensure dust should not fall inside the clean hose area while fitting. Always use recommended genuine air filter element. Do not tap or hit the new filter element. Refit the air cleaner top housing and install the mounting allen screws. Torque : 10 Nm ",
+ "file": null,
+ "display_order": 28
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 120,
+ "sys_id": "THAR.LX-0004-en-SM-Wheel & Tyre",
+ "system_name": "Wheel & Tyre",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1014,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 127,
+ "sys_id": "THAR.LX-0004-Wheel & Tyre",
+ "subsys_id": "THAR.LX-0004-Wheel & Tyre-Front Wheel",
+ "systems": "Wheel & Tyre",
+ "sub_systems": "Front Wheel",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A160002.jpg",
+ "myid": 1511,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Front Wheel-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160002.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/56024.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/56025.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 21 mm Wheel spanner/ deep socket spanner, loosen and remove the wheel mounting bolts.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160003.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque :140\u00b110 Nm",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the mounting bolts and then remove the wheel.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160004.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160005.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 10
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external damage in the tyre or the rim, if found replace.Check for any foreign material on tyre or rim, remove if found.",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 123,
+ "sys_id": "THAR.LX-0004-Wheel & Tyre",
+ "subsys_id": "THAR.LX-0004-Wheel & Tyre-Spare Wheel Carrier",
+ "systems": "Wheel & Tyre",
+ "sub_systems": "Spare Wheel Carrier",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A160022.jpg",
+ "myid": 1244,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Spare Wheel Carrier-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160022.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10412.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10413.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the spare wheel. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1014,1513",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, loosen and remove the spare wheel carrier mounting bolts.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160023.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 50\u00b17.5 Nm",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the spare wheel carrier from the vehicle.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160024.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160025.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 12
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external damage in the spare wheel carrier , if found replace.",
+ "file": null,
+ "display_order": 13
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 129,
+ "sys_id": "THAR.LX-0004-Wheel & Tyre",
+ "subsys_id": "THAR.LX-0004-Wheel & Tyre-Spare Wheel",
+ "systems": "Wheel & Tyre",
+ "sub_systems": "Spare Wheel",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A160019.jpg",
+ "myid": 1513,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Spare Wheel-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160019.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/56034.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/56035.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 21 mm socket spanner, loosen and remove the wheel nuts on the spare wheel carrier.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160021.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque :70\u00b110 Nm",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the spare wheel from the vehicle.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160020.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160005.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 10
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external damage in the tyre or the rim, if found replace.Check for any foreign material on tyre or rim, remove if found.",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 121,
+ "sys_id": "THAR.LX-0004-Wheel & Tyre",
+ "subsys_id": "THAR.LX-0004-Wheel & Tyre-Tyre Rotation",
+ "systems": "Wheel & Tyre",
+ "sub_systems": "Tyre Rotation",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J08-MAT-0530",
+ "cover_image": "/files/tyrerotatioon_cover_image.JPG",
+ "myid": 1242,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 18,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 49,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 88,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 129,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 167,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 208,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 248,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 288,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 328,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 367,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 409,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Tyre Rotation-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Tyre Rotation.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10394.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Preliminary Activities/ Conditions",
+ "content_type": "Description",
+ "content": "Position the vehicle on 2 post lift",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Preliminary Activities/ Conditions",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S2B110007.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Tyre Rotation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S2B110007.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Below illustration shows suggested tyre rotation method:",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Tyres on the front and rear side of vehicles operate at different loads and perform different steering, handling, and braking functions. For these reasons, they wear at unequal rates and develop irregular wear patterns. Rotation will increase tread life. help to maintain mud, snow, and wet traction levels, and contribute to a smooth quiet ride Follow the recommended tyre rotation frequency for your type of driving more frequent rotation is permissible f desired. The reasons for any rapid or unusual wear should be corrected prior to rotation being performedIt is recommended to rotate the tyres as per 'Maintenance Schedule'.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10396.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "TPMS Learning needs to be carried out for vehicle models equipped with TPMS(Tyre Pressure Monitoring System), procedure as below.",
+ "file": null,
+ "display_order": 9
+ }
+ ]
+ },
+ {
+ "procedure_name": "TPMS Learning",
+ "steps": [
+ {
+ "step_name": "Preliminary Activities/ Conditions",
+ "content_type": "Description",
+ "content": "Position the vehicle on a flat surface",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "TPMS Learning - Procedure",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090057.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Press the Scroll Up arrow button on Driver side switch bank and simultaneously turn the ignition ON.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W317.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Wait for cluster\u2019s tachometer & speedometer self-check rotation and then release the arrow button.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A180055.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A180056.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Identifying weather the learning is initiated.Infotainment will show popped out screen TPMS Learning screen.TPMS telltale in cluster shall keep blinking.Three vehicle siren chirps will be heard.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "If failed to enter in to manual learning mode.Try initiating the manual learning once again.Check if reverse gear is engaged, if engaged disengage it.Check MBFM, Infotainment & Cluster software versions.Check if variant coding is done in all three.Check if Scroll Up arrow button on Driver side switch bank button is working fine.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "TPMS learning procedure must be done in the below sequence:Front left tyreFront right tyreRear right tyreRear left tyreSpare tyre",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Start leaking the air from front left tyre for 30 to 40 seconds & stop for 5 seconds.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160044.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Repeat until the tyre gets learnt.If front left tyre is learned 1 siren chirp sound is heard and FL tyre shows learned in infotainment system.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Start leaking the air from front right tyre for 30 to 40 seconds & stop for 5 seconds.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160045.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Notice",
+ "content": "Repeat until the tyre gets learnt.If front right tyre is learned 1 siren chirp sound is heard and FR tyre shows learned in infotainment system.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Start leaking the air from rear right tyre for 30 to 40 seconds & stop for 5 seconds.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160046.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Notice",
+ "content": "Repeat until the tyre gets learnt.If rear right tyre is learned 1 siren chirp sound is heard and RR tyre shows learned in infotainment system.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Start leaking the air from rear left tyre for 30 to 40 seconds & stop for 5 seconds.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160047.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Notice",
+ "content": "Repeat until the tyre gets learnt.If Rear left tyre is learned 1 siren chirp sound is heard and RL tyre shows learned in infotainment system.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Start leaking the air from the spare wheel tyre for 30 to 40 seconds & stop for 5 seconds.",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160048.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Notice",
+ "content": "Repeat until the tyre gets learnt.If spare tyre is also learned then 1 siren chirp sound is heard and ALL tyres show learned at respective tyre positions and \u2018All tyres Learned successfully\u2019 in the center of the screen.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160049.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "At any point of time during the learning process, if learning takes more than 90 seconds of time for each tyre position then the system shall exit the learning mode and show the \u201cLearning not successful\u201d screen.",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160050.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Caution",
+ "content": "After tyre rotation or TPMS sensor replacement, TPMS must be learnt, otherwise the system will show TPMS malfunction indicator.TPMS learning need to be carried out whenever :Tyre rotation happens.2 or more wheels are swapped.TPMS sensor is replaced.MBFM is replaced.The TPMS should not be used as a tyre pressure gauge while adjusting vehicle tyre pressure.",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Notice",
+ "content": "No two vehicles should be done with manual learning process at a time in same location with in radius of 20 meters.Post to manual learning all tire should be filled with recommended tyre pressure value.",
+ "file": null,
+ "display_order": 40
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 124,
+ "sys_id": "THAR.LX-0004-Wheel & Tyre",
+ "subsys_id": "THAR.LX-0004-Wheel & Tyre-Front Wheel Hub",
+ "systems": "Wheel & Tyre",
+ "sub_systems": "Front Wheel Hub",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A160026.jpg",
+ "myid": 1245,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Front Wheel Hub-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160026.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10418.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10419.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the front wheel - R&R.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0005,1014,1245",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using chisel Remove the drive shaft mounting nut caulking.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Front.png",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 36 mm socket spanner, loosen and remove Drive shaft mounting nut by Applying brake.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160027.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 240 \u2013 260 Nm",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the caliper stem mounting bolts then hang the caliper.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130167.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 31 \u2013 38 Nm",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Pull the Brake Pad outwards upto pad contact with clip as shown in the illustration.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130294.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Twist the pad in anti clock wise direction, lift the pad upwards and remove the pad.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130363.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130367.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 19 mm socket spanner, loosen and remove the caliper bracket mounting bolts then remove the caliper bracket.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130331.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 90 \u2013 100 Nm",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using star screw driver, remove the brake disc mounting screw and detach the disc from the front wheel hub.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130173.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the disc separately.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130174.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 19 mm socket spanner, loosen and remove Hub mounting bolts and remove the hub with carrier plate.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160029.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque : 87 - 90 Nm",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160030.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Caution",
+ "content": "Before assembly clean the mating faces of the front wheel hub and brake disc.",
+ "file": null,
+ "display_order": 31
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external damage in the wheel hub, if found replace.Check for any wheel hub bearing condition, if found replace.",
+ "file": null,
+ "display_order": 32
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 126,
+ "sys_id": "THAR.LX-0004-Wheel & Tyre",
+ "subsys_id": "THAR.LX-0004-Wheel & Tyre-Troubleshoot - Wheel & Tyre",
+ "systems": "Wheel & Tyre",
+ "sub_systems": "Troubleshoot - Wheel & Tyre",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1465,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Troubleshoot - Wheel & Tyre-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Symptom Possible Causes",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/6061.pdf",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 128,
+ "sys_id": "THAR.LX-0004-Wheel & Tyre",
+ "subsys_id": "THAR.LX-0004-Wheel & Tyre-Rear Wheel",
+ "systems": "Wheel & Tyre",
+ "sub_systems": "Rear Wheel",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A160051.jpg",
+ "myid": 1512,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Rear Wheel-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160051.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/56030.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/56031.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 21 mm Wheel spanner/ deep socket spanner, loosen and remove the wheel mounting bolts.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160052.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque :140\u00b110 Nm",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the mounting bolts and then remove the wheel.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160053.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160054.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 10
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external damage in the tyre or the rim, if found replace.Check for any foreign material on tyre or rim, remove if found.",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 122,
+ "sys_id": "THAR.LX-0004-Wheel & Tyre",
+ "subsys_id": "THAR.LX-0004-Wheel & Tyre-Tyre Pressure - Check & Adjust",
+ "systems": "Wheel & Tyre",
+ "sub_systems": "Tyre Pressure - Check & Adjust",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J08-MAT-0610",
+ "cover_image": "/files/W4A160038.jpg",
+ "myid": 1243,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 14,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 62,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 101,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 141,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 181,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 220,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 261,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 301,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 341,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 379,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 423,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Tyre Pressure - Check & Adjust-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Tyre Pressure- Inspect & Adjust",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Tyre Pressure - Check & Adjust.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Tyre Pressure- Inspect & Adjust",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Proper Tyre inflation pressure is essential to the safe and satisfactory operation of your vehicle. Three primary areas are affected by improper Tyre pressure:SafetyEconomyRide Comfort and Vehicle StabilityProper Tyre inflation contributes to a comfortable and safe ride. Over inflating produces a jarring and uncomfortable ride. Both under inflation and over inflation affect the stability of the vehicle and can produce a feeling of sluggish response or over responsiveness in the steering. Unequal Tyre pressures can cause erratic and unpredictable steering response or may cause the vehicle to drift left or right.Improper inflation pressures can cause uneven wear patterns to develop across the Tyre tread. These abnormal wear patterns will reduce tread life resulting in a need for earlier Tyre replacement. Under inflation also increases Tyre rolling resistance and results in higher fuel consumption.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Heading",
+ "content": "TYRE PRESSURE LABEL:",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160038.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Tyre Label is located on the driver side inner B-pillar. This label tells you important information about tyre size designed for your vehicle, and the tyre inflation pressures for the front & rear tyres.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Never overload the vehicle. Overloading can cause tyre failure, affect vehicle handling, and increase your stopping distance, resulting in an accident and/ or personal injury.Improper inflated tyres can adversely affect vehicle handling or can fail unexpectedly, resulting in an accident and or personal injury.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10410.jpg",
+ "display_order": 8
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 120,
+ "sys_id": "THAR.LX-0004-Wheel & Tyre",
+ "subsys_id": "THAR.LX-0004-Wheel & Tyre-Wheel Balancing",
+ "systems": "Wheel & Tyre",
+ "sub_systems": "Wheel Balancing",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J08-MAT-0540",
+ "cover_image": "/files/W4A180032.jpg",
+ "myid": 1241,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 19,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 65,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 105,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 144,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 184,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 223,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 264,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 304,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 344,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 382,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 426,
+ "kilometers_applicable": 0
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Wheel Balancing-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "If weight is not equally distributed around the wheel, unbalance centrifugal force by the wheel rotation produces vibration. As the centrifugal force is produced proportional to the square of the rotating speed, the wheel weight should be balanced even at high speed. There are two types of the tire and wheel balancing: static and dynamic. Abnormal vibration may also occur due to unbalanced rigidity or size of tyres",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Heading",
+ "content": "Static Balance",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A180032.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "When the free rotation of the wheel is allowed, the heavier part is stopped on the bottom if the wheel weight is unbalanced and this is called 'Static Unbalance'Also, the state at which tyre's stop position is not same is called 'Static Balance' when the wheel is rotated again. If the part A is heavier as shown in the figure, add the \u201cbalance weight\u201d corresponding to unbalanced weight from B to A to maintain the static balance. If the static balance is not maintained, tramping, up and down vibration of the wheels, occurs.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Heading",
+ "content": "Dynamic Balance",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/DBalance.png",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "The static unbalance of the wheel creates the vibration in the vertical direction, but the dynamic unbalance creates the vibration in the lateral direction. As shown in the figure (A), if two parts, (2) and (3), are heavier when the wheels are under the static balance condition, dynamic unbalance is created, resulting in shimmy, left and right vibration of the wheels, and the torque Fxa is applied in the axial direction. To correct the dynamic unbalance, add the balance weight of a same weight for two points of the circumference of the rim, M1 and M2, as shown in the figure (B), and apply the torque in the opposite direction to the torque Fxa to offset in order to ensure smooth rotation of the wheel.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "The wheel should always be balanced and aligned in order to provide:Enhanced tyre lifeDriving safety and steering control.Better performance of the vehicle.Unbalanced tyre may lead to premature tyre wear and driver fatigue due to vibration. Tyres should always be balanced when they are mounted on wheels for the first timeWhen they are remounted after repairWhen there are signs of shimmy or vibrations.",
+ "file": null,
+ "display_order": 8
+ }
+ ]
+ },
+ {
+ "procedure_name": "Precautions",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Deposits of mud, dust must be cleaned from inside of the rimRemove stones from tread, clean the tyre and rim before balancing to achieve better results.Each tyre should be inspected for any damage.The type of balance weights, when used, must be in accordance with the profile of the rim flange. Refer below recommendations for usage of balance weights.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S1A120027.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "For balancing a wheel, follow the manufacturer\u2019s (of balancing machine) manual for balancing instructions, recommendations and any other additional information.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S1A120028.jpg",
+ "display_order": 12
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 125,
+ "sys_id": "THAR.LX-0004-Wheel & Tyre",
+ "subsys_id": "THAR.LX-0004-Wheel & Tyre-Wheel & Tyre System Technical Spec",
+ "systems": "Wheel & Tyre",
+ "sub_systems": "Wheel & Tyre System Technical Spec",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1246,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Wheel & Tyre System Technical Spec-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Specification",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4726.jpg",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 281,
+ "sys_id": "THAR.LX-0004-en-SM-Interior & Exterior Lighting ",
+ "system_name": "Interior & Exterior Lighting ",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1027,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 295,
+ "sys_id": "THAR.LX-0004-Interior & Exterior Lighting",
+ "subsys_id": "THAR.LX-0004-Interior & Exterior Lighting-Switch Bank Driver Side",
+ "systems": "Interior & Exterior Lighting",
+ "sub_systems": "Switch Bank Driver Side",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A270114.jpg",
+ "myid": 1413,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Switch Bank Driver Side-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270114.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10820.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10821.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Instrumental Panel Assembly.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1020,1342",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270120.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a star driver,loosen and remove the IP driver side switch bank mounting screws.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 1.5 \u00b1 0.5 Nm",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270121.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Detach the IP driver side switch bank from the Instrumental Panel Assembly",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the IP driver side switch bank condition, if required replace.",
+ "file": null,
+ "display_order": 12
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 292,
+ "sys_id": "THAR.LX-0004-Interior & Exterior Lighting",
+ "subsys_id": "THAR.LX-0004-Interior & Exterior Lighting-Switch ORVM",
+ "systems": "Interior & Exterior Lighting",
+ "sub_systems": "Switch ORVM",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A270006.jpg",
+ "myid": 1410,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Switch ORVM-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270006.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10799.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10800.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270007.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "By using Trim Removal tool, remove the bezel rest from front door RH.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270098.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect the electrical connector from the bezel.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270009.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270010.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using flat screw driver detach the switch from the bezel. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the mounting clips condition to avoid rattling and falling down.Check the switch condition. If required replace.",
+ "file": null,
+ "display_order": 12
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 293,
+ "sys_id": "THAR.LX-0004-Interior & Exterior Lighting",
+ "subsys_id": "THAR.LX-0004-Interior & Exterior Lighting-Center Fascia Switch",
+ "systems": "Interior & Exterior Lighting",
+ "sub_systems": "Center Fascia Switch",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A270002.jpg",
+ "myid": 1411,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Center Fascia Switch-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270002.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10805.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10806.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the IP center switch bank assembly.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1027,1412",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270003.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a star driver, loosen and remove the center switch mounting screws.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 1.5 \u00b1 0.5 Nm",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270005.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the center switch from IP center switch bank assembly.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the mounting clips condition to avoid rattling and falling down.
Check the switch condition. If required replace.
",
+ "file": null,
+ "display_order": 12
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 283,
+ "sys_id": "THAR.LX-0004-Interior & Exterior Lighting",
+ "subsys_id": "THAR.LX-0004-Interior & Exterior Lighting-Head Lamp Assembly",
+ "systems": "Interior & Exterior Lighting",
+ "sub_systems": "Head Lamp Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A270019.jpg",
+ "myid": 1401,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Head Lamp Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270019.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10724.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10725.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove front grill assembly.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1024,1368",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270020.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Pull the lock disconnect head lamp electrical connectors.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270021.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen and remove the head lamp mounting bolts.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 6 \u00b11Nm",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270022.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the head lamp assembly separately.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270023.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the head lamp for any damage, crack and glass fading.Inspect the bulbs.",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 286,
+ "sys_id": "THAR.LX-0004-Interior & Exterior Lighting",
+ "subsys_id": "THAR.LX-0004-Interior & Exterior Lighting-Side Marker Lamp",
+ "systems": "Interior & Exterior Lighting",
+ "sub_systems": "Side Marker Lamp",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A270036.jpg",
+ "myid": 1404,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Side Marker Lamp-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270036.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10747.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4696.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250193.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front splash shield lower mounting screws.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250191.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.5 \u00b10.7Nm",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 4 \u00b10.5 Nm",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270037.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the electrical connector.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270038.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using hand, Push the side marker lamp assembly from the cladding and remove.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270039.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the Side Marker Lamp from vehicle.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the side marker lamp assembly for any physical damage/crack etc.Inspect the glass for fading.Inspect the condition of bulbs.Inspect the connectors for proper fitment.",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 284,
+ "sys_id": "THAR.LX-0004-Interior & Exterior Lighting",
+ "subsys_id": "THAR.LX-0004-Interior & Exterior Lighting-Front Turn Indicator And DRL",
+ "systems": "Interior & Exterior Lighting",
+ "sub_systems": "Front Turn Indicator And DRL",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A270113.jpg",
+ "myid": 1402,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Front Turn Indicator And DRL-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270113.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10731.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10732.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250193.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front splash shield lower mounting screws (Front side screws).",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250191.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nut.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the front side of shield to access front turn indicator and DRL.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270110.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the front turn indicator and DRL electrical connectors.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270111.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner loosen and remove the front turn indicator and DRL mounting bolts.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 4\u00b11 Nm",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270112.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully remove front turn indicator and DRL.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the front turn indicator and DRL for any damage, replace if required",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 287,
+ "sys_id": "THAR.LX-0004-Interior & Exterior Lighting",
+ "subsys_id": "THAR.LX-0004-Interior & Exterior Lighting-Side Marker Lamp Bulb",
+ "systems": "Interior & Exterior Lighting",
+ "sub_systems": "Side Marker Lamp Bulb",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A270046.jpg",
+ "myid": 1405,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Side Marker Lamp Bulb-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270046.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10756.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10757.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250193.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front splash shield lower mounting screws.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250191.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.5 \u00b10.7 Nm",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 4 \u00b10.5 Nm",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270047.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Rotate the bulb holder in anti clock wise direction and remove the holder with bulb.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270048.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the bulb from the holder.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the bulb condition to avoid rattling and falling down.Check the bulb condition. If required replace.",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 290,
+ "sys_id": "THAR.LX-0004-Interior & Exterior Lighting",
+ "subsys_id": "THAR.LX-0004-Interior & Exterior Lighting-Reverse Lamp Bulb",
+ "systems": "Interior & Exterior Lighting",
+ "sub_systems": "Reverse Lamp Bulb",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A270080.jpg",
+ "myid": 1408,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Reverse Lamp Bulb-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270080.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10783.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10784.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270041.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove tail lamp cover from tail lamp.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270042.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner unscrew tail lamp mounting bolts.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 4 \u00b10.5 Nm",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270044.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect tail lamp electrical connector.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270081.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove and turn the backup lamp bulb socket in the direction of the arrow.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270082.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the reverse lamp bulb from holder.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the bulb condition to avoid rattling and falling down.Check the bulb condition. If required replace.",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 291,
+ "sys_id": "THAR.LX-0004-Interior & Exterior Lighting",
+ "subsys_id": "THAR.LX-0004-Interior & Exterior Lighting-Rear Indicator Bulb",
+ "systems": "Interior & Exterior Lighting",
+ "sub_systems": "Rear Indicator Bulb",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A270077.jpg",
+ "myid": 1409,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Rear Indicator Bulb-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270077.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10791.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10792.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270041.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove tail lamp cover from tail lamp.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270042.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner unscrew tail lamp mounting bolts.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque :4 \u00b10.5 Nm",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270044.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Disconnect tail lamp electrical connector.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270078.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Remove the bulb from holder by turning the bulb in counter clock wise direction. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270082.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Gently pull out the bulb from holder.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the bulb condition to avoid rattling and falling down.Check the bulb condition. If required replace.",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 289,
+ "sys_id": "THAR.LX-0004-Interior & Exterior Lighting",
+ "subsys_id": "THAR.LX-0004-Interior & Exterior Lighting-Front Park Lamp Bulb",
+ "systems": "Interior & Exterior Lighting",
+ "sub_systems": "Front Park Lamp Bulb",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A270057.jpg",
+ "myid": 1407,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Front Park Lamp Bulb-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270057.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4698.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10775.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250193.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front splash shield lower mounting screws.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250191.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.5 \u00b1 0.7 Nm",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 4 \u00b10.5 Nm",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270058.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect parking lamp electrical connector.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270059.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Rotate and remove the bulb holder from vehicle.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270060.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove bulb from holder by turning the bulb in counter clock wise direction.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Detach the bulb from holder.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the bulb condition to avoid rattling and falling down.Check the bulb condition. If required replace.",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 282,
+ "sys_id": "THAR.LX-0004-Interior & Exterior Lighting",
+ "subsys_id": "THAR.LX-0004-Interior & Exterior Lighting-Head Light Aiming - Check & Adjust",
+ "systems": "Interior & Exterior Lighting",
+ "sub_systems": "Head Light Aiming - Check & Adjust",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J08-MAT-0570",
+ "cover_image": "/files/W4A270085.jpg",
+ "myid": 1400,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 12,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 69,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 110,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 150,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 189,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 228,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 269,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 308,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 349,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 388,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 429,
+ "kilometers_applicable": 0
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Head Light Aiming - Check & Adjust-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Check & Adjust",
+ "steps": [
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Head Lamp Aiming - Check & Adjust.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270085.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "Description",
+ "content": "Vehicle & head lamp aiming board should place on the same level surfaceCheck and ensure all four tyre pressures as per specification.Head lamp levelling switch position is on zero (0).Vehicle needs to be parked 10 meters or 3 meters away from the aiming board. (L = 10 meters / 3 meters which is the distance from starting point of front tyre to the aiming board as shown in illustration below).Select the aiming board according to the value of \u201cL\u201d.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "Heading",
+ "content": "Refer illustration for \u201cL= 10 Meters\u201d",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10713.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270086.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Refer illustration for \u201cL= 3 Meters\u201d.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270091.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Heading",
+ "content": "Refer the illustration for the head lamp adjustment arrangement - ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270087.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270088.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Heading",
+ "content": "Refer the illustration for the head lamp aiming board dimensions of Head Lamps -",
+ "file": null,
+ "display_order": 12
+ }
+ ]
+ },
+ {
+ "procedure_name": "Low Beam Setting Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270089.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270090.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Refer below illustration for the head lamp aiming board dimensions of Head Lamps :",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Low beam & high beam aiming settings are common. Hence if adjust low beam, high beam will also get aligned with low beam.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1A270096.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1A270097.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 5 mm socket spanner, rotate the adjusting screw on motor to vary the Low beam cut-off pattern in vertical direction.Clockwise rotation \u2013 Downwards.Anti-clockwise rotation \u2013 Upwards.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1A270093.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver, rotate the RH side lamp adjusting screw to vary the low beam cut-off pattern in horizontal direction.Clockwise rotation \u2013 Left side.Anti-clockwise rotation \u2013 Right side.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "RH & LH Head lamps are common for New THAR vehicle.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1A270095.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using star screw driver, rotate the LH side lamp adjusting screw to vary the low beam cut-off pattern in horizontal direction.Clockwise rotation \u2013 Right side.Anti-clockwise rotation \u2013 Left side.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Check the function of system, by operating the switch from '0' to '3' and observe the cutoff pattern movement in downward direction accordingly.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "At zero position of switch, the cut- off should come at \u201ch\u201d heights 833 mm (For L= 10,000 mm) & 924 mm (For L=3,000 mm) on screen.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Low beam & high beam aiming settings are common. Hence if adjust low beam, high beam will also get aligned with low beam.",
+ "file": null,
+ "display_order": 27
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 281,
+ "sys_id": "THAR.LX-0004-Interior & Exterior Lighting",
+ "subsys_id": "THAR.LX-0004-Interior & Exterior Lighting-All Lamps, Horns, Wipers & Washers-Check",
+ "systems": "Interior & Exterior Lighting",
+ "sub_systems": "All Lamps, Horns, Wipers & Washers-Check",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J08-MAT-0560",
+ "cover_image": "/files/W4A270063.jpg",
+ "myid": 1399,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 10,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 58,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 97,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 137,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 177,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 216,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 257,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 297,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 337,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 375,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 419,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-All Lamps, Horns, Wipers & Washers-Check-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "All Lamps Horns Wipers & Washers-Check",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270063.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/All Lamps, Horn, Wiper & Washer - Check.mp4",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "RIGHT TURN INDICATOR",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "For inspection, push the lighting control stalk clockwise (to stop position B) to indicate a right turn. The instrument cluster arrow lamp pointing towards the right flashes along with the right side turn signal lamps with chime indicating your intention of turning towards rightAfter you have completed your right turn, the stalk will automatically return to the neutral position. Both the right turn lamp and the right turn signal lamp switch OFF.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "LEFT TURN INDICATOR",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "For inspection, push the lighting control stalk anti-clockwise (to stop position A) to indicate a left turn. The instrument cluster arrow lamp pointing towards the left flashes along with the left side turn signal lamps with chime indicating your intention of turning towards left.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270062.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Heading",
+ "content": "LAMPS OFF",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "For inspection, rotate the outer rotary switch on the lighting control stalk aligning the \u2018Arrow\u2019 on the switch to \u2018O\u2019 on the stalk to switch OFF all lamps.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270066.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Heading",
+ "content": "LANE CHANGING",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "For inspection of signal a lane change, move the light control stalk clockwise or anti-clockwise to the limit point of free movement of the lever and release. The turn signals will flash three times and stop.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270064.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "PARKING LAMPS ON",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "For inspection, rotate the outer rotary switch on the lighting control stalk aligning the \u2018arrow\u2019 on the switch to the \u20181st d\u00e9tente\u2019 position on the stalk to switch ON the parking lamps.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270066.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "HEAD LAMP ON",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "For inspection, rotate the outer rotary switch on the lighting control stalk aligning the \u2018Arrowt\u2019 on the switch to the \u20182nd d\u00e9tente\u2019 position on the stalk to switch ON the head lamps.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270067.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10701.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "HEAD LAMP HIGH BEAM/LOW BEAM",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "For inspection, with the head lamp ON, push the lighting control stalk down (away) from steering wheel to switch ON the head lamp high beam. The head lamp high beam tell-tale lamp in the instrument cluster illuminates indicating high beam option selected.With the head lamp high beam ON, pull the lighting control stalk up towards the steering wheel to switch ON the head lamp low beam.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270068.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Heading",
+ "content": "HEAD LAMP FLASH",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "For inspection, pull the lighting control stalk (from the head lamp low beam position) towards the steering wheel to instantaneously flash the head lamp high beam.The head lamp flash works even when the head lamp is OFF.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270071.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Heading",
+ "content": "FOG LAMPS OFF",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "For inspection, align the inner rotary switch on the lighting control stalk to the fog lamp off \u2018dot\u2019 on the inner fixed stalk as shown to switch OFF the fog lamps.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270070.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Heading",
+ "content": "FRONT FOG LAMPS ON",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "To inspect the front fog lamps, switch ON the ignition and the parking lamps. Turn the inner rotary switch on the lighting control stalk to align to the fog lamp symbol on the inner fixed stalk as shown.The front fog lamp indicator in the instrument cluster indicates the operation status.",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270072.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Heading",
+ "content": "HAZARD WARNING LAMP",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "For inspection, press the hazard switch ON, All the turn signal lamps flash. To turn OFF, press the switch again.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270073.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Heading",
+ "content": "CENTER ROOF LAMP",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "The Roof lamp switch has three operation modes to choose from;The lamp remains permanently ON in this position irrespective of the door open statusThe lamp remains permanently OFF in this positionThe lamp remains in AUTO mode in this position.",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A320001.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/499.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "WIPER CONTROL STALK",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "Wiper Off",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "For inspection, move the wipe stalk in neutral position (B). Wiper remains OFF.",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "Flick-Wipe (Mist)",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "For inspection, push the wipe control stalk to position A for a flick-wipe, hold to operate the wipe continuously (simultaneously lift the wiper stalk towards the steering wheel to operate the wash). The stalk automatically comes back to position B when released.",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "Intermittent (INT) Mode",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "For inspection, push down the stalk down to position C. In the INT mode, the wiper operates on preset intervals.",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "Low Speed Wiping",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "For inspection, push the wipe control stalk up to the position D to operate the wiper at a fixed low speed.",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "High Speed Wiping",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "For inspection, push the wiper control stalk up to position E to operate the wiper at a fixed high speed.",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A320002.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Heading",
+ "content": "FRONT WIPE/WASH",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "For inspection, pull/lift the wiper control stalk towards the steering wheel from any position to activate the front wipe/wash function. Washer fluid is sprayed on the front windshield and the wipers wipe the windshield 3 times after the washer spray is stopped and wipe once after 4 sec. Hold the stalk in position for continuous spray of washer fluid.",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210020.jpg",
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "HORN",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "For inspection, press the pad on the steering wheel to sound the horn. The horn functions even when the ignition has been switched OFF.",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270076.jpg",
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Heading",
+ "content": "STOP LAMP/HIGH MOUNTED STOP LAMP",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "For inspection, Press the brake pedal and the Stop Lamp /high mounted stop lamp will illuminate.",
+ "file": null,
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270040.jpg",
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Heading",
+ "content": "REVERSE LAMP",
+ "file": null,
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "For inspection, Engage the reverse gear and the reverse lamp will illuminate.",
+ "file": null,
+ "display_order": 62
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 296,
+ "sys_id": "THAR.LX-0004-Interior & Exterior Lighting",
+ "subsys_id": "THAR.LX-0004-Interior & Exterior Lighting-Head Lamp Aiming Switch",
+ "systems": "Interior & Exterior Lighting",
+ "sub_systems": "Head Lamp Aiming Switch",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A270124.jpg",
+ "myid": 1414,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Head Lamp Aiming Switch-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Head Lamp Aiming - Check & Adjust.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270124.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10825.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10826.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the switch bank driver side .",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1027,1413",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270122.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the aiming switch lock by using flat screw driver.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Insert the screw driver one side to release lock & release other side.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270123.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Detach the IP driver side switch bank from the vehicle.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 12
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the aiming switch condition, if required replace.",
+ "file": null,
+ "display_order": 13
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 297,
+ "sys_id": "THAR.LX-0004-Interior & Exterior Lighting",
+ "subsys_id": "THAR.LX-0004-Interior & Exterior Lighting-Bulb Specification",
+ "systems": "Interior & Exterior Lighting",
+ "sub_systems": "Bulb Specification",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1415,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Bulb Specification-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Specification",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4700.jpg",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 294,
+ "sys_id": "THAR.LX-0004-Interior & Exterior Lighting",
+ "subsys_id": "THAR.LX-0004-Interior & Exterior Lighting-IP Center Switch Bank Assembly",
+ "systems": "Interior & Exterior Lighting",
+ "sub_systems": "IP Center Switch Bank Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A270130.jpg",
+ "myid": 1412,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-IP Center Switch Bank Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270130.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10810.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10811.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290032.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console RH screvits and detach the panel from vehicle",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 2.5 \u00b1 0.2 Nm",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290031.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console LH screvits and detach the panel from vehicle.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 2.5 \u00b1 0.2 Nm",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290034.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew vertical ascent RH mounting screw and detach the vertical ascent RH from vehicle.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 2.5 \u00b1 0.2 Nm",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290033.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew vertical ascent LH mounting screw and detach the vertical ascent LH from vehicle.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 2.5 \u00b1 0.2 Nm",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290035.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290036.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270129.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "partially detach the switch bank assembly and remove electric connector to take out from the vehicle.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the center switch for any physical damage. Replace if found.",
+ "file": null,
+ "display_order": 21
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 288,
+ "sys_id": "THAR.LX-0004-Interior & Exterior Lighting",
+ "subsys_id": "THAR.LX-0004-Interior & Exterior Lighting-Front Indicator Bulb",
+ "systems": "Interior & Exterior Lighting",
+ "sub_systems": "Front Indicator Bulb",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A270032.jpg",
+ "myid": 1406,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Front Indicator Bulb-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270032.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10764.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10765.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250193.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front splash shield lower mounting screws.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250191.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque :6.5\u00b10.7 Nm",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 4 \u00b10.5 Nm",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270033.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect front indicator electrical connector.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270034.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Rotate and remove the bulb holder from vehicle.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270035.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove bulb from holder by turning the bulb in counter clock wise direction. ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the bulb holder condition to avoid rattling and falling down.Check the bulb condition. If required replace.",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 285,
+ "sys_id": "THAR.LX-0004-Interior & Exterior Lighting",
+ "subsys_id": "THAR.LX-0004-Interior & Exterior Lighting-Tail Lamp Assembly",
+ "systems": "Interior & Exterior Lighting",
+ "sub_systems": "Tail Lamp Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A270040.jpg",
+ "myid": 1403,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Tail Lamp Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270040.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10739.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10740.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270041.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Pull and remove the tail lamp cover from vehicle.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270042.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270043.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen and remove tail lamp mounting bolts and partially detach it.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 4 \u00b1 0.5 Nm",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270044.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect tail lamp electrical connector.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270045.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove tail lamp from vehicle.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the tail lamp/ rear lamp assembly for any physical damage/crack etc.Inspect the glass for fading.Inspect the condition of bulbs.Inspect the connectors for proper fitment.",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 249,
+ "sys_id": "THAR.LX-0004-en-SM-Exterior System",
+ "system_name": "Exterior System",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1024,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 260,
+ "sys_id": "THAR.LX-0004-Exterior System",
+ "subsys_id": "THAR.LX-0004-Exterior System-Convertible Soft Top Frame Complete",
+ "systems": "Exterior System",
+ "sub_systems": "Convertible Soft Top Frame Complete",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A250267.jpg",
+ "myid": 1378,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Convertible Soft Top Frame Complete-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A25026776bc1b.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Convertible Soft top Frame Complete -1.png",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Convertible Soft top Frame Complete.png",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Convertible Soft top Canopy. Remove the support centre Rexine rivets other side. Remove the Support Side Rexines rivets RH & LH. Using star screw driver, loosen and remove the Bow 1 Injection Mould mounting screws (locate 1 screw at bottom side of centre rexine support). Using star screw driver, loosen and remove the Latch mounting screws. Remove the Bow 1 Injection mould from front side bow and remove the Convertible Soft top Frame Complete assembly. Refit in the reverse order of removal. Inspect the Convertible Soft top Frame Complete assembly for any crack or damage. Replace if any. Remove the Spare Wheel Carrier. Remove the air extractor from the vehicle. Refit in the reverse order of removal. Inspect the air extractor for any crack or damage. Replace if any. Remove the convertible soft top assembly Using a star screw driver, loosen and remove Canopy mounting screws from the front side bow assembly RH and LH. Remove the lock from the RH and LH Front side bow assembly. Using star screw driver, loosen and remove Canopy mounting screws from Front side bow assembly inner side. Remove the Canopy from the front side bow assembly. Detach or unlock the spring from the Bow 2 Pivot assembly & remove Canopy from Bow 2 Pivot assembly . Using star screw driver, loosen and remove the canopy mounting screws from bow 2 pivot assembly and detach canopy. Using star screw driver, loosen and remove the canopy mounting screws from bow 3 assembly and detach canopy. Remove the Center Support Rexine Rivets. Remove the Canopy from the Frame. Remove the Cable with Spring from the Canopy (RH &LH;). Refit in the reverse order of removal. While Installation, Insert the cable from bracket side to Spring side (Insert spring inside from top) Inspect the convertible soft top canopy for any crack or damage. Replace if any. Remove the HVAC Mode Actuator. Using star screw driver, Unscrew plate mode main link mounting screws and remove the link. Remove the lever sub assembly and lever foot from the plate mode main link. Install in the reverse order of removal. Inspect the plate mode main link for any damage. Replace if found. Using screw driver, remove the floor console RH panel assembly scrivet and detach the panel from the vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220006.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220007.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the floor console LH panel assembly scrivet and detach the panel from vehicle Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220008.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W749.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the RH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220010.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W750.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the LH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290036.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Partially detach bezel HAVC control panel assembly and disconnect electrical connectors. Disconnect Heater, Mode selection control cables from the HAVC control panel. Disconnect the cable routing clips and take out the bezel Assembly with HVAC control panel. By using star screw driver, remove the HVAC control panel mounting screws and remove the panel from the bezel assembly. Torque : 1.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the HVAC Control Panel Assembly for any damage. Replace if found. Rotate the blower motor and check for any noise due to bearing wear.
Check the blower motor fan blade for damage. Replace the blower motor if necessary.
Whenever over voltage/under voltage situation will occur over ignition Line. These voltages will get sense by MCU and based on these sense voltages panel functionality will disabled or in case of under/over Voltage system will not detect any switch command. It is a kind of Security over connector Pins except Power supplies Pins. If any shorting occur on connector pin either short to battery or short to ground there should be no damage to control panel or circuitry. Over Current/Short to Ground: Face Indicator on off with Frequency 1000 mSec Interval. Short to Battery/ Actuator Stuck: Face Indicator on off with Frequency 500 mSec Interval Over Current/Short to Ground: Air Intake Indicator on off with Frequency 1000 mSec Interval. Short to Battery/ Actuator Stuck: Air Intake Indicator on off with Frequency 500 mSec Interval. Over Current/Short to Ground: Defrost Indicator on off with Frequency 1000 mSec Interval. Short to Battery/ Actuator Stuck: Defrost Indicator on off with Frequency 500 mSec Interval. AC Indicator Blink with 500 mSec Frequency. Do not release the refrigerant into the atmosphere. Use approved recovery/ recycling equipment to capture the refrigerant whenever the air conditioning System is discharged. Always wear eye and hand protection (goggles and gloves) when working with any Refrigerant or air conditioning system. Close the high pressure and low pressure refrigerant lines with dust caps to avoid air entry and/or contamination. Remove the Radiator LH & RH seal. Using 10 mm socket spanner, Unscrew HVAC Suction and return pipe mounting nuts. Torque : 6.0+1.0 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both pipes mounting joints without any damage. Damage to the O-ring may cause A/C refrigerant leakage which leads to A/c failure. Using 10 mm socket spanner, Unscrew condenser mounting bolts from radiator end. Torque : 5 \u00b11 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200186.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200074.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Remove the radiator bottom seal mounting bolts and detach it. Torque : 7\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200076.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Detach the ambient temperature sensor from the routing clip. Carefully remove the condenser from vehicle. Install in the reverse order of removal. Refit the Radiator LH & RH seal. Inspect the condenser for any physical damage, leakages etc. Replace if found any. Inspect for any foreign materials on condenser. Clean if found. Check and ensure free flow of condenser Using screw driver, remove the floor console RH panel assembly scrivet and detach the panel from the vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220006.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220007.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the floor console LH panel assembly scrivet and detach the panel from vehicle Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220008.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220009.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the RH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220010.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220011.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the LH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290035.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200152.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200153.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Partially detach HAVC control panel bezel and remove the mode cable from HVAC control panel end and routing clip. Remove the driver side IP panel assembly Disconnect the mode cable from HVAC unit end. Remove the cable from the vehicle. Install in the reverse order of removal. Inspect the HVAC mode cable for any damage, Replace if required. Inspect the Mode Cable locks for any damage, Replace if required. The Airbag ECU is installed on the floor panel under the floor console. It deploys the proper Airbag according to the signals from the impact sensors. This ECU communicates with other ECU\u2019s through CAN directly. Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Before disconnecting the battery, check for the audible sound of EWP ON Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Front console assembly.
Using star screw driver remove the Airbag ECU Cover screw from airbag ECU. Disconnect the SRS/ Airbag ECU electrical connectors. Using a 10 mm socket spanner, loosen the SRS/ Airbag ECU mounting nuts on the floor panel. Torque :8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210053.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210054.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the SRS/ Airbag ECU from the body. Install in the reverse order of removal. Inspect the airbag ECU for any damage, replace if found any. Inspect the airbag ECU connectors for any damage. For additional information refer to AC Gas Recharging Procedure. Park the vehicle on level work bay Open the left front door. HVAC Particle Filter \u2013 Replace Open the glow box and detach the stopper by pressing it. Disengage the glow box from the assembly. Press and remove the HVAC particulate filter cover from HVAC unit. Remove the HVAC particulate filter. Install the HVAC particulate filter on HVAC unit. Install the HVAC particulate filter cover. Engage the glow box stopper and refit the glow box in its position. While installing the filter take sufficient care to prevent bent, damage etc. Close the co-driver door. Use only genuine filter element. Never clean and reuse the HVAC particle filter element. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220006.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220007.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": " 1. Using screw driver, remove the floor console LH panel assembly scrivet and detach the panel from vehicle ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220008.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W747.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the RH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220010.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W748.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the LH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290035.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200156.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200157.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Partially detach HAVC control panel bezel and remove the heater cable from HVAC control panel end and routing clip. Open the glove box and remove the glove box by removing the glove box lock. Disconnect the heater cable from the HVAC unit end. Remove the cable from the vehicle. Install in the reverse order of removal. Inspect the HVAC heater cable for any damage, Replace if required. Inspect the heater Cable locks for any damage, Replace if required. Position the vehicle on 2 post lift/ 4 post lift. Check the HVAC drain pipe locking grommet fitment condition on BIW. Ensure that pipe is straight downwards. Do not pull the water drain pipe excessively. Disconnect air fresh and recirculation actuator electrical connector. Using star screw driver, Unscrew the actuator mounting screws. Remove the air fresh and recycling actuator . Install in the reverse order of removal. Inspect the actuator for mechanical damage. Check and clean the connector pins for sulphation and deposits. Do not release the refrigerant into the atmosphere. Use approved recovery/ recycling equipment to capture the refrigerant whenever the air conditioning System is discharged. Always wear eye and hand protection (goggles and gloves) when working with any Refrigerant or air conditioning system. Close the high pressure and low pressure refrigerant lines with dust caps to avoid air entry and/or contamination. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Front Grill Assembly. Remove the Air Cleaner Assembly. Using 10 mm open end spanner, Liquid pipe pipe mounting nut from expansion valve end. Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200062.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Remove Liquid pipe routing bracket mounting nut from the vehicle. Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200063.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200129.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen and remove the suction hose routing bracket mounting nut. Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200064.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect the pressure switch electrical connector. Using 10 mm socket spanner, Unscrew radiator LH seal mounting bolt and detach it. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200067.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew Liquid pipe mounting nut from condenser end. Torque : 6.0+1.0 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both end of liquid tube mounting joints without any damage. Damage to the O-ring may cause A/C refrigerant leakage which leads to A/c failure. Remove the liquid pipe from the vehicle. Install in the reverse order of removal. Refit the Air Cleaner Assembly. Refit the Front Grill Assembly. Inspect the suction hose assembly for any physical damage, leakages etc. Replace if found any. Inspect for any foreign materials on condenser. Clean if found. Check and ensure free flow of condenser. Remove the HVAC control panel. Remove the Glove Box Assembly. Remove the driver side IP panel assembly. Remove the wiring harness routing clips from the HVAC assembly. Disconnect the fresh air actuator, mode actuator, blower motor, blower resistor, evaporator temperature sensor and blower switch Connectors. Carefully remove the HVAC wiring harness from the IP assembly. Install in the reverse order of removal. Inspect the electrical connectors for mechanical damage. Replace if found. Check and clean the connector pins for sulphation and deposits. Remove the IP Centre Switch Bank Assembly. Using a star screw driver, Unscrew HVAC control unit mounting screws. Torque : 1.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200083.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the HVAC Control panel. Install in the reverse order of removal. Inspect the HVAC Control Panel Assembly for any damage. Replace if found. By using screw driver remove the TVD screw. Make aligning marks on the flange, UJ and propeller shaft before removal. Torque : 14 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130031.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 14 mm ring and socket spanners unscrew rear propeller shaft mounting bolts and nuts from transfer case end. Torque : 55 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130032.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W315.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W316.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the TVD assembly from vehicle and hang the Rear propeller shaft aside. Install in the reverse order of removal. If the propellers shaft unbalance is suspected then it can be verified by the following procedure, removing & rendering the propeller shaft by 180\u00b0 may eliminate some vibrations. Clean all the foreign material from propeller shaft and the universal joint. Ensure that the propeller shaft is not worn, are properly installed and are correctly aligned with the propeller shaft. Check the companion flange mounting bolts. Raise the vehicle and remove rear wheels & tyres. Install the wheel nuts to lock the brake drum. Mark & number the shaft 6 inches from pinion end at four positions 90\u00b0 apart. Run and accelerate the engine until vibration occurs. Note the intensity & the speed at which the vibration occurs. Start the engine and recheck for vibrations. If there is little vibration or no change in vibrations then move the clamp to the other 3 positions. If there is no difference in vibration at the other position then the vibration is not due to the propeller shaft imbalance. If the vibration decreases, install a second clamp and repeat the test. If the clamps cause an additional imbalance, separate the clamp (\u00bc inch above & below the mark). Repeat the vibration test. Increase the distance between the clamps until the vibration is at the lowest level. At this position bend the slack end of the clamp so that it does not loosen. Install the wheel & tyres. Lower the vehicle. If the amount of the vibration remains unacceptable then repeat the exercise at the gearbox end. After completing above procedure, if vibration is reduced, which indicates there is some imbalance in the propeller shaft. Replace the propeller shaft. Tyres that are out of round or wheels that are out of balance causes a low frequency vibration. \u2022 Brake drums that are unbalanced cause a harsh low frequency vibration. Drive line vibrations can also result from loose or damaged engine mountings Propeller shaft vibrations will keep on increasing as the vehicle speed increase. The propeller shaft does not cause a vibration that is present only in a narrow speed range. Refer below chart for various symptoms, causes and their remedial actions \u2013 ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/propellantshaft.png",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Component Inspection and Testing Table",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/propellantshaft1.png",
+ "display_order": 4
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 95,
+ "sys_id": "THAR.LX-0004-Propeller Shaft",
+ "subsys_id": "THAR.LX-0004-Propeller Shaft-Propeller Shaft Run out \u2013 Check",
+ "systems": "Propeller Shaft",
+ "sub_systems": "Propeller Shaft Run out \u2013 Check",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A130007.jpg",
+ "myid": 1216,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Propeller Shaft Run out \u2013 Check-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the propeller shaft from vehicle. Remove dirt, rust, paint & undercoating from the propeller shaft surface. Keep the propeller shaft on surface plate along with \u2018V\u2019 block at both ends. The dial indicator must be installed perpendicular to the shaft surface. Measure the run out at the center and at the ends by rotating propeller shaft assembly by hand \u2013 away from the weld. Replace the propeller shaft if the run out is beyond the specified limit. Position the vehicle on 2 post lift/ 4 post lift. Inspect the inboard and outboard joint RH side drive shaft boots, clamps for cut, nick, loose, bend, crush or abrasion. Replace if necessary. Rotate Steering wheel from one end to other for better visualization of boots. Inspect the RH side drive shaft condition for cracks or damage. Replace if necessary. Inspect the inboard and outboard joint LH side drive shaft boots, clamps for cut, nick, loose, bend, crush or abrasion. Replace if necessary. Rotate Steering wheel from one end to other for better visualization of boots. Inspect the LH side drive shaft condition for cracks or damage. Replace if necessary. The rack and pinion design is a simple design. However it is still susceptible to various problems in particular to leaks. If the bellows are ripped or are unable to keep the contaminant\u2019s away then it can cause damage to oil seal and subsequent leaks. One complaint, which can be present, is that the steering may be stiff and jerky when the unit is cold and as the vehicle is driven and it warms up the power assist gradually comes back. This normally indicates that grooves have worn into the bore of the pinion aluminum housing by control valve seals which may have hardened due to ageing. Wear in the centre housing causes the fluid to leak around the rack piston. Causing either steering wander or lack of straight- ahead stability. Another cause of steering wander and erratic control often accompanied by clumping, thunking noise is the deterioration of rack mounting bushings. Fluid leaks can be hard to locate. Sometimes you will see a low level in the pump reservoir but no evidence of escaping fluid. Squeeze the bellows and you will probably find that they are full of fluid. To confirm if that side of the rack is the root cause, then remove the both the bellows, clean the rack housing and then operate the system to observe the seepage directly. A rusty input shaft U joint or deteriorated flexible textile coupling could imitate rack problems
2. Check the accessory drive belt for any damage.
3. Check the Tie-rod ends for bend or damage.
4. Check ball joint rubber boots for signs of cracking or deterioration
5. Check inner and outer ball joints for excessive wear
6. Inspect all the steering bushes for signs of wear and deterioration
7. Check the steering oil level in the reservoir. If the level is below \u201cMIN\u201d mark, top up steering fluid.
8. Check the steering gear assembly for any external damage or steering fluid leakage.
9. Check the power steering pressure lines for fluid leakage and deterioration.
10. Check the power steering pump and the reservoir for fluid leakage.
11. Check the steering gear rubber bellows for cuts, cracks, deterioration and oil traces.
",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "If the cause is not visually evident, verify the symptom and refer to the Troubleshooting Chart By using Star Screw driver, remove the scrivets and remove the front RH wheel arch apron. Using a 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially detach the degassing tank. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": "",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A190083.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner, loosen and detach the pressure hose flare nut from the power steering pump. Torque : 22 \u00b1 5 Nm ",
+ "file": "",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A190128.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner, loosen and detach the pressure hose flare nut from the power steering gear. Torque : 22 \u00b1 5 Nm ",
+ "file": "",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Position a tray below the rack to collect the fluid Using a 12 mm socket spanner, loosen and remove the routing bracket mounting bolt. Torque : 10 \u00b1 2 Nm ",
+ "file": "",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A190114.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the supply hose from the vehicle. Install in the reverse order of removal. Fill the fluid and carry-out air bleeding procedure. For additional information refer to Power steering fluid filling procedure. Inspect for any external damage or bent, if found replace. For additional information refer to Front Wheel \u2013 R &R Section. ",
+ "file": "",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1014,1511",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the respective side Front Wheel Hub. Using a 10 mm socket spanner , loosen and remove the wheel speed sensor mounting bolt & routing bracket mounting bolt. Torque :8 \u00b1 2 Nm ",
+ "file": "",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A190009.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a cutting plier and 17 mm socket spanner, remove the tie rod end cotter pin and tie rod end nut and detach from knuckle. Torque :45\u00b19Nm ",
+ "file": "",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A190010.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a cutting plier and 24 mm socket spanner, remove the lower ball joint cotter pin and Lower ball joint nut and detach from knuckle. Torque :130 \u2013 150 Nm ",
+ "file": "",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A190011.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 22 mm socket spanner, loosen and remove the knuckle Lower Half mounting bolts. Torque :140 \u00b1 10 Nm ",
+ "file": "",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A190012.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a cutting plier and 24 mm socket spanner, remove the upper ball joint cotter pin and ball joint nut and detach from knuckle. Torque :90 \u2014 110 Nm ",
+ "file": "",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A190013.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A190014.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the knuckle from the vehicle. After installation of knuckle assembly, Carry out the wheel alignment. Install in the reverse order of removal. Torque tightening should be done without load and with the tyres on level ground. Always use new split pin. Inspect for any external damage or bent, if found replace. For additional information refer to Power steering fluid draining section. ",
+ "file": "",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A050128.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially detach the degassing tank. ",
+ "file": "",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.5\u00b1 0.5 Nm ",
+ "file": "",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the engine feed system cover. For additional information refer into the Engine Feed System Cover \u2013R &R Section. ",
+ "file": "",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A190124.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 14 mm rings spanner rotate the auto tensioner in counter clockwise Partially detach the power steering belt. ",
+ "file": "",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A190083.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner, loosen and detach the pressure hose flare nut from the power steering pump. ",
+ "file": "",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque :22 \u00b1 5 Nm ",
+ "file": "",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A190082.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a hose clip plier, unclip the return hose to reservoir hose clamp from pump. ",
+ "file": "",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A190084.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the power steering pump mounting bolts. ",
+ "file": "",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque :25\u00b1 3 Nm ",
+ "file": "",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Notice",
+ "content": "While loosening the bolt hold the nut using 12 mm ring spanner. ",
+ "file": "",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A190085.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the power steering pump from the vehicle. ",
+ "file": "",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. ",
+ "file": "",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Notice",
+ "content": "While tightening the bolt hold the nut using 12 mm ring spanner. ",
+ "file": "",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Carry-out power steering fluid filling and bleeding procedure. ",
+ "file": "",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1017,1295",
+ "file": null,
+ "display_order": 27
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the pump for any physical damage. Replace the pump if found For additional information refer to Engine Feed System Cover - R &R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the Front wheels (Both RH & LH). For additional information refer into Front Wheel - R &R Section. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "The wheels should be in straight ahead position before disconnecting the steering rack assembly from the vehicle. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050128.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially detach the degassing tank. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190121.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a cutting plier remove the cotter pin from the LH & RH tie rod . ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190009.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using the 17 mm socket spanner, loosen and remove the LH & RH tie rod end ball joint nuts from the knuckle assembly. ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 45 \u00b1 9 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190044.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft mounting nut from the rack and pinion assembly and detach the intermediate shaft. ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 22\u00b14 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190047.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner, loosen and remove the flare nuts and detach the steering rack and pinion supply and return lines. ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": "Plug the steering rack assembly inlet and outlet hose oil passage with dust cap to avoid any foreign particles entry. ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Drain the power steering fluid. ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190048.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the supply line routing bracket mounting bolt. ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190049.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a 19 mm socket spanner, loosen and remove the steering rack and pinion assembly mounting bolts. ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Torque Value",
+ "content": "Torque : 85 \u00b1 13 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Notice",
+ "content": "Use open end torque wrench for tightening RH side mountingbolt. ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190123.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Detach the front differential breather hose routing tag. ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190050.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Remove the steering rack and pinion assembly from the vehicle. ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190135.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Notice",
+ "content": "Always use a new cotter pin. ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Warning",
+ "content": "Ensure I shaft connector is assembled as per given marking. At straight ahead condition bolt head should face top side for easy torquing ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Fill the power steering fluid and do the air bleeding procedure. ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1017,1293",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Carry out the wheel alignment. ",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1015,1250",
+ "file": null,
+ "display_order": 43
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the steering rack assembly for cracks, damages or leakages. Replace the steering rack assembly if required. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Before disconnecting the battery, check for the audible sound of EWP ON Remove the Driver Airbag. Disconnect the electrical connection from steering switches. Using a star screw driver, loosen and remove the steering switches mounting screw then remove the steering switches from the vehicle. Install in the reverse order of removal. Inspect for any external damage or bent, if found replace.
2. Inspect the combination switch connectors for any damage or loose connection
",
+ "file": "",
+ "display_order": 17
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 185,
+ "sys_id": "THAR.LX-0004-Steering",
+ "subsys_id": "THAR.LX-0004-Steering-Steering Grommet",
+ "systems": "Steering",
+ "sub_systems": "Steering Grommet",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A190110.jpg",
+ "myid": 1301,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Steering Grommet-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190110.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10527.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10528.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080024.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance.Before disconnecting the battery, check for the audible sound of EWP ON.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the steering wheel.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1017,1296",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190033.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the ignition key barrel electrical connector.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190118.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190119.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the combination switch & clock spring electrical connectors.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190042.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft bottom mounting bolts and detach the intermediate shaft bottom from the steering column.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 4 Nm",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190039.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering column mounting nuts then remove the steering column from the vehicle.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 4 Nm",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190120.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190111.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the grommet mounting bolts then remove the grommet from vehicle .",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 2 Nm",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 2 Nm",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190133.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Notice",
+ "content": "Ensure to fit the Grommet Projection should face driver side.Ensure Shaft to Grommet clearance is 5 mm in top side.Ensure to install Upper & Lower I shaft connector according to the marking.",
+ "file": null,
+ "display_order": 27
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect for grommet any external damage or cracks, if found replace.",
+ "file": null,
+ "display_order": 28
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 193,
+ "sys_id": "THAR.LX-0004-Steering",
+ "subsys_id": "THAR.LX-0004-Steering-Steering System Technical Spec",
+ "systems": "Steering",
+ "sub_systems": "Steering System Technical Spec",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1309,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Steering System Technical Spec-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Technical Specifications",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10607.pdf",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 190,
+ "sys_id": "THAR.LX-0004-Steering",
+ "subsys_id": "THAR.LX-0004-Steering-Power Steering Return Line Gear End",
+ "systems": "Steering",
+ "sub_systems": "Power Steering Return Line Gear End",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A190076.jpg",
+ "myid": 1306,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Power Steering Return Line Gear End-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A190076.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/10579.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/10580.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Front RH wheel. For additional information refer into Front Wheel - R &R Section. ",
+ "file": "",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1014,1511",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4B190014.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "By using Star Screw driver, remove the scrivets and remove the front RH wheel arch apron. Using a 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially detach the degassing tank. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": "",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A190123.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the front differential breather hose routing clip. Using a 12 mm socket spanner loosen and remove the steering return line routing bracket mounting bolts. Torque : 10 \u00b1 2 Nm ",
+ "file": "",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A190087.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a hose clamp plier, unclip the hose clamp from power steering side. Using a 17 mm open end spanner, loosen the flare nut and detach the return line from the rack and pinion side. Torque : 22 \u00b1 5 Nm ",
+ "file": "",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A190112.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the steering return line hose gear end from the vehicle. Install in the reverse order of removal. Fill the fluid and carry-out air bleeding procedure. For additional information refer to Power steering fluid filling procedure. Inspect for any external damage or bent, if found replace. Position the vehicle on a 2 post/ 4 post lift. Inspect the fluid pressure hoses and clips for proper fitment. Rotate in anti-clockwise and remove the power steering fluid reservoir cap. Do not operate the steering system without power steering fluid. Failure to follow this precaution will lead to the damage of the steering system components. Whenever air enters the power steering hydraulic system, the system must be bleed to ensure free of air. Filling and bleeding the power steering system helps to ensure trouble-free operation as well as prevents the damage of the power steering system components. Inspect the fluid pressure hoses and clips for proper fitment. Rotate in anti-clockwise and remove the power steering fluid reservoir cap. Fill the power steering fluid reservoir to the \u201cMAX\u201d mark. During the bleeding procedure,ensure that the power steering fluid in the power steering fluid reservoir does not fall below the \u201cMIN\u201d mark, as air could enter into the system. Slowly turn the steering wheel to left lock position and hold for about 10 seconds. From left lock position turn the steering wheel slowly to Right lock position. Continue steps 6\u2013 7 till there is no air bubbles visible in the power steering fluid reservoir and smooth operation of power steering is attained. If the air bleeding is not properly performed, the life span of the power steering pump may be shortened. Top up the fluid to MAX mark on reservoir. clockwise rotation (Towards right hand side) until tight (RH lock position).",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/clock1.PNG",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/clock2.PNG",
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "From RH lock position rotate the clock\nspring in opposite direction (anti-clockwise)\napproximately 3 turns and align the marks",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/clock3.PNG",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/clock4.PNG",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Warning",
+ "content": "Failure to follow the instructions can cause the clock spring failure. Clock spring if failed and not corrected can be a concern if the vehicle meets an accident which is above the threshold for airbag deployment. In such cases the airbag may not be deployed even though the signal is given. Even if airbag not deployed it will be giving a signal of airbag failure which will mean a return of customer with a complaint added on. ",
+ "file": null,
+ "display_order": 7
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 180,
+ "sys_id": "THAR.LX-0004-Steering",
+ "subsys_id": "THAR.LX-0004-Steering-Steering Wheel",
+ "systems": "Steering",
+ "sub_systems": "Steering Wheel",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A190020.jpg",
+ "myid": 1296,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Steering Wheel-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A190149.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "The steering wheel is the part of the steering system that is rotated by the driver; the rest of the steering system responds to driver inputs. The steering wheel houses the driver airbag and audio controls. It is connected to the collapsible steering column. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. For additional information refer to Driver Airbag -R &R Section. ",
+ "file": "",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A190022.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 17 mm socket spanner, loosen and remove the steering wheel mounting nut. Torque : 47\u00b17Nm ",
+ "file": "",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A190021.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect clock spring electrical connector. Remove the steering wheel from the vehicle. Do not use excessive force to the steering wheel for removal. This may cause steering wheel bend. Gently tap if needed. While installing steering wheel ensure the splines are aligned properly and the steering wheel slides easily on the column shaft. Install in the reverse order of removal. Ensure the front wheels are in straight ahead position. Improper or incorrect removal and installation of the Restraint components will cause unintentional activation of the system which may lead to personal injury. The service operations should be followed in the correct sequence. Failure to do so may cause the SRS to unexpectedly deploy during service leading to a serious accident. Inspect the steering wheel for any external damage or bent, if found replace. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Remove the steering wheel. Disconnect the ignition key barrel electrical connector. Disconnect the combination switch & clock spring electrical connectors. Using a 12 mm socket spanner, loosen the steering intermediate shaft top bolt and remove bottom mounting bolts and detach the intermediate shaft bottom from the steering column. Torque : 22 \u00b1 4 Nm ",
+ "file": "",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A190039.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering column mounting nuts then remove the steering column from the vehicle. Torque : 22 \u00b1 4 Nm ",
+ "file": "",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A190108.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A190109.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the top intermediate shaft mounting bolts then remove the top intermediate shaft from the steering column. Torque : 22 \u00b1 4 Nm ",
+ "file": "",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A190133.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Ensure to install Upper & Lower I shaft connector according to the marking. Inspect for any external damage or bent, if found replace. For information refer to Engine Feed System Cover - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the front RH wheel.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1014,1511",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "By using Star Screw driver, remove the \nscrivets and remove the front RH wheel arch \napron.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Steering Lower Intermediate Shaft3.PNG",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Steering Lower Intermediate Shaft4.PNG",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen \nand remove the steering intermediate shaft \nbolt from the rack and pinion.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "While attempting to remove the \nintermediate shaft, lock the steering \nwheel at center position.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 22\u00b14Nm",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Steering Lower Intermediate Shaft5.PNG",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen \nand remove the steering intermediate shaft \nlower mounting bolt.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 22\u00b14Nm",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Steering Lower Intermediate Shaft6.PNG",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen \nand remove the steering intermediate shaft \nCenter bracket mounting bolts.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 20\u00b12.0Nm",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Steering Lower Intermediate Shaft7.PNG",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the Steering intermediate shaft \nfrom the vehicle",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Notice",
+ "content": "Ensure to install Upper & Lower I shaft \nconnector according to the marking",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Warning",
+ "content": "DO NOT HAMMER while disassembly /\nassembly.\nEnsure I shaft connector is assembled\nas per given marking. At straight\nahead condition bolt head should face\ntop side for easy torquing.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Steering Lower Intermediate Shaft8.PNG",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Steering Lower Intermediate Shaft88.PNG",
+ "display_order": 25
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect for any external damage or bent, if found replace",
+ "file": null,
+ "display_order": 26
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 195,
+ "sys_id": "THAR.LX-0004-Steering",
+ "subsys_id": "THAR.LX-0004-Steering-Steering Rack Linkage & Boots",
+ "systems": "Steering",
+ "sub_systems": "Steering Rack Linkage & Boots",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J08-MAT-0501",
+ "cover_image": "/files/W4A190046.jpg",
+ "myid": 1449,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 9,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 55,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 95,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 135,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 174,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 214,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 255,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 294,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 335,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 373,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 416,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Steering Rack Linkage & Boots-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Steering Rack Linkage & Boots - Inspect.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190046.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Preliminary Activities/Conditions",
+ "content_type": "Description",
+ "content": "Position the vehicle on 2 post lift/ 4 post lift. Check the steering rack assembly RH side boots, clamps for cut, nick or abrasion, replace if necessary. Check the steering rack assembly LH side boots, clamps for cut, nick or abrasion, replace if necessary. Check the steering rack assembly RH side linkage condition (Without removing boots) for play, damage, replace if necessary. Rotate Steering wheel from one end to other for better visualization of boots. Check the steering rack assembly LH side linkage condition (Without removing boots) for play, damage, replace if necessary. Rotate Steering wheel from one end to other for better visualization of boots. Power Steering Oil - MAHINDRA 'MAXIMILE POWER STEERING FLUID' GENUINE POWER STEERING FLUID, Capacity \u2013 0.85 Litres In case of non-availability of Genuine fluid, SHELL MAKE 'SPIRAX S3 ATF MD3' can be used. NO OTHER BRANDS RECOMMENDED. Rotate in anti-clockwise and remove the power steering fluid reservoir cap. Using star screw driver, remove the front stone guard screvits. Using a 10 mm & 13 mm socket spanner, loosen the front & rear mounting bolts and remove the front stone guard. Using a 10 mm socket spanner remove the steering fluid line bracket mounting bolt. Torque:10\u00b1 2 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190104.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner, loosen the nut and disconnect pump to rack pressure hose. Torque: 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Position a tray below the rack to collect the fluid. Drain the complete fluid in a neat container or bottle. Refit the pump to rack pressure hose.Torque tighten the nut to specified value. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190048.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refit the fluid line mounting clamp with the help of mounting bolt. Torque tighten the bolt to specified value. Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B190009.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Fill the recommended fluid to MAX mark on reservoir. Carry-out Power steering circuit air bleeding procedure. Refit the front stone guard screvits mounting bolts, torque tighten the bolts to specified value. Torque: 4.0 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 33
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 310,
+ "sys_id": "THAR.LX-0004-en-SM-Reverse Parking Assistance System",
+ "system_name": "Reverse Parking Assistance System",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1031,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 311,
+ "sys_id": "THAR.LX-0004-Reverse Parking Assistance System",
+ "subsys_id": "THAR.LX-0004-Reverse Parking Assistance System-RPAS System Technical Spec",
+ "systems": "Reverse Parking Assistance System",
+ "sub_systems": "RPAS System Technical Spec",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1429,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-RPAS System Technical Spec-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/RPAS tech spec.png",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 310,
+ "sys_id": "THAR.LX-0004-Reverse Parking Assistance System",
+ "subsys_id": "THAR.LX-0004-Reverse Parking Assistance System-RPAS Sensors",
+ "systems": "Reverse Parking Assistance System",
+ "sub_systems": "RPAS Sensors",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A330001.jpg",
+ "myid": 1428,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-RPAS Sensors-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A330001.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/rpas1.png",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290044d25f1f.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Disconnect the RPAS sensor electrical connectors. Unlock the RPAS sensors from the cover. Detach the sensors from vehicle. Check sensor, wiring, connector for any damage. Check for mud on sensor, clean gently if found. Remove selective diesel particulate filter (SDPF). Drain the engine coolant. For additional information refer into coolant draining and refilling procedure. Using a 10 mm socket spanner, loosen and remove the OCFM side Mounting bolt. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050190.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the OCFM routing bracket bolt. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050140.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a hose clip plier, loosen and remove the EGR quick coupler from the engine . Using a hose clip plier, loosen the Dosing Module inlet hose clip and remove the hose. Remove the pipe takeout from the vehicle. Install in the reverse order of removal. Carry-out coolant filling and de-aeration process. For additional information refer into coolant draining and refilling procedure. Check inlet pipe for any damage, cracks, kinks and degradation found replace the inlet pipe with a new one Check inlet pipe mounting for proper tightness and damages, replace the inlet pipe if required. * VSCF \u2013 Vehicle Speed Correction Factor
* PWM - Pulse Width Modulation
Fan after run strategy
Coolant Temperature < 98\u00b0C = 0 Sec
Coolant Temperature > 98\u00b0C = 30 Sec
",
+ "file": "/files/elec.JPG",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": ", ",
+ "file": "/files/elec1.JPG",
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": ", ",
+ "file": "/files/electricfan2.JPG",
+ "display_order": 4
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": ", ",
+ "file": "/files/electricfan3.JPG",
+ "display_order": 5
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 400,
+ "sys_id": "THAR.LX-0004-Cooling System",
+ "subsys_id": "THAR.LX-0004-Cooling System-Thermostat Valve Test",
+ "systems": "Cooling System",
+ "sub_systems": "Thermostat Valve Test",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/S2B050146.jpg",
+ "myid": 1080,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Thermostat Valve Test-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the thermostat valve from the thermostat housing. Thermostat and thermometer bulb should be suspended in water. If they touch bottom or the sides then temperature in which thermostat / thermometer operate will not be correct and wrong diagnosis will take place. Insert the thermostat valve in to a container filled with water. Heat the container and measure the temperature of water by Using digital thermometer. Keep track of water temperature and respective valve opening/ travel. Thermostat should start opening at 88 \u00b1 2 \u00b0 C (0.1 mm travel) . Once temperature reaches 96 \u00b1 2\u00b0 C valve should be fully open , at this moment, valve travel will be approximately 8 mm . In case thermostat valve behavior does not confirm to above specifications, it should be replaced. Disconnect the electrical connectors from resistor. Using screw driver, loosen the resistor mounting screw and remove the resistor. Install the reverse order of removal. Check the resistor for any damages, if found then replace it . Coolant flow within the cooling system is shown in the above mentioned schematic diagram.
For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 7 mm socket spanner, Loosen the mounting hose clip and detach the radiator outlet hose OCFM end. Torque : 6.5 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the turbo oil return pipe routing bracket mounting bolt. Torque : 25 \u00b1 3Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the coolant inlet pipe bolts then remove the coolant inlet pipe from OCFM. Torque : 11\u00b11Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A05008536aa24.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external damage, if found please replace. Check coolant inlet pipe hose clamps for proper tightness and damages, replace the clamps if required. Using 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially remove the degassing tank (Without disconnecting the hoses). Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050052.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect radiator fan electrical connector. Using a 10 mm socket spanner, loosen and remove fan mounting bolts. Torque : 6.5\u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050058.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050057.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the shroud holder clips from radiator and fan then remove the clips (Top & Bottom). Using 7 mm socket spanner, loosen the hose clamp and disconnect the intercooler inlet hose from the intercooler assembly. Torque : 6.5 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050186.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050130.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Detach the fan assembly from radiator bottom seating and remove the radiator fan assembly. While Installing ensure the fan bottom seating are properly seated on radiator. Install the reverse order of removal. Check electric fan blades for any damages. Coolant \u2013 Mahindra 'MAXIMILE ULTRA COOL' Genuine Long Life Coolant (READY TO USE COOLANT. NO NEED TO MIX WATER).Refilling Capacity \u2013 ~5.0 Litres.
",
+ "file": "",
+ "display_order": 3
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "Description",
+ "content": "Preliminary Activities/ Conditions
1. Position the vehicle on 2 post lift/ 4 post lift.
2. Open the bonnet and lock it in open position using bonnet stay rod.
",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050155.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Coolant Level And Leak Inspection Procedure: ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the degassing tank pressure cap for any damage or coolant leakage. Rectify the leakage if found. Check the coolant level in the degassing tank, it should be between MAX and MIN marks. Check the coolant level when the engine is cold. If found below MIN mark then top it up with MAHINDRA 'MAXIMILE ULTRA COOL' (ready to use coolant. no need to mix water). Inspect the degassing tank to radiator vent hose for any coolant leakages, also check the mounting spring band clamp for any damage. If found any damage or leak, rectify Inspect the engine to T connection vent hose for any coolant leakages, also check the mounting spring band clamp for any damage. If found any damage or leak,rectify. Inspect the degassing tank outlet hose assembly at every joints such as degassing tank end, T-connector connections, EWP inlet and outlet sides, OCFM side for any coolant leakage, also check the mounting spring band clamp for any damage. If found any damage or leak, rectify. Inspect the radiator inlet hose at radiator and engine block for coolant leakage, rectify the leakage if found. Also inspect the mounting spring band clamp for any damage, replace the mounting spring band clamp if found damaged or loose. Inspect the radiator inlet hose at radiator and engine block for coolant leakage, rectify the leakage if found. Also inspect the mounting spring band clamp for any damage, replace the mounting spring band clamp if found damaged or loose. Inspect the heater inlet & outlet hoses for any coolant leakage at the heater core side, EGR module side, coolant outlet pipe side and coolant nipple heater inlet side, also check the mounting spring band clamp for any damage. If found any damage or leak, rectify. Inspect the Dosing Module inlet hose, Dosing Module outlet hose also check the mounting spring band clamp and bolts for any damage. If found any damage or leak, rectify. Inspect the Coolant Inlet & outlet pipes bolts at OCFM for any damage. If found any damage or leak, rectify. Never remove the degassing tank cap when the engine is hot. Brand Specific. Don't use other Coolants / Water for top up. In case of emergency, Coolant meeting JIS K2234 Specification should be used (30% Concentration Diluted with Distilled water) and coolant change period has to be reduced as 30,000 KM Never mix MAHINDRA MAXIMILE ULTRA COOL with water For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050166.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, release the radiator vent hose spring band clamp and disconnect the hose. Never work with cooling system when the engine is hot. failing to this may cause personal injury. Using 10 mm socket spanner, Unscrew degassing tank mounting bolts. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050129.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully remove the degassing tank. Install in the reverse order of removal. For additional information refer to Coolant filling and de-aeration section. ",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "1. Inspect the degassing tank for any damages or blockages, replace if found replace the degassing tank.
2. Inspect the hoses for any damages, cracks or kinks, if found replace the hose assembly.
3. inspect the coolant hoses clamps for proper fitment, if found loose then replace the clips.
",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 383,
+ "sys_id": "THAR.LX-0004-Cooling System",
+ "subsys_id": "THAR.LX-0004-Cooling System-Coolant - Replace",
+ "systems": "Cooling System",
+ "sub_systems": "Coolant - Replace",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J08-MAT-0100",
+ "cover_image": "/files/W4A050126.jpg",
+ "myid": 1061,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 33,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 75,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 116,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 155,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 195,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 234,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 243,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 314,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 354,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 394,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 434,
+ "kilometers_applicable": 0
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Coolant - Replace-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Coolant - Replace.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050126.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/15017.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "Description",
+ "content": " Coolant \u2013 Mahindra 'MAXIMILE ULTRA COOL' Genuine Long Life Coolant (READY TO USE COOLANT. NO NEED TO MIX WATER). Refilling Capacity \u2013 ~5.0 Litres. Switch OFF the Ignition and allow Engine to cool down. Never remove the degassing cap when the engine is hot Open the degassing tank cap. Using star screw driver, remove the front stone guard screvits. Using a 10 mm & 13 mm socket spanner, loosen the front & rear mounting bolts and remove the front stone guard. Remove the radiator drain plug and allow the entire coolant to get drained. Place a tray beneath the drain plug to collect coolant drained. Start filling the recommended coolant in degassing tank. While filling, open the drain Plug & wait for the coolant to drop & close drain Plug. Check coolant level in degassing tank, add coolant to MAX level and close the degassing cap. Check all the hoses and clips for leakage and correct fitment. Start the engine and run at 3000 rpm for about 10 minutes. (For Thermostat Opening). Maintain Coolant level at MAX level always and ensure coolant never goes below MIN level. Switch OFF the Ignition and allow the engine to cool down, Check coolant level in degassing tank and add coolant to MAX level. Refit the front stone guard screvits & mounting bolts, torque tighten the bolts to specified value. Torque: 4.0 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Inspect the coolant circuit for any leakages. For additional information refer to Coolant level & leak inspection section. Never remove the degassing cap when the engine is hot. Never mix MAHINDRA MAXIMILE ULTRA COOL genuine coolant with water. Brand Specific. Don't use other Coolants / Water for top up. In case of emergency, Coolant meeting JIS K2234 Specification should be used (30% Concentration Diluted with Distilled water) and coolant change period has to be reduced as 30,000 KM Do not overfill the system; allow free space in the degassing tank for expansion of the fluid. For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050089.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a hose clamp plier, release electric water pump inlet hose spring band clamp and disconnect the hose. Using a hose clamp plier, release electric water pump outlet hose spring band clamp and disconnect the hose. Disconnect the EWP electrical connector. Using a 10 mm socket spanner, Unscrew EWP clamp mounting bolts and remove the EWP. Install in the reverse order of removal. For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check EWP for any damage, cracks, kinks and degradation. If found replace the EWP with a new one. Check EWP hose clamps for proper tightness and damages, replace the clamps if required. For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050083.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 7 mm socket spanner, loosen hose clip and detach radiator outlet hose OCFM end. Torque : 6.5 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050084.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the turbocharger oil return pipe routing bracket mounting bolt. Torque : 25\u00b13Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050085.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove coolant inlet pipe bolts and remove coolant inlet pipe OCFM end. Torque : 11\u00b11Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050087.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050162.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Always replace the O ring with New one while removing the thermostat. For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check thermostat valve opening and closing temperatures, if found deviation from specified value, replace the thermostat. Check travel of thermostat valve, if found deviation from specified value, replace the thermostat. Remove the selective diesel particulate filter (SDPF) . For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050141.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the Turbocharger oil drain pipe bottom mounting. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050142.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the Turbocharger oil drain pipe routing bracket. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050143.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the outlet pipe mounting bolt at OCFM end. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050144.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the pipe routing bracket bolt. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050145.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a hose clip plier, loosen and remove Heater outlet hose clamp and detach the hose. Using a hose plier, loosen and remove the EGR quick coupler from the engine . Remove the Pipe EGR Cooler Outlet. Install in the reverse order of removal. For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 26
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check outlet pipe for any damage, cracks, kinks and degradation. If found replace the outlet pipe with a new one. Check outlet pipe mounting for proper tightness and damages, replace the outlet pipe if required. Remove the front grill assembly. Using 10 mm socket spanner, Unscrew the LH and RH radiator seal mounting bolts. Torque : 4.5 \u00b10.5Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050048.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver, loosen and remove the LH and RH radiator seal mounting screw rivets. Torque : 4.5 \u00b10.5Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050134.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the both LH and RH radiator seal from the vehicle. Install the reverse order of removal. Check for any external cracks, replace if found any Check for the obstruction of the air flow, if found please replace. The radiator assembly is a cooler located at the front of the vehicle. The radiator is a heat exchanger that removes the excess heat from the coolant passing through it. The coolant flows inside the radiator from RH to LH. The cool ambient air flows through the fins of the radiator. The heat exchange happens between the coolant to air. Drain Cock is located in the bottom of the Radiator and used to Drain the engine coolant. Drain the engine coolant. For additional information refer into coolant draining and refilling procedure. Remove the Intercooler assembly. Remove the Degassing Tank assembly. Using 10 mm socket spanner, Unscrew degassing tank mounting brackets mounting bolts LH & RH. Torque : 10 \u00b1 0.5Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050179.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect radiator fan electrical connector. Using 10 mm socket spanner, loosen and remove cooling fan mounting bolts. Torque : 6.5\u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050058.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050057.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect the shroud holder clips from radiator and fan then remove the clips (Top & Bottom). Detach the fan assembly from radiator bottom seating and remove the radiator fan assembly. While Installing ensure the fan bottom seating are properly seated on radiator. Using Hose clamp plier, release radiator inlet and outlet hose spring band clamps and disconnect the hoses radiator end. Using hose plier, release vent hose spring band clamp and disconnect hose radiator end. Using 13 mm socket spanner, Unscrew radiator mounting bolts. Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050035.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050036.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew radiator LH & RH seal mounting bolts. Torque : 4.5 Nm ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050033.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050034.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050187.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew condenser mounting bolts and partially detach the condenser from the radiator. Torque : 5 \u00b11Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050032.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Remove the radiator from the vehicle. Install in the reverse order of removal. Carry-out coolant filling and de-aeration process.
2. Check the radiator for coolant leakage, refill if found any.
3. Check the radiator for dust accumulation, clean with compressed air if dust accumulation is noticed.
4. Check for free flow of water from radiator top to bottom.
5. Check the radiator drain plug for any leakage.
",
+ "file": null,
+ "display_order": 50
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 401,
+ "sys_id": "THAR.LX-0004-Cooling System",
+ "subsys_id": "THAR.LX-0004-Cooling System-Troubleshoot - Cooling System",
+ "systems": "Cooling System",
+ "sub_systems": "Troubleshoot - Cooling System",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1454,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Troubleshoot - Cooling System-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Troubleshoot",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/tr 1.png",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/tr 2.png",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/tr 3.png",
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Refer below chart for various symptoms, causes and there remedial actions - Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON Torque :6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010903.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect temperature sensor (T4) electrical connector. Torque :35\u00b15 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach T4 sensor from routing clip and remove it Install in the reverse order of removal. Yellow colour tape provided on T4 Sensor wiring pigtail and engine wiring harness connector for easy identification while refit and ensure to properly connect the T4 Sensor wiring pigtail connector with engine wiring harness Mismatch connection of wiring connectors may leads to affect the engine performance and occur engine trouble. Check for any external cracks, replace if found any Position the vehicle on a 2 post / 4 post lift. Exhaust pipe mountings and damage/leakage - Procedure ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Position the vehicle on a 2 post / 4 post lift. Check the insulators of the exhaust front pipe, exhaust intermediate pipe with muffler and exhaust tail pipe, Replace if found elongated or damaged. Check the joint between exhaust tail pipe with intermediate pipe, if found leakage then replace the gasket and torque tighten the nuts to specified value. Check the joint between exhaust intermediate pipe with front pipe for any leakage, if found leakage then replace the gasket and torque tighten the nuts to specified value. Check the joint between exhaust front pipe with SDPF for any leakage, if found leakage then replace the gasket and torque tighten the nuts to specified value. Do not work when the exhaust system is hot. Failure to follow this instruction will result in personal injury. Check all the exhaust joints for leakage and correct fittings. If leakage is found, check the exhaust pipe gasket. Replace if required. The exhaust after treatment system uses SCR (Selective Catalytic Reduction) technology which requires Diesel Exhaust Fluid (DEF) for reduction of NOx in order to enable the vehicle to comply with emission regulations. DEF is a NOx reduction agent. It is recommended to use MaxiCLEAN DEF meeting IS 17042 (or) ISO 22241 specification. It is basically an aqueous urea solution, having a urea content of 32.5% and remaining 67.5% of water. DEF is a nonflammable, non-toxic, colorless and water-soluble liquid. DEF is stored in vehicle in a tank and provision is provided to refill it as per requirements. To enable SCR system to work efficiently and to ensure emission conformance, DEF meeting quality requirements of IS 17042 (or) ISO 22241 standard is mandatory. Even when DEF of correct specification is filled, it\u2019s useful life remain limited depending upon extent of exposure of storage tank/vehicle to varying environmental temperature conditions. Refilling DEF is part of regular maintenance service. DEF consumption is highly dependent on driving conditions/pattern. It may be necessary to refill DEF reservoir in-between the scheduled service, Need to monitor DEF Indicator Tell Tale and symbols/ Alert messages displayed on Cluster screen. It is unlawful to tamper with or remove any component of the after treatment system. It is also unlawful to use a DEF that does not meet the specification provided or to operate the vehicle without DEF. The exhaust after treatment system uses SCR (Selective Catalytic Reduction) technology which requires Diesel Exhaust Fluid (DEF) for reduction of NOx in order to enable the vehicle to comply with emission regulations. DEF is a NOx reduction agent. It is recommended to use MaxiCLEAN DEF meeting IS 17042 (or) ISO 22241 specification. It is basically an aqueous urea solution, having a urea content of 32.5% and remaining 67.5% of water. DEF is a nonflammable, non-toxic, colorless and water-soluble liquid. DEF is stored in vehicle in a tank and provision is provided to refill it as per requirements. To enable SCR system to work efficiently and to ensure emission conformance, DEF meeting quality requirements of IS 17042 (or) ISO 22241 standard is mandatory. Even when DEF of correct specification is filled, it\u2019s useful life remain limited depending upon extent of exposure of storage tank/vehicle to varying environmental temperature conditions. Refilling DEF is part of regular maintenance service. DEF consumption is highly dependent on driving conditions/pattern. It may be necessary to refill DEF reservoir in-between the scheduled service, Need to monitor DEF Indicator Tell Tale and symbols/ Alert messages displayed on Cluster screen. It is unlawful to tamper with or remove any component of the after treatment system. It is also unlawful to use a DEF that does not meet the specification provided or to operate the vehicle without DEF. Do\u2019s & Don\u2019ts ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1E030276.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Do not hold the Supply Module while carry DEF tank. Do not handle Supply Module using connectors, complete housing to be held to avoid any type of damages. Handle Dosing Module using housing and not on connectors to avoid any type of damages. Structural changes of the Dosing Module is not permitted. Dismounting of dosing valve out of the cooling body is not allowed 1. Avoid painting or application of other coatings on Dosing Module (DM) & Supply Module (SM) to ensure lifetime & functionality.
2. Always remove (manually) protection caps of DM & SM just before assembly of its mating pipes/cables, to avoid contamination of the system.
3. Only use recommended tools for remove & Installation of DM & SM. After removing, cover the openings with protective caps to prevent the entry of contaminants.
4. The entry of contaminants in the interfaces of the DM must be prevented during Installation & removing of DM.
",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Storage Guidelines
2. Parts have to be stored in original M&M; packaging.
3. Parts needs to be protected against rain, snow, heat sources and dust.
4. Max. storage period of DM & SM should be not more than 4 years.
5. Avoid any damages to Supply Module while storing DEF tank.
",
+ "file": null,
+ "display_order": 10
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 343,
+ "sys_id": "THAR.LX-0004-Exhaust & Emission Control",
+ "subsys_id": "THAR.LX-0004-Exhaust & Emission Control-SCR Routines",
+ "systems": "Exhaust & Emission Control",
+ "sub_systems": "SCR Routines",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1014,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-SCR Routines-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "SCR Routines assist in checking the functionality of the SCR system components (DEF supply pump, DEF back flow pump, Dosing module, leaks in system) and also to initialize some SCR system components after replacement. There are 10 routines that can be performed using i- SMART. They are represented in the below table along with serviceable components. Numbers in the cell indicate the order in which a routine has to be done after the respective component replacement. To access these routines Open i-SMART \u2192THAR\u2192THAR_BS6\u2192 EMS \u2192 ROUTINES \u2192SCR ROUTINES. PRE-CONDITIONS FOR SCR ROUTINES: ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/SCR routines3.png",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "All SCR routines have certain pre-conditions which have to be met before they can be performed. Pre-conditions for the routines will be displayed in i-SMART along with actual and acceptable values. SCR routines will not proceed, if even one pre-condition is not met. DEF first filling test when actuated by i-SMART will fill this air gap with DEF. Performing this routine is mandatory on tank / pump replacement to ensure SCR system performance. WHEN TO DO ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "If DEF tank or DEF pump module is replaced. Refer Diagnostic manual for DEF First Filling SCR ROUTINE Procedure. Pressure preparation routine will build up a moderate pressure in the DEF supply hose and vent any air in the supply hose when actuated by i-SMART. Performing this routine is mandatory when any hydraulic component (DEF pump module, DEF tank, supply hose) is removed and re-fitted. WHEN TO DO ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Refer Diagnostic manual for DEF Pressure Preparation SCR ROUTINE Procedure. SCR system emptying routine when actuated by i-SMART will purge / suck the DEF from the supply line back to the DEF tank using the backflow pump. This routine can be done during diagnosis process before removing and SCR system hydraulic connections. WHEN TO DO ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Before removing any SCR hydraulic connections. Refer Diagnostic manual for EMPTYING of SCR System SCR ROUTINE Procedure. DEF leak test is a smart test that can indicate if there could be any DEF leaks. WHEN TO DO ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "1. When diagnosing for any DEF pressure DTCs.
2. After refitting any SCR system hydraulic connectors to check for leaks.
",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Refer Diagnostic manual for DEF Leak Test SCR ROUTINE Procedure. DEF dosing module spray test is a smart test that simulates the spray pattern of DEF dosing. The dosing module has 7 holes through which DEF is sprayed into the exhaust. WHEN TO DO ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "1. When diagnosing for Dosing module stuck DTC.
2. To check dosing module functioning.
3. After refitment of new dosing module.
",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Refer Diagnostic manual for Dosing Module Spray Test SCR ROUTINE Procedure. Dosing module dry actuation test is a smart test that can indicate if the dosing module is not opening or is stuck. WHEN TO DO ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " 1. When diagnosing for Dosing module stuck DTC. ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Refer Diagnostic manual for Dosing Module Dry Actuation Test SCR ROUTINE Procedure. WHEN TO DO ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "1. To check any DEF backflow pump DTCs. ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Refer Diagnostic manual for DEF Metered Dosing Test SCR ROUTINE Procedure. ",
+ "file": null,
+ "display_order": 37
+ }
+ ]
+ },
+ {
+ "procedure_name": "DEF Metered Dosing Test",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "DEF metered dosing test when actuated by i-SMART will build up DEF pressure and dose DEF through the dosing module. This routine can be done to test the dosing module. WHEN TO DO ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " 1. After replacing a new dosing module. ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Refer Diagnostic manual for DEF Metered Dosing Test SCR ROUTINE Procedure. DEF static dosing test when actuated by i-SMART will build up DEF pressure and dose DEF through the dosing module. This routine can be done to test the dosing module. This routine is intended to simulate high mass flow rate dosing. WHEN TO DO ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " 1. After replacing a new dosing module. ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Refer Diagnostic manual for DEF Static Dosing Test SCR ROUTINE Procedure. DEF static dosing test when actuated by i-SMART will build up DEF pressure and dose DEF through the dosing module. This routine can be done to test the dosing module. This routine is intended to simulate low mass flow rate dosing. WHEN TO DO ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " 1. After replacing a new dosing module. ",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Refer Diagnostic manual for DEF Dynamic Dosing Test SCR ROUTINE Procedure. Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. Torque :6.0\u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Warning",
+ "content": "Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury. For removing any SCR hydraulic connections carry out below \u201cSCR ROUTINES\u201d by using i-SMART. For additional information refer Diagnosis Manual. After removal of supply hose, Cover the DEF tank & Dosing Module with dust caps to avoid entry of dust and Contamination of the DEF. Remove Diesel Exhaust Fuel(DEF) tank. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Turn over the DEF tank and position the tank to face bottom side to access Supply Module Using T30 Torx spanner, Unscrew DEF supply Pump Mounting torx screws Firmly release the supply pump from Module & take out from DEF tank. Install in the reverse order of removal. Avoid painting or application of other coatings on Supply Module (SM) to ensure lifetime & functionality Always remove (manually) protection caps of SM just before assembly of its mating pipes/cables, to avoid contamination of the system Only use recommended tools for remove & Installation of SM. After removing, cover the openings with protective caps to prevent the entry of contaminants Do not hold the Supply Module while carry DEF tank Do not handle Supply Module using connectors, complete housing to be held to avoid any type of damages. The Number of Supply Pump Remove & Refit from Supply Module limited to 3 times. If remove & refit beyond 3 times it can affect the torquing of screws leading to un tight assembly of pump with module. Failing to do may affect the supply module performance Always use new Dampers & Sleeves while replace new Supply Pump. Clean Supply Pump seating area on module thoroughly before insert the pump.
using i-SMART. For additional information refer Diagnosis Manual.
\u2022 DEF First Filling
\u2022 DEF Pressure Preparation
\u2022 DEF Leak Test
\u2022 DEF metered dosing test
\u2022 EMPTYING of SCR System
2. For New DEF Supply Pump Replacement carry out \u201cComponent Replacement
Procedures \u2013 DEF Pump Replacement\u201d by using i-SMART. For additional
Check for any external damage, replace if found any. The Electric-Variable Geometry Turbocharger (e-VGT) system variably controls the passages of the turbine housing to regulate the flow rate of the exhaust gas. The actuator for e-VGT has been changed from traditional vacuum actuator to DC motor actuator (E-Actuator), thereby enabling to achieve more fast and precise control The engine ECU controls the E-actuator electronically as follows: At low speed: Narrows the flow passage for the exhaust gas, resulting in increasing the flow speed of the exhaust gas and running the turbine quickly and powerfully. At high speed: Expands the flow passage for the exhaust gas, resulting in increasing the mass flow of the exhaust gas. eVGT Learning: At the end of every driving cycle when ignition is switched OFF, EMS ECU triggers a learning on the eVGT. In the learning EMS ECU will move turbocharger actuator to the open & close end positions. At the end positions, the eVGT position sensor will read and store the signal voltage. At the end of every driving cycle, EMS ECU will read, store & compare the value with the stored value from the previous driving cycle & an absolute value. The SDPF is a combination of Selective Catalytic Reduction (SCR) and Diesel Particulate Filter (DPF). The DOC assembly connected to turbocharger as input and SDPF as output, the SDPF output connect with exhaust pipes. DOC treated exhaust gaseous enters mixer zone where a multiple plate like structure is constructed in such a way it promotes swirl The SDPF functions to reduce particulates and NOx values from the engine out emissions. The Particulate filter filters the particulate emissions coming from the engine and the NOx in the engine out is reduced using the Diesel Exhaust Fluid (DEF) dosed into the exhaust. The SDPF consists of Parallel channels with alternate cells closed in the form of a honeycomb structure and this enables the filtration of the particulates coming from the engine by forcing them through the porous walls of the filter. The SDPF is coated with Zeolite that helps to retain the Diesel Exhaust Fluid (DEF) dosed into the exhaust system thereby helpful for conversion of NOx conversion. Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury. For removing any SCR hydraulic connections carry out below \u201cSCR ROUTINES\u201d by using i-SMART. For additional information refer Diagnosis Manual. , \u2013 EMPTYING of SCR System After removal of supply hose, Cover the DEF tank & Dosing Module with dust caps to avoid entry of dust and Contamination of the DEF Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Remove the Temperature Sensor (T4). For additional information refer to Temperature Sensor (T4) - R &R; section. Remove the Temperature Sensor (T5). For additional information refer to Temperature Sensor (T5) - R &R; section. Remove the DEF Dosing Module. For additional information refer to DEF Dosing Module - R &R; section. For additional information refer to Differential Pressure (DPF) Pipes Assembly - R &R section. ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 15 mm combination and ring spanner, Unscrew exhaust front pipe mounting nuts SDPF end. Using 12 mm socket spanner, Unscrew SDPF front bottom bracket mounting bolt Using 12 mm socket spanner, Unscrew SDPF rear bracket mounting bolt. Using 12 mm socket spanner, Unscrew SDPF mounting bolts cylinder head end. Using 12 mm socket spanner, Unscrew SDPF mounting bolt fire wall end. Using 10 mm socket spanner, Unscrew turbo heat shield mounting bolts. Using 13 mm socket spanner, Loosen Turbocharger and SDPF coupling V Clamp mounting nut. Carefully remove SDPF Assembly from engine compartment. Take at most care not to damage Turbo oil return hose and HVAC pipe lines while take out SDPF from vehicle Check for any external damage, replace if found any . Position SDPF assembly inside the engine compartment. Install SDPF supporting bracket mounting bolts on the engine head. Position the SDPF over Turbocharger housing and pre-engage the V Clamp over the joint. Follow the refitment sequence as instructed in the upcoming steps carefully, false installation can lead to effect the SDPF performance. Always use new V band clamp & Gasket once removed. V Clamp Gasket to be positioned over EATS by aligning the gasket lug with marking on V Clamp as shown in the image V Clamp to be fully opened and put over Turbine Housing before position the SDPF INITIAL TORQUE 7 Nm FINAL TORQUE 13.5\u00b11 Nm ",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install DOC bracket mounting bolts on the engine head . Install SDPF bottom front & rear bracket mounting bolts on the crank case. Torque tighten Turbocharger - SDPF Coupling V clamp to the specified torque value. Initial Torque : 7 Nm Final Torque : 13.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Ensure to fit the clamp in proper position for easy accessing of clamp in subsequent removal. Torque tighten the SDPF supporting bracket bolts to the specified value. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Torque tighten the SDPF bottom front & rear bracket mounting bolts to the specified value. Torque : 25\u00b13 Nm Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030038.jpg",
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install exhaust front flexi pipe mounting nuts. Tighten the nuts to specified torque value. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Refit turbocharger heat shield and install the mounting bolts. Tighten the nuts to specified torque value. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030192.jpg",
+ "display_order": 72
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Refit the Differential Pressure (DPF) Pipes Assembly. Refit the e Temperature Sensor (T4). Refit the e Temperature Sensor (T5). Refit the DEF Dosing Module. Reconnect battery negative cable and torque tighten it to the specified value . Reconnect battery negative cable and torque tighten it to the specified value . Torque :6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 83
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Check and top up the engine coolant if required Pressure preparation test DEF Leak Test Dosing Module Dry Actuation Test Dosing Module Spray Test DEF static metered dosing test DEF dynamic metered dosing test EMPTYING of SCR System Diesel Exhaust Fuel (DEF) - Mahindra MaxiCLEAN Genuine Diesel Exhaust Fluid. Capacity - 20 Liters. Minimum Refill Quantity - 6 Liters. i-SMART diagnostic tester and turn the ignition ON. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": " 2. Launch the i-SMART application. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1E030250.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1E030251.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Select Dearborn Electronics India Pvt Ltd. \u2013 Garuda and then click START. Select THAR from the list of vehicles displayed as in following window then select the THAR_ BS6 . Select EMS from the ECU List Select the LIVE DATA tab. In the menu drop down list select DEF Tank level and Temperature and Water Pump Relay and click Proceed . The volume of DEF in the tank is to be read from the label \u201dFiltered DEF in-tank volume\u201d only . Convert the \u201cFiltered DEF in-tank volume\u201d from mL to Litres The Filtered DEF in-tank volume indicates the volume of the DEF left out in the DEF tank. With the tank volume of 20 liters, by doing the following calculation, the DEF Refill quantity can be arrived: DEF Refill Volume = 20 Liters - Filtered DEF in -tank volume. For Example, Filtered DEF in-tank volume = 12560 mL = 12.5 Liters Then DEF Refill Volume = 20 \u2013 12.5 = 7.5 Liters Refill the required quantity of DEF in the tank, follow the below Refill procedure. Select the suitable combination of SKUs of MaxiCLEAN available in stock. Always fill the Diesel Exhaust Fluid (DEF) in ignition OFF condition.
2. Using vehicle key open the fuel filler door.
",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040125.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the DEF filler cap. Open the Container Pack (Bucket) and fix the filling pipe. The filling pipe supplied with the bucket is to be fitted on the bucket spout. Filling pipe fitment procedure below, Avoid using any funnel or unclean containers for filling. Do not keep container open after use. Fill DEF as required. Maximum Storage capacity is 20 litres. Overfilling DEF more than 20 litres may result in system /component failure. DEF is corrosive against paint and metal surface - Don\u2019t spill DEF on the vehicle, it may damage/ corrode the paint or colour change. If the DEF spills on the metal or plastic or rubber parts, wipe off immediately with a wet cloth or wash it with plain water. This will avoid corrosion. Place DEF filler cap back on DEF filler neck and tighten it moderately by turning it clockwise, then close the DEF filler lid. Close and lock the fuel filler door. Remove the vehicle Key. Turn the ignition ON If Diesel fuel is accidentally filled in the DEF tank, then the following components need to be replaced as the diesel fuel impacts the seals and other components inside the DEF tank. DEF tank along with Supply module Dosing unit pipes and hoses sDPF Assembly sDPF needs to be replaced on further analysis of the vehicle data. Contact your Tekliner for further assistance. Use Genuine DEF MaxiCLEAN always. In case of genuine Diesel Exhaust Fluid (DEF) non-availability, DEF confirming to IS 17042 or ISO 22241 specification only can be used. Overfilling DEF more than 20 litres may result in system /component failure. Don\u2019t expose the DEF or DEF filler container to sun light. By exposing to warm condition or sun light the water gets evaporated from the DEF Solution and results in concentration mismatch or crystallization deposit. The DEF is non toxic and non flammable fluid. DEF is non corrosive to Fabric and humans, but it is recommended to wash immediately on spillage to avoid any stain or allergy. DEF is corrosive against paint and metal surface. Don\u2019t spill DEF on the vehicle, it may damage/ corrode the paint or colour change. If the DEF spills on the metal or plastic or rubber parts, wipe off immediately with a wet cloth or wash it with plain water. This will avoid corrosion. Make sure that no dirt or other foreign matter is allowed to contaminate the DEF. If the DEF is stored in a sealed container for more than a year, before utilizing the DEF perform the following Check the Urea concentration using a refractometer. If it is with in the recommended limit, use the DEF. Check for crystallization deposits. If found discard the DEF. DEF will not deteriorate, if it is stored in sealed container at ambient conditions. It can be used up-to one year. The DEF is available under MaxiCLEAN brand. MaxiCLEAN is available in 10 lit, 6 lit & 2 lit packs. DEF can be filled up to the filler neck, if filled very slowly towards the end. Ensure that the maximum refill quantity is calculated so that the available SKUs are used fully. In the event of requirement of less quantity than the full SKU, use a clean measuring can for calculating the billing amount to the customer. The measuring can should be for the exclusive use of DEF only and should not be used to measure any other fluids like Engine oil or Coolant. MDW/DMS accepts \u201cDecimal\u201d billing. It is always recommended to fill the Maximum qty to maximise the range of vehicle operation. Connect the i-SMART and ensure the Filtered DEF in-tank volume is 20 liters (20000 mL) .
2. If present, then drive the vehicle for 4 to 5 kms.
3. If the warning is still present in the Infotainment System, then connect iSMART and check for any error codes (DTCs\u2019) in \u201cENGINE MANAGEMENT SYSTEM\u201d. Refer the Diagnostic Manual for more details.
",
+ "file": null,
+ "display_order": 46
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 351,
+ "sys_id": "THAR.LX-0004-Exhaust & Emission Control",
+ "subsys_id": "THAR.LX-0004-Exhaust & Emission Control-DOC Post T5 Temperature Sensor",
+ "systems": "Exhaust & Emission Control",
+ "sub_systems": "DOC Post T5 Temperature Sensor",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A030007.jpg",
+ "myid": 1022,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-DOC Post T5 Temperature Sensor-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "DOC Downstream Temperature Sensor (T5) is located at the bottom side of the oxidation catalyst (DOC). T5 temperature used here is of PTC type. EMS ECU uses signal from T5 mainly for,
Torque :6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Warning",
+ "content": "Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON Disconnect temperature sensor (T5) electrical connector. Using 17 mm open end spanner, Loosen temperature sensor T5 mounting on SDPF. Torque : 35\u00b15 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove T5 sensor from routing clip and remove from SDPF. Detach T5 sensor from routing clip and remove it Install in the reverse order of removal. Green colour tape provided on T5 Sensor wiring pigtail and engine wiring harness connector for easy identification while refit and ensure to properly connect the T5 Sensor wiring pigtail connector with engine wiring harness Mismatch connection of wiring connectors may leads to affect the engine performance and occur engine trouble. Check for any external cracks, replace if found any Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury Remove selective diesel particulate filter(SDPF). Remove DPF assembly without removing T4 sensor, T5 sensor mountings and DEF dosing module from SDPF assembly. Using 7 mm socket spanner, Loosen air intake clean hose clip turbo end and detach hose Using 7 mm socket spanner, Loosen turbo outlet hose clip and detach hose . Using 14 mm socket spanner, Unscrew turbocharger oil inlet tube mounting banjo bolt . Torque : 17.5\u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew turbo oil return tube mounting bolts crank case end. Torque : 11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew turbo oil return tube routing bracket mounting bolt Torque :25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect eVGT electrical connector.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030088.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew exhaust manifold mounting bolts. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Notice",
+ "content": "Always use new metal gasket onceremoved. check for any leakages. While installing, Molykote to be applied on both sides of stud on exhaust manifold- turbocharger. Torquing to be done immediately after application of molykote sealant. Nuts to be re torque after initial tightening in the same sequence Using 10 mm socket spanner, Unscrew turbo oil outlet pipe mounting bolt from turbocharger. Torque :11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030165.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Check Engine Oil level & Topup the engine oil. Check oil return tube for any external damage, replace if found any. Drain the coolant. For additional information refer to Coolant draining section. Remove pipe EGR module to intake manifold. Disconnect EGR electrical connector. Disconnect EGR cooler bypass actuator electrical connector. Disconnect Vacuum hose EGR module end. Using 12 mm socket spanner, Unscrew engine wiring routing bracket bolt intake manifold end. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew EGR module mounting bolts. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew EGR cooler mounting bolt. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Disconnect EGR cooler inlet and outlet hose quick couplers. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Disconnect coolant temperature sensor electrical connection. Remove EGR assembly from the vehicle. Install in the reverse order of removal. Always use new gasket once removed. Refill the Coolant. For additional information refer to Engine coolant filling and de-aeration Procedure. Check for any external damage, replace if found any. Conditions to Diesel Exhaust Fuel (DEF) Draining & Filling ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030127.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "If vehicle covers less than 10,000 kms in 2 years then replace DEF in 2nd year end. Place the vehicle on a 2/4 post lift. Switch the ignition OFF. Using vehicle key open the fuel filler door. Remove the DEF filler cap. Using star screw driver, remove DEF tank bottom protection cover scrivets and detach the cover Remove DEF drain hose quick coupler and drain the DEF Refit drain hose quick coupler Position protection cover and install DEF tank bottom cover scrivets Always fill the Diesel Exhaust Fluid (DEF) in ignition OFF condition. Overfilling DEF more than 20 litres may result in system /component failure. DEF is corrosive against paint and metal surface - Don\u2019t spill DEF on the vehicle, it may damage/ corrode the paint or colour change. If the DEF spills on the metal or plastic or rubber parts, wipe off immediately with a wet cloth or wash it with plain water. This will avoid corrosion. Place DEF filler cap back on DEF filler neck and tighten it moderately by turning it clockwise, then close the DEF filler lid. Turn the ignition ON Connect the i-SMART and ensure the \u201cFiltered DEF in-tank volume\u201d is 20 liters (20000 mL). Verify for any warning related to DEF level low in the Infotainment System. If present, then drive the vehicle for 4 to 5 kms. If the warning is still present in the Infotainment System, then connect iSMART and check for any error codes (DTCs\u2019) in \u201cENGINE MANAGEMENT SYSTEM\u201d. Refer the Diagnostic Manual for more details. Use Genuine DEF MaxiCLEAN always. In case of genuine Diesel Exhaust Fluid (DEF) non-availability, DEF confirming to IS 17042 or ISO 22241 specification only can be used. Overfilling DEF more than 20 litres may result in system /component failure Don\u2019t expose the DEF or DEF filler container to sun light. By exposing to warm condition or sun light the water gets evaporated from the DEF Solution and results in concentration mismatch or crystallization deposit. The DEF is non toxic and non flammable fluid. DEF is non corrosive to Fabric and humans, but it is recommended to wash immediately on spillage to avoid any stain or allergy DEF is corrosive against paint and metal surface. Don\u2019t spill DEF on the vehicle, it may damage/ corrode the paint or colour change. If the DEF spills on the metal or plastic or rubber parts, wipe off immediately with a wet cloth or wash it with plain water. This will avoid corrosion Make sure that no dirt or other foreign matter is allowed to contaminate the DEF. If the DEF is stored in a sealed container for more than a year, before utilizing the DEF perform the following Check the Urea concentration using a refractometer. If it is with in the recommended limit, use the DEF Check for crystallization deposits. If found discard the DEF DEF will not deteriorate, if it is stored in sealed container at ambient conditions. It can be used up-to one year The DEF is available under MaxiCLEAN brand. MaxiCLEAN is available in 10 lit, 6 lit & 2 lit packs DEF can be filled up to the filler neck, if filled very slowly towards the end Ensure that the maximum refill quantity is calculated so that the available SKUs are used fully In the event of requirement of less quantity than the full SKU, use a clean measuring can for calculating the billing amount to the customer. The measuring can should be for the exclusive use of DEF only and should not be used to measure any other fluids like Engine oil or Coolant MDW/DMS accepts \u201cDecimal\u201d billing It is always recommended to fill the Maximum qty to maximise the range of vehicle operation Using 10 mm socket spanner, Unscrew SDPF heat shield mounting bolts and remove the heat shield. Torque :11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew SDPF heat shield mounting bolt. Torque :25\u00b1 3 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, Unscrew SDPF heat shield top mounting Struds. Torque :11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, Unscrew turbocharger oil inlet tube mounting banjo bolt turbo end.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030121.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 17.5\u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, Unscrew turbocharger oil inlet tube mounting banjo bolt OCFM end.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030185.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 17.5\u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove turbocharger oil inlet tube.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030186.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Check Engine Oil level & Topup the engine oil. Check for any external damage, replace if found any Conditions to Diesel Exhaust Fuel (DEF) Flushing ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "If any contamination or the concentration level of stored DEF not met with the recommended value. For additional information on DEF Concentration Measurement by using Refractometer & Usage guidelines, Refer to DEF Refractometer Session. If alert message of \u201cWrong DEF Detected\u201d display in the infotainment system. If Diesel fuel is accidentally filled in the DEF tank, then the following components need to be replaced as the diesel fuel impacts the seals and other components inside the DEF tank . DEF tank along with Supply module. Dosing unit. pipes and hoses sDPF Assembly sDPF needs to be replaced on further analysis of the vehicle data. Contact your Tekliner for further assistance.
2. Switch the ignition OFF.
3. Using vehicle key open the fuel filler door.
",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030127.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040125.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the DEF filler cap. Using star screw driver, remove DEF tank bottom protection cover scrivets and detach the cover. Remove DEF drain hose quick coupler and drain the DEF. Refit drain hose quick coupler. Fill 2 litres of DEF for flushing and close the DEF filler cap. Always fill the Diesel Exhaust Fluid (DEF) in ignition OFF condition. Remove DEF drain hose quick coupler and drain the 2 Liters of DEF from tank. Refit drain hose quick coupler. Position protection cover and install DEF tank bottom cover scrivets. Fill DEF Maximum Storage capacity 20 litre. Always fill the Diesel Exhaust Fluid (DEF) in ignition OFF condition. Overfilling DEF more than 20 litres may result in system /component failure. DEF is corrosive against paint and metal surface - Don\u2019t spill DEF on the vehicle, it may damage/ corrode the paint or colour change. If the DEF spills on the metal or plastic or rubber parts, wipe off immediately with a wet cloth or wash it with plain water. This will avoid corrosion. Place DEF filler cap back on DEF filler neck and tighten it moderately by turning it clockwise, then close the DEF filler lid. Close and lock the fuel filler door. Remove the vehicle Key. Connect the i-SMART and ensure the Filtered DEF in-tank volume is 20 liters(20000 mL) . Verify for any warning related to DEF level low in the Infotainment System. If present, then drive the vehicle for 4 to 5 kms. If the warning is still present in the Infotainment System, then connect iSMART and check for any error codes (DTCs\u2019) in \u201cENGINE MANAGEMENT SYSTEM\u201d. Refer the Diagnostic Manual for more details. Use Genuine DEF MaxiCLEAN always. In case of genuine Diesel Exhaust Fluid (DEF) non-availability, DEF confirming to IS 17042 or ISO 22241 specification only can be used. Overfilling DEF more than 20 litres may result in system /component failure. Don\u2019t expose the DEF or DEF filler container to sun light. By exposing to warm condition or sun light the water gets evaporated from the DEF Solution and results in concentration mismatch or crystallization deposit The DEF is non toxic and non flammable fluid. DEF is non corrosive to Fabric and humans, but it is recommended to wash immediately on spillage to avoid any stain or allergy. DEF is corrosive against paint and metal surface. Don\u2019t spill DEF on the vehicle, it may damage/ corrode the paint or colour change. If the DEF spills on the metal or plastic or rubber parts, wipe off immediately with a wet cloth or wash it with plain water. This will avoid corrosion. Make sure that no dirt or other foreign matter is allowed to contaminate the DEF. If the DEF is stored in a sealed container for more than a year, before utilizing the DEF perform the following Check the Urea concentration using a refractometer. If it is with in the recommended limit, use the DEF. Check for crystallization deposits. If found discard the DEF DEF will not deteriorate, if it is stored in sealed container at ambient conditions. It can be used up-to one year. The DEF is available under MaxiCLEAN brand. MaxiCLEAN is available in 10 lit, 6 lit & 2 lit packs. DEF can be filled up to the filler neck, if filled very slowly towards the end. Ensure that the maximum refill quantity is calculated so that the available SKUs are used fully. In the event of requirement of less quantity than the full SKU, use a clean measuring can for calculating the billing amount to the customer. The measuring can should be for the exclusive use of DEF only and should not be used to measure any other fluids like Engine oil or Coolant. MDW/DMS accepts \u201cDecimal\u201d billing It is always recommended to fill the Maximum qty to maximise the range of vehicle operation. If the DEF is stored in a sealed container for more than a year, before utilizing the DEF perform the following. 1. Check the Urea concentration Using refractometer. If it is with in the recommended limit, use the DEF.
2. Check for crystallization deposits. If found discard the DEF.
",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1E030402.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Notice",
+ "content": "DEF will not deteriorate, if it is stored in sealed container at ambient conditions. It can be used up-to one year. Press READ button to START the refractometer. Calibration Add 2-3 drops of Distilled water on the prism. Press CAL button for 2 to 3 seconds till see CAL flashing Press CAL button again during CAL flashing to end calibration process - End will be displayed for 2 to 3 seconds on the screen as notification After calibration completes clean and dry the prism using soft tissue paper. Calibration: ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Add 2-3 drops of Distilled water on the prism. Press CAL button for 2 to 3 seconds till see CAL flashing Press CAL button again during CAL flashing to end calibration process - End will be displayed for 2 to 3 seconds on the screen as notification After calibration completes clean and dry the prism using soft tissue paper. DEF Concentration Measurement: ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Collect small quantity of DEF from the DEF Tank. Add 2-3 drops of DEF on the prism Ensure that there are no air bubbles present in the DEF droplets. Press READ button once & wait for about 15 seconds to get Concentration of DEF Ensure that the Scale should be \u201cS 01\u201d. If not, then press the Scale button again till the scale changes to \u201cS 01\u201d DEF concentration will get displayed on the screen The DEF Concentration acceptance range \u2013 31.8 to 33.2 % Post Measurement: ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Completely clean and dry the prism using soft tissue paper. SCR or selective catalytic reduction is an exhaust after-treatment technology to reduce NOx emissions in diesel vehicles. The technology involves the use of Diesel Exhaust Fluid (DEF) which is an aqueous urea solution (AUS32). The DEF is pressurised and injected into the exhaust gases at the SCR catalyst to reduce the NOx at the tail pipe. So in case of any malfunction in the SCR system, DEF not available in the tank or if any other fluid (not meeting AUS32) is used in the DEF tank, the SCR system will not function as intended. The inducement strategy is a legally mandated warning system to alert the driver if the system is not functioning as intended. In the Thar, the inducements are displayed on the Cluster screen. The EMS will enter into a inducement (warning message) when certain emission or functional DTCs are detected. Every inducement always comes with a DTC & the SCR warning lamp in the Cluster. The aim of each inducement is to ensure that the root cause of any malfunction in the SCR system is identified & fixed. So for the inducement to stop the DTC causing the inducement has to be tested again and healed. Inducement will not stop by clearing the DTC using i-SMART For the inducement to stop the DTC will have to be healed, i. e. The root cause identified & then tested. Only when the EMS tests for the DTC again & detects that the DTC is healed inducement stops displaying in the Cluster. If any inducement causing DTC is present in i-SMART, DO NOT CLEAR THE DTC without ensuring that the issue is fixed & tested again. Always generate DTC report in i-SMART at the start of diagnosis of a DTC. There are 3 different inducement messages for Low DEF level, malfunction in DEF dosing system and incorrect DEF present in the system. Each inducement then has 5 levels. At the final inducement (level 5), vehicle will not be allowed to start unless root cause for the inducement (warning message) is fixed. When DEF level in tank fall below pre-defined values, warning lamp turns ON and Alert messages are flashed in five stages in the Cluster. These five warning stages are explained below: If the DEF warning lamp turns on due to the DEF level, refill the DEF tank. Failure to refill may cause the engine start restriction. Overfilling DEF more than 20 litres may result in system /component failure. In absence of DEF level low warning, refilling is not recommended. If SCR system detects quality of DEF inside the tank is not meeting IS 17042 (or) ISO 22241 specification, warning lamp turns ON and Alert messages are flashed in five stages in the Cluster. These four warning stages are explained below: 1. DEF tank along with Supply module
2. Dosing unit
3. pipes and hoses
4. sDPF Assembly
",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "SDPF needs to be replaced on further analysis of the vehicle data. Contact your Tekliner for further assistance. If the DEF warning lamp turns on due to the DEF quality, see contamination/ incorrect fluid for corrective action. Failure to correct may cause the engine start restriction. If SCR system detects any malfunction due to failures in components or tampering, warning lamp turns ON and Alert messages are flashed in five stages in the Cluster. These five stages are explained below: If the DEF warning lamp turns on due to dosing malfunction, refer diagnostic manual for more information. Failure to repair the system may cause the engine start restriction. 1. Driving the vehicle to service center if vehicle is shut off.
2. Testing and healing certain DTCs that may cause DOSING MALFUNCTION or INCORRECT DEF inducement.
",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Refer Diagnostic manual for Inducement Extension Procedure. After extension, the Cluster will display 50 kms and reduce when the vehicle is being driven. Once the distance comes to 0 kms in the Cluster, the extension option can be used again to extend by another 50 kms. The distance can be extended only by 50 kms at a time. Clicking Reset in i-SMART multiple times will not extend the drive distance more than 50 kms. Using 10 mm socket spanner, Unscrew EGR pipe mounting bolts EGR cooler end. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew EGR pipe mounting bolts intake manifold side. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew EGR pipe routing bracket mounting bolts and remove the pipe. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030118.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Always use new metal gasket once removed. Check for any external cracks, replace if found any. The oil filter is located after the oil pump and before the oil starts getting distributed. Any impurity whose size can cause breakdown of lubrication film and cause metal to metal contact are entrapped in the oil filter element\u2019s filtration medium. ground level/ 2 post lift/ 4 post lift and turn engine OFF.
2. Open the bonnet and lock it in open position using bonnet stay rod.
",
+ "file": null,
+ "display_order": 6
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 27 mm 12 point doublehexagonal socket spanner, Loosen the engine oil filter cap. To access Oil filter cap mounting slightly move the Intercooler hose (without removing) and Carefully remove the damaging the hose. Remove the engine oil filter with cap from engine assembly. Ensure gasket isn\u2019t in casting housing and element assembly should come along with filter cap. Carefully rotate the oil filter element in clockwise direction, pull upward and remove the filter element. Remove the filter element carefully, with no damage to the plastic snaps. Pay attention not to damage the oil bypass valve while removing the oil filter element. Smear a layer of fresh oil on new oil filter O-ring and Position the O-ring on filter cap. Replace the O-ring with new one when replacing the oil filter element. Ensure no damage to O-ring during assembly, with no sharp edges damaging O-ring or element. Ensure to fix the oil bypass valve in proper position on oil filter cap. Place the oil filter in the bowl projection, push the filter inside and rotate the filter in anti-clockwise direction to lock it. Install the element carefully , with no damage to snaps. Position the oil filter cap with filter on the oil cooler surface. Tighten the oil filter cap in clockwise direction and torque tighten cap to the specified value. Torque :25 - 30 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Don\u2019t apply improper torque which leads to damage in threads. Check the engine oil level. Start the engine and check for Oil leakage/ seepage at: Oil pan & crankcase joint. Oil pan drain plug. Oil filter joint. Recommend to use only the Mahindra genuine oil filter for better engine protection and lubricant life. Make sure for all the subassembly and components going into engine assembly should be clean and away from foreign material. Remove the timing case cover. For additional information refer to Timing Case Cover - R &R; Section. Remove MST 0307ABH0001ST - Flywheel Locking Tool - Eagle mounting bolts and detach it. Position engine front lifting hook and hand tighten the mounting bolts. Using 18 mm socket spanner, unscrew engine mounting bracket nuts (Both RH & LH). Provide engine support beam to support engine. Lift the engine with care, don\u2019t over lift since chances of damaging parts are high Ensure none of the components are effected or damaged during lifting. Using 14 mm combination spanner and socket spanner , unscrew LH engine mounting bracket mounting bolts and remove the LH bracket. Using 6 mm square socket spanner, loosen and remove TDC locking dummy from crankcase. Refit damper pulley and install damper pulley mounting bolt on crankshaft. Lock the crankshaft by Inserting the TDC locking pin (MST\u2013 0312ABH0001ST). Ensure the crankshaft locking tool is seated properly into the slot on crankshaft and ensure the TDC locking pin insert upto Red mark in the pin as shown. Check and ensure the 1st cylinder piston position to TDC. Ensure that correct TDC locking tool is used. TDC locking hole is near crankcase left side below intake manifold (Near Engine LH Mounting bracket). If not able to position the MST in proper position into crankshaft, Slightly rotate damper pulley and align the crankshaft to insert MST:- 0312ABH0001ST Crankshaft Locking Tool - TDC Pin on crankshaft. Install the (MST \u2013 0310ABH0001ST Cam Shaft locking tool) on the front side of cylinder head as the location shown below using appropriate bolts. The Cam shaft 2D Matrix must be on the top side for both Intake and Exhaust camshaft. Crank Sprocket Key must be at 12\u2019O Clock Position. Ensure that locking tool is seated properly on Cam shaft. If the tool is not properly seat on the cam shaft slot then the engine is not in proper timing and follow the below steps for Engine timing adjustment . Using T55 socket spanner, loosen exhaust Cam sprocket mounting bolt. The Exhaust Camshaft Sprocket mounting bolt must be loosened first and then the Intake camshaft Sprocket Mounting bolt to be loosened. Using 15 mm socket spanner, loosen intake CAM sprocket mounting bolt. Loosen (MST\u2013 0310ABH0001ST Cam Shaft locking tool) mounting bolt and adjust cam shaft till MST locking properly at camshaft slot, then tighten MST mounting bolts. Follow below Sequence and procedure for Torque tightened the Intake & Exhaust Cam shaft sprocket bolts. 1. Place the MST203 - Companion Flange Holding Tool into the Primary Chain Intake Cam shaft sprocket as shown and hold the tool in opposite direction of torqueing. 2. Torque tightened the Intake Cam shaftsprocket bolt to 50\u00b12 Nm + 90\u00b0\u00b15\u00b0 . 3. Holding the MST Tool and Torque tightened the Exhaust Cam shaft sprocket bolt after intake sprocket to 50\u00b12 Nm + 80\u00b0\u00b15\u00b0 . MST : 0301BM011ST (cam chain tensioning tool) can be used instead of MST203 - Companion Flange Holding Tool. Using a suitable tool, loosen and remove the MST- 0310ABH0001ST Alignment Tool Camshaft separately. Remove the TDC locking pin. Refit damper pulley and install damper pulley mounting bolt on crankshaft. Rotate the crankshaft (360?) 4 times towards clockwise direction and check the free rotation. To reconfirming proper cam and crank timing, Once again Insert TDC locking pin and ensure cam shaft locking tool properly seating on the cam shafts position. Remove the cam shaft locking tool & TDC locking pin after confirmation Apply Loctite 574 , Install the TDC locking dummy on crankcase and torque tighten. Torque : 20\u00b12 Nm ",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Remove the damper pulley. Position the engine LH mounting bracket and install the mounting bolts. torque tighten the bolts to specified value. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Detach the engine support beam from engine and remove support beam from vehicle. Install the engine mounting bracket nuts (Both RH & LH) on engine beds and torque tighten the nuts to specified value. Torque : 110\u00b1 10 Nm. ",
+ "file": null,
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1662.jpg",
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Remove the engine front lifting hook. Refit Flywheel locking tool (MST\u2013 0307ABH0001ST) with suitable mounting bolts on crankcase. Refit the timing case cover. For additional information refer to Timing Case Cover \u2013 R&R; Section. For additional information refer to the Crankshaft Pulley \u2013 R &R; section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a suitable tool remove the front end oil seal. Remove the seal from the engine. Install in reverse order of removal. The crankshaft oil seals are one time use, should never be reused. Apply thin layer of oil on the new oil seal lip.
Visually inspect the oil seal for proper seating. Check & Top-up the engine oil. Check and clean the oil seal seating area thoroughly for any damage. Hydro lock or hydrostatic lock is an abnormal condition in internal combustion engine. This occurs when a volume of liquid (Coolant/water or fuel) greater than the volume of the cylinder at its minimum (end of the piston stroke) enters the cylinder. Since liquids are nearly incompressible the piston cannot complete its travel; either the engine stop rotating or a mechanical failure occurs. When an engine is suspected to be hydrostatically locked, regardless of what caused the problem, the following steps should be used DO NOT use starter motor to rotate the engine, severe damage may occur.
2. Disconnect negative battery cable
3. Place a shop towel around the injectors when removing them from the engine. This will catch any fluid that may possibly be in the cylinder under pressure
4. With all injectors removed, rotate engine crankshaft.
5. Identify the fluid in the cylinder(s) (i.e., coolant, fuel, oil or other).
6. Make sure all fluid has been removed from the cylinders. Inspect engine for damage (i.e., connecting rods, pistons, valves, etc.)
7. Repair engine or components as necessary to prevent this problem from recurring.
",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Squirt approximately one teaspoon of oil into the cylinders, rotate engine to lubricate the cylinder walls to prevent damage on restart. Drain engine oil and remove oil filter. Install a new oil filter. Fill engine with specified amount of approved oil. Connect negative battery cable. Install all Injectors. Start engine and check for any leaks The oil Sump is the reservoir for the oil and also cover for the crank case. It is secured to the engine block by bolts. A liquid sealant is used to provide an leak proof joint. For additional information refer to engine oil draining procedure section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the stone guard. For additional information refer to Stone Guard \u2013 R &R Section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove electric disconnect stone guard. For additional information refer to Electric Disconnect Stone Guard \u2013 R &R Section. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 14 mm ring and 15 mm socket spanner, Unscrew the front cross member mounting bolts and nuts. Torque : 65 \u00b110 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the front cross member from the vehicle.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010916.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect the front axle electrical connector. Provide jack to support the front axle assembly. Using a 19 mm Socket spanner, loosen and remove the front axle assembly mounting bolts. Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Partially down the front axle assembly . For additional information refer to AC compressor belt - R &R Section. ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the AC compressor bottom mounting bolts. Torque : 23 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the transmission bottom mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the oil sump bottom mounting bolts. Torque : 22.5 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a 8 mm socket spanner, loosen and remove the oil sump bottom mounting bolts. Torque : 11 \u00b1 1.0 Nm ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Detach engine oil sump from the vehicle.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010919.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010626.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010879.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Notice",
+ "content": "Clean the sump and sump seating area on bed plate. Gently apply sealant for engine oil sump. Apply sealant as per recommendation and position the sump on crankcase. Please refer Sealant pattern session for sealant apply pattern. Torque tighten the bolts as per below sequence. Refill the engine oil and check for oil leakage. Check the oil sump for any cracks, damage etc, replace if found any. A glow plug is a heating device used to aid in cold starting. In cold weather, high speed diesel engines can be difficult to start because the mass of the cylinder block and cylinder head absorb the heat of compression, preventing ignition due to the higher surface-to-volume ratio. The glow plug is a pencil-shaped piece of metal with a heating element at the tip. This heating element, when electrified, heats due to its electrical resistance and begins to emit light in the visible spectrum, hence the term glow-plug. The heat generated by the glow plugs is directed into the cylinders and serves to warm the engine block immediately surrounding the cylinders. This aids in reducing the amount of thermal diffusion which will occur when the engine attempts to start. The fuel injector spray pattern then impinges directly upon the hot tip of the glow plug during the injection of fuel at top dead center. This enables the fuel to ignite even when the engine is insufficiently hot for normal operation. This reduces the cranking time needed to start the diesel engine. The glow plugs are controlled by the EMS ECU. The ECU decides the actuation of the glow plugs based on operating conditions, engine temperature and environment temperature. Disconnect the glow plug electrical connector. Using 8 mm deep socket spanner, Carefully loosen and remove the glow plug from the cylinder head. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010678.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "Follow the same procedure for all glow plugs. Install in reverse order of removal. Check for any cracks, damage etc, replace if found any. For additional information refer to Engine Oil Strainer \u2013 R&R Section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 8 mm allen socket spanner, loosen and remove the engine oil pump tensioner mounting bolt. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010632.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 25\u00b1 3 Nm",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, Remove engine oil pump mounting bolts.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010633.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 26 \u00b1 2 Nm",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the engine oil pump from oil pump chain.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010634.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully remove the engine oil pump.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1566.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1567.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refill the engine oil and check for oil leakage.",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the oil pump for any damage. Replace if found.Drain the engine coolant. For additional information refer to coolant drain Procedure. For additional information refer to OCFM-Degassing Tank Outlet Pipe - R &R. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Recover the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. Using 12 mm socket spanner, Unscrew air cleaUsing a 12 mm socket spanner, loosen and remove the AC compressor suction and discharge pipes mounting nuts from compressor. Torque : 14.0+1.0 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using T45 Torx spanner, loosen and remove the Oil Cooler Mounting torx Bolts. Remove the oil cooler from the engine. Replace New O ring while refitting. Ensure to clean the Engine oil spillages Install in reverse order of removal. Refill the engine oil and check for the oil leakage. Refill the engine coolant and carry-out deaeration procedure. Check and clean the oil cooler thoroughly for any damage. Remove the engine oil sump. Using a 8 mm Allen socket spanner, loosen and remove the engine oil pump tensioner mounting bolt. Torque : 25\u00b1 3 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the starter motor mounting bolts. Torque : 44\u00b15 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using MST\u2013 0307ABH0001ST lock the flywheel. Using a 14 mm socket spanner, loosen and remove the sprocket nut from the sprocket. Torque : 40\u00b15 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the sprocket from the chain and take out from the vehicle. Ensure to match the Sprocket slot projection to Oil pump shaft slot. Refill the engine oil and check for oil leakage. Inspect the engine oil pump chain for any physical damage. If found replace Using a screw driver, remove the crankshaft rear end oil seal. Install the rear end oil seal by using MST 0302ABH0001ST - Engine Rear End Oil Seal Installer on the crankshaft. Always use new oil seal while installation. Install in reverse order of removal. Check & Top-up the engine oil. Check for any cracks, damage etc, replace if found any. For additional information refer into engine coolant draining procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the water pump pulley. For additional information refer into Water Pump Pulley \u2013 R&R Section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Detach the wiring routing clip from the water pump.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1555.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1556.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, Unscrew water pump mounting bolts.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1557.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully remove the water pump from the engine.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1558.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the O ring from the water pump.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Always replace the O ring new one once removal of water pump.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Refill the engine coolant and carry-out de-aeration procedure.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Check for coolant seepage and any oil seepage on the engine and transmission. Replace if any traces found.",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the water pump for any damage or leakage or noise. Replace if found.Inspect the impeller for any damage, Replace if found.",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 6,
+ "sys_id": "THAR.LX-0004-Engine",
+ "subsys_id": "THAR.LX-0004-Engine-Engine Assembly",
+ "systems": "Engine",
+ "sub_systems": "Engine Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A010774.jpg",
+ "myid": 1088,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Engine Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010774.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11163.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11164.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen the battery negative cable mounting nut disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Drain the engine coolant. For additionalinformation refer to engine coolant draining procedure. Recover the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. Drain the power steering oil. For additional information refer to power steering oil draining procedure. Remove the transmission with transfer case. For additional information refer to Clean Side Hose Assembly - R &R section. ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the Hose Turbocharger to Intercooler. For additional information refer to Hose Turbocharger To Intercooler - R &R section. ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": "For additional information refer to Intercooler Outlet Hose - R &R section. ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": "For additional information refer to Degassing Tank - R &R section. ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Disconnect the boost pressure sensor electrical connector. Using a 13 mm Socket Spanner, Unscrew the Intercooler mounting bolts and remove the intercooler. Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020090.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Press and release the dosing module DEF supply quick coupler. Using a 7 mm socket spanner, loosen the coolant hose mounting clamp and detach the coolant inlet hose from Dosing Module end. Using a hose clip piler, release vacuum hose spring band clamp and detach the vacuum hoses from EGR module and vacuum pump end. Detach the vacuum hose from the routing clip and keep aside. Using a 7 mm socket spanner, loosen the radiator outlet hose clamp and detach radiator outlet hose. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using a hose clip plier, release the spring band clamp and detach degassing tank Outlet hose OCFM end. Using a 7 mm socket spanner, loosen the radiator inlet hose clamp and detach radiator inlet hose engine end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Using a hose clip plier, release the spring band clamp and detach the Vent hose pipe end. Using a hose clip plier, release the spring band clamp and detach heater outlet hose heater outlet pipe end. Using a hose clip plier, release the spring band clamp and detach the heater inlet hose from cylinder head side. Using a 13 mm socket spanner, loosen and remove alternator positive cable mounting nut. Torque : 15 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen starter motor positive cable mounting nut and detach cable from starter motor end. Torque : 12\u00b12 Nm ",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": "Using a 8 mm socket spanner, Unscrew starter motor solenoid switch electrical connector. Torque : 2.5\u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Remove AC compressor suction and discharge pipes mounting nuts and detach the pipes. Torque : 14.0+1.0 Nm ",
+ "file": null,
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Disconnect the fuel pipe quick coupler metering unit end. Press and disconnect the quick coupler carefully to avoid seal damages. Using a hose clip plier, unclip the spring band clamp detach fuel return hose from T joint Using a hose clip plier, unclip the spring band clamp detach the fuel line metering unit to return T- Joint hose. Disconnect ECU electrical connector and & routing clip. Using a 10 mm socket spanner, loosen and remove the engine wiring harness carrier mounting struds and detach partially. Disconnect fuel filter electrical connector. Using 15 mm combination spanner, Remove exhaust front pipe mounting nuts SDPF end. Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "Description",
+ "content": "Using 17 mm open end spanner, Remove the power steering pump to steering gear box oil line mounting power steering pump side. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "Description",
+ "content": "Remove radiator air guide. For additional information refer to Radiator Air Guide - R &R section. ",
+ "file": null,
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the front top cross member mounting bolts. Torque : 25 \u00b1 4.0 Nm ",
+ "file": null,
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the front top cross member mounting bolts.",
+ "file": null,
+ "display_order": 83
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250115.jpg",
+ "display_order": 84
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "Torque Value",
+ "content": "Torque : 10.50 \u00b1 1.5Nm ",
+ "file": null,
+ "display_order": 85
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew degassing tank mounting brackets mounting bolts LH & RH. Torque : 10 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050043.jpg",
+ "display_order": 89
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050044.jpg",
+ "display_order": 90
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "Description",
+ "content": "Provide jack support to the engine with the supporting of floor crane. Improper tie-up of the lifting rope chain will cause damage to the vehicle and the persons involved. Using a 19 mm socket spanner, loosen and remove the engine mounting nut from the vehicle. Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-40",
+ "content_type": "Description",
+ "content": "Jack up the crane and take out the engine from the vehicle.",
+ "file": null,
+ "display_order": 97
+ },
+ {
+ "step_name": "Step-40",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010781.jpg",
+ "display_order": 98
+ },
+ {
+ "step_name": "Step-40",
+ "content_type": "Warning",
+ "content": "Improper tie-up of the lifting rope chain will cause damage to the vehicle and the persons involved. Disconnect AC compressor electrical connector. Disconnect engine oil pressure switch electrical connector. Disconnect EGR unit electrical connectors. Disconnect throttle body electrical connector. Disconnect fuel injection pump electrical connector. Disconnect temperature T4, T5 sensor electrical connectors. Yellow colour tape provided on T4 Sensor wiring pigtail and engine wiring harness connector for easy identification while refit and ensure to properly connect the T4 Sensor wiring pigtail connector with engine wiring harness. Mismatch connection of wiring connectors may leads to affect the engine performance and occur engine trouble. Green colour tape provided on T5 Sensor wiring pigtail and engine wiring harness connector side for easy identification while refit and ensure to properly connect the T5 Sensor wiring pigtail connector with engine wiring harness. Mismatch connection of wiring connectors may leads to affect the engine performance and occur engine trouble. Disconnect EVGT unit electrical connector and routing clip. Disconnect coolant temperature sensor electrical connector. Disconnect glow plug electrical connector. Disconnect fuel injector electrical connector. Disconnect differential pressure sensor electrical connector and remove the routing tag from the engine compartment. Disconnect CAM phase sensor electrical connector. Remove the SDPF mounting bolts and Turbo-SDPF Coupling V clamp and detach SDPF. While Installation, Firmly keep the SDPF Assy on th turbo and Take at most care not to damaging SDPF & near by components. Always use new V band clamp & Gasket once removed V Clamp Gasket to be positioned over EATS by aligning the gasket lug with marking on V Clamp as shown in the image. V Clamp to be fully opened and put over Turbine Housing before position the SDPF. Ensure to fit the clamp in proper position for easy accessing of clamp in subsequent removal. Using 12 mm socket spanner loosen and remove clutch cover assembly mounting bolts and remove it. Torque : 25 \u00b1 5.0 Nm (Step Torque : 5,15,25) ",
+ "file": null,
+ "display_order": 149
+ },
+ {
+ "step_name": "Step-59",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011111.jpg",
+ "display_order": 150
+ },
+ {
+ "step_name": "Step-59",
+ "content_type": "Notice",
+ "content": "Install the MST : 0307ABH0001ST \u2013 Flywheel locking tool and lock the flywheel rotation. Insert MST \u2013 0801BUA0001ST \u2013 Master clutch plate assembly, before loosening the clutch cover bolts to prevent clutch plate falling down and getting damage. While Installation, the projected part of clutch disc should come towards transmission side only, fails may result in clutch disc damage. Install in reverse order of removal. Refill the power steering oil. For additional information refer to power steering oil filling procedure. Refit the battery -negative cable Check & Top-up the engine oil. Check for coolant seepage and any oil seepage on the engine and transmission.Replace if any traces found. Check the accessory drive belt for any cracks, damage etc, replace if found any. Check SMF face-out and run-out. Check SMF Surface thermal cracks condition. Check the flywheel ring gear for worn-out or damage, Refer SMF Inspection procedures for more details. Engine Oil \u2013 MAHINDRA 'MAXIMILE ULTRA' Gen-NXT Technology Genuine Engine Fluid Capacity \u2013 6.0 Liters. Pull out the dip stick gauge and wipe it clean with a cloth/paper. Insert the dip stick gauge into the dip stick guide fully till the end. Pull out the dip stick slowly and check for the oil level mark between Maximum and Minimum level - if found below minimum level, top up with recommended oil. Insert the dip stick back and fix properly. Start the engine and check for oil leakage/ seepage at: Oil sump & crankcase joint. Oil sump drain plug. Oil filter joint. Always use MAHINDRA 'MAXIMILE ULTRA'Gen-NXT Technology GENUINE ENGINE Fluid. This is specially developed for your engine\u2019s efficiency. In extreme cases of emergency and non-availability of above oil, we suggest to use 'Maximile Feo' engine oil, take the vehicle to nearest Mahindra Authorised Service centre and replace the oil with 'MAXIMILE ULTRA'. No other brand / grade oil recommended. Remove the air cleaner assembly. Disconnect engine oil pressure switch electrical connector. Using a 24 mm deep socket spanner, loosen and remove engine oil pressure switch from the vehicle. Torque : 17 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010680.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Check engine oil level and Top up engine oil. Refill the engine oil and check for oil leakage. Check oil pressure switch for any cracks, damage etc, replace if found any. The cylinder head gasket failure can be easy to determine. A large stream of white smoke blowing from the exhaust and an overheating engine are sure signs. However, more suitable cylinder head gasket failure signs may be more difficult to diagnose. The engine may experience mysterious coolant loss, or only lose coolant when the engine is driven under heavy load. You may even experience a rough running engine when you first start the vehicle. An initial inspection of cooling system components and a comprehensive test drive may be necessary to confirm the customer's complaint of coolant loss or overheating. Check for the presence of white steam/smoke coming from the exhaust. Steam coming out of the exhaust may smell slightly sweet as the steam gently dissipates into the surrounding air. Another sign that the head gasket may be leaking is the presence of oil in the cooling system. Check for oil residue in the coolant reservoir. It is important to confirm actual engine running temperature and accuracy of the temperature gauge. This can be verified by using a non-contact infrared heat detection gun. It is a non intrusive method used by most repair shops to verify temperature gauge accuracy and actual engine running temperature. Pressurizing the cooling system (to eliminate coolant leaks as being the source of coolant loss), checking for proper operation of the cooling fan, and checking radiator efficiency are important before jumping to the conclusion that the head gasket is defective. Cylinder to Cylinder Leakage Test ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the cylinder compression pressure as already explained. Leakage between cylinders will be result in drop of compression pressure by nearly 50 to 70% in the affected cylinders. Cylinder to Water jacket Leakage Test ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the degassing pressure cap Warm up the engine and allow it to warm up until the engine thermostat opens. If large combustion pressure leak exist, bubbles will be visible in coolant If bubbles are not visible, install a pressure tester and pressurize the cooling circuit. If a cylinder is leaking combustion pressure into the water jackets then the tester\u2019s needle will pulsate with every combustion stroke of the cylinder. This vehicle is equipped with one autotensioner to maintain the accessory drive belt tension for Alternator and Power steering pump drive belt. It is mandatory to maintain belt tension through out the belt life in-order to have maximum efficiency and life. A tensioner is a device that applies a force to create or maintain recommended belt tension. ground level/ 2 post lift/ 4 post lift and turn engine OFF.
2. Open the bonnet and lock it in open position using bonnet stay rod.
",
+ "file": null,
+ "display_order": 6
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially detach it (Without detaching the hoses). Torque : 4.5\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the engine fead cover mounting bolts. Torque : 11 \u00b1 1Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the engine fead cover from engine compartment. Random Cracking Across the Ribs ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010286.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Small yet visible cracks along the length of a rib or ribs. Causes: ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Continuous exposure to high temperatures and the stress of bending around the pulleys leads to cracking. Cracks begin at the rib top and grow to the cord line. As a rule, if cracks appear 1 or 2 cm apart, 80% of the life is gone and the belt should be replaced. Chunk-Out ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010287.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Pieces or chunks of rubber material have come off the belt. When chunk-out has occurred, a belt can fail at any moment. Belt should be replaced immediately Causes: ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Chunk-out can happen when several cracks in one area move parallel to the cord line. Heat, age and stress are the primary contributors. Pilling ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Belt material wears off from the ribs and builds up in the belts grooves. Causes: ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "There are a number of causes, including misalignment, new belt on worn pulleys, lack of tension or a combination of these factors. Gravel Penetration ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W309.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Small pinholes are visible on the backside of the belt. Bumps may be visible and fabric around the holes can be frayed. Causes: ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Granular gravel or pebble gravel is wedged between the belt groove(s) and pulley ridge(s). Damaged Outermost Ribs ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010290.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Sidewalls of the belt may appear glazed or the edge-cord may become frayed and ribs removed. A noticeable noise may result. Causes: ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Pulley misalignment is a common cause of premature belt failure. Misalignment forces the belt to twist while running, causing premature wear. Oil Contamination ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010291.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "The belt surface is flaky, sticky or swollen. Causes: ",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Oil and grease are a rubber compound\u2019s worst enemies, weakening the compound\u2019s bonds and making the belt soft and spongy. Eventually, such a belt will slip, create heat and fail. Abrasion ",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W310.jpg",
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "The backside of the belt appears very shiny or glazed. In advance stages, the fabric or even the cord becomes exposed and gets damaged. Causes: ",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "When in motion, the belt makes contact with the foreign objects in its path such as a flange or bolt. This may be caused by improper belt tension or by belt flutter (vibrations) on longer span lengths between two pulleys. Rib Separation ",
+ "file": null,
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010293.jpg",
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "The belt rib shears off or begins to separate from the belt base. Causes: ",
+ "file": null,
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "The belt is not correctly positioned. One of the belt ribs is placed outside the pulley groove, causing a belt rib to run without a supporting or aligning pulley groove. Uneven Rib Wear ",
+ "file": null,
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010294.jpg",
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Wear that is more severe on one rib than on the others or one rib that exhibits a different wear pattern than the others. A thumping or grinding noise may also be heard. Causes: ",
+ "file": null,
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "A foreign object \u2014 such as a pebble \u2014 in the pulley will cause uneven wear and cut into the belt and break the tensile cords. Broken Belt ",
+ "file": null,
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010295.jpg",
+ "display_order": 72
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "A large foreign object between the belt and pulley can cut into the belt and break the tensile cords. Tensile break may occur but go unnoticed when the belt is forced or pried on during installation. Other possible causes may be severe shock loads or a blocked pulley and/or accessory. Belt Noise ",
+ "file": null,
+ "display_order": 77
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010296.jpg",
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Run the engine and inspect for Chirping, squealing. tapping, ticking or grinding noise coming from the belt. It is recommended to remove & check the drive belts thoroughly if any abnormality noticed Check belt tension as per procedure mentioned below: ",
+ "file": null,
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011102.jpg",
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Turn ON belt tension gauge Select reading mode in hertz (Hz) and hold the probe approximately 5mm distance in front of the belt. Do not touch the probe to the belt, this can damage the probe. Belt tension needs to be checked at the green points shown in illustration. 1. Between Crank pulley & water pump pulley.
2. Between water pump pulley & AC Compressor Pulley.
",
+ "file": null,
+ "display_order": 86
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Tap on the belt near the probe.",
+ "file": null,
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Note the reading, if the reading is within 195 \u2013 228 Hz, belt tension is OK. If the reading is not within the above limit, check & replace the belt if required.
2. Open the bonnet and lock it in open position using bonnet stay rod.
",
+ "file": null,
+ "display_order": 90
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010924.jpg",
+ "display_order": 91
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30158.jpg",
+ "display_order": 92
+ },
+ {
+ "step_name": "Preliminary Activities /Conditions",
+ "content_type": "Description",
+ "content": "1. Position the vehicle on ground level/ 2 post lift/ 4 post lift and turn engine OFF.
2. Open the bonnet and lock it in open position using bonnet stay rod.
",
+ "file": null,
+ "display_order": 93
+ }
+ ]
+ },
+ {
+ "procedure_name": "Accessory Drive Belt Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, socket spanner, loosen and remove the degassing tank mounting bolts and partially detach it (Without detaching the hoses). Torque : 4.5\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the engine fead cover mounting bolts. Torque : 11 \u00b1 1Nm ",
+ "file": null,
+ "display_order": 99
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the engine fead cover from engine compartment. Random Cracking Across the Ribs ",
+ "file": null,
+ "display_order": 104
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010286.jpg",
+ "display_order": 105
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 106
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Small yet visible cracks along the length of a rib or ribs. Causes: ",
+ "file": null,
+ "display_order": 108
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Continuous exposure to high temperatures and the stress of bending around the pulleys leads to cracking. Cracks begin at the rib top and grow to the cord line. As a rule, if cracks appear 1 or 2 cm apart, 80% of the life is gone and the belt should be replaced. Chunk-Out ",
+ "file": null,
+ "display_order": 110
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010287.jpg",
+ "display_order": 111
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 112
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Pieces or chunks of rubber material have come off the belt. When chunk-out has occurred, a belt can fail at any moment. Belt should be replaced immediately.",
+ "file": null,
+ "display_order": 113
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 114
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Chunk-out can happen when several cracks in one area move parallel to the cord line. Heat, age and stress are the primary contributors. Pilling ",
+ "file": null,
+ "display_order": 116
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010288.jpg",
+ "display_order": 117
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 118
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Belt material wears off from the ribs and builds up in the belts grooves. Causes: ",
+ "file": null,
+ "display_order": 120
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "There are a number of causes, including misalignment, new belt on worn pulleys, lack of tension or a combination of these factors. Gravel Penetration ",
+ "file": null,
+ "display_order": 122
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W309.jpg",
+ "display_order": 123
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 124
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Small pinholes are visible on the backside of the belt. Bumps may be visible and fabric around the holes can be frayed. Causes: ",
+ "file": null,
+ "display_order": 126
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Granular gravel or pebble gravel is wedged between the belt groove(s) and pulley ridge(s). Damaged Outermost Ribs ",
+ "file": null,
+ "display_order": 128
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010290.jpg",
+ "display_order": 129
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 130
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Sidewalls of the belt may appear glazed or the edge-cord may become frayed and ribs removed. A noticeable noise may result. Causes: ",
+ "file": null,
+ "display_order": 132
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Pulley misalignment is a common cause of premature belt failure. Misalignment forces the belt to twist while running, causing premature wear. Oil Contamination ",
+ "file": null,
+ "display_order": 134
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010291.jpg",
+ "display_order": 135
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 136
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "The belt surface is flaky, sticky or swollen. Causes: ",
+ "file": null,
+ "display_order": 138
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Oil and grease are a rubber compound\u2019s worst enemies, weakening the compound\u2019s bonds and making the belt soft and spongy. Eventually, such a belt will slip, create heat and fail. Abrasion ",
+ "file": null,
+ "display_order": 140
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W310.jpg",
+ "display_order": 141
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 142
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "The backside of the belt appears very shiny or glazed. In advance stages, the fabric or even the cord becomes exposed and gets damaged. Causes: ",
+ "file": null,
+ "display_order": 144
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "When in motion, the belt makes contact with the foreign objects in its path such as a flange or bolt. This may be caused by improper belt tension or by belt flutter (vibrations) on longer span lengths between two pulleys. Rib Separation ",
+ "file": null,
+ "display_order": 146
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010293.jpg",
+ "display_order": 147
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 148
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "The belt rib shears off or begins to separate from the belt base. Causes: ",
+ "file": null,
+ "display_order": 150
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "The belt is not correctly positioned. One of the belt ribs is placed outside the pulley groove, causing a belt rib to run without a supporting or aligning pulley groove. Uneven Rib Wear ",
+ "file": null,
+ "display_order": 152
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010294.jpg",
+ "display_order": 153
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 154
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Wear that is more severe on one rib than on the others or one rib that exhibits a different wear pattern than the others. A thumping or grinding noise may also be heard. Causes: ",
+ "file": null,
+ "display_order": 156
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "A foreign object \u2014 such as a pebble \u2014 in the pulley will cause uneven wear and cut into the belt and break the tensile cords. Broken Belt ",
+ "file": null,
+ "display_order": 158
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010295.jpg",
+ "display_order": 159
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 160
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 161
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 162
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "A large foreign object between the belt and pulley can cut into the belt and break the tensile cords. Tensile break may occur but go unnoticed when the belt is forced or pried on during installation. Other possible causes may be severe shock loads or a blocked pulley and/or accessory. Belt Noise ",
+ "file": null,
+ "display_order": 164
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010296.jpg",
+ "display_order": 165
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Heading",
+ "content": "Inspection: ",
+ "file": null,
+ "display_order": 166
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Run the engine and inspect for Chirping, squealing. tapping, ticking or grinding noise coming from the belt. It is recommended to remove & check the drive belts thoroughly if any abnormality noticed Inspect the auto-tensioner carefully for symptoms such as cracked arms, excessive vibration during idle speeds, looseness, noise (clatter or rattling) and sticking or seized operation. These all can be signs that roller needs replacement. Rust bleed and cracks ",
+ "file": null,
+ "display_order": 171
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S2B010321.jpg",
+ "display_order": 172
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 173
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S2B010322.jpg",
+ "display_order": 174
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Rust bleeding between arm and base or dripping from the tensioner. Also, check the tensioner for cracks or damage to arm, housing and bracket. Causes: ",
+ "file": null,
+ "display_order": 176
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Rust bleeding or dripping is a sign of internal component wear. Most common crack damage occurs at tensioner \u201cStops\u201d and mounting bolts. Solution: ",
+ "file": null,
+ "display_order": 178
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Replace the auto-tensioner. Pulley bearing wear ",
+ "file": null,
+ "display_order": 180
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S2B010323.jpg",
+ "display_order": 181
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 182
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "If any abnormality noticed, remove the belt and manually rotate the pulley. If you notice, resistance or roughness, the problem is likely to be pulley bearing wear. Causes: ",
+ "file": null,
+ "display_order": 184
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Defective bearing and/or pulley. Solution: ",
+ "file": null,
+ "display_order": 186
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Replace the complete tensioner. Do not attempt to replace a worn pulley in a used tensioner assembly but always replace the entire tensioner assembly, as part failure will inevitably follow quickly. TENSIONER ASSEMBLY MISALIGNMENT ",
+ "file": null,
+ "display_order": 188
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S2B010324.jpg",
+ "display_order": 189
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 190
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S2B010325.jpg",
+ "display_order": 191
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Abnormal belt tracking on tensioner pulley.. Causes: ",
+ "file": null,
+ "display_order": 193
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Bent or misaligned mounting bracket,improper tensioner installation or corrosion/ contamination between tensioner base and mounting surface. A small amount of contamination results in a large amount of at tensioner pulley Tensioner Noise ",
+ "file": null,
+ "display_order": 195
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 196
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Squeaks and rattles coming from the tensioner. Causes: ",
+ "file": null,
+ "display_order": 198
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Failure of bearings or pivot are will cause excessive noise. Solution: ",
+ "file": null,
+ "display_order": 200
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Replace the tensioner assembly EMS (Engine Management System) ECU is an electronic control unit which is used to ensure optimal engine performance. It does this by analyzing values or signals from various sensors and other ECU\u2019s and adjusting the actuators accordingly. EMS ECU is mounted on engine compartment LH apron. ECU electrical connector should be disconnected before carrying out any welding activities in the vehicle. Using 10 mm socket spanner, Loosen battery negative terminal mounting nut and disconnect the terminal. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Open the lock and gently pull-out and disconnect EMS ECU electrical connector. Using 10 mm socket spanner remove MS ECU mounting bolts. Torque : 6\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011053.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. For New EMS ECU replacement carry out \u201cComponent Replacement Procedures \u2013 EMS ECU replacement\u201d by using i-SMART. For additional information refer Diagnosis Manual. ECU electrical connector should be disconnected before carrying out any welding activities in the vehicle. Check for any external damage, if found replace.
",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1004,1104",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Clean the cylinder head assembly thoroughly, if any cracks or damages are found replace the cylinder head.
",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1004,1088",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Engine Oil \u2013 MAHINDRA 'MAXIMILE ULTRA' Gen-NXT Technology Genuine Engine Fluid. Capacity \u2013 6.0 Liters. ground level/ 2 post lift/ 4 post lift and turn engine OFF. Remove the engine top encapsulation cover. Remove the engine oil filler cap. Using 22 mm ring/ socket spanner, Unscrew engine oil drain plug located under the oil sump. Torque value: 33\u00b12 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Allow the entire oil to get drained. Place a tray under the drain plug to collect the oil. Refit the drain plug with a new copper washer and tighten the drain plug to specific torque. Torque : 33\u00b1 2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Always replace the copper washer with a new one. Fill fresh recommended oil to specified quantity. Refit the engine oil filler cap. Refit the engine encapsulation cover.
Pull out the dip stick gauge and wipe it clean with a cloth/paper. Insert the dip stick gauge into the dip stick guide fully till the end. Pull out the dip stick slowly and check for the oil level mark between Maximum and Minimum level - if found below minimum level, top up with recommended oil. Insert the dip stick back and fix properly. Start the engine and check for oil leakage/ seepage at: Oil sump & crankcase joint. Oil sump drain plug. Oil filter joint. Always use MAHINDRA 'MAXIMILE ULTRA'Gen-NXT Technology GENUINE ENGINE Fluid. This is specially developed for your engine\u2019s efficiency. In extreme cases of emergency and non-availability of above oil, we suggest to use 'Maximile Feo' engine oil, take the vehicle to nearest Mahindra Authorised Service centre and replace the oil with 'MAXIMILE ULTRA'. No other brand / grade oil recommended. For additional information refer to coolant drain Procedure. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the turbocharger with exhaust manifold. For additional information refer to the turbocharger with exhaust manifold - R&R. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the AC/water pump belt. For additional information refer to AC/water pump belt - R&R. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the OCFM to turbo oil inlet banjo bolt.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010959.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 17.5+2.5 Nm",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the EGR cooler inlet pipe routing bracket mounting bolt from the OCFM .",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010960.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque :11\u00b11 Nm",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew EGR cooler outlet pipe mounting bolt at OCFM end.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010961.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque :11\u00b11 Nm",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the turbo oil return pipe routing bracket bolt.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010962.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque :25\u00b13 Nm",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 7 mm socket spanner, loosen and remove the radiator outlet hose clamp OCFM pipe end.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010963.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.5\u00b10.6 Nm",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the degassing to OCFM pipe mounting bolt.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010964.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque :11\u00b11 Nm",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the wiring harness routing bracket bolts from the water pump and OCFM.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1569.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque :11\u00b11 Nm",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1570.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque : 10\u00b11 Nm",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the OCFM mounting bolts from engine.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010966.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Torque Value",
+ "content": "Torque :25\u00b13 Nm",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Caution",
+ "content": "Replace New rubber gasket while refitting",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Remove OCFM from the vehicle.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011055.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew water pump pulley mounting bolts and remove pulley from water pump.",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010253.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Torque Value",
+ "content": "Torque : 11 \u00b1 1 Nm",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Notice",
+ "content": "Using a suitable tool hold the pulley then remove the water pump pulley.",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, Unscrew water pump mounting bolts and remove the water pump from the OCFM.",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010254.jpg",
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010267.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Refill the engine oil and check for the oil leakage.",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Refill the engine coolant and carry-out de-aeration procedure.",
+ "file": null,
+ "display_order": 48
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the OCFM for any external cracks, replace if found any.",
+ "file": null,
+ "display_order": 49
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 32,
+ "sys_id": "THAR.LX-0004-Engine",
+ "subsys_id": "THAR.LX-0004-Engine-Troubleshoot - Engine",
+ "systems": "Engine",
+ "sub_systems": "Troubleshoot - Engine",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1455,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Troubleshoot - Engine-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Trouble Shooting",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/6041.pdf",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 5,
+ "sys_id": "THAR.LX-0004-Engine",
+ "subsys_id": "THAR.LX-0004-Engine-Auto Tensioner & Belts - Replace",
+ "systems": "Engine",
+ "sub_systems": "Auto Tensioner & Belts - Replace",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J08-MAT-0080",
+ "cover_image": "/files/W4A010604.jpg",
+ "myid": 1087,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 31,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 73,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 114,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 153,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 193,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 232,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 273,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 312,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 353,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 392,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 402,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Auto Tensioner & Belts - Replace-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Auto Tensioner & Belts - Replace.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "This vehicle is equipped with one autotensioner to maintain the accessory drive belt tension for Alternator and Power steering pump drive belt. It is mandatory to maintain belt tension through out the belt life in-order to have maximum efficiency and life. A tensioner is a device that applies a force to create or maintain recommended belt tension. ground level/ 2 post lift/ 4 post lift and turn engine OFF.
2. Open the bonnet and lock it in open position using bonnet stay rod
",
+ "file": null,
+ "display_order": 6
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew degassing tank mounting bolts and partially detach it (Without detaching the hoses). Torque : 4.5\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen and remove the engine fead cover mounting bolts. Torque : 11 \u00b1 1Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the engine fead cover from engine compartment Place the MST 0306GAM0006ST - Stretch Fit Belt Removal Tool on damper pulley side as shown in the image. Using a 24 mm socket spanner, rotate the damper pulley to clockwise direction then remove the water pump drive belt and MST separately Place the MST 0306GBH0001ST - Stretch Fit Belt Installation Tool on damper pulley as shown in the image. Using a 24 mm socket spanner, rotate the damper pulley in anticlockwise direction. By rotating pulley, belt started getting into pulley groove and once belt installed properly on pulley, then remove the MSTand spanner Ensure proper engagement of belt teeth in all the pulley grooves after Installation. Check the Belt tension. Refer Belt Tension Checking Procedure session. Refit the engine fead cover on engine compartment, torque tighten the bolts to specified value Torque : 11\u00b1 1Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011070.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit the degassing tank mounting bolts on the bracket and Torque tighten the bolts to specified value. Torque : 4.5\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 33
+ }
+ ]
+ },
+ {
+ "procedure_name": "Checking",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Check belt tension as per procedure mentioned below: ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011102.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Run the engine for few minutes. Turn ON belt tension gauge. Select reading mode in hertz (Hz) and hold the probe approximately 5mm distance in front of the belt. Do not touch the probe to the belt, this can damage the probe Belt tension needs to be checked at the green points shown in illustration. Between Crank pulley & water pump pulley Between water pump pulley & AC Compressor Pulley Tap on the belt near the probe Note the reading, if the reading is within 195 \u2013 228 Hz, belt tension is OK. ground level/ 2 post lift/ 4 post lift and turn engine OFF.
2. Open the bonnet and lock it in open position using bonnet stay rod.
",
+ "file": null,
+ "display_order": 46
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove AC Compressor /Water Pump Stretch Fit Belt. For additional information refer to Accessory Drive Belt (AC Compressor /Water Pump) \u2013 Replace section. Using 14 mm ring spanner, turn the hexagon knob in the belt tensioner Anti clockwise direction to release the tension. Using 14 mm socket spanner, remove the alternator/power steering auto tensioner mounting bolt and remove the tensioner. Refit the new auto-tensioner assembly . Torque tighten the mounting bolt to specified value. Torque : 45 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010933.jpg",
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 14 mm ring spanner, swing the auto-tensioner in counter clock-wise direction and install the belt. Refit AC Compressor /Water Pump Stretch Fit Belt. For additional information refer to Accessory Drive Belt (AC Compressor /Water Pump) \u2013 Replace section. The cylinder compression test is performed to determine the compression pressure of individual cylinders. The test is performed in two stages. 1. Dry Test. 2. Wet Test The results of the cylinder compression test can be utilized to diagnose several engine malfunctions. Before carrying out the compression test ensures that the battery is in good working condition. Otherwise the indicated pressures may not be valid for diagnostic purpose Check engine oil level and add oil if necessary. Drive the vehicle until engine reaches normal operating temperature. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present.
2. Fit the dummy injector and connect it with the compression gauge.
3. Disconnect the cam phase sensor and crank shaft sensor (for safety) electrical connector.
4. Crank the engine for 10\u201315 seconds.
5. Note down the max value the gauge indicates
6. Repeat the procedure for all the other cylinders.
7. Tabulate the results
8. Refer to the specification for the value.
",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11072.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Wet Test",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "1. Spray 10 to 20 ml of engine oil inside the bore through the injector port with the help of an oil can.
2. Fit the dummy injector and connect it with the compression gauge.
3. Disconnect the cam phase sensor and crank shaft sensor (for safety) electrical connector.
4. Crank the engine.
5. Note the maximum value the gauge indicates.
6. Repeat the procedure for all the other cylinders.
7. Tabulate the results.
8. Refer to the specification for the value.
",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Compare both the dry and the wet values with the specifications. The wet test values should always be higher than the dry test values. If the reading does not change during wet test this can hint towards compression leakage from cylinder head or through the valves. If the wet and dry test values vary considerably between cylinders then the piston rings can be suspected. For additional information refer to coolant drain Procedure. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the turbocharger with exhaust manifold. For additional information refer to the turbocharger with exhaust manifold - R&R. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the AC/water pump belt. For additional information refer to AC/water pump belt - R&R. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the OCFM to turbo oil inlet banjo bolt.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010959.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 17.5+2.5 Nm",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the EGR cooler inlet pipe routing bracket mounting bolt from the OCFM.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010960.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque :11\u00b11 Nm",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew EGR cooler outlet pipe mounting bolt at OCFM end.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010961.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque :11\u00b11 Nm",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the turbo oil return pipe routing bracket bolt.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010962.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque :25\u00b13 Nm",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 7 mm socket spanner, loosen and remove the radiator outlet hose clamp OCFM pipe end.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010963.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.5\u00b10.6 Nm",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the degassing to OCFM pipe mounting bolt.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010964.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque :11\u00b11 Nm",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the wiring harness routing bracket bolts from the water pump and OCFM.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1569.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque :11\u00b11 Nm",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1570.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque : 10\u00b11 Nm",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the OCFM mounting bolts from engine.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010966.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Torque Value",
+ "content": "Torque :25\u00b13 Nm",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Caution",
+ "content": "Replace New rubber gasket while refitting",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Remove OCFM from the vehicle.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011055.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew water pump pulley mounting bolts and remove pulley from water pump.",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010253.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Torque Value",
+ "content": "Torque : 11 \u00b1 1 Nm",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Notice",
+ "content": "Using a suitable tool hold the pulley then remove the water pump pulley.",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, Unscrew water pump mounting bolts and remove the water pump from the OCFM.",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010254.jpg",
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010267.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Refill the engine oil and check for the oil leakage.",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Refill the engine coolant and carry-out de-aeration procedure.",
+ "file": null,
+ "display_order": 48
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the OCFM for any external cracks, replace if found any.",
+ "file": null,
+ "display_order": 49
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 9,
+ "sys_id": "THAR.LX-0004-Engine",
+ "subsys_id": "THAR.LX-0004-Engine-Cylinder Head",
+ "systems": "Engine",
+ "sub_systems": "Cylinder Head",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A010581.jpg",
+ "myid": 1091,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Cylinder Head-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/files_VST-0060_Cylinder Head Installation.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The cylinder head contains valves, fuel injectors, camshafts, glow plugs, vacuum pump, intake manifold, exhaust manifold and Fuel pump. In the diesel engine cylinder head performs several functions. It provide as the top seal for the cylinders bore. The cylinder head even consists of ports which are used to allow air in to the combustion chamber and allows the exhaust gases to move out. The cylinder is made by gravity casting and integrated with water jacket. The cylinder oil passage is drilled and sealed by Expansion plug or steel ball. The Camshafts bearing cap is also made by casting and installed on the cylinder head. Remove the turbocharger with exhaust manifold. Remove the intake manifold. For additional information refer to the HLA assemblies \u2013 R &R section. ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 12 mm ring spanner, loosen and remove common rail mounting bolts. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the CAM shaft lower bearing caps from cylinder head. Disconnect the electrical connectors from the glow plug. Using a 8 mm deep socket spanner, loosen and remove the glow plugs from the cylinder head. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 19 mm socket spanner, loosen and remove the coolant temperature sensor. Torque : 20 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the heater inlet pipe mounting bolt and detach from cylinder head. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the engine rear hanging hook mounting bolts. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a 17 mm socket spanner, loosen and remove the cylinder head mounting bolts. Torque : 90\u00b110 Nm + 2x90\u00b0\u00b15\u00b0 ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Remove the cylinder head from engine. Install in reverse order of removal. Always replace the mounting bolts New ones while installing head assembly. Replace the cylinder head gasket with a new one. Failure to follow this will lead to compression failure. When fitting the cylinder head with it fitted to the glow plug, be careful not to damage the glow plug, since the broken pieces may enter inside the cylinder and damage the engine if the glow plug is exposed to an impact, which results in breakage of it. Refill the power steering oil. For additional information refer to power steering oil filling procedure. For additional information refer to the engine coolant and carry-out de-aeration procedure. ",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Check & Top-up the engine oil. Check for coolant seepage and any oil seepage on the engine and transmission. Replace if any traces found. Clean the cylinder head assemblies thoroughly, replace it if any cracks or damages are found. Check the Cylinder Head for external damages. Check the cylinder head height and if not meeting the specified value, replace the cylinder head assembly. Check the Cylinder Head bottom face for distortion. Using 10 mm Allen key, loosen and remove rear axle filler plug. Using 10 mm Allen key, remove rear axle drain plug and drain the entire oil. Wait till the entire oil get drained. Place a tray beneath the rear axle for collecting the oil while draining. Using 13 mm and 16 mm ring and open end spanners unscrew rear propeller shaft mounting bolts and nuts rear axle end. Torque : 65 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "By using Special tool MST 203\u2013Companion Flange Holding Tool, hold the companion flange and Using 32 mm deep socket spanner loosen and remove the companion flange mounting nut Remove the companion flange using mallet. If companion flange shows wear in the area of seal contact, it should be replaced. Remove the pinion oil seal by using screw driver. Ensure not to damage the oil seal mating surface while remove the Oil seal. Using MST 0502AUA0004ST Rear Axle Pinion Oil Seal Installer, Place and Press New oil seal uniformly on banjo gear carrier housing. Apply a light coat of oil to the lip of oil seal before installation. Install the dust cap into the companion flange. Install the companion flange on the banjo housing and Install the new mounting nut with washer. Always use new flange mounting nut once it removed. Hold the companion flange Using MST203 Companion Flange Holding Tool and torque tighten the companion flange mounting nut. Tighten nut to Initial torque as 270 Nm Measure the Pinion Rotational Torque (PTTR), It should be within 2.5 - 3.5Nm. If measured Pinion Rotational Torque (PTTR) not within 2.5 - 3.5 Nm, Then tighten nut to incremental torque from 270 Nm onwards to 330 Nm until specified PTTR (Pinion torque to rotate) is achieved. Measure and ensure the Final Pinion Rotational Torque (PTTR), It should be within 2.5 - 3.5 Nm. PTTR SPEC : 2.5 to 3.5 Nm Attach the propeller shaft to the rear axle with mounting nuts, torque tighten it to the specified value. Torque : 65 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refit the drain plug and torque tighten tospecified value. Clean the drain plug and differential housing with a clean cloth before refitting. Torque : 47 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Refill specified quantity of recommended differential oil into differential assembly Never reuse drained oil. Always use recommended oil only. Never mix different types of oil and use. Clean filler plug area properly using acloth before filling the oil. Check the oil level and ensure its up to the level. Ensure that the oil level is up to lower most point of the filler plug. Refit the filler plug back and torque tighten to mounting plug specified value. Clean the filler plug with a clean cloth before refitting. Torque : 29 \u00b1 5Nm ",
+ "file": null,
+ "display_order": 57
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 119,
+ "sys_id": "THAR.LX-0004-Rear Axle",
+ "subsys_id": "THAR.LX-0004-Rear Axle-Troubleshoot - Rear Axle",
+ "systems": "Rear Axle",
+ "sub_systems": "Troubleshoot - Rear Axle",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1464,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Troubleshoot - Rear Axle-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Trouble Shooting",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Certain rear axle and driveline trouble symptoms are also common to the engine, transmission, tyres and other parts of the vehicle. For this reason be sure that the cause of the trouble is in the rear axle before adjusting, repairing or replacing any of the axle parts.",
+ "file": null,
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Rear Axle Noise Diagnosis",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Basic characteristics in a rear axle are more difficult to diagnose and repair than mechanical failures. Slight axle noise heard only at certain speed or under particular conditions must be considered normal. Axle noise tend to peak or be more pronounced at particular speeds and the noise is in no way a sign of the trouble in the vehicle.Where noise is present in objectionable form (Loud and/ or at all speeds) the first effort should be to isolate the noise.Isolation of noise in any one unit requires care and experience and an attempt to eliminate a slight noise may baffle even the most experienced mechanic/ technician.",
+ "file": null,
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Gear Noise",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "The most important characteristic of the gear noise is that it is usually sensitive to accelerator position. E.g. noise audible under drive condition will often disappear under coast condition (i.e. driving in neutral with the clutch released and engine running) at the same vehicle speed and vice versa.Axle gear noise whine will always occur at the same road speed and throttle setting i.e. drive or coast (i. e. driving in neutral with the clutch released and engine running). Gear whine is usually a fairly high pitched pure tone as opposed to a low-pitched rumble caused by a spalled bearing.Some noises, which can be confused with axle gear whine, are: -Whine from an engine component; this will always occur at the same engine speed irrespective of which transmission gear is used.Whine from an indirect transmission gear (e. g. 5th gear on some vehicles produces a whine comparable with axle whine) however this will disappear when the direct transmission ratio is selected.Whine from tyres or wind noise from a rack or aerial. These noise generally occur over a very broad speed range and do not change with driving mode i. e. drive or coast (i.e. driving in neutral with the clutch released and engine running).",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before diagnosing the whine as axle gear noise, ensure that the whine:Occurs in direct transmission ratio (4th gear).Changes with throttle/ accelerator variations (drive and coast) (i.e. driving in neutral with the clutch released and engine running).Always occur at the same road speed and not engine speed.Occurs over a limited vehicle speed. (This can vary over a wide band should the axle be in extremely bad condition.).",
+ "file": null,
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Bearing Noise",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Bearing noise is inclined to be less throttle sensitive than gear noise and frequently occurs over a wide speed range. Bad cases of faulty bearings can, in fact be detected from walking speed, building up in pitch as speed increases and is not directly affected by changing from drive to coast (i. e., driving in neutral with the clutch released and engine running) and vice versa.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Rear wheel bearing noise tends to be low pitched grumble, which can normally be detected and confirmed when driving on a smooth road at constant speed, with the noise most audible while swerving sharply from left to right. If the noise increases or a decrease as the car is swerved, it is probable that a wheel bearing is faulty. Driving close to a wall or a curb at a suitable speed can carry out a further check for wheel bearing noise.Differential bearing noise is usually similar to in pitch to wheel bearing noise but is not affected by the swerve check referred to previously.Pinion bearing noise is normally at a higher pitch than wheel or differential bearings and is often slightly sensitive to throttle position, although not to the same extent as gear noise.",
+ "file": null,
+ "display_order": 6
+ }
+ ]
+ },
+ {
+ "procedure_name": "Other Noise",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "A further condition, which can exist, is due to a worn bearing that allows the gear set to move out of its correct mesh cause gear noise. This condition is usually throttle sensitive, with the noise frequently disappearing on a \u201cdrive\u201d condition. Any amount of or end play in either the pinion bearings or differential carrier bearings are detrimental to the gears and bearings and will cause axle noise.A high spot sometimes occur on either the ring gear or the drive pinion; this shows up as a ticking or light knocking noise over a restricted range of throttle position. The frequency of the noise will indicate whether the high spot is on the pinion (drive shaft frequency) or on the ring gear. The severity of the noise indicates the size of the defect. A light \u201ctick\u201d is seldom detrimental and usually occurs in new axle and will normally disappears once the axle has been run in.Louder noise usually indicates a more serious defect and a knock occurring in an axle which was previously free from this type of noise must always be investigated.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16402.pdf",
+ "display_order": 8
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 115,
+ "sys_id": "THAR.LX-0004-Rear Axle",
+ "subsys_id": "THAR.LX-0004-Rear Axle-Rear Axle Shaft Oil Seal Outer & Wheel Bearing",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Axle Shaft Oil Seal Outer & Wheel Bearing",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A140066.jpg",
+ "myid": 1235,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Rear Axle Shaft Oil Seal Outer & Wheel Bearing-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140066.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20121.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20122.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the rear axle shaft RH.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1013,1233",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using circlip plier, remove the toner wheel circlip.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140050.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "By using hydraulic press, remove toner wheel along with Rear bearing carrier assembly.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140061.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Take sufficient care not to damage the toner ring while removing.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140052.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the bearing from Rear bearing carrier.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140062.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Replace the toner ring and bearing assembly once removed.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140065.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a suitable tool, Remove the oil seal from Rear bearing carrier.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140063.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Replace the outboard oil seal once removed.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140064.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Check differential oil level, top up the oil if required.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Carry out Parking Brake Adjustment.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1016,1275",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the axle shaft outer oil seal & bearing for any damage, Replace if necessary.",
+ "file": null,
+ "display_order": 24
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 113,
+ "sys_id": "THAR.LX-0004-Rear Axle",
+ "subsys_id": "THAR.LX-0004-Rear Axle-Rear Axle Shaft Assembly",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Axle Shaft Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A140033.jpg",
+ "myid": 1233,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Rear Axle Shaft Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/files_VST-0068_Rear axle shaft removal.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140033.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20105.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20106.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove rear brake drum LH and RH.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Detach the hand brake cable from brake shoe.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140007.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the hand brake cable lock clip and detach the hand brake cable from backplate.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140010.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 11 mm open end spanner, Loosen brake bundy tube flare nut wheel cylinder end.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140049.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 16 \u00b1 2 Nm",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 17 mm socket spanner, loosen and remove axle shaft mounting nuts.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140034.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 35 \u2013 50 Nm",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using MST 0505AAA0001ST puller rear axle shaft banjo remove rear axle shaft, dust shield with brake liner assembly from vehicle.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140045.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Notice",
+ "content": "To avoid the back plate falling down,using a plastic tag tie it with any other fixed member before the shaft is pulled out.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Clean sealant on the axle housing flange, Back Plate and apply new sealant on the housing.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140054.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Apply Locktite Sealant 5060 during Installation and Ensure that sealer bead is on the inside of screw holes as shown above.Bead must be 3 to 6mm high and 3 to 6mm wide.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Check differential oil level, top up the oil if required.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Carry out Parking Brake Adjustment.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1016,1275",
+ "file": null,
+ "display_order": 25
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the axle shaft for any damage, crack or bend.Inspect the toner ring for any damage.Inspect the rear wheel bearing for any damage.Inspect the back plate for any damage.",
+ "file": null,
+ "display_order": 26
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 110,
+ "sys_id": "THAR.LX-0004-Rear Axle",
+ "subsys_id": "THAR.LX-0004-Rear Axle-Rear Axle Oil - Replace",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Axle Oil - Replace",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.18,
+ "rts": null,
+ "mat": "J08-MAT-0340",
+ "cover_image": "/files/W4A140025.jpg",
+ "myid": 1230,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 23,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 47,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 108,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 148,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 186,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 227,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 267,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 286,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 347,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 386,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 427,
+ "kilometers_applicable": 0
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Rear Axle Oil - Replace-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Rear Axle Oil - Replace.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "RearAxleOil\u2013Mahindra MAXIMILEELITE NewGenerationGenuineDifferentialFluid.Capacity\u20132.0Litres.",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20001.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Preliminary Activities/Conditions",
+ "content_type": "Description",
+ "content": "Position the vehicle on 2 post lift/ 4 post lift.
Rear Axle Oil \u2013 Mahindra 'MAXIMILE ELITE' New Generation Genuine Differential Fluid.Capacity \u2013 2.0Litres.Using 0502CAA0012ST \u2014Puller Oil Seal Pinion /Flange Inbord-X ,remove the inboard oil seal. Refit in the reverse order of removal. Use a MST (0502BUA0001ST \u2014 Rear Axle Shaft Inboard Oil Seal Installer, during Installation. Check differential oil level, top up the oil if required. Carry out Parking Brake Adjustment. For additional information refer to Rear Propeller Shaft - R&R section. ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the stabilizer bar rear. For additional information refer to Stabilizer Bar Rear-R&Rsection.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": " Remove the Pan hard rod.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1015,1254",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using a 24 mm socket spanner, loosen and remove the upper link mounting bolt/nut.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170028.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Torque Value",
+ "content": "Torque : 230 \u00b1 20 Nm",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170029.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 21mm ring spanner.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a 24 mm socket spanner, loosen and remove the lower arm mounting bolt/nut.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170025.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 21mm ring spanner.",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Torque Value",
+ "content": "Torque:230\u00b120Nm",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using a 17 mm socket spanners, loosen and remove the both rear shock absorbers bottom side mounting bolts and nuts.",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170014.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Torque Value",
+ "content": "Torquevalue:110\u00b111NmTorque Wrench Type - Open end Torque Wrench",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using15mmringspanner.",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Remove the rear coil spring and pad securelyfromvehicle.",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170016.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Caution",
+ "content": "Pay attention while Installation Locking lug to be matched with hole on Rear Coil spring dome bracket of Chassis.Yellow coloured PU sleeve should be on chassis side while assembling the coil spring ashown in illustration.",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170018.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170149.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170113.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Carefully remove the rear axle assembly from vehicle.",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140032.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": " Check differential oil level,top up the oil if required.",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Caution",
+ "content": " All Suspension Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 56
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the axle shaft for straightness, cracks, damage, wear or distortion, replace it if necessary. Check the axle case for yield,deformation or cracks,replace if necessary. Inspect rear axle for any oil leakage,seepage. ",
+ "file": null,
+ "display_order": 57
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 42,
+ "sys_id": "THAR.LX-0004-en-SM-Starting System",
+ "system_name": "Starting System",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1006,
+ "active_status": true,
+ "Assets": [
+ {
+ "systemdisplayorder": 14,
+ "system_asset": "/files/Security.mp4",
+ "active_status": true
+ }
+ ],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 44,
+ "sys_id": "THAR.LX-0004-Starting System",
+ "subsys_id": "THAR.LX-0004-Starting System-Ignition Switch",
+ "systems": "Starting System",
+ "sub_systems": "Ignition Switch",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A090001.jpg",
+ "myid": 1126,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Ignition Switch-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The ignition key barrel consists of ignition switch and steering lock. It is located on the steering column. The ignition barrel when switched ON by the mechanical key,switches the power supply to all controllers. Using a 10 mm combination spanner,loosen battery negative cable mounting nut and disconnect cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON Should not remove the battery connection when the EWP is ON,Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Remove Combination switch. Disconnect the ignition switch electrical connection. Using a Small sizzle and hammer, hit and remove the key barrel screws. Use new screw while installing key barrel. Remove the Ignition key with ICU from the vehicle. Using a star screw driver, loosen and remove the ICU mounting screws then remove the ICU from the key barrel. Insert the key and turn the key into AC position. Cut the micro switch routing tag and detach the connector holding clip from the ICU. Install in reverse order of removal. Always use new mounting bolts while installing the Ignition Switch Assembly clamping unit. The starter relay is an electromechanical device that switches battery current to the starter solenoid when the ignition switch is turned to the Start position. The starter relay is made of two separate circuits The control circuit which includes the electromagnet The power circuit which includes the contact blade. Remove the relay from fuse box Give 12 volt supply to pin number 86 and earth pin number 85 Once supply is given sound can be noticed which indicated control circuit is perfect If sound is not noticed, replace the relay Using multi-meter, check continuity between pin number 30 & 87. (Power given to pin number 86 and earth given to pin number 85). If continuity is there, which indicates that the power circuit is perfect. If Continuity is not there then replace the relay Using multi-meter, check for continuity between pin numbers 30 and 87 (No power given to pin number 86 and no earth given to pin number 85). If continuity is there which indicates power circuit is NOT OK (Short internally). Replace the relay. If continuity is not there, Relay is OK This test can only be performed with starter motor removed from vehicle. Remove Starter Motor from vehicle. Disconnect wire from solenoid field coil terminal. Check for continuity between solenoid terminal and solenoid field coil terminal with a continuity tester. There should be continuity. If OK, go to Step 4. If not OK, replace faultystarter motor. Check for continuity between solenoid terminal and solenoid case. There should be continuity. If not OK, replace faulty starter motor. The cranking voltage test measures the voltage available for ignition while the starting motor cranks the engine. Turn off the ignition, connect a voltmeter across the battery and crank the engine. Note the voltage reading. 1. If the starting motor cranks normally and the voltmeter reads 9 volts or higher, cranking voltage is normal. 2. Slow cranking with the voltage above 9 volts indicates high resistance in the motor circuit or starting motor. 3. Low cranking speed and low voltage may indicate a discharger battery. If the battery is charger, look for trouble in the starter motor or engine. 1. Supplies power to antenna.
2. Receives and analyses signal from the key via antenna.
3. Conveys the key status information to EMS ECU thru CAN.
Using a 10 mm combination spanner,loosen battery negative cable mounting nut and disconnect cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON Should not remove the battery connection when the EWP is ON,Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Remove Combination switch. Disconnect the ignition switch electrical connection. Using a star screw driver, loosen and remove ICU mounting screws then remove ICU from the key barrel. Install in reverse order of removal. Ensure the wheels are straight ahead. Also the steering rack should be in center. Check and ensure both the front wheels for straight ahead position while fitting the steering wheel and also after fitting. Carefully install the clock spring without damaging the locks. When installing the DAB, make sure that all electrical connectors are fixed in proper position. When installing the driver airbag into steering wheel, make sure the horn pad buttons are fixed properly and correct position.
2. Inspect ICU connector for any damage or loose connection. Rectify if found.
",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 47,
+ "sys_id": "THAR.LX-0004-Starting System",
+ "subsys_id": "THAR.LX-0004-Starting System-Voltage Drop Test",
+ "systems": "Starting System",
+ "sub_systems": "Voltage Drop Test",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A090033.jpg",
+ "myid": 1129,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Voltage Drop Test-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The following operation will require a voltmeter accurate to 1/10 (0.10) volt. The battery should be fully-charged. Engage the parking brake. Position the gearshift selector lever in the neutral position and lock the clutch pedal in the fully depressed position. Verify that all lamps and accessories are turned off. In-order to avoid the engine from starting, remove the starter relay. Connect the positive lead of the voltmeter to the battery negative terminal post and then connect the negative lead of the voltmeter to the battery negative cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery negative cable terminal clamp and the battery negative terminal post. Connect the positive lead of the voltmeter to the battery positive terminal post. Connect the negative lead of the voltmeter to the battery positive cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery positive cable terminal clamp and the battery positive terminal post. Connect the voltmeter to measure between the battery positive cable terminal clamp and the starter solenoid terminal stud.Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt. Clean and tighten the battery positive cable eyelet terminal connection at the starter solenoid terminal stud. Repeat the test. If the reading is still above 0.2 volt,replace the faulty battery positive cable. Connect the voltmeter to measure between the battery negative cable terminal clamp and ground on the transmission. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery negative cable eyelet terminal connection to the engine block. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery negative cable. The starting motor is a device that converts electric energy into mechanical energy to generate rotational power, and transfers the energy required for starting the engine initially with this power. The starter motor is composed of three parts, which are: The solenoid, which moves the starter pinion by means of a fork and at the same time closes the power circuit to feed the electric motor. The direct current electric motor, which cranks the engine. The fork and pinion assembly, which makes the connection between the starter motor and the ring gear on the flywheel. Using a 10 mm combination spanner,loosen battery negative cable mounting nut and disconnect cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON Should not remove the battery connection when the EWP is ON,Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Using a 13 mm socket spanner, loosen and remove the battery positive cable mounting nut on starter motor end. Torque : 12\u00b12 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 8 mm socket spanner, loosen and remove the starter motor solenoid switch mounting nut on starter motor end. Torque : 2.5\u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen and remove the starter motor mounting bolts and remove starter motor from vehicle. Torque : 44\u00b15 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090046.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.
2. Check the starter motor external crack or damage. Replace if found any.
3. Check the starter motor internal gear crack or damage. Replace if found any.
",
+ "file": null,
+ "display_order": 21
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 222,
+ "sys_id": "THAR.LX-0004-en-SM-Instrument Panel",
+ "system_name": "Instrument Panel",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1020,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 227,
+ "sys_id": "THAR.LX-0004-Instrument Panel",
+ "subsys_id": "THAR.LX-0004-Instrument Panel-IP Top Cover Assembly LH",
+ "systems": "Instrument Panel",
+ "sub_systems": "IP Top Cover Assembly LH",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A220020.jpg",
+ "myid": 1345,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-IP Top Cover Assembly LH-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220020.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5571.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5572.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080024.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON,Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance.Before disconnecting the battery, check for the audible sound of EWP ON",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6 Nm",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Glove Box Assembly.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1020,1341",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220022.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the IP grab handle cover.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220023.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 9.5 \u00b1 1 Nm",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220024.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting screws.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220025.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220139.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220065.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Partially detach the door edge beading and using a trim removal tool, remove the IP LH side cover.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220076.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque : 8\u00b11.2 Nm",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220066.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220077.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220134.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Take out the IP LH side top cover with Passenger air bag from the IP.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210046.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using a 10 mm ring spanner, loosen and remove the air bag mounting bolt from IP top cover.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Torque Value",
+ "content": "Torque :4.5\u00b11.2 Nm",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210047.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210048.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Expand the PAB module holder both sides using screw driver and detach the PAB separately from IP top cover.",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A2200189586bd.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew LH side AC vent mounting screws.",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220017126ac3.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A22001900bbbf.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Remove the AC Vent.",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Caution",
+ "content": "Carefully release the vent locking clips from the cover and detach the vent.",
+ "file": null,
+ "display_order": 44
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external damages or damaged locking clips, Replace if necessary.Inspect the PAB module for any damage. Replace if found any.Inspect the PAB module connector for any damage.Inspect the PAB module trim for any damage.",
+ "file": null,
+ "display_order": 45
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 224,
+ "sys_id": "THAR.LX-0004-Instrument Panel",
+ "subsys_id": "THAR.LX-0004-Instrument Panel-Instrumental Panel Assembly",
+ "systems": "Instrument Panel",
+ "sub_systems": "Instrumental Panel Assembly",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A220097.jpg",
+ "myid": 1342,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Instrumental Panel Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220097.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5495.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5496.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Combination Switch.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step 1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1017,1298",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the A Pillar Upper Trim LHS & RHS.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step 2",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1023,1361",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the Glove Box Assembly.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step 3",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1020,1341",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220121.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the cluster bezel..",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220133.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220075.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Partially detach the door edge beading and using a trim Removal tool, Remove the IP side trim RH side.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220074.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220073.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew Driver side top cover mounting screw and remove the cover.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220072.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew the cluster mounting screws.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 2 \u00b1 0.25 Nm",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220071.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Partially Detach Cluster and disconnect the electrical connector.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220021.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the Instrument Cluster.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the Floor Console Assembly. For additional information refer to Floor Console Assembly \u2013 R&R Section.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1020,1340",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220070.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220069.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using trim removal tool, Remove IP side vertical trim LHS And RHS",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W323.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W324.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "partially detach the switch bang assembly and remove electric connector to take out from the vehicle.",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220067.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Detach the USB Docking station bezel and disconnect the electrical connectors.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220125.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Disconnect Driver switch bank electrical connector.",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220022.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Remove the IP grab handle cover.",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W752.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts.",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Torque Value",
+ "content": "Torque : 9.5 \u00b1 1 Nm",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220024.jpg",
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting bolts.",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220025.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle.",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W325.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220065.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Partially detach the door edge beading and using a trim removal tool , remove the IP side trim LH side.",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220076.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt.",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Torque Value",
+ "content": "Torque : 8\u00b11.2 Nm",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220066.jpg",
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw.",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220077.jpg",
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector.",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220078.jpg",
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220080.jpg",
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Remove IP Speaker Grill from LH and RH Sides..",
+ "file": null,
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220081.jpg",
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220082.jpg",
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": "Disconnect speaker electrical connectors from both the sides.",
+ "file": null,
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220087.jpg",
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220083.jpg",
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Using a trim removal tool Detach the infotainment trims.",
+ "file": null,
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220084.jpg",
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220085.jpg",
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew the infotainment mounting screws.",
+ "file": null,
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 1.5 \u00b1 0.5 Nm",
+ "file": null,
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220086.jpg",
+ "display_order": 72
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Partially detach infotainment and disconnect the electrical connectors",
+ "file": null,
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290007.jpg",
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Remove the infotainment from Instrument panel.",
+ "file": null,
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W326.jpg",
+ "display_order": 76
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W327.jpg",
+ "display_order": 77
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W328.jpg",
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W329.jpg",
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W330.jpg",
+ "display_order": 80
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W331.jpg",
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290094.jpg",
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290095.jpg",
+ "display_order": 83
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew instrument panel mounting bolts.",
+ "file": null,
+ "display_order": 84
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.5\u00b1 0.5 Nm",
+ "file": null,
+ "display_order": 85
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220096.jpg",
+ "display_order": 86
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "Description",
+ "content": "Carefully remove the instrument panel from vehicle.",
+ "file": null,
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 88
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external damages or damaged locking clips, Replace if necessary.",
+ "file": null,
+ "display_order": 89
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 228,
+ "sys_id": "THAR.LX-0004-Instrument Panel",
+ "subsys_id": "THAR.LX-0004-Instrument Panel-IP Top Cover Assembly RH",
+ "systems": "Instrument Panel",
+ "sub_systems": "IP Top Cover Assembly RH",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A220013.jpg",
+ "myid": 1346,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-IP Top Cover Assembly RH-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220013.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5591.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5592.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220016.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using trim removal tool remove the cluster bezel.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190016.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, remove the IP panel assembly driver side.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220133.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220017.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Partially detach the door edge beading and using a trim removal tool, remove the IP RH side cover.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220018.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew driver side IP cover mounting screw.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220019.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the driver side IP cover.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220014.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew AC vent mounting screws.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220015.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220016be3bc3.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the RH side AC vent.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Carefully release the vent locking clips from the cover and detach the vent.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 22
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "check for any external damages or damaged locking clips, Replace if necessary.",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 225,
+ "sys_id": "THAR.LX-0004-Instrument Panel",
+ "subsys_id": "THAR.LX-0004-Instrument Panel-Instrument Panel",
+ "systems": "Instrument Panel",
+ "sub_systems": "Instrument Panel",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A220099.jpg",
+ "myid": 1343,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Instrument Panel-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220099.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5540.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5541.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Instrument Panel Assembly.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step 1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1020,1342",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220137.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220136.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220135.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew the Instrument Panel AC & defroster Duct mounting screws and remove the ducts.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220103.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP driver switch bank mounting screws.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 1.5 \u00b10.5 Nm",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270121.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the Driver Switch bank from Instrument Panel",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220102.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP centre air vent mounting screws.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220101.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220100.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the Centre Air Vents from Instrument Panel.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "check for any external damages or damaged locking clips, Replace if necessary.",
+ "file": null,
+ "display_order": 21
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 229,
+ "sys_id": "THAR.LX-0004-Instrument Panel",
+ "subsys_id": "THAR.LX-0004-Instrument Panel-IP AC Vent RH",
+ "systems": "Instrument Panel",
+ "sub_systems": "IP AC Vent RH",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A220126.jpg",
+ "myid": 1347,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-IP AC Vent RH-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220126.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5603.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5604.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220016.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using trim removal tool remove the cluster bezel.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190016.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, remove the IP panel assembly driver side.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220133.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220017.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Partially detach the door edge beading and using a trim removal tool, remove the IP RH side cover.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220018.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew driver side IP cover mounting screw.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220019.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the driver side IP cover.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220014.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew AC vent mounting screws.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220015.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220127.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the IP AC Vent RH.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Carefully release the vent locking clips from the cover and detach the vent.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 22
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "check for any external damages or damaged locking clips, Replace if necessary.",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 222,
+ "sys_id": "THAR.LX-0004-Instrument Panel",
+ "subsys_id": "THAR.LX-0004-Instrument Panel-Floor Console",
+ "systems": "Instrument Panel",
+ "sub_systems": "Floor Console",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A220042.jpg",
+ "myid": 1340,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Floor Console-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220042.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5459.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5460.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280032.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console RH screvits and detach the panel from vehicle",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220005.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 2.5 \u00b1 0.2 Nm",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W322.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220007.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console LH screvits and detach the panel from vehicle.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 2.5 \u00b1 0.2 Nm",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220036.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220037.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Loosen and Remove Gear Knob and Transfer case shifter knobs",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220044.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the gear shifter cover with trim",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the rummier mat from the cup holder",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110306.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "For AT Variants top trim removal follow (Steps 6\u2013 11) :Remove the 4WD selection knob by rotating it in anti-clock wise direction.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110269.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Pull and fold the gear shifter boot from gear shifter bezel.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110134.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Partially detach the bezel from the console.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Notice",
+ "content": "Excessive pull may leads to damage of the electrical connector",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110135.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Disconnect the AT gaiter electrical connector from the bezel.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110134.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Carefully remove the bezel trim from the TGS lever.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Caution",
+ "content": "Handle bezel assembly carefully to prevent it from damage or scratches.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110269.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using trim removal tool, carefully remove the floor console top trim with transfer case shifter boot",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220047.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220048.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew floor console LH and RH side mounting bolts",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.5\u00b1 0.5 Nm",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220050.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220049.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew floor console LH and RH side mounting screws",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220043.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Remove the bottle holder rubber mat",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220046.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew floor console mounting bolts",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220051.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220052.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew floor console LH and RH side mounting bolts",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.5\u00b1 0.5 Nm",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220053.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Lift the floor console and disconnect the floor console electrical connector",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220055.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Remove the floor console from vehicle.",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220054.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220056.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Remove the power window switch assembly from floor console.",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": " Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 55
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check floor console assembly for any damage, replace if found any.",
+ "file": null,
+ "display_order": 56
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 226,
+ "sys_id": "THAR.LX-0004-Instrument Panel",
+ "subsys_id": "THAR.LX-0004-Instrument Panel-Cross Car Beam Assembly",
+ "systems": "Instrument Panel",
+ "sub_systems": "Cross Car Beam Assembly",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A220099.jpg",
+ "myid": 1344,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Cross Car Beam Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220099.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5540.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5541.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Instrument Panel Assembly",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1020,1342",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew fuse box mounting bolts.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220104.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 5.5 \u00b1 1 Nm",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect ignition key barrel electrical connector.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220105.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the bonnet cable from the lever",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220106.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen\nthe steering intermediate shaft top bolt and\nremove bottom mounting bolts and detach\nthe intermediate shaft bottom from the\nsteering column.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190042.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 4 Nm",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew\nsteering column mounting bolts and nuts.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220107.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220108.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 4 Nm",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "using mm socket spanner, loosen and\nremove the Ip RH & LH speaker from Cross\nCar Beam.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220109.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220110.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 3 \u00b1 1Nm",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Disconnect the IP wiring routing clips and\nHVAC unit electrical connector.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220111.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the Scuttle Grill",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1024,1373",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew\nCCB front facing mounting bolts.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220114.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque : 22\u00b13 Nm",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew\nCCB bottom mounting bolts",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220116.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220115.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Torque Value",
+ "content": "Torque : 22\u00b13 Nm",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew\nCCB LHS & RHS mounting bolts/nuts.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220113.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220112.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Torque Value",
+ "content": "Torque : 22\u00b13 Nm",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew\nCCB LHS & RHS side bottom mounting bolts",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220117.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220118.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Torque Value",
+ "content": "Torque : 22\u00b13 Nm",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew\nCCB to HVAC unit mounting screws",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220119.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Torque Value",
+ "content": "Torque : 9.5 \u00b1 1 Nm",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Remove the Cross Car Beam from\nvehicle.",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220120.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal",
+ "file": null,
+ "display_order": 48
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 223,
+ "sys_id": "THAR.LX-0004-Instrument Panel",
+ "subsys_id": "THAR.LX-0004-Instrument Panel-Glove Box",
+ "systems": "Instrument Panel",
+ "sub_systems": "Glove Box",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A220031.jpg",
+ "myid": 1341,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Glove Box-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220031.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5487.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5488.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200131.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Open the Glove Box",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200132.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Unlock glove box lock and remove the glove box assembly from IP",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220027.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver, remove the handle mounting screws",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220028.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220029.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the glove box handle from the glove box assembly",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 13
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the glove box for damage, replace if necessary.",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 230,
+ "sys_id": "THAR.LX-0004-Instrument Panel",
+ "subsys_id": "THAR.LX-0004-Instrument Panel-IP AC Vent LH",
+ "systems": "Instrument Panel",
+ "sub_systems": "IP AC Vent LH",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A220128.jpg",
+ "myid": 1348,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-IP AC Vent LH-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220128.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5615.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5616.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080024.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance.Before disconnecting the battery, check for the audible sound of EWP ON.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6 Nm",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Glove Box Assembly.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1020,1341",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220022.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the IP grab handle cover.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220023.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 9.5 \u00b1 1 Nm",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220024.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting screws.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220025.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220139.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220065.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Partially detach the door edge beading and using a trim removal tool, remove the IP LH side cover.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220076.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque : 8\u00b11.2 Nm",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220066.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220077.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220134.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Take out the IP LH side top cover with Passenger air bag from the IP.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A2200189586bd.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew LH side AC vent mounting screws.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220017126ac3.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220129.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Remove the IP AC Vent LH.",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Caution",
+ "content": "Carefully release the vent locking clips from the cover and detach the vent.",
+ "file": null,
+ "display_order": 38
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external damages or damaged locking clips, Replace if necessary.",
+ "file": null,
+ "display_order": 39
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 231,
+ "sys_id": "THAR.LX-0004-en-SM-Instrument Cluster",
+ "system_name": "Instrument Cluster",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1021,
+ "active_status": true,
+ "Assets": [
+ {
+ "systemdisplayorder": 17,
+ "system_asset": "/files/INSTRUMENT CLUSTER.mp4",
+ "active_status": true
+ }
+ ],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 231,
+ "sys_id": "THAR.LX-0004-Instrument Cluster",
+ "subsys_id": "THAR.LX-0004-Instrument Cluster-Instrument Cluster",
+ "systems": "Instrument Cluster",
+ "sub_systems": "Instrument Cluster",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A220023.jpg",
+ "myid": 1349,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Instrument Cluster-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/Instrument Cluster.png",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Tachometer",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The tachometer indicates the real-time engine speed in thousands of RPM(revolutions per minute). Each division is 500 RPM. Operating the engine at very high RPM may lead to excessive engine wear and low fuel economy. Maintain steady engine speed below 2500 RPM and do not accelerate or decelerate abruptly. ",
+ "file": "",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/tachoinstrumentcluster.JPG",
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Caution",
+ "content": "Do not over-accelerate the engine during idling, this can cause severe engine damage and would be treated as abuse of the engine which is not covered by warranty ",
+ "file": "",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Speedometer",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The speedometer indicates the real time road surface speed of the vehicle in kilometers per hour. ",
+ "file": "",
+ "display_order": 5
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/instrumentclusterspeedo.JPG",
+ "display_order": 6
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Notice",
+ "content": "The vehicle speedometer is affected by size of the tyres used. If the size of the tyres are changed from those fitted at the factory, the speedometer might not display the correct road surface speed and distance travelled ",
+ "file": "",
+ "display_order": 7
+ }
+ ]
+ },
+ {
+ "procedure_name": "Features",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": "",
+ "file": "files/4724.pdf",
+ "display_order": 8
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step 1",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/instrument cluster.PNG",
+ "display_order": 9
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/Instrument Cluster2.png",
+ "display_order": 10
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using trim removal tool, remove the cluster bezel mounting clips and remove the cluster bezel ",
+ "file": "",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/Instrument Clusterstep1.png",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using trim removal tool, remove the IP side trim. ",
+ "file": "",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/Instrument Clusterstep2.png",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP cover mounting screw and detach the IP cover using trim removal too. ",
+ "file": "",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/Instrument Clusterstep3.png",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/Instrument Clusterstep33.png",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew instrument cluster mounting screw. ",
+ "file": "",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 2 \u00b1 0.25 Nm ",
+ "file": "",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/Instrument Clusterstep4.png",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect cluster electrical connector and remove instrument cluster. ",
+ "file": "",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/Instrument Clusterstep5.png",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/Instrument Clusterstep55.png",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal ",
+ "file": "",
+ "display_order": 24
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any damage or crack, replace if found. ",
+ "file": "",
+ "display_order": 25
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 150,
+ "sys_id": "THAR.LX-0004-en-SM-Brake",
+ "system_name": "Brake",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1016,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 162,
+ "sys_id": "THAR.LX-0004-Brake",
+ "subsys_id": "THAR.LX-0004-Brake-Tandem Master Cylinder (TMC) - R&R",
+ "systems": "Brake",
+ "sub_systems": "Tandem Master Cylinder (TMC) - R&R",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B130007.jpg",
+ "myid": 1280,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Tandem Master Cylinder (TMC) - R&R-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130186.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30003.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30004.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Disconnect the TMC electrical connector then detach from the routing clips.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130184.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 13 mm open end spanner, loosen and remove the TMC to EHCU Primary & Secondary bundy tubes from TMC side flare nuts.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130001.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque :16 \u00b1 2 Nm",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using hose clip plier, release brake fluid reservoir tank to clutch TMC hose clip then detach the hose.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130002.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 12 mm combination spanner, Unscrew TMC mounting nuts and remove the TMC assembly from the brake booster.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130003.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 16 \u00b1 2 Nm",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130187.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Check and top up the brake fluid, If required.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Carry-out the brake bleeding procedure. For additional information refer to Brake bleeding procedure.",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for master cylinder external damage, if found replace.",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 163,
+ "sys_id": "THAR.LX-0004-Brake",
+ "subsys_id": "THAR.LX-0004-Brake-Front Brake Caliper Assembly - R&R",
+ "systems": "Brake",
+ "sub_systems": "Front Brake Caliper Assembly - R&R",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A130163.jpg",
+ "myid": 1281,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Front Brake Caliper Assembly - R&R-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130163.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4684.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4685.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the front brake pad assembly. For additional information refer to front brake pad assembly \u00a0R&R section.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1016,1273",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, loosen and remove the brake hose banjo bolt then detach the brake hose.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130085.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque :24 \u00b1 2 Nm",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Replace the banjo bolt washers with new ones always while installation, else brake fluid leakage may happen.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 19 mm socket spanner, loosen and remove the caliper assembly mounting bolts.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130165.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 95 \u00b1 5 Nm",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the caliper assembly from the vehicle.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130169.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Check and top up the brake fluid, If required.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Carry-out the brake bleeding procedure. For additional information refer to Brake bleeding procedure.",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the caliper for any physical damage. Replace if found any.",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Carefully refit the rubber seal. ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/front brake caliper assembly.PNG",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Clean all the internal parts thoroughly with fresh brake fluid or alcohol. Do not use mineral oil like kerosene, petrol, diesel etc. ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refit the dust cover.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Front Brake Caliper Assembly.PNG",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Insert the piston.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Front Brake Caliper Assembly1.PNG",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "If the piston does not move smoothly, remove it and examine the sealing ring for correct seating in its groove. Fit the other end of the piston boot on to the caliper housing",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Refit the front caliper assembly.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1016,1281",
+ "file": null,
+ "display_order": 28
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 167,
+ "sys_id": "THAR.LX-0004-Brake",
+ "subsys_id": "THAR.LX-0004-Brake-ABS EHCU",
+ "systems": "Brake",
+ "sub_systems": "ABS EHCU",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B130010.jpg",
+ "myid": 1285,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-ABS EHCU-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130195.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30042.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30043.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 13 mm open end spanners, loosen and remove the TMC to primary and secondary bundy tubes flare nuts on EHCU side.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130025.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque :16 \u00b1 2 Nm",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130026.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 11 and 13 mm open end spanners, loosen and remove the EHCU to FL,FR,RL, RR output bundy tubes flare nuts on EHCU side.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 16 \u00b1 2 Nm",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Carefully detach the bundy pipe without any bend. if the bundy tube bends, Constant pressure will not be maintained.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the EHCU electrical connector.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130027.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew air cleaner housing mounting bolts to partially detach and keep aside.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130028.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 5 Nm",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanners, Unscrew EHCU mounting bolts and remove the EHCU assembly with EHCU mounting bracket.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130029.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 23 \u00b1 2 Nm",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner , Unscrew EHCU mounting nuts from the bracket.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130030.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 8 \u00b1 2 Nm",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130196.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "After removing the bundy tubes from EHCU, seal each port of ECHU with dummy plugs to avoid dust entry.Do not give any impact to hydraulic unit and take at most care not to allow dust to enter the hydraulic unit.Do not place hydraulic unit on its side or upside down. Handling it in inappropriate way will affect its original performance.Take sufficient care while installation and ensure correct bundy is connected to the specified inlet port. Use colour code for identification.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Check and top up the brake fluid, If required.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Carry-out the brake bleeding procedure. For additional information refer to Brake bleeding procedure.",
+ "file": null,
+ "display_order": 26
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the EHCU for any external damage, if found replace.",
+ "file": null,
+ "display_order": 27
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 159,
+ "sys_id": "THAR.LX-0004-Brake",
+ "subsys_id": "THAR.LX-0004-Brake-Brake Pedal Assembly (AT Variant) - R&R",
+ "systems": "Brake",
+ "sub_systems": "Brake Pedal Assembly (AT Variant) - R&R",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4D180001.jpg",
+ "myid": 1277,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Brake Pedal Assembly (AT Variant) - R&R-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4D180001.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20506.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20507.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using trim removal tool, remove the IP panel trim driver side.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4D180002.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the brake switch.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1016,1278",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using Nose plier, remove the R-clip and the clevis pin from the pedal shank.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130008.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the pedal box top mounting bolt.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130009.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque :25 \u00b1 5.0 Nm",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the pedal box mounting nuts then remove the brake pedal box assembly.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130010.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque :25\u00b15.0 Nm",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Brake Pedal Assembly (AT Variant) - R&R.PNG",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the brake pedal assembly for any physical damage. Replace if found any.",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 168,
+ "sys_id": "THAR.LX-0004-Brake",
+ "subsys_id": "THAR.LX-0004-Brake-Front Wheel Speed Sensor",
+ "systems": "Brake",
+ "sub_systems": "Front Wheel Speed Sensor",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A130229.jpg",
+ "myid": 1286,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Front Wheel Speed Sensor-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130229.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30052.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30053.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Disconnect battery negative connector.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130321.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance.Before disconnecting the battery, check for the audible sound of EWP ON.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect the wheel speed senor electrical connector.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130032.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Detach the wheel speed sensor cable from the routing clips.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130033.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen and remove the wheel speed sensor mounting bolt then remove the sensor.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130034.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque :9 \u00b1 1 Nm",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130035.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the sensor for any physical damage. Replace if found any.Inspect the sensor for foreign particles segregation. Clean if found.Inspect the sensor connector for any damage.",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 166,
+ "sys_id": "THAR.LX-0004-Brake",
+ "subsys_id": "THAR.LX-0004-Brake-Parking Brake Lever Assembly",
+ "systems": "Brake",
+ "sub_systems": "Parking Brake Lever Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A130142.jpg",
+ "myid": 1284,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Parking Brake Lever Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130142.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30033.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30034.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the floor console assembly.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1020,1340",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm open end spanner, loosen and remove the parking brake adjusting nut.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130300.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Detach the parking brake cable from parking brake lever.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130144.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the parking brake switch electrical connector.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130145.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew parking brake lever assembly mounting nuts.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130146.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque :25 \u00b1 3 Nm",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the parking brake switch from parking brake lever assembly.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130147.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130148.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Carry-out parking brake adjustment. For additional information refer to Parking brake adjustment section",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the park brake lever for any physical damage. Replace if found any.",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 164,
+ "sys_id": "THAR.LX-0004-Brake",
+ "subsys_id": "THAR.LX-0004-Brake-Front Caliper Piston Assembly",
+ "systems": "Brake",
+ "sub_systems": "Front Caliper Piston Assembly",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A130266.jpg",
+ "myid": 1282,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Front Caliper Piston Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the front caliper assembly.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1016,1281",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Blow dry compressed air into the caliper gradually through the inlet port connected to banjo bolt, to gradually move the piston out of the caliper.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130266.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the piston from the caliper housing.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130268.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the dust cover from the caliper housing.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130263.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the rubber seal from the groove in the caliper housing.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130262.jpg",
+ "display_order": 10
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Piston Outer surface should be free from nicks, score or rust and should feel smooth to touch. Do not use emery paper on piston surface, Replace if found any.Caliper Housing bores should be free from score, pitting, and corrosion, Replace if found any.",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Carefully refit the rubber seal.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130262.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Clean all the internal parts thoroughly with fresh brake fluid or alcohol. Do not use mineral oil like kerosene, petrol, diesel etc.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refit the dust cover.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130263.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Insert the piston.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130268.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "If the piston does not move smoothly, remove it and examine the sealing ring for correct seating in its groove. Fit the other end of the piston boot on to the caliper housing.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Refit the front caliper assembly.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1016,1281",
+ "file": null,
+ "display_order": 21
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 152,
+ "sys_id": "THAR.LX-0004-Brake",
+ "subsys_id": "THAR.LX-0004-Brake-Brake Switch Adjustment",
+ "systems": "Brake",
+ "sub_systems": "Brake Switch Adjustment",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A130129.jpg",
+ "myid": 1270,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Brake Switch Adjustment-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Open the driver door.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130129.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Press the lock and disconnect the electrical connector from the brake switch.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130128.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Place the brake pedal in release position.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130235.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Turn the brake switch in anti-clock wise direction to get the brake switch free from adjuster lock.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130119.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/P4J140272.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130120.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/P4J140273.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Insert the brake switch (A) in adjuster (B) till the switch plunger get completely pressed against brake pedal (at this point switch body will rest on brake pedal).",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Ensure no play between adjuster and the mounting bracket . Replace the adjuster if play is observed.While replacing new Switch with adjuster - Adjuster is to be snapped on mounting bracket. Ensure no play between the adjuster and mounting.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Rotate the brake switch in clock wise direction till the switch gets locked.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130121.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "After locking the switch, the gap between the switch body and brake pedal will set to 1\u00b10.15mm.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/P4J140270.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Connect the brake switch electrical connector.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130128.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Close the driver door.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130133.jpg",
+ "display_order": 21
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 160,
+ "sys_id": "THAR.LX-0004-Brake",
+ "subsys_id": "THAR.LX-0004-Brake-Brake Switch",
+ "systems": "Brake",
+ "sub_systems": "Brake Switch",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A130182.jpg",
+ "myid": 1278,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Brake Switch-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Open the driver door.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130129.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Press the lock and disconnect the electrical connector from the brake switch.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130128.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Place the brake pedal in release position.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130235.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Turn the brake switch in anti-clock wise direction to get the brake switch free from adjuster lock.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130119.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/P4J140272.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130120.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/P4J140273.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Insert the brake switch (A) in adjuster (B) till the switch plunger get completely pressed against brake pedal (at this point switch body will rest on brake pedal).",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1016,1270",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Ensure no play between adjuster and the mounting bracket . Replace the adjuster if play is observed.While replacing new Switch with adjuster - Adjuster is to be snapped on mounting bracket. Ensure no play between the adjuster and mounting.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Rotate the brake switch in clock wise direction till the switch gets locked.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130121.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "After locking the switch, the gap between the switch body and brake pedal will set to 1\u00b10.15mm.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/P4J140270.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Connect the brake switch electrical connector.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130128.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Close the driver door.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130133.jpg",
+ "display_order": 22
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 154,
+ "sys_id": "THAR.LX-0004-Brake",
+ "subsys_id": "THAR.LX-0004-Brake-Brake Fluid - Replace",
+ "systems": "Brake",
+ "sub_systems": "Brake Fluid - Replace",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J08-MAT-0390",
+ "cover_image": "/files/20.JPG",
+ "myid": 1272,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 39,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 79,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 119,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 159,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 169,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 238,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 278,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 318,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 330,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 399,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 438,
+ "kilometers_applicable": 0
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Brake Fluid - Replace-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Brake & Clutch Fluid - Replace.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Brake Fluid - Mahindra 'Maximile DOT 4' Genuine brake fluid.Capacity - 1.75Liters (Including bleeding quantity).",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Notice",
+ "content": "Entire bleeding operation should be done with engine ON condition.In case of fluid reservoir or brake fluid replacement, bleeding of brake circuit is required.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C040001.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Caution",
+ "content": "Always use recommended fluid and do not mix different brand fluids.Always use fresh and clean fluid from a sealed container.Do not pump the brake pedal at any time while bleeding (i. e. when the bleeding screw is opened). Air in the system will be further compressed into small bubbles and distributed throughout the hydraulic system and will result in additional bleeding operations.Do not reuse the drained fluid.Fluid level in the reservoir must be at MAX level at the start of bleeding and should be checked after bleeding each brake circuit and top up as required.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20561.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Preliminary Activities/Conditions",
+ "content_type": "Description",
+ "content": "2 post lift/ 4 post lift. \u201cMAX\u201d mark on the brake fluid reservoir.",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100013.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Press and release brake pedal gently several times, so that brake fluid will get circulated throughout the circuit.",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100076.jpg",
+ "display_order": 48
+ }
+ ]
+ },
+ {
+ "procedure_name": "Manual Bleeding",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "For vehicles equipped with ABS/ESP, brake circuit air bleeding needs to be carried out in 3 steps as mentioned below:
Manual Bleeding Procedure ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130236.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Connect a transparent tube into Rear LH side bleeding nipple and insert the other end of tube in a transparent container.",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Ensure other end of tube is submerged in liquid, else chances for air entry is high.MAX mark on the brake fluid reservoir.",
+ "file": null,
+ "display_order": 91
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130134.jpg",
+ "display_order": 92
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Refit the brake fluid reservoir cap.",
+ "file": null,
+ "display_order": 93
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130241.jpg",
+ "display_order": 94
+ }
+ ]
+ },
+ {
+ "procedure_name": "Tool (i-SMART) Bleeding",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Connect i-SMART diagnostic tester and turn the ignition \u201cON\u201d. ",
+ "file": null,
+ "display_order": 95
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "During the tool-bleeding process, ensure that the fluid level in the reservoir does not drop below minimum.",
+ "file": null,
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Launch i-SMART Select ABS ECU and Navigate to Write Data. ",
+ "file": null,
+ "display_order": 97
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W318.jpg",
+ "display_order": 98
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Routine screen will appear. Click on \u201cROUTINE SELECTION\u201d drop down list and select \u201cREPAIR BLEEDING\u201d. ",
+ "file": null,
+ "display_order": 99
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W319.jpg",
+ "display_order": 100
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Click on \u201cSTART ROUTINE\u201d to initiate the tool bleeding.",
+ "file": null,
+ "display_order": 101
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W320.jpg",
+ "display_order": 102
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "Ensure the fluid level in brake fluid reservoir is at \u201cMAX\u201d mark.",
+ "file": null,
+ "display_order": 103
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W321.jpg",
+ "display_order": 104
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Connect a transparent tube into rear LH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Loosen and open the rear LH bleeding screw and then press \u201cOK\u201d button. \u201cBleeding phase I\u201d. \u201cOK\u201d button. \u201cYES\u201d button to proceed for \u201cBleeding phase II\u201d. \u201cOK\u201d button. ",
+ "file": null,
+ "display_order": 116
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030240.jpg",
+ "display_order": 117
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Notice",
+ "content": "Ensure other end of tube is submerged in liquid, else chances for air entry is high.",
+ "file": null,
+ "display_order": 118
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Click on \u201cYES\u201d button to proceed for \u201cBleeding phase III\u201d. ",
+ "file": null,
+ "display_order": 119
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030241.jpg",
+ "display_order": 120
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Notice",
+ "content": "After pressing \u201cYES\u201d button, Press and hold the brake pedal for 3 seconds and then release for 0.5 seconds.\u201cOK\u201d button. ",
+ "file": null,
+ "display_order": 122
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030242.jpg",
+ "display_order": 123
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Notice",
+ "content": "Ensure other end of tube is submerged in liquid, else chances for air entry is high.",
+ "file": null,
+ "display_order": 124
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Click on \u201cYES\u201d button to proceed for \u201cBleeding phase IV\u201d. ",
+ "file": null,
+ "display_order": 125
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030243.jpg",
+ "display_order": 126
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Notice",
+ "content": "After pressing \u201cYES\u201d button, Press and hold the brake pedal for 3 seconds and then release for 0.5 seconds.For additional information refer to Manual bleeding section. ",
+ "file": null,
+ "display_order": 128
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Check brake pedal for sponginess. If found spongy, repeat the entire procedure of bleeding.Brake and Clutch Fluid: - Mahindra Maximile DOT 4 Genuine Brake fluid.
Brake and Clutch Fluid: - 1.75 Liters.
",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Preliminary Activities/Conditions",
+ "content_type": "Description",
+ "content": "Use recommended fluid & do not mix different brand fluids. In case fluid reservoir replaced, brake and clutch system needs bleeding. Brake/Clutch fluid level & leak check to be done at every service interval (Excludes fluid replacement intervals). Use the same brand fluid for top up; do not top up brake fluid from used and unsealed brake fluid container. The brake/clutch fluid reservoir cap container should not be opened with dirty Avoid direct water spray on reservoir while washing engine compartment. Always use Mahindra Maximile DOT 4 genuine brake fluid. For additional information refer to Front Stabilizer Bar \u2013 R&R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170124.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 24 mm socket spanner, loosen and remove the front lower control arm mounting nuts on chassis.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 24 mm ring spanner.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque value: 250 \u00b1 20 Nm",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 19 mm socket spanner, loosen and remove strut fork mounting bolt.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170125.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.Ensure to insert the washer before Install the bolt.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 120 \u00b1 12 Nm",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a cutting plier, remove the cotter pin from the ball joint",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170126.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Never reuse the split pin, always replace with a new one.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 24 mm socket spanner, loosen and remove lower arm ball joint mounting nut.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170127.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 130 \u2013 150 Nm",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 22 mm socket spanner, loosen and remove knuckle bracket mounting bolts,remove the knuckle lower half.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170127.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque value: 140 \u00b1 10 Nm<n>Torque Wrench Type - Open end Torque Wrench",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a hammer, tap strut fork and release it from lower arm.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170128.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170129.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the lower control arm mounting bolts from the vehicle frame.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170130.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque value: 250 \u00b1 20 Nm",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the lower control arm from the vehicle",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170091.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Perform wheel alignment.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170131.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1015,1250",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170120.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Caution",
+ "content": "Pay attention while InstallationTorque tightening should be done without load and with the tyres on level ground.LH and RH identification sticker available on part for orientation.Camber and caster bolt marking position required at centerCamber and caster bolt should be fitted in the direction of Arrow shown in illustration",
+ "file": null,
+ "display_order": 40
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the lower control arm for any external damage or bent, if found replace.Inspect the lower control arm ball joint and bushes for any damage.",
+ "file": null,
+ "display_order": 41
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 144,
+ "sys_id": "THAR.LX-0004-Suspension",
+ "subsys_id": "THAR.LX-0004-Suspension-Panhard Rod Bushes Overhaul",
+ "systems": "Suspension",
+ "sub_systems": "Panhard Rod Bushes Overhaul",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170248.jpg",
+ "myid": 1262,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Panhard Rod Bushes Overhaul-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/VST-0075_Rear Suspension Panhard Rod Bushes Removal & Installation.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Panhard rod.",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step 1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1015,1254",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Place the Pan hard on suitable base block.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170248.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Place the suitable dolly on the Pan hard bush One end.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170259.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a hydraulic press or hammer remove the Pan hard bush one end.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170250.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Place the Pan hard other end on base block and place the dolly on Pan hard bush. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170252.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170253.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a hydraulic press or hammer remove the Pan hard bush other end.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170273.jpg",
+ "display_order": 14
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Place the Pan hard one end on base block and place the bush installer MST:0401BAA0043ST).on the bush.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170251.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a hydraulic press or hammer, Install the Pan hard bush One end.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170285.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Panhard bush should be fitted in center of panhard and ensure to maintain equal distance on both side of panhard as shown.Dimensions are in mm.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170287.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Place the Pan hard other end on base block and place the bush installer (MST:0401BAA0043ST).on the bush. ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170274.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a hydraulic press or hammer, Install the Pan hard bush other end.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170286.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Refit the Panhard rod.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step 5",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1015,1254",
+ "file": null,
+ "display_order": 26
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 142,
+ "sys_id": "THAR.LX-0004-Suspension",
+ "subsys_id": "THAR.LX-0004-Suspension-Upper Arm Bushes Overhaul",
+ "systems": "Suspension",
+ "sub_systems": "Upper Arm Bushes Overhaul",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170219.jpg",
+ "myid": 1260,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Upper Arm Bushes Overhaul-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Front Lower Control Arm.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1015,1252",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Place the base block (MST:0401BAA0033ST) and place the collar support (MST: 0401BAA0037ST). on the base block.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170219.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Place the upper arm one end on the base block.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170220.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Place the upper arm bush remover(MST: 0401BAA0040ST)on the bottom bush.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170221.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Place the Pin cage (MST:0401BAA0041ST) & the support cage (MST: 0401BAA0013ST)as shown.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170222.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a hydraulic press remove the upper arm one side (bottom) bush.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170223.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Place the upper arm other end on the base block (MST: 0401BAA0033ST) and collar support (MST: 0401BAA0037ST).",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170225.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Place the upper arm bush remover (MST: 0401BAA0040ST) on the bush.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170226.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Place the upper arm dummy bush (MST:0401BAA0042ST) on the upper side bush seating hole.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170227.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Place the upper arm pin cage (MST:0401BAA0041ST) & the support cage (MST:0401BAA0013ST)as shown.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170228.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a hydraulic press remove the other side bush.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170229.jpg",
+ "display_order": 22
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Place the Upper arm on the base block (MST: 0401BAA0033ST) & collar support (MST: 0401BAA0037ST) and place the bush over the upper arm.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170230.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Place the bush installer (MST:0401BAA0043ST)on the bush.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170231.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a hydraulic press, Install the upper arm one side bush.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170232.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Place the Upper arm other side on the base block (MST: 0401BAA0033ST) & collar support (MST: 0401BAA0037ST) and place the bush over the upper arm.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170233.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Place the bush installer (MST:0401BAA0043ST).on the bush.",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170234.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a hydraulic press, Install the upper arm bush.",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170235.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refit the Front Upper Control Arm.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1015,1251",
+ "file": null,
+ "display_order": 36
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 137,
+ "sys_id": "THAR.LX-0004-Suspension",
+ "subsys_id": "THAR.LX-0004-Suspension-Rear Upper Link",
+ "systems": "Suspension",
+ "sub_systems": "Rear Upper Link",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170031.jpg",
+ "myid": 1255,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Rear Upper Link-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/VST-0073_Rear Suspension Rear upper Link Bushes Removal & Installation.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170031.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20248.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20249.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170028.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 24 mm socket spanner, loosen the mounting bolt and nut in the chassis end then remove nut from the link.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 230 \u00b1 20 Nm",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 21 mm ring spanner.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.Torque Wrench Type - Open end Torque Wrench for LH chassis & axle ends.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 24 mm socket spanner, loosen and remove the link mounting nut from the axle end.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170029.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 230 \u00b1 20 Nm<n>Torque Wrench Type - Open end Torque Wrench for LH chassis & axle ends",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 21 mm ring spanner.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a appropriate jack support slightly lift the rear axle.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170013.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 17 mm socket spanners, loosen and remove the both rear shock absorbers bottom side mounting bolts and nuts.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170014.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque value : 110\u00b111 Nm<n>Torque Wrench Type - Open end Torque Wrench",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.While loosening the nut, hold the bolt using 15 mm ring spanner.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Lower the jack support.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the respective side coil spring.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170027.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Jack up the rear axle slightly.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the rear upper link chassis end mounting bolt then remove the front and rear upper link from the vehicle.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170026.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": "Pay attention while InstallationBolt should be fitted in the direction of Arrow shown in illustration",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170050.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170102.jpg",
+ "display_order": 29
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the upper link for any damage, crack or twisting. Replace if found any.Inspect the upper link bushes for any damage, crack or material deterioration. Replace the bushes if found any.",
+ "file": null,
+ "display_order": 30
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 145,
+ "sys_id": "THAR.LX-0004-Suspension",
+ "subsys_id": "THAR.LX-0004-Suspension-Rear Lower Link Bushes Overhaul",
+ "systems": "Suspension",
+ "sub_systems": "Rear Lower Link Bushes Overhaul",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170276.jpg",
+ "myid": 1263,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Rear Lower Link Bushes Overhaul-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/VST-0074_Rear Suspension Rear lower Link Bushes Removal & Installation.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Rear Lower Link.",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1015,1256",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Place the base block (MST:0401BAA0033ST) & place the Rear Lower and Upper Link Coller (MST :0401BDD0001ST).",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170276.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Place the Lower link one end on the base block.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170254.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) on the lower link one end bush.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170255.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a hydraulic press, remove the lower link one end bush.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170256.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Place the Lower link other end on the base block.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170257.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) on the lower link other end bush.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170276.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a hydraulic press, remove the lower link other end bush.",
+ "file": "/files/W4A170277.jpg",
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Place the Lower link one end on then base block and place the bush over the lower link.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170278.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Place the Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170258.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "While Installation ensure to maintain Bush Void at 45\u00b0 angle as shown.Ensure to Install the Bush with Void end should be fitted in Chassis end on vehicle.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170279.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170269.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Place the Lower link other end on the base block and place the bush over the lower link.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170259.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Place the Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170280.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170279.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Refit the Rear Lower Link.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1015,1256",
+ "file": null,
+ "display_order": 30
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 148,
+ "sys_id": "THAR.LX-0004-Suspension",
+ "subsys_id": "THAR.LX-0004-Suspension-Suspension System Technical Spec",
+ "systems": "Suspension",
+ "sub_systems": "Suspension System Technical Spec",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1266,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Suspension System Technical Spec-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Front Suspension",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/frontsuspension.png",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Rear Suspension",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/rearsuspension.png",
+ "display_order": 2
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 135,
+ "sys_id": "THAR.LX-0004-Suspension",
+ "subsys_id": "THAR.LX-0004-Suspension-Front Strut Assembly",
+ "systems": "Suspension",
+ "sub_systems": "Front Strut Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170098.jpg",
+ "myid": 1253,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Front Strut Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170098.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20226.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20227.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove front wheel.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1014,1511",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner , loosen and remove the brake hose routing bracket mounting nut.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170124.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 19 mm socket spanner , loosen and remove the strut fork mounting bolt at lower arm end and detach it.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170133.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 120 \u00b1 12 Nm",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using hammer, tap strut fork graduall and release strut fork from lower arm.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170218.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170134.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 17 mm ring spanner, loosen and remove the strut top mounting nuts from chassis.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170135.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque value: 40 \u00b1 5Nm<n>Torque Wrench Type - Open end Torque Wrench",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Detach Wheel speed sensor routing clips from upper control arm.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170138.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner and 18 mm open end spanner, unscrew upper arm bolt and nut and detach partially.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170136.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque value: 97\u00b1 10 Nm",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170137.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove front strut assembly from front suspension.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170139.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": "LH and RH identification sticker available on part for orientation.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 17 mm socket spanner and 19mm open end spanner, loosen the fork ounting bolt and nut and remove fork from strut assembly.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170145.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Perform wheel alignment.",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1015,1250",
+ "file": null,
+ "display_order": 32
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for the coil spring for any damage, crack etc.Check for oil leakage from the shock absorber.",
+ "file": null,
+ "display_order": 33
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 146,
+ "sys_id": "THAR.LX-0004-Suspension",
+ "subsys_id": "THAR.LX-0004-Suspension-Rear Upper Link Bushes Overhaul",
+ "systems": "Suspension",
+ "sub_systems": "Rear Upper Link Bushes Overhaul",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170276.jpg",
+ "myid": 1264,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Rear Upper Link Bushes Overhaul-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/VST-0073_Rear Suspension Rear upper Link Bushes Removal & Installation.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Rear Upper Link.",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1015,1255",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Place the base block (MST:0401BAA0033ST) & Place the Rear Lower and Upper Link Coller (MST : 0401BDD0001ST).",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170276.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Place the upper link one end on the base block.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170260.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) on the lower link one end bush.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170255.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Place the upper link other end on the base block.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170261.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) on the upper link other end bush and Using a hydraulic press, remove the bush.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170263.jpg",
+ "display_order": 13
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Place the upper link one end on then base block and place the bush over the upper link.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170265.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Place the bush & Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170267.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "While Installation ensure to maintain Bush Void at 90\u00b0 angle as shown.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170282.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170283.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Place the upper link other end on the base block and place the bush over the upper link.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170264.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Place the bush & Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170266.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Refit the Rear Upper Link.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1015,1255",
+ "file": null,
+ "display_order": 26
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 136,
+ "sys_id": "THAR.LX-0004-Suspension",
+ "subsys_id": "THAR.LX-0004-Suspension-Panhard Rod",
+ "systems": "Suspension",
+ "sub_systems": "Panhard Rod",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170039.jpg",
+ "myid": 1254,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Panhard Rod-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170039.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20239.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20240.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a appropriate jack support and slightly lift the rear axle.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170013.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170038.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 24 mm deep socket spanner,loosen and remove the pan hard rod mounting nut and bolt from chassis side.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 230\u00b1 20 Nm",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt with the help of 21 mm deep socket.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 21 mm socket spanner, loosen and remove the pan hard rod mounting bolt from axle side.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170037.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 230\u00b1 20 Nm",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove pan hard rod separately.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170051.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "Yellow color all round marking added on Pan hard rod to identify chassis end.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170148.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170101.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "After installation of pan hard rod remove the jack support.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Pay attention while Installation. Bolt should be fitted in the direction of Arrow shown in illustration.While Installation, ensure to refit the Anti Rotation Bracket in the axle end bold side.",
+ "file": null,
+ "display_order": 22
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Inspect the pan hard rod for any external damage/bend or crack, if found replace.",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 131,
+ "sys_id": "THAR.LX-0004-Suspension",
+ "subsys_id": "THAR.LX-0004-Suspension-Suspension Bushes / Arms & Links - Inspect",
+ "systems": "Suspension",
+ "sub_systems": "Suspension Bushes / Arms & Links - Inspect",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J08-MAT-0470",
+ "cover_image": "/files/W4A170083.jpg",
+ "myid": 1249,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 22,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 67,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 93,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 147,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 172,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 226,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 253,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 306,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 333,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 385,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 414,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Suspension Bushes / Arms & Links - Inspect-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Suspension Bushes \u2013 Inspect",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Suspension Bushes, Arms & Links - Inspect.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Heading",
+ "content": "Preliminary Activities/Conditions",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": " Position the Vehicle on 4 post lift.",
+ "file": null,
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Front Suspension Bushes Inspection procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check lower control arm front and rear bush condition (both LH & RH) for wear & tear, cracks & shift. Replace if necessary.Check upper control arm front and rear bush condition (both LH & RH) for wear & tear, cracks & shift. Replace if necessary.Check the ball joint boots for damage, cracks, replace if necessary.Check shock absorber bushes, shock absorber dust boot, stabilizer bar bushes,stabilizer bar link boots, bump stop for wear & tear, cracks and shift, replace if necessary.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170083.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Rear Suspension Bushes Inspection Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the lower link, pan hard rod, Upper link, stabilizer bar and stabilizer bar links bushes for any damage/crack or deterioration. Replace the bushes if found any.Check shock absorber bushes, dust boot & bump stop for wear, crack and shift.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170082.jpg",
+ "display_order": 7
+ }
+ ]
+ },
+ {
+ "procedure_name": "Suspension Arms & Links \u2013 Inspect",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Preliminary Activities/Conditions",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " Position the Vehicle on 4 post lift.",
+ "file": null,
+ "display_order": 9
+ }
+ ]
+ },
+ {
+ "procedure_name": "Front Suspension Lower Control Arm",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect front suspension lower control arm for any bend, damage or crack.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170070.jpg",
+ "display_order": 11
+ }
+ ]
+ },
+ {
+ "procedure_name": "Front Suspension Upper Control Arm",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect front suspension upper control arm for any bend, damage or crack.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170071.jpg",
+ "display_order": 13
+ }
+ ]
+ },
+ {
+ "procedure_name": "Front Suspension Stabilizer Bar",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect front suspension stabilizer bar for any bend, twisting, damage or crack.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170064.jpg",
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Rear Suspension Lower Link",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect rear suspension lower link for any bend, damage or crack.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170055.jpg",
+ "display_order": 17
+ }
+ ]
+ },
+ {
+ "procedure_name": "Rear Suspension Upper Link",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect rear suspension upper link for any bend, twisting, damage or crack.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170065.jpg",
+ "display_order": 19
+ }
+ ]
+ },
+ {
+ "procedure_name": "Rear Suspension Panhard Rod",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect rear suspension panhard rod for any bend, twisting, damage or crack.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170068.jpg",
+ "display_order": 21
+ }
+ ]
+ },
+ {
+ "procedure_name": "Rear Suspension Stabilizer Bar",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect rear suspension stabilizer bar for any bend, twisting, damage or crack.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170072.jpg",
+ "display_order": 23
+ }
+ ]
+ },
+ {
+ "procedure_name": "Front/Rear Stabilizer Bar Links",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect front & rear suspension stabilizer bar link for any bend, twisting, damage or crack.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170061.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "While tightening the link & torquing ensure that wheels are resting on the ground/ 4post lift. If it is not done, the ride quality will get adversely affected.",
+ "file": null,
+ "display_order": 26
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 143,
+ "sys_id": "THAR.LX-0004-Suspension",
+ "subsys_id": "THAR.LX-0004-Suspension-Lower Arm Bushes Overhaul",
+ "systems": "Suspension",
+ "sub_systems": "Lower Arm Bushes Overhaul",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170219.jpg",
+ "myid": 1261,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Lower Arm Bushes Overhaul-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Front Lower Control Arm.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1015,1252",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Place the base block (MST:0401BAA0033ST) and place the Front Lower Arm Big End Bush Collar (MST: 0401BBB0001ST). on the base block.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170219.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Place the Lower arm big bush end over the fixture.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170236.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Place the LCA big bush remover (MST: 0401BAA0038ST) and Front Lower Arm Bushs Support tool (MST: 0401BBB0002ST) on the big end bush.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170237.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170238.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Place the Pin cage (MST:0401BAA0019ST) & the support cage (MST:0401BAA0013ST) as shown.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170239.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a hydraulic press, remove the lower arm big end bush.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170240.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Place the LCA small bush end on the base block (MST: 0401BAA0033ST) and LCA small bush collar support (MST : 0401BAA0036ST).",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170219.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Place the Lower arm small bush end over the fixture.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170270.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Place the LCA small bush remover (MST: 0401BAA0039ST) & Front Lower Arm Bushs Support tool (MST :0401BBB0002ST) over the lower arm bush.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170271.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Place the dummy bush (MST:0401BAA0016ST) on the big end bush seating hole.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170272.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Place the Pin cage (MST:0401BAA0019ST) & support cage (MST:0401BAA0013ST)as shown.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170241.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using a hydraulic press, remove the LCA small bush.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170242.jpg",
+ "display_order": 25
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Place the lower arm on the base block (MST: 0401BAA0033ST).",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170243.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Place the bigger end bush on the lower arm & place the bush installer (MST: 0401BAA0044ST)on the bush.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170244.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Lower arm big end bush has Void profile and While Installation ensure to maintain Bush Void at appropriate angle as shown.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170255.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170284.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a hydraulic press, Install the lower arm big end bush.",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170247.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Place the lower arm small end on the base block (MST: 0401BAA0033ST)",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170245.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Place the lower arm small end bush & the installer (MST: 0401BAA0045ST).",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170246.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a hydraulic press, Install the lower arm small end bush.",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170247.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refit the Lower Upper Control Arm.",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1015,1252",
+ "file": null,
+ "display_order": 42
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 139,
+ "sys_id": "THAR.LX-0004-Suspension",
+ "subsys_id": "THAR.LX-0004-Suspension-Rear Coil Springs",
+ "systems": "Suspension",
+ "sub_systems": "Rear Coil Springs",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170012.jpg",
+ "myid": 1257,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Rear Coil Springs-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170012.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20266.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20267.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Support the rear axle using the appropriate hydraulic jack.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170013.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170014.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 17 mm socket spanners, loosen and remove the both rear shock absorbers bottom side mounting bolts and nuts.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque value : 110\u00b111 Nm<n>Torque Wrench Type - Open end Torque Wrench",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 15 mm ring spanner.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Lower the jack support.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170015.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the rear coil spring and pad securely from vehicle.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170016.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170018.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170017.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170149.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Pay attention while InstallationLocking lug to be matched with hole on Rear Coil spring dome bracket of ChassisYellow coloured PU sleeve should be on chassis side while assembling the coil spring ashown in illustration.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170113.jpg",
+ "display_order": 20
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the coil spring for any damage, crack. Replace if found.Inspect the coil spring pad for any damage. Replace if found.",
+ "file": null,
+ "display_order": 21
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 149,
+ "sys_id": "THAR.LX-0004-Suspension",
+ "subsys_id": "THAR.LX-0004-Suspension-Troubleshoot - Suspension",
+ "systems": "Suspension",
+ "sub_systems": "Troubleshoot - Suspension",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1466,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Troubleshoot - Suspension-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/6064.pdf",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Components Inspection and action table",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/6065.pdf",
+ "display_order": 2
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 141,
+ "sys_id": "THAR.LX-0004-Suspension",
+ "subsys_id": "THAR.LX-0004-Suspension-Assembly Front Strut Overhaul",
+ "systems": "Suspension",
+ "sub_systems": "Assembly Front Strut Overhaul",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170158.jpg",
+ "myid": 1259,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Assembly Front Strut Overhaul-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Disassembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Front strut assembly.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1015,1253",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a spring compressor compress the strut coil spring.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170158.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Danger",
+ "content": "Ensure that the spring compressor is tightened with the spring, else expansion of the spring cause severe injury.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 6 mm open end spanner hold the shock absorber & using a 16 mm ring spanner remove the mounting nut.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170159.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the mounting nut.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170160.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the shock absorber washer & bush.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170161.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the bracket coil spring guide assembly.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170162.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the coil spring seat.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170163.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the compressed coil spring.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170164.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the shock absorber bush.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170165.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the bump stopper cap.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170166.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the shock absorber dust seal.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170167.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Remove the front bump stopper.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170168.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Remove the shock absorber.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170169.jpg",
+ "display_order": 27
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect shock absorber for oil leak.Inspect the dust seal for damage, if found replace.Check the bush condition, if worn out please replace.",
+ "file": null,
+ "display_order": 28
+ }
+ ]
+ },
+ {
+ "procedure_name": "Assembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Install the front bump stopper on the shock absorber.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170168.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Install the shock absorber dust seal.",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170167.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install the bump stopper cap.",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170166.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install the shock absorber bush.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170165.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install the compressed spring.",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170164.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install the coil spring seat.",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170163.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install the coil spring bracket.",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170163.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install the shock absorber washer & bush.",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170161.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install the mounting nut.",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170160.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Install the top mounting nut. Torque tighten the nut to specified value.",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170160.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque : 40 \u2013 45 Nm<n>Torque Wrench Type - Open end Torque wrench",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the spring compressor tool.",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170158.jpg",
+ "display_order": 51
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 133,
+ "sys_id": "THAR.LX-0004-Suspension",
+ "subsys_id": "THAR.LX-0004-Suspension-Front Upper Control Arm",
+ "systems": "Suspension",
+ "sub_systems": "Front Upper Control Arm",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170055.jpg",
+ "myid": 1251,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Front Upper Control Arm-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170055.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20203.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20204.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove front wheel. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1014,1511",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a cutting plier, remove the cotter pin from the ball joint",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170121.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "Never reuse the split pin, always replace with a new one.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170057.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 24 mm socket spanner, loosen and remove the upper control arm ball joint nut.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 90 \u2013 110 Nm",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the wheel speed sensor routing clips from the upper control arm.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170123.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 18 mm ring spanner, hold the mounting nut & using an 14 mm socket spanner loosen the bolt, remove the bolts & nuts.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170058.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 97 \u00b1 10 Nm",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Detach and remove the upper control arm.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170059.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170119.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Pay attention while InstallationBolt should be fitted in the direction of Arrow marks shown in illustration",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Perform wheel alignment.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1015,1250",
+ "file": null,
+ "display_order": 25
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the upper control arm for any external damage or bent, if found replace.",
+ "file": null,
+ "display_order": 26
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 147,
+ "sys_id": "THAR.LX-0004-Suspension",
+ "subsys_id": "THAR.LX-0004-Suspension-Rear Shock Absorber Bushes Overhaul",
+ "systems": "Suspension",
+ "sub_systems": "Rear Shock Absorber Bushes Overhaul",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170290.jpg",
+ "myid": 1265,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Rear Shock Absorber Bushes Overhaul-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the rear shock absorber.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1015,1258",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Place the rear shock absorber one end on the suitable base block.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170290.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Place the suitable dolly on the rear shock absorber.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170289.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a hydraulic press or hammer remove the rear shock absorber bush.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170288.jpg",
+ "display_order": 8
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Place the rear shock absorber one end on then base block and place the bush over the rear shock absorber.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170291.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Place the bush & Installer rear shock absorber End Bush (MST) over the bush and Refit the bush by loading the hydraulic press",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170292.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170293.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Refit the rear shock absorber,",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1015,1258",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 140,
+ "sys_id": "THAR.LX-0004-Suspension",
+ "subsys_id": "THAR.LX-0004-Suspension-Rear Shock Absorber",
+ "systems": "Suspension",
+ "sub_systems": "Rear Shock Absorber",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170041.jpg",
+ "myid": 1258,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Rear Shock Absorber-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170041.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20277.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20278.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Support the rear axle using the appropriate hydraulic jack and lift the vehicle to compress the coil springs.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170013.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 17 mm socket spanners, loosen and remove the bottom mounting bolts and nuts of rear shock absorbers from the rear axle.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170014.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque value : 110\u00b111 Nm<n>Torque Wrench Type - Open end Torque Wrench",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.While loosening the nut, hold the bolt using 15 mm ring spanner.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the top mounting bolts of both rear shock absorbers from the chassis.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170043.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque value : 65\u00b110Nm",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the shock absorber from the vehicle.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170040.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170100.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Pay attention while InstallationBolt should be fitted in the direction of Arrow shown in illustrationEnsure the arrow on Rear Shock absorber should be on rear side of vehicle.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170150.jpg",
+ "display_order": 19
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the shock absorber for any damage or oil leakage, replace if found any.Inspect the shock absorber bushes for any damage.",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 132,
+ "sys_id": "THAR.LX-0004-Suspension",
+ "subsys_id": "THAR.LX-0004-Suspension-Wheel Alignment",
+ "systems": "Suspension",
+ "sub_systems": "Wheel Alignment",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J08-MAT-0510",
+ "cover_image": "/files/W4A170079.jpg",
+ "myid": 1250,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 21,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 56,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 107,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 146,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 175,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 225,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 266,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 295,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 346,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 384,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 417,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Wheel Alignment-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": " Wheel alignment (adjustment of Camber, Caster and Toe) is part of standard automobile maintenance that consists of adjusting the angles of the wheels so that they are set to the specification. The purpose of these adjustments is to reduce tyre wear, and to ensure that vehicle travel is straight and true (without pulling to one side).Wheel alignment consists of adjusting the angles of the wheels so that they are perpendicular to the ground and parallel to each other. The purpose of these adjustments is maximum tyre life and a vehicle that tracks straight and true when driving along a straight and level road. The symptoms of a vehicle that is out of alignment are: Uneven or rapid tyre wear, Pulling or drifting away from a straight line, Wandering on a straight level road, Spokes of the steering wheel off to one side while driving on a straight and level road.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20181.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "Description",
+ "content": " Before doing wheel alignment, ensure front and rear tyre pressure are as per specifications.Vehicle to be run for some distance before starting the wheel alignment. This will settle the load on each tyre.Ensure that the turn table & roller plate move freely to avoid suspension block & no rocking of turn tables.Check for any damage of the rims or bushes & suspension joints/ wheel end for play.Ensure that the front turntables & rear plates are at the same level.Do the setting of steering wheel for Straight Ahead Position (SAP) and lock the steering column rotation.Refer the wheel alignment specification chart for the front Suspension.Refer decision tree for wheel alignment:",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20180.pdf",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Wheel Alignment Sequence<n>Run Out Compensation",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U3A130002.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": " If above sequence is not followed, it will lead to incorrect wheel alignment even though individual adjustments are done correctly.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " Park the vehicle on 4 post wheel alignment equipment to do the run-out compensation.Refer wheel alignment equipment manufacturer's guide lines while doing run-out compensation.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Heading",
+ "content": "Steering Straight Ahead Position Setting",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": " Keep the wheels on turntables of the wheel alignment machine. Rotate the steering wheel to LHS lock position.From LHS lock position, rotate steering wheel to RHS Lock position.Count the number of turns of steering wheel from LHS to RHS lock position.From RHS lock position, rotate steering wheel exactly half the number of turns towards LHS.Lock the steering wheel.If the steering straight ahead does not match the wheel straight ahead, then adjust the OBJ of the desired side. Ensure that the silent bushes in the front suspension are in satisfactory condition. Ensure that the front suspension fasteners are tightened to specified torque.Ensure that there is no play in steering linkages and suspension ball joints.Follow instruction manual of wheel aligning system manufacturer.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Heading",
+ "content": "Wheel Alignment - Check & Adjust<n>Specification for Wheel Alignment<n>Front Suspension",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20183.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": " Wheel alignment consists of adjusting the angles of the wheels so that they are parallel to each other and perpendicular to the ground, thus maximizing tyre life and ensures straight and true tracking along a straight and level road.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Front Suspension<n>Steering Angle Parameters",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20184.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Wheel alignment procedure to be done in vehicle unladen condition onlyDo wheel alignment only according to manufacturer's specifications.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170079.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": " Front tyre should have uniform wear and inflated to recommended pressure.Ensure that hub play is correct.Ensure that the front suspension fasteners are tightened to specified torque.Ensure that there is no play in steering linkages and suspension ball joints.",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ },
+ {
+ "procedure_name": "Camber Adjustment",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Camber is defined as the inward or outward tilt of the top of the wheel as viewed from the front.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170110.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "While adjusting camber angle vehicle should be unladen and nobody should sit inside.The camber values should be within: 0\u00e2\u0081\u00b0 \u00b1 0.2\u00e2\u0081\u00b0.The difference between two wheels should be within: 0\u00e2\u0081\u00b0\u00b1 0.4\u00e2\u0081\u00b0.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 24 mm socket spanner, loosen the camber bolt locking nut.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170080.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "While loosening hold the bolt with the help of a 24 mm ring spanner.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "To adjust camber angle, rotate the camber bolt using 24 mm ring/socket spanner, to clockwise or anti clockwise direction. Clockwise rotation will reduce the camber angle and anti-clockwise rotation will increase the camber angle.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170080.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "After adjusting camber angle tighten the camber bolt locking nut and recheck the camber angle.",
+ "file": null,
+ "display_order": 27
+ }
+ ]
+ },
+ {
+ "procedure_name": "Caster Adjustment",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "The angle between the vertical line and king pin, which fixes the steering knuckle and front axle, (steering column which connects the top and bottom ball joints in the independent axle type) when viewed the tyres from the side is called caster angle.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170111.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "While adjusting caster angle vehicle should be unladen.The values should be within: 4.2\u00b0 \u00b10.4\u00b0.The difference between two wheels should be within: 0\u00b0 \u00b1 0.4\u00b0Adjust caster bolt until red zone becomes green. (Only if wheel alignment is out of specs).",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 24 mm socket spanner, loosen the caster bolt locking nut.",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170081.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 24 mm ring spanner.",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "To adjust castor angle, rotate the caster bolt to clockwise or anti clockwise direction using 24 mm socket spanner. Clockwise rotation will decrease the caster angle and anti-clockwise rotation will increase the caster angle.",
+ "file": null,
+ "display_order": 34
+ }
+ ]
+ },
+ {
+ "procedure_name": "Toe-in Adjustment",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Toe is the difference of measured distances between the front ends of the tyres (A) and the rear ends of the tyres (B) along the same axle when viewed the wheels from the top.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170112.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": " Front Toe In to be adjusted individually on LH and RH side tie rod ends.The values should be within: 4.2\u00b0 \u00b10.4\u00b0.Front Total toe between two wheels should be within: 0.23\u00e2\u0081\u00b0 \u00b1 0.1\u00e2\u0081\u00b0.",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 19 mm open end spanner, hold tie rod end first and then loosen tie rod end lock nut with the help of 19 mm open end spanner.",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170078.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 14 mm open end spanner, Toe-in is adjusted by varying the length of tie rods.",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170077.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "While adjusting toe-in, adjust the length of both the tie rods by rotating them in the same direction such that their lengths remain equal at all times. ",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Perform steering angle sensor (SAS) calibration if steering wheel is removed and adjusted during straight ahead position setting and procedure as below. ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "After adjusting the length of tie rods, recheck toe in and then hold tie rod end with 19 mm open end spanner and then tightening locknut with 19 mm open end spanner. ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170078.jpg",
+ "display_order": 45
+ }
+ ]
+ },
+ {
+ "procedure_name": "Steering Angle Sensor Calibration",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Ensure the Steering Wheel is at center and the front wheels are straight.Connect the i-SMART diagnostic tester and turn the ignition ON.Launch i-SMART Select ABS ECU and Navigate to Write Data.Select the WRITE DATA tab.",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170207.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Click on \u201cROUTINE SELECTION\u201d drop down list and select \u201cSteering Angle Sensor Calibration\u201d.",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170208.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Click on \u201cSTART ROUTINE\u201d to initiate the SAS Calibration.",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170209.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "Ensure the Steering Wheel is at center and the front wheels are straight.",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "The following pop up window appears once the SAS Calibration completed. Press \u201cOK\u201d button to complete SAS Calibration through i-SMART.",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170210.jpg",
+ "display_order": 54
+ }
+ ]
+ },
+ {
+ "procedure_name": "Wheel Turning Angle (Steering setting angle) Check",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Refer wheel alignment equipment manufacturer's guide lines for wheel turning angle check.",
+ "file": null,
+ "display_order": 55
+ }
+ ]
+ },
+ {
+ "procedure_name": "Ride Height",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Ride height is to be measured from wheel arch center (Bottom Surface) to ground for both front and rear in unladen condition.",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170105.jpg",
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Front ride height : Front wheel arch center (Bottom Surface) to ground.Rear ride height : Rear wheel arch center (Bottom Surface) to ground.",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "R16 SF 6S - Rim Size 16, Side Facing 6 SeaterR16 FF 4S<M</b> - Rim Size 16, Front Facing 4 SeaterR18 FF 4S- Rim Size 18, Front Facing 4 Seater",
+ "file": null,
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20195.jpg",
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "Correct Wheel alignment values.Recommended Tyre pressure.DEF tank filled full.Fuel tank filled 90%.Spare Wheel mounted.Correct tyre pressure.Coil spring damage. Loosened suspension mounting bolts.Rubber bushes of UCA and LCA.",
+ "file": null,
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20196.jpg",
+ "display_order": 62
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 130,
+ "sys_id": "THAR.LX-0004-Suspension",
+ "subsys_id": "THAR.LX-0004-Suspension-Ball Joint Checking",
+ "systems": "Suspension",
+ "sub_systems": "Ball Joint Checking",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170171.jpg",
+ "myid": 1248,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Ball Joint Checking-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Ball joint checking",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Position the vehicle on a 2 post lift and Raise the vehicle.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Prior to inspect the ball joint, inspect the wheel bearings for any play. Check 1 On Vehicle.",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Inspect the ball joint for relative movement by, grasp the top and bottom of the wheel and rock it in and out along the wheel\u2019s vertical axis.Observe any relative movement between the wheel knuckle and ball joints.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170171.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Ensure wheel nuts/bolts are not in loosen condition while checking, as that may cause movement when rocking the wheel.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "If relative movement play is little or no play then the ball joint is in good condition.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "If relative movement play that seems excessive or noises, then Visual check the ball joints.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "Any noises or play heard towards the top are most likely indicative of a problem with the upper ball joint, while, any play or noise coming from the bottom of the wheel are probably indicative of a problem with the lower ball joint.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Check 2 (On Vehicle)",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the wheel.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Take a pry bar and place it between the lower control arm and the steering knuckle, the two parts that are connected together by the ball joint and attempt to pry them apart. ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170159.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Loose ball joints will have an excessive amount of play and movement when you pry on them, may even make knocking or clicking sounds.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Heading",
+ "content": "Check 3 On Vehicle \u2013 Visual Inspection",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170172.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Inspect the ball joints for any signs of rust, damage to the dust boot, grease leakage, or other potential problems that may indicate a need for replacement.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Check the looseness of ball joints in Control arms.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the Ball joints from Vehicle. Refer Respective Ball Joints R&R Section.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Heading",
+ "content": "Check 4 Off Vehicle",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Check the ball joint for free rotational torque by rotate the ball pin through the periphery of ball joint cup for checking the movement.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170173.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Caution",
+ "content": "Replace the ball joint only if movement is found jerky during rotation.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Check the Axial lift by holding the ball Joint and lifting the ball pin in upward direction.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Caution",
+ "content": "If the play was observed more than 0.5 mm replace the ball joint.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Notice",
+ "content": "Lift the ball pin by one hand & hold the lower end of ball joint grounded by other hand.",
+ "file": null,
+ "display_order": 25
+ }
+ ]
+ },
+ {
+ "procedure_name": "Steering Straight Ahead Setting",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Refer the procedure given below for SAP setting",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Keep the wheels on turntables of the wheel alignment machine.Rotate the steering wheel to LHS lock position.From LHS lock position, rotate steering wheel to RHS Lock position.Count the number of turns of steering wheel from LHS to RHS lock position.From RHS lock position, rotate steering wheel exactly half the number of turns towards LHS.Lock the steering wheel.If the steering straight ahead does not match the wheel straight ahead, then adjust the OBJ of the desired side.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Ensure that the silent bushes in the front suspension are in satisfactory condition.Ensure that the front suspension fasteners are tightened to specified torque.Ensure that there is no play in steering linkages and suspension ball joints.Follow instruction manual of wheel aligning system manufacturer.",
+ "file": null,
+ "display_order": 28
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 138,
+ "sys_id": "THAR.LX-0004-Suspension",
+ "subsys_id": "THAR.LX-0004-Suspension-Rear Lower Link",
+ "systems": "Suspension",
+ "sub_systems": "Rear Lower Link",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170030.jpg",
+ "myid": 1256,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Rear Lower Link-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Component Location Index",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/VST-0074_Rear Suspension Rear lower Link Bushes Removal & Installation.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170030.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20259.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20260.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170025.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 24 mm socket spanner loosen and remove the rear lower link front and rear mounting nuts and bolts.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque value: 230 \u00b1 20 Nm<n>Torque Wrench Type - Open end Torque Wrench for LH chassis side",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 21 mm ring spanner.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Detach the rear wheel speed sensor routing from the lower link",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170024.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the rear lower link from the vehicle.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170022.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170103.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Pay attention while InstallationBolt should be fitted in the direction of Arrow shown in illustration",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the rear lower link for any damage. Replace if found.Inspect the rear lower link bushes for any damage. If found replace",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 273,
+ "sys_id": "THAR.LX-0004-en-SM-Mechanisms",
+ "system_name": "Mechanisms",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1026,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 275,
+ "sys_id": "THAR.LX-0004-Mechanisms",
+ "subsys_id": "THAR.LX-0004-Mechanisms-Front Door Latch Assembly",
+ "systems": "Mechanisms",
+ "sub_systems": "Front Door Latch Assembly",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A380041.jpg",
+ "myid": 1393,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0004-Front Door Latch Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380041.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Front Door Latch Assembly.png",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Front Door Latch Assembly1.png",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Front Door Trim. For additional information refer to Front Door Trim R&R section.
",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0004,1026,1393",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, unscrew glass channel mounting nuts and detach the run channel beading from the channel and take out the channel from door. Torque :5\u00b11 Nm ",
+ "file": "/files/W4A380076.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the door latch electrical connector. Detach the mounting link from latch to exterior door handle. Detach link from the handle lever. Using a 5 mm Allen key, Unscrew the latch to door mounting Allen screws. Torque : 7 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the front door latch assembly separately. Install in the reverse order of removal. Inspect the latch assembly for any damage, replace if found. Inspect the linkages for any damage or bend. Inspect the latch assembly for any damage, replace if found. Inspect the linkages for any damage or bend. Open the bonnet and lock it using bonnet stay rod. Using a star screw driver, loosen and remove both side front splash shield mounting screw rivets. Remove both front splash shields from vehicle. Using a 10 mm socket spanner, loosen and remove the front stone guard front mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen and remove the rear stone guard rear mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the stone guard mounting screw rivets. Remove the stone guard from the vehicle. Disconnect the fog lamp electrical connectors LH & RH sides. Pull and remove the front bumper top panel trim clips and remove the panel. Using a 10 mm socket spanner, Unscrew front bumper mounting nuts. Torque : 4.0\u00b10.5Nm ",
+ "file": "/files/W4A290004.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, Unscrew front bumper bottom mounting bolts. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew front bumper top side mounting bolts. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front bumper top centre mounting screw rivets. Remove the front bumper assembly from the vehicle. Using a 13 mm socket spanner, Unscrew front bumper center bracket mounting bolts and remove the front bumper center mounting bracket. Torque : 10.0\u00b11 Nm ",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the front grill mounting screw rivets. Using a star screw driver, loosen and remove the bottom side front grill mounting screw rivets. Using a 10 mm socket spanner, loosen and remove the front grill mounting bolts. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Remove the front grill assembly from the vehicle. Using a 10 mm socket spanner, Unscrew hood catcher mounting nuts both the sides. Torque : 7 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380105.jpg",
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Remove the hood catchers from the vehicle. Install in the reverse order of removal. Inspect the hood catcher for any damages. Replace if found any. Disconnect the front door window glass motor electrical connector. Using a 10 mm socket spanner, loosen and remove the front door window glass mechanism to door mounting nuts. Torque : 10.50 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": ", ",
+ "file": "/files/W4A3800346a245a.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the front door window glass mechanism separately. Install in the reverse order of removal. Inspect the glass for any damage. Replace if found. Inspect the regulator for any damages, Replace if found any. For additional information refer to Tail Door Trim R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a star screw drive, unscrew tail door handle top mounting screw and remove the cover. Carefully pull and detach the outer door handle from tail door. Using a star screw driver, unscrew handle inside support mounting screw from the tail gate. Torque : 1.3 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal. Inspect the rear door exterior handle for any damages. Replace if found any. Pull out the bonnet latch cable and open the bonnet. Lock it using bonnet stay rod. Disconnect cable guide and link from latch. Detach cable from routing clips. Press the lock and pull lever to detach bonnet cable lever with cable and take out the cable from the vehicle. Install in the reverse order of removal. Inspect the bonnet cable for any damage, replace if found. For additional information refer to Tail Door Trim \u2013 R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "For Softtop Variants, remove the Tail Door Inner Handle. For additional information refer to Tail Door Inner Handle - R&R Section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect tail door latch electrical connector. Disconnect latch lever from the key lock and handle. Using a 5mm allen key, unscrew the tail door latch mounting screw. Torque : 7 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully detach tail door latch. Inspect the latch assembly for any damage, replace if found. Remove the Front Door Window Glass Regulator LH. Using a T20 torx socket spanner, unscrew the regulator motor mounting screws. Torque : 2.5 to 3 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380081.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the glass for any damage. Replace if found. Inspect the regulator for any damages, Replace if found any. Remove the Intercooler Assembly. Disconnect cable guide and link from latch. Using a 10 mm socket spanner, unscrew bonnet latch mounting nuts. Torque : 10.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the bonnet latch from hood. Install in the reverse order of removal. While Installation, hand tighten the latch mounting nuts first and align the latch in appropriate position. And ensure smooth locking of latch in holding bracket , finally torque tighten the mounting nuts. Inspect the bonnet latch for any damage, replace if found. For additional information refer to the Wiper Washer Nozzle Front - R&R section.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the stay rod. For additional information refer to the Stay Rod - R&R section.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the wiper hose routing clips from the bonnet. Remove the bonnet rubber beading from the bonnet. Using 12 mm socket spanner, loosen and remove the bonnet catcher bracket mounting bolts (Both sides). Torque : 13.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W334.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using T40 socket spanner, loosen and remove the bonnet mounting bolts. Torque : 24\u00b14 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260053.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the bonnet from the vehicle. Install in the reverse order of removal. Inspect the bonnet hinges for any crack or damage. Replace if found. Remove Side window RH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Remove Side window LH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Unzip the tail gate window, detach the tail gate bar locking from rear RH & LH belt rails remove the tailgate window. Unhook the \u2018C\u2019 pillar cover from rear RH & LH belt rails and fold the cover at top of the soft top. Using a T30 socket spanner, loosen and remove the belt rear rail Mounting bolts and remove the belt rail from the vehicle. Follow the same procedure for LH side. Remove the seal from the body. Install in the reverse order of removal. Inspect the tail door half seal for any damage or wears. Replace if found any. Detach the key handle lever from the key lock set. Detach lock holding bracket and remove key lock from the vehicle. Install in the reverse order of removal. Detach the key handle lever from the key lock set. Detach lock holding bracket and remove key lock from the vehicle Install in the reverse order of removal. Remove Glove Box Assembly. Using Screw driver, Remove Glove box Latch Mounting Screws. Using Screw driver, Remove Lock from Latch by pressing lock locking clips. Install in the reverse order of removal. Using vehicle key open the fuel filler door. Detach lock holding bracket and remove key lock from the fuel filler door. Install in the reverse order of removal. Inspect the key locks for any damage or wears. Replace if found any. Lift and open the tail gate glass. Using a screw driver carefully lift and open the gas strut lock at both the ends. Carefully remove tail gate glass gas strut. Install in the reverse order of removal. Inspect the gas strut assembly for any damage, replace if found. Pull the door outer handle and slowly close the door with outer door handle pulled in condition. Check and feel for the condition of latch fouling with striker. If the latch fouling with the striker then loosen the striker mounting screws and align the striker so that there is no fouling. Tighten the striker mounting screws to specific torque. Torque : 23.5 \u00b1 2.5 ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "Ensure that door closing should be smooth and latch is not foul on the striker. Follow the same procedure for other doors. Lower the window glass to prevent from damage. Disconnect door accessory electrical connector. Protect the electrical connectors to avoid water entry, which may leads to short circuit. Detach the wiring harness bunch from holding bracket \u2018A\u2019 Pillar end. Using 12 mm socket spanner, Unscrew door stopper mounting bolts BIW end. Using T40 Torx Socket, Unscrew door hinge pin at bottom of the hinge. Carefully lift and remove the door assembly from vehicle. Refit in the reverse order of removal. Key IN Reminder & Park Lamp Reminder will not function in case of driver door is removed. Roof lamp will not work with respect to door status. Lock & Unlock functions will not work through Master Actuator in case of driver door is removed. Hinge pin can break if overtightened during door reinstall \u2014 Max. Torque 10 Nm. Doors are heavy, Take at most care when removing the doors, Failing to this may cause personal injury. After Door removal vehicle will be left with only IRVM (as ORVM\u2019s fitted on doors) In such scenario driving the vehicle on road is not permitted as per regulations. Do not drive your vehicle on public roads with the doors removed as you will lose the protection they can provide. This procedure is furnished for use during off-road operation only. All occupants must wear seat belts during off-road operation with doors removed. Disconnect the Door wiring harness electrical connector and detach WH bunch from \u2018A\u2019 pillar lower. Using 12 mm socket spanner, Unscrew door stopper mounting bolt BIW side. Torque : 23.5 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew door hinge mounting bolts from body. Torque : 50 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the door assembly from vehicle. Support the door while removing the bolts. Using star screw driver , Unscrew door hinge mounting screw door end. Torque : 24\u00b1 4.0 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260042.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Before tightening the bolts align the door assembly correctly, else door operation won\u2019t be smooth. Refit in the reverse order of removal. Do the door alignment, if required. Inspect the door hinge for any damage. Replace if required. Remove the tail door electrical connector and remove the wiring routing clips from the tail door. Using a screws driver, loosen and remove the mounting screws from the hinges. Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, loosen and remove the stopper mounting bolt from the Body. Torque : 23.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the hinge mounting bolts inside tail door. Torque : 50\u00b15 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260033.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Ensure to hold the tail door with spare wheel properly while remove, failing will lead door falling down which may lead to personal injuries. Using 12 mm socket spanner, loosen and remove the Hinge Mounting bolts from body. Torque :27\u00b14 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260032.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the tail door hinges for any physical damage, replace if found. Disconnect the demister electrical connectors. Using 4 mm Allen key, Unscrew glass hinge mounting screws. Torque : 2.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260115.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using the screw driver Unlock the strut to detach the strut and remove the glass. Ensure to hold the Rear Windshield glass while detach the struts, failing to hold leads to glass falling. Using 10 mm socket spanner, Unscrew strut bracket mounting bolts from glass. Torque : 5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260085.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Ensure not to over tigthen the strut bracket mounting bolts while Installation. Remove strut mounting grommet and cap nuts from the glass. Install in the reverse order of removal. Inspect the rear windshield glass for any damage or wears. Replace if found any. Remove the spare wheel carrier. Remove the tail door latch. Remove the tail door outer handle . Remove the tail door lock. For additional information refer to the Tail Door Lock section. Remove the tail door weather strip from the tail door. Remove the tail door electrical connector and remove the wiring routing clips from the tail door. Using a Screws driver, loosen and remove the mounting screws from the hinges. Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, loosen and remove the Stopper Mounting bolt from the Body. Torque : 50\u00b15 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, loosen and remove the hinge mounting bolts inside tail door. Torque : 50\u00b15 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Remove the tail door from vehicle. Install in the reverse order of removal. Inspect the tail door for any physical damage, replace if found. Remove the seal from the body. Install in the reverse order of removal. Inspect the tail door half seal for any damage or wears. Replace if found any. Remove the scuttle grill. Using T40 socket spanner, loosen and remove the bonnet mounting bolts. Torque : 24\u00b14 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260058.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the bonnet hinge mounting bolts from the body and detach hinge. Torque : 24\u00b14 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the hood hinge from the bonnet. Install in the reverse order of removal. Inspect the bonnet hinges for any crack or damage. Replace if found. Remove Front LH wheel Hub. For additional information refer to Front LH wheel Hub \u2014 R&R section. Remove Front Stabilizer Bar. For additional information refer to Front Stabilizer Bar \u2014 R&R section. Using 10 mm socket spanner, Unscrew front LH wheel speed sensor mounting bolt and remove the sensor. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the wheel speed sensor routing clips from the upper control arm. Using cutting plier, remove upper arm ball joint cotter pin. Never reuse the cotter pin, always replace with a new one. Using 24 mm socket spanner, unscrew upper arm ball joint mounting nut. Torque : 90 \u2013 110 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Using suitable lever, partially detach the knuckle and remove the drive shaft. Pull the drive shaft downwards and remove it. Install in the reverse order of removal. Move the joint up, down, left, right, and in axial direction. Check for any rough movement or significant looseness. Check the drive shaft boot for cracks or other damage, and for grease leakage. If damaged, disassemble the drive shaft to verify the damage, repair or replace if necessary. Check the splines for wear and tear. Drain the front differential oil.For additional information refer to Front differential oil draining and filling procedure. Remove Front LH wheel Hub. For additional information refer to Front LH wheel Hub \u2014 R&R section. Remove Front Stabilizer Bar.For additional information refer to Front Stabilizer Bar \u2014 R&R section. Using 10 mm socket spanner, Unscrew front RH wheel speed sensor mounting bolt and remove the sensor. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the wheel speed sensor from routing bracket. Using cutting plier, remove upper arm ball joint cotter pin. Never reuse the cotter pin, always replace with a new one. Using 24 mm socket spanner, unscrew upper ball joint mounting nut. Torque : 90 \u2013 110 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Remove E-Disconnect stone guard.For additional information refer to E-Disconnect stone guard \u2013 R&R section. Disconnect E \u2013 Disconnect electric connector. Provide a jack to support front axle. Using 19 mm socket spanner, unscrew front axle mounting bolts and partially down the axle. Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150037.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using suitable lever partially detach the knuckle and remove the drive shaft. Pull the drive shaft downwards and remove it. Install in the reverse order of removal. Refill the front axle oil upto Max level.For additional information refer to Front differential oil draining and filling procedure. Move the joint up, down, left, right, and in axial direction. Check for any rough movement or significant looseness. Check the drive shaft boot for cracks or other damage, and for grease leakage. If damaged, disassemble the drive shaft to verify the damage, repair or replace if necessary. Check the splines for wear and tear. Remove Front LH drive shaft. Replace the Inboard Oil Seal once removed. Using MST 0502AUA0002ST Front Axle Shaft Inboard Oil Seal Puller, remove the Oil seal from the housing. Remove E-Disconnect stone guard.For additional information refer to E-Disconnect stone guard \u2013 R&R section. Disconnect E \u2013 Disconnect electric connector. Using 10 mm socket spanner, Unscrew electric disconnect housing mounting bolts and Carefully remove the E-Disconnect Housing with Fork . Torque : 17\u00b12 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150265.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using circlip plier remove the intermediate shaft circlip from housing. Tool should not damage the splines on the axle shaft this affects disconnect operation. Pull out the axle shaft from wheel end side of e-disconnect housing. Using MST 0502AUA0008ST Front Axle Tube Needle Bearing Puller, remove the Needle bearing from e-disconnect housing LH side. By using MST 0502AUA0007ST - F Axle Tube Needle Bearing Dolly, Install the LH Side needle bearing In the disconnect housing. Clean and Insert the axle shaft through wheel end side of the disconnect housing. Align the shifter sleeve on the intermediate shift through disconnect housing window and Install the circlip on the axle shaft with the help of circlip tool. Ensure there should not be excessive play between two shafts this affects the disconnect . Install the new cover gasket while locating in the dowel on the disconnect housing. Ensure to use New Gasket while Installation. Ensure the cleanliness of disconnect housing cover face and cover resting face. Do not bent the wrap the Gasket while installing. Gasket orientation is fixed by dowel on the disconnect housing hence it will fit in one direction only . Bent or warped cover gasket may lead to leak during running. Locate the disconnect cover on the dowel and install the bolts. Tighten the mounting bolts to specified torque value. Ensure to use New bolts while Installation. Apply locktite sealant on the bolts while installing, this avoid the leakthrough cover. Torque : 17\u00b12 Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Connect e-Disconnect electrical connector. Refit E-Disconnect stone guard. For additional information refer to E-Disconnect stone guard \u2013 R&R section. Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, refit the Oil seal on the housing. Refit Front LH drive shaft. Inspect the Front axle Tube Needle Bearing for any damage, Replace if necessary Remove Front LH drive shaft. Using MST 0502AUA0002ST Front Axle Shaft Inboard Oil Seal Puller, remove the Oil seal from the housing. Replace the Inboard Oil Seal once removed. Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, refit the Oil seal on the housing. Refit Front LH drive shaft. Inspect the axle shaft Inboard Oil Seal for any damage, Replace if necessary. Remove Front RH drive shaft. Position the Special tool support piece inside the axle housing and using MST 0502AUA0002ST Front Axle Shaft Inboard Oil Seal Puller, remove the Oil seal from the housing. Replace the Inboard Oil Seal once removed. Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, refit the Oil seal on the housing. Refit Front RH drive shaft. Inspect the axle shaft Inboard Oil Seal for any damage, Replace if necessary. Using 8 mm socket spanner, Unscrew front propeller shaft mounting bolts/nuts at front axle end. Torque : 19\u00b13 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Front LH drive shaft. Drain the front differential oil.For additional information refer to Front differential oil draining and filling procedure. Remove Front RH Wheel Hub. For additional information refer to Front RH Wheel Hub \u2014 R&R section. Using 10 mm socket spanner, Unscrew front RH wheel speed sensor mounting bolt and remove the sensor. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Detach the wheel speed sensor from routing bracket. Using cutting plier, Remove upper arm ball joint cotter pin. Never reuse the cotter pin, always replace with a new one. Using 24 mm socket spanner, unscrew upper arm ball joint mounting nut and remove the ball joint. Torque : 90 \u2013 110 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Remove E-Disconnect stone guard.For additional information refer to E-Disconnect stone guard \u2013 R&R section. Disconnect E \u2013 Disconnect electric connector. Provide a jack to support front axle. Using 19 mm socket spanner, unscrew front axle mounting bolts and partially remove the axle downwards. Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Partially detach the knuckle and remove the drive shaft by using a suitable lever. Pull the drive shaft downwards and remove it. Remove the front axle assembly from Vehicle. Install in the reverse order of removal. Refill the front axle oil upto Max level.For additional information refer to Front differential oil draining and filling procedure. Check the axle shaft for straightness, cracks, damage, wear or distortion, replace it if necessary. Check the axle case for yield, deformation or cracks, replace if necessary. Inspect front axle for any oil leakage, seepage. Drain the Front Differential Oil. For additional information refer to Front differential oil draining and filling procedure. Remove the Front Axle Assembly. Mount the Front Axle Assembly on a suitable stand. Using 15 mm socket spanner, Unscrew front axle RH bracket mounting bolts and remove the RH bracket. Using 13 mm socket spanner, Unscrew differential assembly cover bolts and remove the cover. Clean the sealant on cover & banjo housing. Liquid sealant is used to seal cover with banjo beam. Scrap the sealant and clean the cover and banjo surfaces. Using 10 mm socket spanner, Unscrew e-disconnect cover assembly mounting bolts and remove the cover with shifter fork & motor. Using 10 mm socket spanner, Unscrew e-disconnect motor mounting bolts and remove the e-disconnect motor. Hit the shift shaft on suitable block and remove the shift shaft, shaft fork & spring from the disconnect cover. Using MST 0502AUA0002ST - Front Axle Shaft Inboard Oil Seal Puller, remove housing LH Oil seal. Replace the Inboard Oil Seal once removed. Position the Special tool support piece inside the axle housing and using MST 0502AUA0002ST Front Axle Shaft Inboard Oil Seal Puller, remove the RH Oil seal from the housing. Using circlip plier remove the intermediate shaft circlip from housing. Tool should not damage the splines on the axle shaft this affects disconnect operation. Pull out the axle shaft from wheel end side of e-disconnect housing. Remove the shifter shaft thrust washers from e-disconnect housing. Remove the shifter sleeve from e-disconnect housing. Using MST 0502AUA0008ST Front Axle Tube Needle Bearing Puller, Needle bearing from e-disconnect housing LH side. Remove LH Side differential shaft from the housing wheel end side. Using 16 mm socket spanner, Remove the Differential bearing caps mounting bolts. Remove the Differential bearing caps. Identification marks are punched on bearing cap; this is to ensure correct bearing cap is installed on correct side. Ensure correct bearing caps used While reassembly. Mount MST 0502AUA0030ST Front Axle Expander on carrier and Spread carrier by rotating nut on expander. Do not spread more than 0.5 mm. Using MST 0502AAA0001ST - Tommy Bars-X, Pry out differential case from carrier. Remove the expander from housing. Mount the MST 0502AUA0023ST \u2014 Front Axle Diff Case Bearing Puller Adapter and Using MST 0502AUA0012ST \u2014 Axle Bearing Puller on side bearing cone and remove the bearing from differential case assembly. Identify shims and side bearings on both sides, they are not to be interchanged during assembly. Similarly remove ring gear other side bearing cone by using MST 0502AUA0023ST \u2014 Front Axle Diff Case Bearing Puller Adapter and MST 0502AUA0012ST \u2014Axle Bearing Puller. Identify shims and side bearings on both sides, they are not to be interchanged during assembly. Using 17 mm socket spanner, Remove the ring gear mounting bolts and remove the ring gear. If require tap ring gear by mallet to remove the ring gear. By Using MST 0502AUA0033ST \u2014 Front Axle Diff Case Pin Remover & Installer and hammer, remove the roll pin retaining the cross shaft. Using suitable punch & hammer, remove the cross pin from case. To remove side gears and pinion mate gears, rotate the side gears, this will allow the pinion mate gears to turn to opening of the case. Remove pinion mate gears and spherical washers behind the gears. Lift out the side gears and thrust washers. Using MST 203 - Wrench Universal Joint Flange Holding tool hold the companion flange and remove the pinion nut and washer using 30 mm socket spanner from the differential housing. Using mallet tap and remove the companion flange along with dust cover. If not able to remove the companion flange tapping by mallet, use suitable 2 Jaw puller for removal. If companion flange shows wear in the area of seal contact, it should be replaced. Using a mallet, tap the pinion assembly and remove the pinion assembly from the differential housing. Make a centre punch and tap at top of the pinion assembly by using a mallet. Hold the pinion with hand to avoid falling. Gear teeth have sharp edges. Handle gears carefully to avoid injury Discard collapsible washer. Remove the Pinion Oil seal By using Screw driver/ Oil Seal Puller. Remove the slinger and outer bearing. Turn Carrier and Using MST 0502AUA0028ST Front Axle Pinion Inner Bearing Cone Remove Adapter and MST 0502AUA0032ST Front Axle Universal Handle, Remove the Inner Pinion bearing cone. Turn Carrier and Using MST 0502AUA0029ST \u2014 Front Axle Pinion outer Bearing Cone Remove Adapter and MST 0502AUA0032ST \u2014 Front Axle Universal Handle, Remove the outer Pinion bearing cone. Using the MST 0502AUA0022ST Front Axle Pinion Inner Bearing Puller Adapter and MST 0502AUA0012ST Axle Bearing Puller, Remove the Pinion Inner Bearing. Take out the pinion shims from the pinion. Using MST 0502AUA0006ST Front Axle Tube Cyl Roller Bearing Puller, Remove the Cylindrical roller bearing from disconnect housing. Inspect all bearings and races for pitting or uneven wear. The inner carrier bearing races should not spin on the carrier journals. The carrier races should fit snugly in the differential housing. Inspect the carrier race bores for grooves from spinning races. The side gear bores inside the carrier should not have any abnormal wear. Inspect all gear teeth for pitting, chips, breaks, and for signs of uneven wear and overheating. Inspect the axles for pitted, grooved or dull and rough bearing surfaces. Inspect gear teeth of side gears and pinion mate gears for wear and cracks. Inspect external teeth of side gears for wear & cracks. Inspect cross pin for excessive wear. Replace if necessary. If replacement of one gear is required, then both side gears, pinion mate gears and washers have to be replaced. Always replace gears as a complete set, do not mix new gears with old gears, as this may cause uneven wear and short gear life. Ring gear and pinion is supplied as a set. They are matched with each other during service. Matching numbers on both pinion and ring gear are etched for verification. Refer illustration shown below for more clarity. If a new gear set is used, verify numbers on pinion and ring for matching before proceeding with assembly. Standard mounting distance from centre line of ring gear to back face of pinion is 103.5 \u00b1 0.1mm. This dimension is controlled by selecting shims, which are positioned between the inner pinion bearing cone and pinion gear. Best running position of gear set is achieved by proper shim selection. This dimension for front live axle will be different. On the bottom face of pinion, a number is etched. It can be a plus (+) number, a minus (-) number or Zero (0). Required pinion shim selection is achieved with help of this number. If alphabet 'm' appears on pinion face shim, selection has to be done in mm (Metric). If alphabet 'm' does not appear on pinion face, shim selection has to be done in inches (English). Shims with different thicknesses are available for selection. Use tables shown below for selecting correct thickness of shims either for addition or for subtraction from old shim pack. Ring and pinion etched with inch identification. Refer Table A. Ring and pinion etched with metric identification. Refer Table B. Observe the marking on pinion. If \u2018m\u2019 is found etched on the face, refer table B. If not refer table A. Pinion Position shims selection can be done using MST\u2019s Pinion Height Master Block & Pinion Height Setting Gauge, in the absence of removed Ring/Pinion gear or Old shim not available. Position the MST 0502AUA0010ST - Front Axle Pinion Height Master Block on the pinion inner bearing setting area. Fix the dial gauge on MST 0502AUA0009ST Front Axle Pinion Height Setting Gauge and set dial gauge to zero reading on surface plate. Place the MST 0502AUA0009ST Front Axle Pinion Height Setting Gauge with Dial gauge on differential housing as shown. Rock the MST 0502AUA0009ST Front Axle Pinion Height Setting Gauge and load the Dial gauge on MST 0502AUA0010ST - Front Axle Pinion Height Master Block and measure the reading on Dial Gauge (X mm). Say X mm for example which is measured by using special tool - 0.79 mm (i.e X = 0.79 mm) Convert mm to thau, i.e (0.79*39) = 31 Thau Then see the Pinion off set i.e (+ 2) Thou (For example) Final shim size = 31 - 2 = 29 Thau Convert to mm = 29*0.0254 = 0.74 mm If Pinion offset is Positive (+), then subtract the pinion offset value. If Pinion offset is Negative (-), then add the pinion offset value. Using MST 0502AUA0026ST Front Axle Pinion Inner Bearing Cone Press Dolly and MST 0502AUA0032ST Front Axle Universal Handle, refit the pinion inner bearing cone into carrier housing. Using MST 0502AUA0027ST - Front Axle Pinion Outer Bearing Cone Press Dolly and MST 0502AUA0032ST - Front Axle Universal Handle, refit pinion outer bearing cone into carrier housing. Place shims selected as per Shim Selection procedure on pinion gear. Using MST 0502AUA0025ST Front Axle Pinion Inner Bearing Press Dolly, Install pinion inner bearing cone. Take care to avoid damaging the pinion teeth while installing the bearing. Place the Pinion outer Bearing cone and slinger into housing. Using MST - 0502AUA0031ST Front Axle Pinion Oil Seal Installer, Install the New pinion seal into housing. Ensure to replace New Oil seal while Install. Apply a light coat of oil to the lip of oil seal. Install a new collapsible spacer into pinion shaft. Collapsible spacer should rest on bearing inner race and pinion shoulder and it can be fitted in any one direction. Assemble the Pinion into differential housing. Install the end yoke, washer and new pinion mounting nut. Hold the end yoke using (MST203 - Companion Flange Holding Tool) and torque tighten the mounting nut. Tighten nut to Initial torque as 217 Nm. Measure the Pinion Rotational Torque (PTTR), It should be within 17 \u2013 34 Kgf\u2013cm (1.7 to 3.3 Nm). If measured Pinion Rotational Torque (PTTR) not within (1.7 to 3.3 Nm), Then tighten nut to incremental torque from 217 Nm onwards to 678 Nm until specified PTTR ( Pinion torque to rotate) is achieved. Excessive care must be taken during bearing preload torque adjustment. Do not over tighten, loosen and then retighten nut. Do not exceed specified bearing preload torque . Measure and ensure the Final Pinion Rotational Torque (PTTR), It should be within 17 \u2013 34 Kgf\u2013cm (1.7 - 3.3 Nm). PTTR SPEC : 17 \u2013 34 Kgf\u2013 cm (1.7 to 3.3Nm). If preload torque is exceeded, a new collapsible spacer must be installed and torquing sequence as above to be repeated. If only oil seal needs to be changed, measure rotating torque of pinion with the help torque measuring tool. In this case use new collapsible spacer and keep same rotational torque of pinion as before. Apply grease to new side gear thrust washers and hubs of side gears. Assemble both side gears. Apply grease to new pinion mate spherical washers, and pinion mate gears. Assemble pinion mate gears. Assemble both side gears and thrust washers, hold them in place with one hand and then assemble the pinion mate gears with thrust washer to hold the side gears in place. An easy way to assemble the side gears and pinion mate gears is to have all parts lubricated before assembly. Always replace gears as a complete set. Do not mix new gears with old gears, as this may cause uneven wear and shorter gear life. Rotate the side gears until the holes of the spherical washers and pinion mate gears line up with the holes in the case by the help of engaging the splines of axle shaft to side gears. When both the cross bore hole matched and insert the differential shaft. Use MST 0502AUA0033ST Front Axle Differential Case Pin Remover and Installer to line holes of the gears up with case. Assemble differential shaft and pull out MST. Be sure vertical lock pin hole is lined up with that of the case, and that pinion mate washers are in place and lined up with gear and case. Align the differential shaft hole, insert the lock pin and fix using (0502AUA0033ST - Differential gear lock pin removal tool) and hammer. Always replace with new Lock pin while Installation. When roll pin bottoms out, stake (peen) metal of case over pin in two places, 180 degrees apart. Assemble MST 0502AUA0011ST Front Axle Dummy Bearings on to differential case as shown in the illustration. Assemble the differential case with Dummy Bearings on housing (Without Ring Gear). Mount the magnetic dial indicator with magnetic base, locate its tip on that surface of case. Force differential assembly to the extreme in the direction towards indicator, With force still applied set indicator to 0.00. Force differential assembly to the extreme end in opposite direction. Repeat above steps until the same reading is obtained, Record reading in the format given as' A'. Remove dummy bearing and keep aside. Assemble ring gear to the differential case using mounting bolts. Tighten the bolts to specified torque value in recommended sequence. Torque : 95 - 122 Nm ",
+ "file": null,
+ "display_order": 210
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Notice",
+ "content": "Always use new ring gear bolts. Assemble MST 0502AUA0011ST Front Axle Dummy Bearings on differential case as shown in the illustration. Position differential assembly into housing and Mount the magnetic base dial indicator on housing and locate the tip of indicator on the surface of one of the ring gear screws. Force differential case assembly away from pinion gear. With force still applied set indicator to zero. Force differential case assembly and ring gear to mesh with pinion gear. Rock the ring gear to allow teeth to mesh, Repeat to obtain the reading and continue the procedure until the same reading is obtained. Record reading in the format given as' B'. Remove dial indicator and dummy differential bearings from differential housing. Calculate the Ring Gear Backlash & Differential Bearing Preload shims based on below calculation. Install the selected shim pack in between side bearing and carrier assembly. Using MST 0502AUA0024ST Front Axle Differential Case Bearing Dolly, Install side bearing cone on hub of differential assembly. It is always preferred to replace side bearings once pulled out. But one can confirm free rolling of bearings and reuse it, if they are defect free. Install the selected shim pack in between other side bearing and carrier assembly. Using MST 0502AUA0024ST Front Axle Differential Case Bearing Dolly, Install other side bearing cone on hub of differential assembly. It is always preferred to replace side bearings once pulled out. But one can confirm free rolling of bearings and reuse it, if they are defect free. Install spreader and dial indicator and expand the carrier. Never expand the differential housing over 0.5 mm to avoid distortion. Remove dial indicator from the differential housing. Install differential case assembly into carrier with the help of mallet. Ensure differential case shim is behind the bearing cap. Carelessness while installing differential case assembly may result in injury. Position the bearing caps and install the mounting bolts and torque tighten the bolts to specified torque. Torque : 47 - 68 Nm ",
+ "file": null,
+ "display_order": 245
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "Notice",
+ "content": "Ensure correct fitment of caps by matching letters on caps and carrier on either side. Remove the expander from differential housing. Check ring gear and pinion backlash at three equally spaced points with dial indicator. Backlash tolerance is 0.13 to 0.20mm and should not vary more than 0.08 mm between the three points checked . Fix the Dial Gauge on Housing, Set the Dial Indicator 0 on Ring gear teeth as shown. Hold the pinion flange at the bottom side. Rotate the ring gear by using ring spanner & measure the backlash. High backlash is corrected by moving ring gear closer to pinion. Low backlash is corrected by moving ring gear away from pinion. These corrections are made by switching shims from one side of differential case to other. If backlash is as per specification, check ring gear and pinion tooth contact pattern. Interpretation of Contact Pattern ",
+ "file": null,
+ "display_order": 254
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Front Axle Overhual.PNG",
+ "display_order": 255
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "Description",
+ "content": "The TOE of the gear is the portion of the tooth surface at the end towards the centre. The HEEL of the gear tooth is the portion of the tooth surface at the outer end. The TOP LAND of a gear tooth is the surface of the top of the tooth. Every gear has a characteristic pattern. Measure and ensure the Final Total Torque To Rotate (TTTR) at pinion nut, It should be within 28 - 51 Kgf-cm (2.8 - 5 Nm). TTTR SPEC : 28 - 51 Kgf-cm (2.8 - 5 Nm). Using MST 0502AUA0005ST Front Axle Tube Cyl Roller Bearing Dolly, Install the RH housing cylindrical roller bearing through the oil seal bore In the housing. Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, Install the RH side housing Oil seal. Clean the intermediate shaft and insert the shims in intermediate shaft. Push intermediate shaft in same way the direction used during removal. Install the synthetic bush in the bore of axle shaft with the help of light nylon mallet. Press force must not so high which may damage the bush during pressing. Insert the thrust washers in the sequence opposite to removal in the disconnect housing. Shaft End Play Checking ",
+ "file": null,
+ "display_order": 284
+ },
+ {
+ "step_name": "Step-47",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150129.jpg",
+ "display_order": 285
+ },
+ {
+ "step_name": "Step-47",
+ "content_type": "Description",
+ "content": "Insert the axle shaft through wheel end side of the disconnect housing. Install the circlip on the axle shaft with the help of circlip pressing tool. Check end play with dial gauge at the axle shaft end. End play should be 0.025 to 0.1 mm. End play can be adjusted by adding/deleting shims from the intermediate shaft. After adjusting end play, remove the circlip & axle shaft from the housing. Install the shifter sleeve on the intermediate shift through disconnect housing window while aligning with the splines on it. shift splines and shifter sleeve must be free from foreign particles and burr. Insert the axle shaft through wheel end side of the disconnect housing. Install the circlip on the axle shaft with the help of circlip pressing tool. Ensure there should not be excessive play between two shafts this affects the disconnect . Insert the spring and shaft fork through the disconnect cover window while aligning the spring into bore in the cover and sitting in the slit of shift fork. Insert the shaft shift fork in the opposite way of removal ensuring that it passing through shift fork as well as spring. Orientation of the shift fork is important and it should be in same way while was removing. Ensure old spring is discarded and to use spring during installation. Ensure cleanliness of the disconnect housing cover, shift fork shaft , shift fork and spring. Press the shaft shift fork in the bore by hand. Install the new cover gasket while locating in the dowel on the disconnect housing. Ensure to use New Gasket while Installation. Ensure the cleanliness of disconnect housing cover face and cover resting face. Do not bent the wrap the Gasket while installing. Gasket orientation is fixed by dowel on the disconnect housing hence it will fit in one direction only . Bent or warped cover gasket may lead to leak during running. Locate the disconnect cover on the dowel and install the bolts. Tighten the mounting bolts to specified torque value. Torque : 17\u00b12 Nm ",
+ "file": null,
+ "display_order": 314
+ },
+ {
+ "step_name": "Step-54",
+ "content_type": "Notice",
+ "content": "Ensure to use New bolts while Installation. Apply locktite sealant on the bolts while installing, this avoid the leak through cover. Install the electrical motor on the cover assembly and tighten the screw with specified torque. Torque : 12.5\u00b13.5 Nm ",
+ "file": null,
+ "display_order": 318
+ },
+ {
+ "step_name": "Step-55",
+ "content_type": "Notice",
+ "content": "Ensure that the 'O' ring on the electrical motor is not cracked or damaged if so replace the 'O' ring as new one. By using MST 0502AUA0007ST - F Axle Tube Needle Bearing Dolly, Install the LH Side needle bearing In the disconnect housing. By using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, Install the housing LH side Oil seal. Apply the uniform sealant bid along the carrier cover face and avoiding the bolt holes as far as possible. Use Anabond A-676 or 3M sealant on the cover plate. Ensure the cleanliness of the carrier cover face before Installation. Install the carrier cover plate and locate it on the cover plate mounting studs on the carrier Install cover plate bolts and tighten them to specified torque value. Torque : 38 - 45 Nm ",
+ "file": null,
+ "display_order": 334
+ },
+ {
+ "step_name": "Step-60",
+ "content_type": "Notice",
+ "content": "Discard the old bolts and Use new bolts for cover plate mounting as the bolts are coming with sealant patch on it and during sealant patch wears off. Reusing cover bolts may leads to leakage from cover bolts sides. Refit the Front Axle Assembly. Refill the front axle oil upto Max level. For additional information refer to Front differential oil draining and filling procedure. Remove E-Disconnect motor. Using 10 mm socket spanner, Unscrew electric disconnect housing mounting bolts Torque : 17\u00b12 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Carefully remove the E-Disconnect Housing with Fork . Refit in the reverse order of removal. While Installation Apply Locktite sealant on the E-Disconnect Housing bolts to avoid the leak through cover. Check the e-disconnect housing with fork for any damage, Replace if necessary. Remove E-Disconnect stone guard.For additional information refer to E-Disconnect stone guard \u2013 R&R section. Disconnect E \u2013 Disconnect electric connector. Using 10 mm socket spanner, unscrew E \u2013 Disconnect motor mounting bolts. Torque : 12.5\u00b13.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the E-Disconnect motor. Refit in the reverse order of removal. While Installation ensure to replace the New O Ring for E \u2013 Disconnect motor. Torque : 90 \u2013 110 Nm ",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the E-Disconnect motor, connector for any damage, Replace if necessary. Position the vehicle on 2 post lift/ 4 post lift. Differential Oil Front Replace - Procedure Front Axle Oil \u2013 Mahindra 'MAXIMILE ELITE' New Generation Genuine Differential Fluid Capacity \u2013 1.25 Litres.Using 10 mm square bit spanner, loosen and remove front axle filler plug. Using 10 mm square bit spanner, loosen and remove front axle drain plug and drain the entire oil. Wait till the entire oil get drained. Place a tray beneath the front axle for collecting the oil while draining. Refit the drain plug and torque tighten to specified value. Clean the drain plug and differential housing with a clean cloth before refitting. Torque : 34 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refill specified quantity of recommended differential oil into differential assembly. Never reuse drained oil. Always use recommended oil only. Never mix different types of oil and use. Clean filler plug area properly using a cloth before filling the oil. Check the oil level and ensure its up to the level. Ensure that the oil level is up to lower most point of the filler plug. Refit the filler plug back and torque tighten to specified value. Clean the filler plug with a clean cloth before refitting. Torque : 34 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Recommend to use only Mahindra 'MAXIMILE Elite' new generation genuine differential fluid. In case of non availability of 'Maximile' brand, other brands meeting API GL5, SAE 80W-90 specification can be used as second preference and oil change period should be reduced as 20,000 km. Verify the customers concern. Visually inspect the front axle for any noticeable signs of mechanical damage. If an obvious cause is found during the inspection, correct the same before proceeding to the next step. If the cause is not found visually during the inspection, refer to the troubleshooting chart. Check for oil level and condition. Check for any oil leakage in the differential assembly, gasket and axle shaft oil seal. Check for any noise in the bearing, pinion gear, crown wheel and planet gears. Open the seat cover strip back side of back rest assembly. Press the lock and remove the head rest. Unzip the seat cover LH & RH sides. Press the lock and remove the head rest guide inside seat cover. Detach the seat cover with foam from the frame and remove from back rest frame. Install in the reverse order of removal. Check for any damages. Replace if required. Check for any damages on seat trims. Replace if required. Remove the Driver Seat Back Rest foam with Cover. Using star screw driver, Unscrew lumber support Mechanism mounting screws and remove mechanism. Disconnect lumber support cable link from back rest frame. Using star screw driver, Unscrew luggage hook mounting screw and remove it from the frame assy. Separate the driver seat back rest frame. Install in the reverse order of removal. Check the frame for any damages. Replace if required. Remove Driver Seat Back Rest Assembly. Open the seat cover strip back side of back rest assy. Unzip the seat cover LH & RH sides. Pull and detach the lumber support handle. Press the lock and remove the head rest guide inside seat cover. Remove foam with cover from back rest frame. Excessive pull or improper removal may leads to damage the foam and seat cover Install in the reverse order of removal. Check for any damages.Replace if required. Check for any damages on foam and cover. Replace if required. Remove Driver Seat Back Rest Foam with Cover. Using Nose Plier, Remove the copper ring locks and remove cover from foam . Take extreme care to not to damage the foam and seat cover. Install in the reverse order of removal. Check the foam for any damages. Replace if required. Check for seat cover any damages. Replace if required. Remove the Rear Seat Recliner Cover. For additional information refer to the Rear Seat Recliner Covers - R&R section. Detach the seat folding cable from the lock and remove the cable. Remove the cable from the bottom cushion routing bracket. Remove the cable from the seat. Install in the reverse order of removal. Check seat folding cable for any damages. Replace if found. Remove Driver Seat Back Rest Assembly. Unlock the seat cover lock from the bottom side. Using Nose plier and Screw driver, Remove the seat cover locking rings. Using star screw driver, Unscrew seat side cover mounting screw and remove the cover. Detach the cover with foam. Install in the reverse order of removal. Check the Cushion and Frame Assembly for any damages. Replace if required. Remove Driver Seat Assembly. Remove seat recliner and height adjustment handle cover. By using star screw driver remove seat height adjustment handle mounting screws & remove the handle. By using star screw driver, remove LH & RH valance cover mounting screws and detach the covers. Detach back cushion cover lock from seat bottom. Using T50 torx socket spanner, Unscrew back rest mounting bolts. Torque: 47.5 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4B230110.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4B230111.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Detach the back rest from Seat assembly. Press the Lock and remove the head rest from the back rest assembly. Install in the reverse order of removal. Check for any damages. Replace if required. Check for any damages on seat trims. Replace if required. Remove the copper locks from the rear front facing bottom cushion. Detach the both side the cable from the lock. Remove the both routing bracket cable tie from the seats. Remove the bottom cushion from the frame assembly and separate the Bottom Cushion Frame. Install in the reverse order of removal. Check for any damages. Replace the frame if required. Check for any damages on seat trims. Remove the Wiper Motor & Link Assembly.
By using screw driver partially remove the wiper link from the motor. Using a 10 mm open end spanner, loosen and remove the wiper motor link assembly mounting bolt. Torque : 10 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A320051.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the wiper motor separately. Install in the reverse order of removal. Check the motor for any damage. Replace if found any. Check the linkage for any damage. Replace if found any. Using a screw driver, Carefully remove the dust tray from vehicle. Disconnect wiper motor electrical connector. Using a 10 mm open end spanner ,loosen and remove the wiper motor link assembly mounting bolt. Torque : 10.50 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A320035.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A320036.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the wiper motor and link assembly from vehicle. Install in the reverse order of removal. Check the motor for any damage. Replace if found any. Check the linkage for any damage. Replace if found any. Using a trim removal tool pull out center bow trim and disconnect roof lamp electrical connector. Disconnect the sound bar electrical connector. Using 10 mm socket spanner, Unscrew sound bar mounting bolts. Detach the Wiring Harness from routing and remove from the sound bar assembly. Install in the reverse order of removal. Inspect the Wiring Harness for any physical damage. Replace if found. Inspect the connector for any damage. Using Torx screw driver, Unscrew Centre bow trim mounting screw and detach the bow trim. Torque Value: 5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280012.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the MIC electrical. Remove the MIC from Centre bow trim. Install in the reverse order of removal. Inspect the MIC unit for any damage. Inspect the electrical connectors for any damage. Using trim removal tool remove the infotainment center bezel. Using trim removal tool remove infotainment top side cover. Using star screw driver, Unscrew infotainment mounting screws. Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W344.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect Infotainment electrical connectors. Remove the Infotainment unit. Install in the reverse order of removal. Inspect the infotainment unit for any damage. Inspect the electrical connectors for any damage. Using star screw driver remove front LH wheel arch mounting screw rivets. Using T25 socket spanner remove the antenna mounting screw Torque Value: 3 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290049.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290051.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the antenna electrical connector through wheel arch. Remove the antenna assembly separately. Inspect the antenna assembly and connector for any physical damage. Replace if found. Remove the Infotainment Assembly. Using star screw driver, Unscrew cluster bezel mounting screw and remove the bezel. Cut the GNSS antenna wire routing tag. Install in the reverse order of removal. Inspect the GPS Antenna for any damage. Inspect the electrical connector for any damage. Using star screw driver unscrew the panel assembly floor console RH screvits and detach the panel from vehicle. Using star screw driver unscrew the panel assembly floor console LH screvits and detach the panel from vehicle. Using star screw driver unscrew vertical ascent RH mounting screw and detach the vertical ascent RH from vehicle. Using star screw driver unscrew vertical ascent LH mounting screw and detach the vertical ascent LH from vehicle. partially detach the switch bang assembly and remove electric connector to take out from the vehicle. Carefully pull and remove the Audio Unit port Assembly. Disconnect the Audio Unit port electrical connectors and 12 volt electric connector. Using a small screw driver pull out the power port and remove the power port. Install in the reverse order of removal. Inspect the 12V power point for any physical damage. Replace if found. Using a star screw driver, loosen and remove the front splash shield mounting screw rivets from both the sides of vehicle. Remove the front splash shield both the sides from vehicle Using a 10 mm socket spanner, loosen and remove the front stone guard front mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250064.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen and remove the rear stone guard rear mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250033.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the stone guard mounting screw rivets. Remove the stone guard from the vehicle. Disconnect the fog lamp electrical connectors LH & RH sides. Pull and remove the front bumper winch cover clips and remove the panel. Using 10 mm socket spanner, Unscrew front bumper mounting nuts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290005.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscre front bumper bottom mounting bolts. Torque 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/front_bumper_11_01.png",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front bumper top side mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/front_bumper_12_01.png",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front bumper top centre mounting screw rivets. Remove the front bumper assembly from the vehicle. Install in the reverse order of removal. Inspect the front bumper assembly for any crack or damage. Replace if found. Remove Front Turn Indicator And DRL LH. Using a screw driver, unscrew the antenna from the fender LH. Torque : 3\u00b11 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250060.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the front grill mounting screw rivets Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250140.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250139.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm combination spanner, Unscrew show lock mounting nut fender end. Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250142.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew fender top mounting bolts. Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250143.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew fender side mounting bolts. Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250180.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew fender bottom mounting bolts. Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250144.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew fender mounting bolts door side. Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250183.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250182.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the fender from vehicle. Refit in the reverse order of removal. Inspect the fender panel for any damage. Replace if found. For additional information refer to Cladding Rear Wheel Arch LH - R&R section. ",
+ "file": "",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Open the tail gate.",
+ "file": "",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A260100.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a star screw driver , loosen and remove the rear fender RH/ LH side mounting screws.",
+ "file": "",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/front_bumper_04_01.png",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/front_bumper_04_02.png",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the stone guard mounting screw rivets.",
+ "file": "",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/front_bumper_05_01.png",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a star screw driver , loosen and remove the rear bumper side mounting screws.",
+ "file": "",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/reaer_bumper_6_01.png",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/reaer_bumper_6_02.png",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew the rear bumper mounting bolts body end.",
+ "file": "",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A290040.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5 Nm",
+ "file": "",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Flip the bumper and disconnect the electrical main connectors and remove rear bumper.",
+ "file": "",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/reaer_bumper_8_01.png",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/reaer_bumper_8_02.png",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the wiring routing clips from the bumper assembly.",
+ "file": "",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/419_01.png",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Disconnect the rear parking sensor electrical connectors.",
+ "file": "",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/reaer_bumper_10_01.png",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Disconnect license plate electrical connector.",
+ "file": "",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/reaer_bumper_11_01.png",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Remove the rear bumper wiring harness.",
+ "file": "",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/reaer_bumper_12_01.png",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Remove the parking sensors with holder.",
+ "file": "",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/rear_bumper_13_01.png",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Remove the license plate lamp from rear bumper assembly.",
+ "file": "",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/rear_bumper_14_01.png",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/rear_bumper_14_02.png",
+ "display_order": 35
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the license plate lamp from rear bumper assembly.",
+ "file": "",
+ "display_order": 36
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 325,
+ "sys_id": "THAR.LX-0005-en-SM-Electrical Components And Electrical Wiring Harness",
+ "system_name": "Electrical Components And Electrical Wiring Harness",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1034,
+ "active_status": true,
+ "Assets": [
+ {
+ "systemdisplayorder": 10,
+ "system_asset": "/files/Wiring harness (D)_v281869c.mp4",
+ "active_status": true
+ },
+ {
+ "systemdisplayorder": 9,
+ "system_asset": "/files/Fuse Box (D)_v3b44a92.mp4",
+ "active_status": true
+ },
+ {
+ "systemdisplayorder": 8,
+ "system_asset": "/files/Electrical Components (D)_v22bd191.mp4",
+ "active_status": true
+ },
+ {
+ "systemdisplayorder": 6,
+ "system_asset": "/files/ECU (D)_v2d85252.mp4",
+ "active_status": true
+ },
+ {
+ "systemdisplayorder": 5,
+ "system_asset": "/files/CAN Communication (D)_v3a23a48.mp4",
+ "active_status": true
+ },
+ {
+ "systemdisplayorder": 7,
+ "system_asset": "/files/ECU IP & OP (D)_v2bc2b0e.mp4",
+ "active_status": true
+ }
+ ],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 325,
+ "sys_id": "THAR.LX-0005-Electrical Components And Electrical Wiring Harness",
+ "subsys_id": "THAR.LX-0005-Electrical Components And Electrical Wiring Harness-DTC (Diagnostic Trouble Code) \u2013 Check",
+ "systems": "Electrical Components And Electrical Wiring Harness",
+ "sub_systems": "DTC (Diagnostic Trouble Code) \u2013 Check",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J09-MAT-0690",
+ "cover_image": "/files/W1E030251.jpg",
+ "myid": 1434,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 15,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 63,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 102,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 142,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 183,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 221,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 263,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 303,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 343,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 381,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 425,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0005-DTC (Diagnostic Trouble Code) \u2013 Check-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/DTC - Check.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "Description",
+ "content": "Position the vehicle on 2 post lift/ 4 post lift. Turn the ignition OFF. Connect the i-SMART diagnostic tester and turn the ignition ON. Select Dearborn Electronics India Pvt Ltd. \u2014 Garuda and then click START. Select THAR from the list of vehicles displayed as in following window then select the HAR_ BS6. Click on the GENERATE button on the bottom right side of the Express View screen to generate DTC report. This will generate and store a report. Once completed, i-SMART will prompt to open Excel file. If any DTC is active, Refer Diagnostic manual for more information. Connect the miniSMART Bluetooth VCI on DLC and turn the ignition ON. Pair the Bluetooth of android tablet / smartphone with miniSMART VCI. Launch the miniSMART App and select the THAR from the vehicle list. Connect the miniSMART Android and select each \u201cECU\u201d from the list of controllers. From the list, select DTC Fetch. The ECU will be analysed and the registered DTCs will be displayed, then take screen shots of all registered DTCs and their Freeze Frame data by clicking over the DTC / FF icon, for records. If any DTC is active, Refer Diagnostic manual for more information. Repeat the above steps 4 to 7 for other ECU\u2019s present in the vehicle. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Disconnect EMS ECU connector with routing clip. Disconnect e-VGT electrical connector. Disconnect T4 temperature sensor electrical connector. Disconnect T5 temperature sensor electrical connectors. Disconnect Dosing Module electrical connectors. Disconnect DPF sensor electrical connector. Disconnect fuel metering Unit electrical connector. Disconnect fuel injector electrical connectors.(4NOS) Disconnect CAM phase sensor electrical connector. Disconnect Common rail pressure sensor electrical connector. Disconnect coolant temperature sensor electrical connector. Disconnect Glow Plug inter-connector Disconnect throttle valve actuator electrical connector. Disconnect engine speed sensor electrical connector. Disconnect alternator telltale electrical connector. Disconnect EGR module electrical connectors. Using 8mm socket spanner unscrew starter motor solenoid electrical connector. Torque : 2.5\u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A03C016.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A03C017.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Disconnect reverse switch electrical connector. Disconnect GNS electrical connector. Disconnect transfercase switch electrical connector Detach Engine WH on intake manifold side. Using a 10 mm socket spanner unscrew wiring carrier mounting nuts. Disconnect fuel filter electrical connector. Disconnect engine compartment to Engine WH inter-connectors (2NOS) and routing clips(2NOS). Disconnect MAP sensor electrical connector. Detach engine wiring harness from engine compartment. Install in the reverse order of removal. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Torque tighten the earth mounting nuts to specified values. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Remove HVAC Control Panel (Manual). Carefully pull the Telltale Bank from inside. Disconnect the Telltale Bank electrical connectors and 12 volt electric connector and remove the Assy from IP. Using star screw driver remove Telltale bank mounting screws. Torque : 1.5 \u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220131.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the telltale bank. Install in the reverse order of removal. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the telltale bank for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Using 10 mm socket spanner, Unscrew fuse box mounting bolts. Using 10 mm socket spanner, Unscrew fuse box mounting bolts. Torque : 4 .0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A05C046.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the RH side door to IP interconnector and holding clip. Disconnect engine compartment to IP RH side inter-connector and holding clips. Disconnect the MBFM electrical connectors. Using 10 mm socket spanner, Unscrew ground cable mounting nuts and detach the connectors. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A05C003.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Disconnect the ignition key barrel electrical connectors. Disconnect the HVAC assembly electrical connectors. Disconnect LH door electrical connector. Disconnect the IP to Roof wiring harness inter-connector. Disconnect LH side IP to engine interconnectors with holding clip. Using 10 mm socket spanner, Unscrew earth cable mounting nuts. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220111.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Remove the IP wiring routing clips from CCB. Detach the LH B pillar partially. Disconnect the Pre tensioner electrical connectors LH side. Disconnect the LH seat electrical connector and routing clips. Disconnect the Airbag ECU electrical connector. Using a 10 mm socket spanner, Unscrew earth cable mounting nut and disconnect the cable. Disconnect the parking brake switch electrical connector. Detach the RHS B pillar partially. Disconnect the Pre tensioner electrical connectors RH side. Disconnect the floor console inside wiring Harness routing clips. Disconnect the RH seat electrical connector and routing clips. Remove the wiring harness from vehicle. Install in the reverse order of removal. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness Torque tighten the earth mounting nuts to specified values. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Remove the Intake Manifold. Disconnect the interconnection glow plug to engine C 435 M connector. Disconnect the glow plug-1 C 39 connector. Disconnect the glow plug-2 C 38 connector. Disconnect the glow plug-3 C 37 connector. Disconnect the glow plug-4 C 36 connector. Remove the wiring harness from the engine compartment. Install in the reverse order of removal. Refit the Intake Manifold. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Remove A Pillar Upper Trim LH. Disconnect speaker electrical pigtail inter-connector. Detach MIC wire from routing. Detach roof wiring harness from routing clips. Disconnect IP to roof WH inter-connector and holding clip with routing clips. Remove IP TOP Cover with PAB Assembly LH. Detach WH routing clip and from vehicle. Install in the reverse order of removal Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Remove the Rear RH Tail Lamp Assembly. Disconnect floor to tail door interconnector and holding clips. Detach the tail door WH grommet. Disconnect BIW pigtail inter-connector and connector holding clip. Remove the tail door Trim. For additional information refer to Tail Door Trim - R&R Section. Disconnect door latch electrical connector. Remove the Tail Door Wiring Harness from vehicle. Install in the reverse order of removal Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Service Reminder Indicator Reset Procedure ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "In the instrument cluster, the service reminder alert will start popping up in the cluster screen at 200 kms before the actual kilometers at which the service is due. This will continue at every ignition cycle. It is necessary to reset the service reminder once the service is rendered to the vehicle. If not reset, the service alert will continue to pop up at every ignition cycle, till it is reset by using recommended procedures. Press the OK button on Driver side switch bank and simultaneously turn the ignition ON. Release the OK button within 5 seconds after ignition on. Check and ensure that the service reminder alert is OFF in the cluster. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Disconnect the MBFM electrical connectors. Detach the IP wiring harness holding clip from MBFM bracket. Using 10 mm socket spanner, Unscrew MBFM bracket mounting bolts from BIW and remove MBFM with bracket from the vehicle. Torque : 6.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370060.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370057.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew MBFM mounting bolts from the bracket and detach the MBFM. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the MBFM and bracket for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Using star screw driver, Unscrew the DEF tank bottom protection cover mounting screws and remove the cover. Disconnect the reduction agent temp sensor C 535 connector. Disconnect the magnetic coil & reduction agent surge pump C 276 connector. Disconnect the chassis C 707 M interconnector. Remove the Wiring Harness from routing clips and detach from the DEF tank. Install in the reverse order of removal. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Disconnect the HFM sensor C 19 connector. Disconnect EMS ECU connector with routing clip. Using 10 mm socket spanner remove earth cable mount nut and a routing clip. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C046.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove LH Side marker lamp connector with a routing clip. Disconnect LH side turn lamp electrical connector. Disconnect LH DRL connector and detach grow mat to take out connector. Disconnect LH Head lamp and levelling motor(HLLD) electrical connectors. Disconnect Horn electrical Connectors (2Nos) and 3 routing clip. Disconnect Electrical fan electrical connector. Disconnect LH Crash sensor electrical connector. Disconnect fog lamp electrical connector routing clips. Disconnect ambient temperature sensor electrical connector. Using 10 mm socket spanner, Unscrew engine compartment fuse box mounting bolts. Torque : 10\u00b11 Nm ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370065.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using 8 mm socket spanner remove fuse box positive cable mounting nut and disconnect from battery fuse connection. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370017.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Disconnect engine compartment to engine wiring harness inter-connector. Detach WH routing clips from fire wall. Using 10 mm socket spanner unscrew earth cable mounting nut from fire wall and detach cable. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C005.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Disconnect NOx Sensor electrical connector. Remove Air Cleaner Assembly. Using 10 mm combination spanner Remove LH fender ground mounting nut and detach it. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C003.jpg",
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Disconnect brake fluid level sensor electrical connector. Disconnect ABS ECU electrical connector. Disconnect HVAC triple pressure switch electrical connector. Disconnect EWP electrical connector and routing clip. Disconnect RH Crash sensor electrical connector. For additional information refer to Splash Shield Front RH - R&R section.",
+ "file": null,
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C009.jpg",
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Description",
+ "content": "Disconnect RH fog lamp electrical connector routing clips. Disconnect RH head lamp electrical connector. Disconnect RH head lamp levelling motor(HLLD) electrical connector. Disconnect RH side marker lamp electrical connector with a routing clip. Disconnect Front RH indicator and DRL connector and detach grow mat to take out connector. cxc Using 10 mm socket spanner unscrew earth cable mounting nut from RH fender and detach cable. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370030.jpg",
+ "display_order": 80
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370029.jpg",
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "Description",
+ "content": "Detach WH routing clips from fender. Disconnect engine compartment to IP electrical connectors. Disconnect accelerator pedal electrical connector. Disconnect brake switch electrical connector with a routing clip. Disconnect clutch sensor electrical connector. Detach WH routing clips and take out wiring. Detach WH from inside to outside . Remove the scuttle Grill. Disconnect Wiper motor electrical connector and a routing clip. Disconnect IP to Engine compartment wiring harness inter-connectors. Disconnect engine compartment to chassis WH inter-connector. Disconnect washer tank electrical connector. Using 12 mm socket spanner remove fuel filter mounting bolts and partially detach it. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 110
+ },
+ {
+ "step_name": "Step-48",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/EngineCompartmentWiringarness.png",
+ "display_order": 111
+ },
+ {
+ "step_name": "Step-48",
+ "content_type": "Description",
+ "content": "Detach Engine compartment Wiring Harness from engine compartment. Install in the reverse order of removal. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Torque tighten the earth mounting nuts to specified values. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Disconnect the Front RH wheel speed sensor C 361 connector. Detach wiring harness routing clips on front cross member. Disconnect the e-disconnect motor C 231 connector. Disconnect the front LH wheel speed sensor C 360 connector. Detach wiring harness routing clips on chassis. Disconnect engine compartment WH to Chassis WH inter-connector. Detach routing clips on chassis LH side. Disconnect the chassis to FDM C 485 F inter-connector. Disconnect the rear LH wheel speed sensor C 362 connector. Detach routing clips on chassis rear LH side . Disconnect the chassis to bumper C 434 F inter-connector. Disconnect the DEF pigtail C 707 F inter-connector. . Detach rear chassis routing clips. Disconnect the rear RH Wheel Speed Sensor C363 connector. Detach routing clips on chassis rear RH side. Remove the Rear LH Tail Lamp Assembly. Using 10 mm socket spanner unscrew LH tail lamp earth cable mounting nut and detach it. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/ChassisWiringHarness3.png",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370015.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Detach routing clip and grow mate. Remove the Rear RH Tail Lamp Assembly. Using 10 mm socket spanner unscrew RH tail lamp earth cable mounting nut and detach it. Disconnect the tail lamp RH C 153 connector. Disconnect the tail lamp LH C 154 connector. Disconnect the chassis to tail gate-2 C 708 F inter- connector. Disconnect the chassis to tailgate-3 C 709 F inter-connector. Remove the chassis wiring harness from vehicle. Install in the reverse order of removal. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Torque tighten the earth mounting nuts to specified values. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Remove the HVAC Control Panel. Open the glove box and remove the glove box by detaching the lock. Remove the Driver side IP panel assembly. Disconnect the HVAC control panel C 720 connector. Disconnect the intake actuator C 722 connector. Disconnect the blower motor C 721 connector. Disconnect the blower resistor C 723 connector. Disconnect the thermo amplifier C 724 connector. Disconnect the HVAC unit C 117 M connector. Disconnect the blower switch C 720A connector. Using 10 mm socket spanner, loosen and disconnect the HVAC ground G 2 connector. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Remove the wiring harness separately. Install in the reverse order of removal. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Torque tighten the earth mounting nuts to specified values. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Remove the sensor from the routing slot. Take out the sensor and disconnect the electrical connector. Install in the reverse order of removal. Inspect the ambient temperature sensor for any external damage, If any replace it. Remove the hard top assembly. Inspect the Hard-Top windshield upper frame Seal and replace if needed when the seal loses its softness or if found any damages. Follow the below steps for replacement of Hard-Top windshield upper frame Seal Remove the X-mas tree clips by trim remover from over the roof rail outer frame. Then pull the seal by manually, due to this seal has fixed with two-way pasting tape. Clean the surface by digresses cloth. Peel the sticker label sheet from the new Seal, then paste on the roof rail outer frame followed by press the X-mas tree clips. The Seal must be replaced along with X-mas tree clips, when the seal loses its softness or if found any damages, don't reused the X-mas tree clips. This seal is for preventing the water leakage and wind noise only. Seal coming with Two-way pasting tape. Install in the reverse order of removal. Using a star screw driver, Unscrew hard top quarter glass frame mounting screws from the rear window. Pull - out the glass beading from Quarter Glass. Carefully push from inside to outside and remove the rear window from the vehicle. Install in the reverse order of removal. While Installation always replace with New frame mounting screws. Inspect the hard top quarter glass for any damage/crack etc. Replace if found any. Inspect the hard top quarter glass mounting fasteners for any damage. Replace the fasteners if required. Remove the centre roof bow trim. Open the top cover and Using a 14 mm socket spanner, loosen and remove the seat belt upper mounting bolt. Torque :38 \u00b16 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A210069.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A210071.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the upper trim from vehicle. Install in the reverse order of removal. Inspect the B-pillar upper trim for any damage/crack/cut etc. Replace if found any. Inspect the B-pillar upper trim fasteners for any damage. Replace the fasteners if found any damage. Remove the Hardtop Assembly. Remove the Seal from the vehicle. Install in the reverse order of removal. Inspect the Front Lateral trim for any damage/crack/cut etc. Replace if found any. Inspect the Front Lateral trim mounting legs for crack/bend etc. Remove Side window RH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Remove Side window LH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Unzip the tail gate window, detach the tail gate bar locking from rear RH & LH belt rails remove the tailgate window. Unhook the \u2018C\u2019 pillar cover from rear RH & LH belt rails and fold the cover at top of the soft top. Using a T30 socket spanner, loosen and remove the belt rear rail Mounting bolts and remove the belt rail from the vehicle Follow the same procedure for LH side. Using a T30 socket spanner, loosen and remove the belt center rail Mounting bolts and remove the belt rail from the vehicle. Follow the same procedure for LH side. Torque : 5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/convertible2.PNG",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using T30 socket spanner, loosen and remove the belt vertical rail mounting bolts and remove the belt rail from the vehicle. Follow the same procedure for LH side. Torque : 5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W354.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the belt corner rail from the vehicle.. Follow the same procedure for LH side. Torque : 5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/convertible3.PNG",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using T30 socket spanner, loosen and remove the belt door rail mounting bolts and remove the belt rail from the vehicle. Follow the same procedure for LH side. Torque : 5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/convertible4.PNG",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/convertible5.PNG",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/convertible6.PNG",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/convertible7.PNG",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the Seal/rail for any damage/crack/cut etc. Replace if found any. Using a trim removal tool pull out center bow trim and disconnect roof lamp electrical connector. Remove the centre bow trim from the vehicle. Remove the roof lamp from bow trim. Install in the reverse order of removal. Inspect the trim for any damage/crack/cut etc. Replace it if found. Remove the B Pillar Upper Trim. Using a 10 mm socket spanner unscrew Grab handle mounting bolts. Torque : 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A240065.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A240066.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner unscrew front lateral trim mounting bolt. Torque : 2 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the Front lateral trim. Install in the reverse order of removal. Inspect the Front Lateral trim for any damage/crack/cut etc. Replace if found any. Inspect the Front Lateral trim mounting legs for crack/bend etc. Using a T40 Torx Socket spanner unscrew centre bow trim mounting screws. Torque : 5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A240011.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a trim removal tool carefully detach the trim and remove electrical connector. Detach the MIC carefully from the trim. install in the reverse order of removal. Inspect the trim for any damage/crack/cut etc. Replace it if found . When the engine is stopped and the ignition switched off, the battery feeds accessories which are directly connected to battery, such as alarms, clock, radio code and certain computers that operate continuously. Dark currents are considered normal if they do not exceed a few tens of milli amperes. If the value is more than that, one or more permanent electrical component is drawing too much current. They can be isolated by withdrawing the fuses one by one until the faulty circuit is identified. A multi-meter is the best tool for these measurements. A current clamp cannot accurately measure currents of less than 1 A. The measurement must be taken at the battery itself. Before carrying out leakage current test,Turn all accessories OFF. Switch OFF the ignition and remove the key. Close all doors and windows. Wait for minimum 3 Minutes and then do the checking procedure. In multi-meter, current selection should be in milliampere. ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Set the current measuring range of the ammeter to 10 A. Disconnect the negative terminal from the battery. Connect the positive terminal of multimeter (Red probe) with the negative terminal removed from the battery and connect the negative terminal of multimeter (black probe) with negative pole of the battery. Read the value in multi-meter. If the current measured is more than permissible value (For MT Variants \u2013 7 mA (Max) & for AT Variants \u2013 12 mA (Max)) , check for any:. Loose connection in ground points. Check for any active loads ( like roof lamp,etc;). Hydrometer is a float-type device used to determine the State-of-Charge by measuring the specific gravity of the electrolyte in each cell. It is an accurate way of determining a battery's state of charge and weak or dead cells. Wear suitable eye protectors (goggles). With the help of a flat end screw driver, remove the vent caps or covers from the battery. Squeeze the hydrometer bulb and insert the pickup tube into the cell close to the battery positive terminal. Slowly release the bulb to draw in only enough electrolyte to cause the float to rise. Do not remove the tube from the battery. Read the specific gravity indicated on the float. Be sure the float is drifting free, and does not contact with sides of the barrel. Read the hydrometer at eye level. Disregard the slight curvature of liquid on the float. Note the reading for all the cells. The difference in specific gravity readings should not be more than 0.05. The specific gravity for fully charged battery is as follows: .AMARON - 1.270 \u00b1 0.010 at 27\u00b0C.Specific gravity readings ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080030.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "By measuring the specific gravity of the electrolyte, you can identify whether the battery is fully charged, requires charging, or must be replaced. Specific gravity varies with the temperature. If the electrolyte temperature is substantially above 27\u00b0 C add seven points (0.007) to the observed specific gravity reading for every 10\u00b0 C by which the actual temperature is above 27\u00b0 C. Deduct seven points per 10\u00b0 C where the observed reading is below 27\u00b0 C to obtain the temperature corrected reading at 27\u00b0 C. Inspect battery electrolyte specific gravity whenever required. An alternator consists of two main components rotor and stator. The rotor is connected directly to the Over running Alternator Pulley (OAP). The drive belt drives the pulley by taking power from engine, which in turn spins the rotor. The stator is mounted to body of the alternator and remains stationary. The rotor is an electromagnet which rotates past the stator windings, and thus the rotor induces an alternating current in the stator. The induced current is proportional to the energizing current of the electromagnet. Alternating current cannot be used to recharge the battery, so it must be converted to direct current before use. The voltage regulator incorporated in the alternator adjusts the electricity produced to the requirements of the battery and the vehicle. If the alternator output voltage is too low, the regulator increases the energizing current in the rotor windings. If the output voltage is too high, the regulator decreases the energizing current in the rotor windings. Voltage regulator ensures the alternator voltage upper limit to 14.0 V. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Using 10 mm socket spanner, Unscrew degassing tank mounting bolts and partially detach the degassing tank and keep aside. (Without detaching the hoses). Torque : 4.5\u00b10.5 Nm. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen and remove the engine fead cover mounting bolts. Torque : 11 \u00b1 1Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the engine fead cover from engine compartment. Using 14 mm ring spanner, turn the hexagon knob in the belt tensioner Anti clockwise direction to release the tension and detach the accessory belt. Using 14 mm socket spanner, loosen and remove the auto tensioner mounting bolt then remove the auto tensioner to access the alternator mounting. Torque : 45\u00b13 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect the alternator electrical connector. Remove alternator positive cable cover. Using 13 mm socket spanner, loosen and remove the alternator positive cable nut. Torque : 15 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 12 mm socket and ring spanner, Remove the alternator top mounting bolt and nut. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the alternator bottom mounting bolt and nut. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080014.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Carefully remove the alternator from engine compartment. Install in reverse order of removal.
Check free play of alternator pulley.
Check alternator drive belt for any damage. If found replace with a new one.
",
+ "file": null,
+ "display_order": 41
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 33,
+ "sys_id": "THAR.LX-0005-Charging System",
+ "subsys_id": "THAR.LX-0005-Charging System-Battery Health Checkup",
+ "systems": "Charging System",
+ "sub_systems": "Battery Health Checkup",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J09-MAT-0550",
+ "cover_image": "/files/W4A080023.jpg",
+ "myid": 1115,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 36,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 56,
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+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 95,
+ "kilometers_applicable": 1
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+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 135,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 176,
+ "kilometers_applicable": 1
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+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 214,
+ "kilometers_applicable": 1
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+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 256,
+ "kilometers_applicable": 1
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+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 296,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 336,
+ "kilometers_applicable": 1
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+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 374,
+ "kilometers_applicable": 1
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+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 418,
+ "kilometers_applicable": 1
+ }
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+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0005-Battery Health Checkup-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/15130.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Battery Health - Checkup.mp4",
+ "display_order": 2
+ },
+ {
+ "step_name": "Preliminary Activities/ Conditions",
+ "content_type": "Description",
+ "content": "Park the vehicle on flat work bay. Open the bonnet and lock it in open position using bonnet stay rod. Connect the MDX - 650P battery tester to battery terminals connecting probes on the battery posts respectively. When you start a new test, the last test results in memory are overwritten. Remember to record or print the results if you need to retain them. Press the Enter button and confirm the BATTERY LOCATION by selecting the \u201cIN VEHICLE\u201d in the tester using navigation button Up or Down. . Press the Enter button and confirm the POST TYPE by selecting the \u201cTOP POST\u201d in the tester using navigation button Up or Down . Press the Enter button and confirm the APPLICATION by selecting the \u201cAUTOMOTIVE\u201d in the tester using navigation button Up or Down . Press the Enter button and confirm the BATTERY TYPE by selecting the \u201cREGULAR FLOODED\u201d in the tester using navigation button Up or Down . Press the Enter button and confirm the BATTERY STANDARD by selecting the \u201cJIS\u201d in the tester using navigation button Up or Down . Press the Enter button and get the recommended JIS Number value by pressing button Up or Down . Press the Enter button and perform the TESTING. Once the TESTING done, the initial battery result will be display. Press the PRINT button to get the hard copy print out. Disconnect the battery tester probes from battery terminals. Follow the below table for Battery Testing test results condition and remedial action: ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/15133.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16412.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Disconnect the battery tester probes from battery terminals. Follow the below table for Battery Testing test results condition and remedial action: ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/15133.jpg",
+ "display_order": 31
+ }
+ ]
+ }
+ ]
+ },
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+ "sys_id": "THAR.LX-0005-Charging System",
+ "subsys_id": "THAR.LX-0005-Charging System-Charging System Technical Spec",
+ "systems": "Charging System",
+ "sub_systems": "Charging System Technical Spec",
+ "symptom": 0,
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+ "rts": null,
+ "mat": null,
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+ "myid": 1122,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0005-Charging System Technical Spec-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Battery Specifications",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/6042.png",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 36,
+ "sys_id": "THAR.LX-0005-Charging System",
+ "subsys_id": "THAR.LX-0005-Charging System-Open Circuit Voltage Test",
+ "systems": "Charging System",
+ "sub_systems": "Open Circuit Voltage Test",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A080022.jpg",
+ "myid": 1118,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0005-Open Circuit Voltage Test-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Turn ON the head lamp high beam for 30 seconds to remove any surface charge. Digital voltmeter checks the battery\u2019s open circuit voltage. Analogue meters do not show accurate readings and should be avoided. Turn OFF the head lamp, disconnect the battery and connect the digital voltmeter across the battery terminals. Note the readings in the voltmeter. A fully charged battery will have an open-circuit voltage based on below table value. Check the electrolyte level. Add distilled water to all the cells which require water. Ensure the electrolyte level between MIN and MAX marks. Refit the vent plugs properly. Topping up should be done with distilled water only. .Never use normal water or mineral water to top battery electrolyte. .Vent holes should be clear. .Clean the terminals. .Tighten terminals to specified torques. Check battery electrolyte level whenever required. Do battery electrolyte level inspection when required. Verify the customers concern. Visually inspect the charging system for any noticeable signs of mechanical or electrical damage. If any obvious cause is found, correct the same before proceeding to the next step. Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. . Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Using 10 mm socket spanner, loosen battery positive cable mounting nut and disconnect the cable. Torque : 6 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, loosen and remove the battery holding clamp mounting nuts. Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the battery from the vehicle. Install in reverse order of removal. Check for cracks in the battery case and broken terminals which allows electrolyte leakage. Check for any cracked or broken cables/connections, and replace the cables if necessary. Check for corrosion on terminals and dirt/acid on the battery case top. Clean the terminals and the battery case top with mixture of water and baking soda. A battery wire brush tool can also be used to clear heavy corrosion on the terminals. Prevent further corrosion by applying petroleum jelly to the outside of the terminals. The Passenger Airbag Module is a bag within the module inflates to protect the passenger in the event of a collision severe enough to deploy the system and located on LH side of Instrument panel, above the glove box and its functioning is controlled by the airbag ECU. Within the passenger airbag module is a squib which, when given the correct current by the airbag ECU, inflates the airbag by initiating a chemical reaction. In deployment, the airbag inflates within a fraction of a second and then deflates at a controlled rate as the passenger body regions; typically head and chest interact with airbag. Vents in the airbag control its deflation. Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Before disconnecting the battery, check for the audible sound of EWP ON Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Glove Box Assembly. Remove the IP grab handle cover. Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts. Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220024.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting screws. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220025.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle. Partially detach the door edge beading and using a trim removal tool, remove the IP LH side cover. By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt. Torque : 8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220066.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220077.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector. Take out the IP LH side top cover with Passenger air bag from the IP. Using a 10 mm ring spanner, loosen and remove the air bag mounting bolt from IP top cover. Torque :4.5\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210047.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210048.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Expand the PAB module holder both sides using screw driver and detach the PAB separately from IP top cover. Install in the reverse order of removal. Inspect the PAB module for any damage. Replace if found any. Inspect the PAB module connector for any damage. Inspect the PAB module trim for any damage. The Airbag ECU is installed on the floor panel under the floor console. It deploys the proper Airbag according to the signals from the impact sensors. This ECU communicates with other ECU\u2019s through CAN directly. Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Before disconnecting the battery, check for the audible sound of EWP ON Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Front console assembly. For additional information refer to Front Console Assembly R&R section. Using star screw driver remove the Airbag ECU Cover screw from airbag ECU. Disconnect the SRS/ Airbag ECU electrical connectors. Using a 10 mm socket spanner, loosen the SRS/ Airbag ECU mounting nuts on the floor panel. Torque :8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210053.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210054.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the SRS/ Airbag ECU from the body. Install in the reverse order of removal. Inspect the airbag ECU for any damage, replace if found any. Inspect the airbag ECU connectors for any damage. Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Before disconnecting the battery, check for the audible sound of EWP ON Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250193.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front splash shield lower mounting screws. Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts. Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield. Disconnect the front Crash sensor electrical connector. Using a 10 mm socket spanner, loosen and remove the front Crash sensor mounting bolt from the vehicle. Torque :8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210058.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the front crash sensor from the vehicle. Install in the reverse order of removal. Inspect the front crash sensor for any damage. Replace if found. The driver airbag module is located in the steering wheel and its function is controlled by the airbag ECU. A bag within the module inflates to protect the driver in the event of a collision severe enough to deploy the system. The driver airbag module connects to the steering column wiring harness via a rotary coupler called as clock spring. Within the driver airbag module there is a squib which, when given the correct current by the airbag ECU, inflates the airbag by initiating a chemical reaction. In deployment, the airbag inflates within a fraction of a second and then deflate at a controlled rate as the driver body regions; typically head and chest interact with airbag. Vents in the airbag control its deflation Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Before disconnecting the battery, check for the audible sound of EWP ON Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Steering Column Shrouds. Turn the steering wheel to 90\u00b0 counter clockwise direction from the steering wheel straight position and using a screw driver press the RHS DAB lock then release the lock. DAB locks are made up of plastic, ensure to press the locks softly by screwdriver. Turn the steering wheel to 90\u00b0 clockwise direction from the steering wheel straight position and using a screw driver press the LHS DAB lock then release the lock. DAB locks are made up of plastic, ensure to press the locks softly by screwdriver. Gently pull-out the DAB module from the steering wheel. Using a small flat end screw driver release the lock of the DAB electrical connector, then disconnect the DAB and horn electrical connectors. While refit ensure wires are routed out of the snapping zones to avoid damage. Remove the DAB module separately. Install in the reverse order of removal. Inspect the DAB module for any physical damage. Replace if found any Inspect the DAB connector for any damage. Precautions to be followed: ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040221.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Never interchange injectors between engines / ECU's Never change ECU's between vehicles. Never interchange injectors between cylinders in same engine. When Injectors are replaced/Changed Injector IQA values must be loaded correctly as per cylinder order. For additional information refer to EMS diagnostic manual. Whenever an injector or ECU need to be replaced, the new injector\u2019s IQA code need to be written in to the ECU, using i-FLASH/ i-SMART. IQA code is engrave on the top of the injector. It is a 6 character alphanumeric code. ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/IQA_2.png",
+ "display_order": 4
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 370,
+ "sys_id": "THAR.LX-0005-Fuel System",
+ "subsys_id": "THAR.LX-0005-Fuel System-Water In Fuel Filter - Clean",
+ "systems": "Fuel System",
+ "sub_systems": "Water In Fuel Filter - Clean",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J09-MAT-0150",
+ "cover_image": "/files/W4A040021.jpg",
+ "myid": 1039,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 3,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 45,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 85,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 150,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 165,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 205,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 270,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 285,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 326,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 389,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 406,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0005-Water In Fuel Filter - Clean-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "Description",
+ "content": "Park the vehicle on level work bay Open the bonnet and lock it in open position using bonnet stay rod Connect the transparent pipe to the drain plug outlet of the fuel filter assembly Using a Nose plier, rotate drain plug anticlockwise till the water starts flowing from the tube. Drain plug requires hand tight only; do not use any tool and avoid over tightening. Do not over tight the drain plug Rotate drain plug in clockwise directio to stop the flow as soon as water gets over and fuel flow starts. Tighten the drain plug. Start the engine and check for any leaks. Remove the engine top encapsulation cover. Using 10 mm socket spanner, Unscrew engine wiring harness carrier mounting stud from Cam cover and detach it partially. Press the lock and disconnect fuel control unit electrical connector. Using 17 mm open end spanner, Unscrew High pressure pipe mounting flare nut from common rail end. Using 19 mm open end spanner, unscrew High pressure pipe flare nut from injection pump end. Press the lock and disconnect fuel control unit inlet and outlet pipes. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Using nose plier release fuel return hose spring band clamp and detach hoses from fuel injection pump & FCU. Using 10 mm socket spanner, Unscrew fuel return line 'T' bracket mounting bolts. Using 12 mm socket spanner, Unscrew Cam box mounting bolts and remove the bolts. Rotate the Cam Box Assembly as direction shown in the image to access fuel high pressure pump mounting bolts. Using T30 socket spanner unscrew fuel high pressure pump mounting bolts and detach pump. Remove Cam box assembly along with FCU from engine. While taking out Cam box, ensure to move the tappet in upward direction by hand. Using 5 mm Allen socket spanner unscrew tappet roller guide bolt. Remove roller tappet from the cam box housing. Using 12 mm socket spanner Unscrew Fuel Control Unit mounting bolts and separate the CAM Box. Inspect the CAM box for any damage. Replace if found any. Refit Fuel Control Unit and install the mounting bolts. Tighten the bolts to specified torque value. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refit the roller tappet and install the guide bolt. Tighten the bolt to specified torque value. Torque : 20\u00b12 Nm ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011182.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Insert the roller tappet in correct orientation so that the locking pin will seat properly in the slot ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Position the Cam box on Intake cam shaft rear end. While Installing Cam box, ensure to move the tappet in upward direction by hand. Ensure to replace New Cam box gasket during Installation. Before Installation of Cam box mounting bolts, Rotate the Cam Box Assembly as direction shown in the image to install fuel high pressure pump mounting bolts. Position the fuel pump on Cam box and install mounting bolts. Tighten the mounting bolts to the specified torque value. While Installing the pump always replace the Gasket with a new one. While torque tighten the Pump mountings, hold the Cam box Assembly by second technician asshown. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011138.jpg",
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Rotate the Cam Box Assembly direction as shown in the image to original position. Install the Cam box mounting bolts.Tighten the bolts to the specified torque value. Torque : 25 \u00b1 3 Nm Torque : 25 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010061.jpg",
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Heading",
+ "content": "Tightening Sequence ",
+ "file": null,
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install fuel return line 'T' bracket mounting bolts. Tighten the bolts to the specified torque value. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Refit fuel return hoses and lock it by spring band clamp. Connect fuel inlet tube quick coupler at pump end & FCU. Position the Fuel HP pipe and tighten the mounting on Common rail end to the specified torque value. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Position the Fuel HP pipe and tighten the mounting on FIP end to the specified torque value. Torque : 30 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 85
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Refit the engine wiring harness carrier mounting studs on Cam cover and torque tighten the studs. Torque : 8 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Connect the fuel control unit electrical connector. Refit the engine top encapsulation cover. Other observations ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "No error codes registered. In the live data the status of torque limitation, synchronization status and the state of staring system are correct If HP pipe is removed at the rail end then fuel can be observed. Parts Required ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Test tube with graduations, capacity 30 to 75 ml (Quantity : 04 Nos). Engine tube connection injection, Part Number : 9350042680, Length 310 mm (Quantity : 04 Nos.). The ID of the tube is important hence use only the part number specified. ",
+ "file": null,
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Checking Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove engine top encapsulation cover from engine. Blow air around the injectors to remove the dust. Remove injector leak-off hose clips and then gently pullout and remove leak-off hose from injectors. Keep the removed leak-off pipe behind injectors. Do not remove overflow tube connection from the fuel return line \u2018T\u2019 joint. Insert the hose firmly in each injector and insert the other end in test tubes as shown in illustration below. (Use rubber band to hold the test tubes in stand). Images are only for representation. Actual image for this vehicle may vary. Start engine and keep it in idle. Collect fuel in test tube for one minute. Stop the engine, ignore first reading.Empty the test tubes & reconnect. If any test tube gets filled during the test, \u201cSTOP\u201d the test and replace that cylinder injector. Start engine & repeat test for exactly one minute. Observe the quantity of leakage fuel corresponding to each injector. If the leakage quantity of any injector is higher than 3 times the minimum of any three injector, then that injector is faulty. Replace the injector. Crank the engine for 30 seconds, the faulty injector's will show leakage quantity more than 3 times the minimum of any four injector Replace the defective injector's. Repeat the test with new replaced injector & confirm the resolution of for starting problem. Images shown is just for representation. The fuel tank is a reservoir for the fuel and incorporates the Fuel delivery module inside. Remove the fuel tank assembly Disconnect the fuel tank electrical connector and remove the FDM pigtail from the fuel tank. Remove the Fuel tank heat Shield mounting clamp from the tank. Using screw driver, loosen and remove the Fuel tank Bracket mounting clips from the tank. Remove the fuel supply and return hose quick coupler from the fuel delivery module. Remove the fuel supply and return hose from the fuel tank. Using suitable metal shaft and hammer,tap the FDM lock ring and remove the lock ring from FDM unit Remove fuel delivery module and O ring from the tank Drain the fuel from the fuel tank and refill the fuel in new tank Install in the reverse order of removal. Always replace the O ring with a new one once FDM removed. Ensure the FDM top flange extension should be matched with the arrow mark on the fuel tank shell as shown in the above illustration. Using a suitable metal shaft and hammer, tap the FDM lock ring to get properly lock. ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Caution",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040182.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Caution",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040218.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Caution",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040220.jpg",
+ "display_order": 28
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the fuel tank for any damage and replace it if necessary. Check the tank ventilation hose for clog/debris. Check for free movement of float assembly without any restriction. Fuel System Low Pressure Circuit Test Gauge. ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040231.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Fuel System Low Pressure Circuit Test Gauge tool kit is used to diagnose Fuel System Low pressure circuit related concerns only. Without removing FDM Assembly or Fuel Tank assembly from vehicle, we can able to check the Fuel Delivery Module supply pressure. Any blockages/ choke or air entrapment in Fuel line low pressure circuit can be diagnosed by using this Kit. This high pressure fuel line connects High pressure pump with common rail and supplies compressed high pressure fluid to common rail. Remove the engine top encapsulation cover. Using 10 mm socket spanner, Remove engine WH carrier mounting nuts and detach partially. Torque : 8 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 17 mm open end spanner loosen the mounting nut from the common rail. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 19 mm open end spanner, Unscrew fuel injection pump mounting. Torque : 30 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the high pressure pipe. Install in the reverse order of removal. Inspect the high pressure fuel pipes for any damage. Replace if found any. Inspect the high pressure fuel pipes for leakage, rectify if found. Press the lock and disconnect fuel control unit electrical connector. Using 10 mm socket spanner, Unscrew engine wiring harness carrier mounting stud from Cam cover and detach it partially. Using 17 mm open end spanner, Unscrew High pressure pipe mounting flare nut from common rail end Using 19 mm open end spanner, unscrew High pressure pipe flare nut from injection pump end. Disconnect fuel inlet tube quick couplers from fuel injection pump & FCU. All are quick fix connectors, press gently and remove it carefully to avoid seal damages. Using nose plier release fuel return hose spring band clamp and detach hoses from fuel injection pump & FCU. Using 10 mm socket spanner, Unscrew fuel return line 'T' bracket mounting bolts. Using 12 mm socket spanner, Unscrew Cam box mounting bolts and remove the bolts. Rotate the Cam Box Assembly as direction shown in the image to access fuel high pressure pump mounting bolts. Using T30 socket spanner unscrew fuel high pressure pump mounting bolts and detach pump. Remove Cam box assembly along with FCU from engine. While taking out Cam box, ensure to move the tappet in upward direction by hand. Inspect the FIP for any physical damage. Replace if found Position the Cam box on Intake cam shaft rear end. While Installing Cam box, ensure to move the tappet in upward direction by hand. Check the condition of Cam box gasket during Installation and replace if it damaged ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011137.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Before Installation of Cam box mounting bolts, Rotate the Cam Box Assembly as direction shown in the image to install fuel high pressure pump mounting bolts. Position the fuel pump on Cam box and install mounting bolts. Tighten the mounting bolts to the specified torque value. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040214.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "While Installing the pump always replace the Gasket with a new one. While torque tighten the Pump mountings, hold the Cam box Assembly by second technician as shown. Rotate the Cam Box Assembly direction as shown in the image to original position. Install the Cam box mounting bolts.Tighten the bolts to the specified torque value Torque : 25 \u00b1 3 Nm Torque : 25 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010061.jpg",
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Tightening Sequence ",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install fuel return line 'T' bracket mounting bolts. Tighten the bolts to the specified torque value Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refit fuel return hoses and lock it by spring band clamp. Connect fuel inlet tube quick coupler at pump end & FCU. Position the Fuel HP pipe and tighten the mounting on Common rail end to the specified torque value. Torque : 25 \u00b1 2.5 Nm</bl> ",
+ "file": null,
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Position the Fuel HP pipe and tighten the mounting on FIP end to the specified torque value. Refit the engine wiring harness carrier mounting studs on Cam cover and torque tighten the studs. Torque : 8 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Connect the fuel control unit electrical connector. Refit the engine top encapsulation cover. The injector uses electronically controlled solenoid actuation for precise control of injection. The solenoid injectors can inject very small quantities of fuel. The injection can be split into pilot, main and post injection. Or without pilot, post and only main injection. Each fuel injector is mounted directly above the piston within the cylinder head and is connected to the fuel rail by rigid steel lines that can withstand the high fuel pressure. The actuation of injectors is done by EMS ECU. Remove the Injectors 3rd & 4th HP Pipes. Using a 10 mm socket spanner, loosen and remove the engine WH carrier mounting nuts and detach partially. Torque : 8 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 17 mm open end spanner, loosen and remove the HPP pump to common rail at rail end. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 19 mm open end spanner , loosen and remove the HPP pump to common rail at pump end. Torque : 30 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove injector leak-off pipe lock clip and detach leak off pipes from the injector end. Disconnect Injectors 3rd & 4th electrical connectors from the injectors. Using 8 mm Allen socket spanner, loosen and remove the injector clamp mounting bolt. Torque : 32 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the Injectors 3rd & 4th from cylinder head. Injector Bore must be covered with lint free cloth/Masking tape to avoid foreign objects entering injector bore/ cylinder. Plug the fuel inlet and wiring harness connector slot as soon as injector is removed. Store the injector in a neat tray. Never drop the injectors. Never clean the injector using pressurized water. Install in reverse order of removal. Always replace the injector lower copper washer and O\u2013 ring with new ones when ever injector is removed ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040234.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "For New Injector replacement carry out Component Replacement Procedures Injector replacement by using i-SMART. For additional information refer Diagnosis Manual. ",
+ "file": null,
+ "display_order": 33
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any cracks, damage etc, replace if found any Fuel control unit consists of a solenoid valve which controls the amount of fuel entering the PF pump according to the instruction from EMS ECU and thus regulates the optimum fuel pressure desired for various engine conditions. Remove the engine top encapsulation cover Press the lock and disconnect fuel control unit electrical connector Press the lock and disconnect fuel control unit inlet and outlet pipes. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Using hose clamp plier, Release metering unit fuel return hose clamp and disconnect hose. Using 12 mm socket spanner Unscrew Fuel Control Unit mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove fuel control unit assembly from vehicle Install in the reverse order of removal. Inspect Fuel Control Unit for any physical damage, replace if found any. . Inspect fuel pipes for any damage. Replace if found any. Using hose clip plier release the hose clip from the fuel filler neck Disconnect the fuel vent hose quick coupler from fuel filler neck. Using vehicle key open the fuel lid Rotate the fuel cap anti-clockwise to remove from the fuel filler neck. Using 10 mm socket spanner, Unscrew fuel filler neck mounting nuts. Torque : 5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040124.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Gently pull out the fuel filler neck from the vehicle. Install in the reverse order of removal. Inspect the filler neck for any damage. Replace if found any Check the mounting clips for any damage. Replace the clips if found damaged. Fuel Delivery Module delivers the fuel to the low pressure line and to measure the fuel level in the tank. Fuel delivery module consists : ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040184.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Float assembly for fuel level status. An electric motor with inbuild reservoir for pumping the fluid. The entire fuel delivery module is immersed in fluid and the electric motor is lubricated by fuel itself. Remove the fuel tank assembly. Disconnect the pig tail electrical connector. Using screw driver, loosen and Remove the Fuel tank heat Shield mounting clamp from the tank. Press the lock and disconnect the fuel supply line and return line pipe from the fuel delivery module and remove the hoses from the fuel tank. Using suitable metal shaft and hammer, tap the FDM lock ring and remove the lock ring from FDM unit. Remove fuel delivery module and O ring from the tank Install in the reverse order of removal. Always replace the O ring with a new one once FDM removed. Ensure the FDM top flange extension should be matched with the arrow mark on the fuel tank shell as shown in the above illustration Using a suitable metal shaft and hammer, tap the FDM lock ring to get properly lock. ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040218.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040220.jpg",
+ "display_order": 27
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect fuel delivery module for any damage. Inspect the float assembly for any damage. The common fuel rail is a high pressure accumulator in which the fuel from high pressure PF Pump is accumulated and is maintained at required pressure. This pressure sensor is fitted on the fuel rail and gives a close loop control of the rail pressure. Fuel is maintained at a high pressure in the fuel rail depending on requirement of the engine. Remove the intake manifold. Press the lock and disconnect the rail pressure sensor electrical connector. Using 17 mm open end spanner, loosen and remove the HPP pump to common rail at rail end. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 17 mm open end spanner loosen the high pressure pipe flare nuts at common rail side and injector side. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040094.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "While loosening the high pressure pipes at Injector end, hold the injector pipe connector by 13 mm Open end spanner. Using 12 mm socket spanner, loosen and remove common rail mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the common rail from the vehicle. Install in the reverse order of removal. Inspect the common rail for any damage. Replace if found. Inspect the connector for any damage. Inspect the rail pressure sensor for any damage. The fuel tank is a reservoir for the fuel and incorporates the Fuel delivery module inside. Disconnect the fuel tank electrical connector Remove the fuel supply and return hose quick coupler from tank side. Detach the vent hose to fuel tank quick fix coupler. Using hose clip plier remove the fuel filler hose clip then remove the fuel filler hose. Using hydraulic jack support tank to remove from the vehicle Using 14 mm socket spanner, loosen and remove the fuel tank mounting bolts and nut. Torque : 50\u00b15 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using Supported hydraulic jack lower the fuel tank from the vehicle . Install in the reverse order of removal. Check the fuel tank for any damage and replace it if necessary. Check the tank ventilation hose for clog/debris. The fuel filter filters impurities that may be present in the fuel. The fuel system operates under high pressure which makes it absolutely essential for the fuel to be dust free and moisture free. The fuel filter also has the water separator which filters the moisture that may have crept into the fuel. The high pressure pump in the fuel system operates at high speeds and fine clearance which needs the diesel to be dust free and also be free of moisture at the same time. Since the diesel itself lubricates the PF Pump, If water content is present in fuel, the fuel looses its lubrication property and thus PF Pump and injectors will get damaged. Also the moisture content may lead to formation of rust on the pump elements. This makes it advisable not to use diesel with additives which may cause damage to the PF Pump. Press the lock and disconnect the electrical connector from the fuel filter Press the lock and disconnect fuel filter supply line from the fuel filter All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Press the lock and disconnect fuel filter return line from the fuel filter. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Using 12 mm socket spanner loosen and remove the fuel filter assembly mounting bolts from the vehicle. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the filter from the vehicle Install in the reverse order of removal. Check and ensure proper fitment of fuel lines, any leakage can lead to fire. Inspect the fuel filter assembly for any physical damage, replace if found. Inspect the fuel lines and connectors for any damage. Replace if damaged Fuel Delivery Module delivers the fuel to the low pressure line and to measure the fuel level in the tank. Fuel delivery module consists : ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Float assembly for fuel level status. An electric motor with inbuild reservoir for pumping the fluid. The entire fuel delivery module is immersed in fluid and the electric motor is lubricated by fuel itself. Remove the Fuel Delivery Module Assembly. Press the level sensor towards swirl pot center with moderate strength and unlock the sensor from the clip of the holder Then move the level sensor in upward direction with moderate strength towards swirl pot center from the holder and remove the sensor assembly from the FDM. Detach the wiring from the FDM housing. By Using suitable pin take out the wiring pins from sensor. Pressing the both sided snap-on tabs of the cable connector through the opening of the housing and cover carefully and simultaneously pull out the wire connectors from float unit. Prior to the Installation, both the wiring connector snap-on tabs have to be bent back to the right position as shown below (By using Knife or suitable tool) Plug the wiring connectors pins on the New sensor housing at appropriate place with moderate force Ensure to Plug the wiring connectors pins on the New sensor housing at appropriate slots based on wiring colour as shown. The firm snap-on of the wire connectors is to be examined by a moderate pulling examination. ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040203.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Attach the wiring on FDM housing Lock the sensor on the mount & refit the sensor assembly on the FDM. Refit the Fuel Delivery Module Assembly. Check for free movement of float assembly without any restriction. Inspect the float assembly for proper working condition. Check for any damage in float assembly, If any damage found replace it. The fuel filter filters impurities that may be present in the fuel. The fuel system operates under high pressure which makes it absolutely essential for the fuel to be dust free and moisture free. The fuel filter also has the water separator which filters the moisture that may have crept into the fuel. The high pressure pump in the fuel system operates at high speeds and fine clearance which needs the diesel to be dust free and also be free of moisture at the same time. Since the diesel itself lubricates the PF Pump, If water content is present in fuel, the fuel looses its lubrication property and thus PF Pump and injectors will get damaged. Also the moisture content may lead to formation of rust on the pump elements. This makes it advisable not to use diesel with additives which may cause damage to the PF Pump. Park the vehicle on level work bay Open the bonnet and lock it in open position using bonnet stay rod Ensure that the fuel is drained from filter assembly before the fuel filter element is removed. Do not hold fuel filter body part and avoid damage to the fuel filter body. Press the lock and disconnect the electrical connector from the fuel filter. Disconnect the fuel supply pipe by disconnecting the quick coupler. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Disconnect the fuel return pipe by disconnecting the quick coupler. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Using a 12 mm socket spanner, loosen and remove the fuel filter assembly mounting bolts. Remove the filter from the vehicle. Use two approx. 2\u2013 3 inches long size M12 bolts and nuts to hold fuel filter assembly in a bench vice as shown in illustration. Using a 36 mm ring/socket spanner, rotate the fuel filter bottom cover in anticlockwise direction and loosen. Remove the fuel filter body. Take out the filter element from the fuel filter housing. Remove the O-ring from the fuel filter housing. Assemble the new O-ring back on to filter housing, which is supplied along with new filter element. Ensure little oil is smeared on to the surface of O-ring before assembly on to head. Insert the filter element correctly into housing as shown in illustration. Press the filter element by gentle push into the head. Refit the fuel filter element into the fuel filter housing. Assemble filter element on to head in the direction shown. Ensure open end of filter element goes inside first. Tighten the filter body using 36 mm size socket spanner to specified torque value. Do not over tighten beyond 25\u00b15 Nm. This may cause damage to the bowl and Head. Is it recommended to tight the fuel filter using torque wrench. Remove the filter assembly from the wise. Refit the fuel filter assembly and install the mounting bolts. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Reconnect the fuel filter fuel return line quick coupler. All are quick fix connectors, press gently and refit it carefully; avoid seal damages. Check and ensure proper fitment of fuel lines, any leakage can lead to fire. Reconnect the fuel filter fuel supply pipe quick coupler. All are quick fix connectors, press gently and refit it carefully; avoid seal damages. Check and ensure proper fitment of fuel lines, any leakage can lead to fire. Reconnect the fuel filter electrical connector. Always use recommended filter element only. Before removing the fuel filter, open the fuel tank cap to release the pressure from the tank and fuel lines. Fuel filter cartridge needs to be replaced earlier in case of repeat water in fuel warning in cluster even after the water is drained from the system. The injector uses electronically controlled solenoid actuation for precise control of injection. The solenoid injectors can inject very small quantities of fuel. The injection can be split into pilot, main and post injection. Or without pilot, post and only main injection. Each fuel injector is mounted directly above the piston within the cylinder head and is connected to the fuel rail by rigid steel lines that can withstand the high fuel pressure. The actuation of injectors is done by EMS ECU. Remove the Injectors 1st & 2nd HP Pipes. Remove injector leak - off pipe lock clip and detach leak off pipes from the injector end. Disconnect the Injectors 1st & 2nd electrical connectors from the injectors. Using socket spanner 10 mm, Unscrew engine WH carrier mounting nuts and detach the carrier partially. Torque : 8 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 8 mm Allen socket spanner, Unscrew the injector clamp mounting bolt. Torque : 32 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the Injectors 1st & 2nd from cylinder head. Injector Bore must be covered with lint free cloth/Masking tape to avoid foreign objects entering injector bore/ cylinder. Plug the fuel inlet and wiring harness connector slot as soon as injector is removed. Store the injector in a neat tray . Never drop the injectors. Never clean the injector using pressurized water. Install in reverse order of removal. Always replace the injector lower copper washer and O\u2013 ring with new ones when ever injector is removed. ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040234.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "For New Injector replacement carry out \u201cComponent Replacement Procedures \u2014Injector replacement\u201d by using i-SMART. For additional information refer Diagnosis Manual. Check for any cracks, damage etc, replace if found any. This high pressure fuel lines connects common rail with injectors and thus supplies high pressure fluid to injectors. Remove the engine top encapsulation cover. Using 17 mm open end spanner loosen the high pressure pipe flare nuts at common rail side and injector side. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040094.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "While loosening the high pressure pipes at Injector end, hold the injector pipe connector by 13 mm Open end spanner. Remove the high pressure fuel pipes from the vehicle. Install in the reverse order of removal. Inspect the high pressure fuel pipes for any damage. Replace if found any Inspect the high pressure fuel pipes for leakage, rectify if found. Remove the wheel. For additional information refer to Wheel \u2013 R&R Section. Remove the tyre from the rim. Using a T10 Socket Spanner, loosen and remove the TPMS sensor mounting screw and detach the sensor. The TPMS and Valve cannot be replaced separately. These can be replaceable as assembly. The valve must be positioned just left of the start position to avoid sensor damage. Do not touch the sensor with the tyre tool. Starting to mount the tyre from the valve location is a wrong fitment. The fixing tool/ stem may hit the sensor and damage it. Start from the opposite direction. By using suitable TPMS removal/Installer tool, remove the valve from the rim. Install in the reverse order of removal. Ensure that the TPMS Sensor is not damaged while removing the tyre. Check the tyre inner surface for cuts and punctures. TPMS Manual Learning is the process by which the identities of 5 sensors installed inside the tyres are learnt & programmed in to the memory of receiver module. It should be mandatory to performe on any of the following conditions or operations done. Any of the old TPMS sensors are damaged & sensors are replaced. Any of the tyre among 5 tyres are replaced. If any of the tyres or set of tyres are shuffled or swapped in position. If tyres rotation operation is performed. If observed that the alert indications in TPMS screen are not correlating with respect to their actual position in vehicle. Once the manual learning is initiated the sensors inside the tires needs to triggered by leaking the air from each tire one at a time and should be completed within 90 secs post to each event for learning all 5 tires. Do not perform Manual learning process at the same time on two vehicles with in the radius of 20 meters. Any of the tyre among 5 tyres are replaced. If any of the tyres or set of tyres are shuffled or swapped in position. It is mandatory that manual learning of tyres should follow the sequence of \u2018front left tyre position, front right tyre, rear right tyre, rear left tyre and spare tyre\u2019. It is required to ensure the tires are having pressure > 32 psi & < 36 psi before initiating the manual learning process. Post to manual learning all tire should be filled with recommended tyre pressure value . At any point of time during the learning process if learning takes more than 90 secs of time for each tire position then the system shall exit the learning mode and show the Learning not successful screen. At a time, only one tyre can be swapped with the spare wheel and then follow the learning procedure. Position the vehicle on a flat surface. Press the Scroll Up arrow button on Driver side switch bank and simultaneously turn the ignition ON. Wait for cluster\u2019s tachometer & speedometer self-check rotation and then release the arrow button. Identifying weather the learning is initiated. Infotainment will show popped out screen TPMS Learning screen. TPMS telltale in cluster shall keep blinking. Three vehicle siren chirps will be heard. If failed to enter in to manual learning mode Try initiating the manual learning once again. Check if reverse gear is engaged, if engaged disengage it. Check MBFM, Infotainment & Cluster software versions. Check if variant coding is done in all three. Check if Scroll Up arrow button on Driver side switch bank button is working fine. TPMS learning procedure must be done in the below sequence: Front left tyre Front right tyre Rear right tyre Rear left tyre Spare tyre Start leaking the air from front left tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If front left tyre is learned 1 siren chirp sound is heard and FL tyre shows learned in infotainment system. Start leaking the air from front right tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If front right tyre is learned 1 siren chirp sound is heard and FR tyre shows learned in infotainment system. Start leaking the air from rear right tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If rear right tyre is learned 1 siren chirp sound is heard and RR tyre shows learned in infotainment system. Start leaking the air from rear left tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If Rear left tyre is learned 1 siren chirp sound is heard and RL tyre shows learned in infotainment system. Start leaking the air from the spare wheel tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If spare tyre is also learned then 1 siren chirp sound is heard and ALL tyres show learned at respective tyre positions and \u2018All tyres Learned successfully\u2019 in the center of the screen. At any point of time during the learning process, if learning takes more than 90 seconds of time for each tyre position then the system shall exit the learning mode and show the \u201cLearning not successful\u201d screen. After tyre rotation or TPMS sensor replacement, TPMS must be learnt,otherwise the system will show TPMS malfunction indicator. TPMS learning need to be carried out whenever : Tyre rotation happens. 2 or more wheels are swapped. TPMS sensor is replaced. MBFM is replaced. The TPMS should not be used as a tyre pressure gauge while adjusting vehicle tyre pressure. No two vehicles should be done with manual learning process at a time in same location with in radius of 20 meters. Post to manual learning all tire should be filled with recommended tyre pressure value. Verify the customer concern. Visually inspect the transfer case for any noticeable signs of mechanical damage. If an obvious cause is found during the inspection, correct the same before proceeding to the next step. If the cause is not visually evident, verify the symptom and refer to troubleshooting chart. Mechanical ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Check for any oil leakage in the transfer case. Check the yoke, flange and drive gear for any damage. Check for loose mounting bolts. Remove the gear shifter level knob and 4WD selection knob by rotating them in anticlock wise direction. Using trim removal tool, remove the gear selection rod cover with trim. For AT Variants top trim removal follow (Steps 3 - 8) : Pull and fold the gear shifter boot from gear shifter bezel. Partially detach the bezel from the console. Excessive pull may leads to damage of the electrical connector. Disconnect the AT gaiter electrical connector from the bezel. Carefully remove the bezel trim from the TGS lever. Handle bezel assembly carefully to prevent it from damage or scratches. Using trim removal tool, carefully remove the floor console top trim with transfer case shifter boot. Detach the transfer case cable abutment from the shifter bracket by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Using 13 mm socket spanner unscrew transfercase shifter lever assembly mounting nuts. Take out the shifter and tilt the lever assembly gear shifter lever side to remove the TC shifter cable 'R' clip. Detach the TC shifter cable from shifter assembly. Remove the transfer case shifter from the vehicle. Inspect the transfer case shifter for any damage. Replace if found any. Position the transfer case cable on shift lever bracket. Install the shifter cable locking R clip Position the transfer case shifter lever assembly Position the transfer case shifter lever at 2H position. Ensure that the transfer case link should be in 2H position on transfer case (Extreme Rear end position from front of the vehicle). Refit the transfer case cable abutments on shift lever bracket. Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Refit the shifter lever assembly mounting nuts. Tighten the mounting nuts to specified torque value. Torque : 22.51\u00b14 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120007.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120048.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from '2H' to other range. If Shifting not smooth Carry-out Transfer Cable setting. For AT Variants top trim Installation follow (Steps 8 \u2013 12) : Connect the AT gaiter electrical connector with the bezel. Refit the bezel trim with shifter bezel Handle bezel assembly carefully to prevent it from damage or scratches. Unfold the gear shifter boot and refit the boot with gear shifter bezel. Refit the 4WD selection knob by rotating it in clock wise direction Refit the Manual transmission gear selection rod cover with trim. Refit gear shifter level knob and 4WD selection knob by rotating them in clock wise direction. Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from 'N' to other range Inspect that engine can be started with shift lever only 'N' or 'P', but not in other range (For AT variants) Inspect that indicating lamp can be turned on correctly in PRND positions (For AT variants). Remove the Air Cleaner Assembly. Using MST 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the transfer case shifter cable from the transfer case ball pins. Detach the transfer case cable abutment from the cable bracket on transmission by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don't hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Using 10 mm socket spanner unscrew shifter cable grommet mounting bolts on fire wall. Remove the gear shifter level knob and 4WD selection knob by rotating them in anticlock wise direction. Using trim removal tool, remove the gear selection rod cover with trim. For AT Variants top trim removal follow (Steps 7 \u2013 12) : Remove the 4WD selection knob by rotating it in anti-clock wise direction.Pull and fold the gear shifter boot from gear shifter bezel. Partially detach the bezel from the console. Excessive pull may leads to damage of the electrical connector. Disconnect the AT gaiter electrical connector from the bezel. Carefully remove the bezel trim from the TGS lever. Handle bezel assembly carefully to prevent it from damage or scratches. Using trim removal tool, carefully remove the floor console top trim with transfer case shifter boot. Remove the floor console side trim mounting screw rivet and remove the trim both sides. Detach the transfer case cable abutment from the shifter bracket by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Detach the transfer case cable from the cable bracket routing clamp. Using nose plier, remove cable cross pin from the transfer case shifter and detach shifter cable. Keep the Transfercase shifter in 4L position while remove R Clip. Detach the cable from lever and take out from vehicle. Keep the Transfercase shifter in 2H position while remove the cable. Inspect the transfer case for any damage. Replace if found any. Position and route the cable inside the vehicle. Move shifter to 2H position and attach the cable with the shifter lever. Keep the Transfercase shifter in 2H position while refit the cable. Refit shifter cable R clip with the transfer case shifter cable. Keep the Transfercase shifter in 4L position while refit R Clip. Attach the transfer case cable abutment with the shifter bracket by pressing locking clip. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Attach the transfer case cable with the cable bracket routing clamp. Refit the floor console side trim and install the mounting screw rivet. Refit the gear selection rod cover with trim. Refit gear shifter level knob and 4WD selection knob by rotating them in clock wise direction. For AT Variants top trim Installationfollow (Steps 9 \u2013 13) : Connect the AT gaiter electrical connector with the bezel. Refit the bezel trim with shifter bezel. Handle bezel assembly carefully to prevent it from damage or scratches. Unfold the gear shifter boot and refit the boot with gear shifter bezel. Refit the 4WD selection knob by rotating it in clock wise direction. Refit shifter cable grommet and install the mounting bolts on fire wall. Ensure the cable grommet should get assemble from outside of the cabin. Torque :10 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120013.jpg",
+ "display_order": 89
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Position the transfer case lever at 2H position on transfer case (Extreme Rear end position from front of the vehicle). Refit the transfer case cable abutments on transmission cable brackets. Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. For adjust cable length, move the cable quick adjuster outer cover in forward direction and unlock the QA clip. Adjust the cable length to fix the cable on link ball pin. After adjusting the length, position the quick adjuster body on link ball pin. Once quick adjuster body snap on ball pin, press the QA clip towards arrow mark shown to lock it fully and release the cable quick adjuster outer cover. Ensure the proper locking by confirming/ hearing the click noise while install. Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from '2H' to other range. Using a 10 mm socket spanner, loosen and remove the battery negative terminal. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance .Before disconnecting the battery, check for the audible sound of EWP ON. Remove Rear Propeller Shaft Assembly. For additional information refer to Rear Propeller Shaft R&R Session. Using a 8 mm socket spanner, loosen and remove the front propeller shaft mounting C clamp bolts from the transfer case. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120021.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the transfer case electrical connector. Using a MST 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool , detach the transfer case cable from the transfer case ball pins. Pressing locking clip and detach the transfer case cable abutment from the cable bracket on transmission and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Provide a jack to support the transmission. Using a 12 mm socket spanner, loosen and remove the transmission bed mounting bolts. Torque : 70\u00b15 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110012.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 14 mm, 15 mm socket and ring spanners, unscrew transmission cross member mounting bolts, nuts and detach it. Torque : 65 \u00b110.0 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110030.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using a 15 mm socket spanner, loosen and remove the transfer case mounting nuts. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W311.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W312.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W313.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110043.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Heading",
+ "content": " For Automatic Transmission ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner unscrew AT shifter cable routing bracket mounting bolts Using 12 mm socket spanner unscrew transfercase front facing mounting bolts. Using 12 mm socket spanner unscrew transfercase rear facing bottom mounting bolt Using 12 mm ring spanner unscrew transfercase rear facing top mounting bolt. Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Torque Value",
+ "content": " Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Torque Value",
+ "content": " Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110029.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Remove the transfer case from the vehicle. Install in reverse order of removal. While Installation of transfer case cable abutments on transmission cable brackets, Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. After Installation of Transfer Case Assembly on vehicle, Carry-out below cable setting Procedure. For adjust cable length, move the cable quick adjuster outer cover in forward direction and unlock the QA clip. Adjust the cable length to fix the cable on link ball pin. After adjusting the length position the quick adjuster body on link ball pin. Once quick adjuster body snap on ball pin, press the QA clip towards arrow mark shown to lock it fully and release the cable quick adjuster outer cover. Ensure the proper locking by confirming/ hearing the click noise while install. Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from '2H' to other range. Check transfer case oil level & top up if required. Inspect the transfer case for any damage. Replace if found any. Drain the Transfer case fluid. For additional information refer to Transfer case fluid Drain & Filling Section. Remove the Transfer case from the vehicle. Position the transfer case on the suitable Wooden/ Nylon blocks. Ensure the oil is drained prior to disassembly of the transfer case. Using a Special tool MST 203 Companion Flange Holding Tool, hold the transfer rear flange. Using a 30 mm socket spanner, loosen and remove rear flange center nut. Torque Value : 340 - 370 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120066.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120131.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120132.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120067.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a magnetic stick, take out flange washer and remove seal from transfer case rear flange. Ensure the use New washer & Seal while installation. Using a mallet, remove the transfer case rear flange. Use suitable 2 Jaw puller to remove the flange, In case of flange not able to remove by mallet. Using a 10 mm square bit spanner, remove the transfer case draining & filling oil plugs from the cover. Using a 15 mm socket spanner remove the assembly cover mounting bolts and remove the mounting bolts & identification tag. Separate the front assembly cover and the rear case assembly To avoid damage of the metal surface, apply limited force to the bosses on the cover and the transfer case while breaking the sealant bond. Using a flat end screw driver, remove transfer case Rear output shaft oil seal from the cover. Remove the Spacer from the cover. Separate the return spring from the front assembly cover by pulling them outwards. Using flat screw driver& circlip plier, remove the ball bearing snap ring. Rotate the cover and by using MST 0707BBA0003ST - Universal Mandtral remove the ball bearing from the cover. By using suitable Internal puller, pull out the needle bearing from the cover. Care must be taken not to damage the metal surface while removing the needle bearing. Position the transfer case casing and remove the shift collar hub from the output shaft. Remove the 2W-4W lock up assembly and lock up fork together from output shaft and separate lock up fork from the 2W-4W lock up assembly. To dismantle 2W-4W lockup assembly, remove snap ring, lock up hub return spring from lock up collar. Using a circlip plier & flat screw driver, remove the snap ring from the output shaft and remove the spacer. Remove the drive chain with sprocket and drive sprocket from the output shaft. Separate the drive chain, driven sprocket and drive sprocket. Remove the magnet from the slot in the case. Remove the coupler from the case. Remove the output shaft and the gear rotor (Gearotor) pump from the case. Rotate and align the guide pin of the shaft to the slot on the pump body and Separate the gear rotor pump and strainer assembly from the output shaft. By using nose plier, remove the hose clip and remove the hose from pump and remove the strainer. Remove the rail shaft assembly from the case. Remove the reduction hub and the reduction fork from the case. Separate the reduction hub and the reduction fork. Remove the two shift fork facings from the shift fork assembly (if required). Using a Special tool MST 203 Companion Flange Holding Tool, hold the transfer case output shaft yoke. Using a 30 mm socket spanner, loosen and remove rear output shaft yoke center nut. Torque Value : 340 - 370 Nm ",
+ "file": null,
+ "display_order": 94
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120142.jpg",
+ "display_order": 95
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120143.jpg",
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "Description",
+ "content": "Using a magnetic stick & flat screw drive , take out flange washer and remove seal from transfer case output shaft yoke. Ensure the use New washer & Seal while installation. Using a mallet, remove the transfer case rear flange. Use suitable 2 Jaw puller to remove the flange, In case of flange not able to remove by mallet. Remove the lower output shaft from the casing. Using a 15 mm socket spanner, remove the adapter assembly, input shaft and carrier assembly bolts. Take out the adapter assembly with input shaft and carrier assembly. Using an outer circlip plier, Expanding the long ends snap ring unlock the bearing lock circlip and remove the input shaft and carrier assembly. Remove snap ring and oil seal from adapter assembly. Remove the input shaft bearing retaining ring. Remove the bearing by hitting input shaft by mallet and remove the thrust washer from input shaft. Remove the ASM Carrier from the input shaft. Remove the sun gear snap ring from ASM Carrier. Remove the thrust plate & sun gear from ASM Carrier. By using suitable Internal puller, remove the copper bush from the input shaft. By using suitable Internal puller, remove the needle bearing from the input shaft. By using 17 mm Open end spanner, remove the Breather (For MT variants located at Adapter plate & for AT variants at Adapter case assembly). By using 13 mm socket spanner, remove the hexagonal nut of the shift shaft. By using T25 torx spanner, remove the transfer case and shift cam torx screws. By using flat end screw driver & mallet, remove the clip ring and pull out shift shaft & lever. Remove shift lever from shift shaft. By using flat end screw driver, remove the \u2018o\u2019 ring from shift shaft. Remove 4L assist spring and roller, shifter cam. Remove plunger and spring from the transfer case. By using 24 mm ring spanner, remove 4WD indicator switch from the transfer case (If required). By using flat end screw driver, remove the oil seal from the assembly case. By using flat end screw driver, remove the retaining ring from the assembly case. By using MST 0707BBA0003ST \u2014 Universal Mandtral remove the ball bearing from the case. By using cutting plier, remove the dowel pin from transfer case. Do not remove the ring gear shown in the below figure from the case. Using a cleaning solvent, clean the old oil and dirt deposits. Before cleaning, check the magnet for the presence of metal particles which indicate internal chipping of the transfer case. After cleaning dry the parts with low pressure (20 psi maximum) compressed air. Lubricate the ball bearings and needle bearing with Transfer Case oil. Protect lubricated bearings from dust. Visually check all the parts for damage. Referring to normal gear tooth face, specifically inspect the uneven wear and chips of gear tooth. Replace or repair if necessary. Always replace the hose coupling, O-ring , oil seal and flange/Yoke Nut with new parts. Insert dowel pins to the ring gear casing. Use respective Special tools for Bearings & Oil Seal Installation. Do not directly use hammer/mallet for Installation. Lubricate oil seals, O-rings, bushings and matching metal parts before assembly (with Transfer Case oil). Lubricate the ball bearings and needle bearing with Transfer Case oil. Protect lubricated bearings from dust. Dropping of heavy/large objects will damage the part and cause personal injury. Press the ball bearing to the front casing by using MST\u2019s (0707AUA0005ST - Trasfer case Case Covers Ball Bearing Pressing tool) & (0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer). Check the ball bearing for functionality prior to installation. Using a snap ring removal tool/screw driver install the retainer ring to the front casing. Install the new output oil seal into the case by using MST\u2019s (0707BBA0001STTransfer Case Output Shafts Oil Seal Installer) & (0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer). Install new \u2018O\u2019 ring on the shift shaft and lubricate it. Refit the shift shaft in to the shift lever. Position spring and plunger in the hole of the transfer case. Ensure spring and plunger are properly seated in the hole of the transfer case and not to unseat plunger while Install Cam assembly. Partially Insert star splined end of the shift shaft into the transfer case. Position shift cam into transfer case with flat end of cam approximately parallel with front face of case (as shown in the picture). Install 4L assist spring roller in groove of shift cam and Install other end to slot of transfer case. Pressing cam against plunger and compressing spring align splines in cam and on shift shaft and press shaft fully into cam and Install clip ring in groove near inside end of shift shaft. Refit the transfer case and shift cam torx screws by using screwdriver. Torque Value : 7 \u2013 8 Nm ",
+ "file": null,
+ "display_order": 212
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Notice",
+ "content": "Make sure that shift shaft is fully engaged so that second screw end enters groove in shaft. Refit the hexagonal nut of the shift shaft, Torque tighten mounting nut to specified value. Torque Value : 41 \u2013 48 Nm ",
+ "file": null,
+ "display_order": 216
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120178.jpg",
+ "display_order": 217
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Install 4WD indicator switch to transfer case. Torque Value : 34 \u2013 48 Nm ",
+ "file": null,
+ "display_order": 219
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120180.jpg",
+ "display_order": 220
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120179.jpg",
+ "display_order": 221
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Press the needle bearing into the input shaft by using MST\u2019s (0707AUA0004ST - T Case Input Shaft NRB Pressing tool & 0707BBA0003ST - Universal Mandtral - Oil Seal/ Bearing Installer). Press the new sleeve bearing into the input shaft by using MST\u2019s (0707AUA0003ST - T Case Input Shaft Sleeve Pressing tool & 0707BBA0003ST - Universal Mandtral - Oil Seal/ Bearing Installer. Install the sun gear & thrust plate on ASM Carrier. Install the sun gear snap ring on ASM Carrier. Refit the input shaft to the carrier assembly by matching the splines. Install the thrust washer onto the input shaft. Position and press the bearing onto the input shaft by using a MST 0707AUA0002ST - T Case Input Shaft Ball Brg Pressing tool. Install the retaining ring on the input shaft assembly by using circlip plier. Install snap ring by making sure that snap ring is correctly install in the groove. Using a circlip plier expand the snap ring and insert the carrier assembly with input shaft to the adapter case and release the snap ring. Ensure that carrier assembly with input shaft position properly to the adapter case and snap ring seated properly to hold the assembly. Install the oil seal on carrier assembly body by using a MST\u2019s For MT Variants : 0707BBA0002ST - Transfer Case Input Shaft Oil Seal Installer - MT For AT Variants : 0707BAJ0001ST \u2014 Transfer Case Input Shaft Oil Seal Installer - AT and 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Apply a 1.6 mm bead of Loctite RTV598 sealant on the mounting face for the transfer case. Refit the carrier assembly to the case and using a 16 mm socket spanner, tighten the mounting nuts to specified torque. Torque Value : 34 \u00b1 6 Nm ",
+ "file": null,
+ "display_order": 263
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120204.jpg",
+ "display_order": 264
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Refit the breather nipple. Torque Value : 5 \u2013 8 Nm ",
+ "file": null,
+ "display_order": 266
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120205.jpg",
+ "display_order": 267
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120206.jpg",
+ "display_order": 268
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Description",
+ "content": "Position the output shaft in the transfer case. Position the output shaft in transfer case, and install the end yoke assembly, seal, washer and the lock nut. Using a Special tool MST 203 Companion Flange Holding Tool, tighten the front flange mounting lock nut to specified torque. Torque Value : 340 - 370 Nm ",
+ "file": null,
+ "display_order": 279
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120216.jpg",
+ "display_order": 280
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "Description",
+ "content": "Install the two forks facing on the reduction shift fork assembly. Install the reduction hub in to the fork. Refit the reduction hub and reduction shift fork into the planet carrier. Slide roller of fork in to the cam groove. Insert shift rail in reduction fork bore, to match with case bore. Align rotor slot of the pump and slot of the pump body in line. Align the slide the pump assembly on output shaft over pump pin. Align the guide pin of the shaft to the slot on the pump body and slide the pump assembly onto the output shaft over pump pin. Assemble the strainer and hose to the gear rotor pump. Install the output shaft and gear rotor pump assembly into the reduction hub housing by matching the splines. Couple strainer with case and insert the magnet into the transfer case slot. Install the drive chain onto the sprockets. Position the drive sprocket to the rear output shaft end and driven sprocket to the front output shaft end. Holding each sprocket with the drive chain tight and parallel with the transfer case, install the drive chain assembly to the output shaft. Rotate the driven sprocket slightly to engage splines on the front output shaft. Install the spacer to the front output shaft. Install the snap ring into the groove of the front output shaft. Install the lockup hub and return spring to the lockup collar and insert the snap ring. Install new facings to the fork. Engage the lockup fork in the groove in 2WD-4WD lockup assembly and slide this assembly down over output shaft and rail shaft. Install shift collar engaging splines on output shaft and in 2WD-4WD lockup assembly. Position the cover with the open end facing up on the table. Position the end of the needle bearing with the identification mark and up the press into the cover by using a MST\u2019s (0707AUA0006ST \u2014 T Case Rear Cover NRB Pressing tool & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer). Press the ball bearing into cover by using MST\u2019s (0707AUA0005ST \u2014 T Case Covers Ball Brg Pressing tool & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer). Install snap ring over the ball bearing into cover by using screw driver or circlip plier. Install the return spring over rail shaft in the transfer case. Position the cover with the open end facing down on the table. Install the spacer over output shaft spline in the cover assembly. Press the new oil seal into the cover assembly by using MST\u2019s (0707BBA0001ST \u2013 Transfer Case Output Shafts Oil Seal Installer & 0707BBA0003ST \u2013 Universal Mandtral - Oil Seal/ Bearing Installer). Apply 1.6 mm bead of Loctite RTV598 to the transfer case mounting surface. Position and align the transfer case with cover. Do not use excessive force. Follow the below steps while Installing the cover into the transfer case Align the cover holes with the transfer case dowel pins. Align the cover bearing with output shaft. Align the cover blind hole with rail shaft and make sure that return spring is not cocked. Do not apply excessive force while Installation. Refit the front and rear housing cover mounting bolts along with identification tag and torque tighten the bolts to specified value. Torque Value : 34 \u00b1 6 Nm ",
+ "file": null,
+ "display_order": 369
+ },
+ {
+ "step_name": "Step-61",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120274.jpg",
+ "display_order": 370
+ },
+ {
+ "step_name": "Step-61",
+ "content_type": "Description",
+ "content": "Install the two oil plugs to the cover, torque tighten the nuts to specified value. Torque Value : 34 \u00b1 6 Nm ",
+ "file": null,
+ "display_order": 372
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120275.jpg",
+ "display_order": 373
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120276.jpg",
+ "display_order": 374
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120277.jpg",
+ "display_order": 375
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120278.jpg",
+ "display_order": 376
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "Description",
+ "content": "Install the flange,seal, washer and lock nut to the output shaft. Do not fully tighten the bolts at this stage. Using a Special tool MST 203 Companion Flange Holding Tool, hold the transfer case output shaft yoke and torque tighten the nut to specified value. Refit the Transfer case on the vehicle. Refill the Transfer case fluid. For additional information refer to Transfer case fluid Drain & Filling Section. Position the transfer case shifter lever at 2H position. Ensure cable cross pin is properly fitted on transfer case shifter Ensure the transfer case cable abutment is properly fitted on shifter bracket. Ensure the transfer case cable abutment is properly fitted on transmission cable bracket. Using a 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the transfer case cable from the transfer case ball pins. Ensure that the transfer case link should be in 2H position on transfer case (Extreme Rear end position from front of the vehicle). For adjust cable length, move the cable quick adjuster outer cover in forward direction and unlock the QA clip. Adjust the cable length to fix the cable on link ball pin. After adjusting the length, position the quick adjuster body on link ball pin. Once quick adjuster body snap on ball pin, press the QA clip towards arrow mark shown to lock it fully and release the cable quick adjuster outer cover. Ensure the proper locking by confirming/ hearing the click noise while install. Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from 2H to other range. Transfer case Oil \u2013 MAHINDRA MAXIMILE POWER STEERING FLUID Genuine Power Steering FluidCapacity \u2013 1.2 Litres.Position the vehicle on a 2 post /4 post lift Using a 10 mm square bit spanner,remove the oil filling plug from the transfer case. Place a tray beneath the drain plug for collecting the oil while draining. Using a 10 mm square bit spanner, loosen and remove the drain plug. Collect the drained oil in a suitable container. Refit the drain plug. Torque tighten the drain plug to specified value. Torque : 34\u00b16 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110414.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110412.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Fill recommended transfer case fluid with the help of a mechanical pump through filler plug. Ensure that the oil level by insert the 8 mm allen key and check the oil level mark. Refit the filler plug and torque tighten the filler plug to specified torque value. Torque : 34\u00b16 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Recommend to use only MAHINDRA MAXIMILE POWER STEERING FLUID Genuine Power Steering Fluid. In case of non-availability of Genuine fluid, SHELL MAKE SPIRAX S3 ATF MD3 can be used. In emergency conditions, fluid meeting DEXRON III specification can be used and oil change interval should be at every 40000 km. It is a structure of a pipe, which carries air into the combustion chamber in an engine. The primary function of the intake manifold is to evenly distribute the air to each intake port in the cylinder head. Even distribution is important to optimize the efficiency and performance of the engine. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the terminal. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Remove the throttle assembly. Remove the alternator assembly. Remove the EGR module assembly. Using a 10 mm socket spanner, Unscrew NVH cover mounting bracket mounting bolt. Using a 10 mm socket spanner, Unscrew wiring routing bracket mounting bolt from manifold end. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020080.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew dipstick routing bracket mounting bolt. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020115.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 8 mm socket spanner, Unscrew boost temperature sensor mounting bolt and remove it. Torque : 6 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020081.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, Unscrew intake manifold mounting bolts from cylinder block. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020112.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the intake manifold carefully from the engine. Replace the gaskets to the intake manifold whenever removed from the engine. Install in the reverse order of removal. Check the intake manifold for the external damage. If any damage found replace it. The boost downstream temperature sensor is used to monitor the intake air temperature at the intercooler outlet. The sensor is an NTC type sensor. EMS ECU uses signal from this sensor for Air-intake system control & flow rate modelling. The boost downstream temperature sensor is used to monitor the intake air temperature at the intercooler outlet. The sensor is an NTC type sensor. EMS ECU uses signal from this sensor for Air-intake system control & flow rate modelling. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the terminal. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Disconnect the boost pressure sensor electrical connector. Using 10 mm Socket Spanner, Unscrew Boost pressure sensor mounting bolt. Torque : 2.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020089.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the boost pressure sensor. Install in the reverse order of removal. Check for any external cracks or damage, replace if found any. Using 10 mm socket spanner, Loosen battery negative terminal mounting nut and disconnect the terminal. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Using 7 mm socket spanner, Loosen the intercooler inlet hose clip and disconnect the hose intercooler end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020036.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner, Loosen the intercooler outlet hose clip and disconnect the hose intercooler end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020113.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, remove boost pressure sensor mounting bolt and detach it. Torque : 2.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020114.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect the boost pressure sensor electrical connector. Using 10 mm socket spanner, Unscrew degassing tank mounting bolts and partially detach it. Torque : 4.5\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020034.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 13 mm Socket Spanner, Unscrew the Intercooler mounting bolts. Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020090.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020037.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Carefully remove the intercooler from vehicle. Install in the reverse order of removal. Check for the external damage. If found replace it. Check for any oil seepage ,if found please inspect the turbocharger for any oil leakage. Inspect intercooler hoses for any damage. Replace if found any. Inspect intercooler rubber Isolators for any damage. Replace if found any. The air filter housing is made up of two parts. The bottom housing and top housing with the air filter element sandwiched in between. Air is drawn through the dirty side intake duct into the bottom housing. It gets filtered and passes on via top housing, throttle valve into the intake manifold. Using 10 mm socket spanner, Loosen battery negative terminal mounting nut and disconnect the terminal. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Using 7 mm socket spanner, Loosen the intercooler inlet hose clip and disconnect the hose intercooler end. Torque : 6.5 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Ensure the sensor is stored in a dust free area Using 12 mm socket spanner, Unscrew air cleaner assembly mounting bolts from BIW. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020118.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully take out the air cleaner assembly and air intake dirty duct. Using a 5 mm allen key, loosen and remove the dirty side duct mounting bolts from the air cleaner assembly then separate the air cleaner assembly. Install in the reverse order of removal. Check the air cleaner housing for the external damage. If any damage found replace it. The air cleaner element is Non woven +Pleated Media type (Dry Type). Filtration happens in two stages. Coarser particles are filtered in first stage by foam media and fine particles are filtered by Paper media in second stage. The dust and other fine particles which are sucked inside along with air gets trapped in the air cleaner while passing through the filter element. Don\u2019t tap or hit the filter element. Park the vehicle on flat work bay. Open the bonnet and lock it in open position using bonnet stay rod. The air filter element should be inspected and replaced from time to time, when driving under the following conditions: Unpaved road. Dusty air-polluted road. Long-term driving in rainy weather. Using 5 mm allen key, Unscrew air cleaner dirty duct mounting screws and lift the top housing. Gently take out the air cleaner element from the housing. Clean the inner side of the air cleaner housing using a lint free cloth. Refit the New air filter element gently inside the air cleaner housing. During Installation ensure to keep foam side of the filter element in the bottom side. Ensure dust should not fall inside the clean hose area while fitting. Always use recommended genuine air filter element. Do not tap or hit the filter element. Position the air cleaner assembly top cover and refit the mounting screws. Torque : 10 Nm ",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 346,
+ "sys_id": "THAR.LX-0005-Air Intake",
+ "subsys_id": "THAR.LX-0005-Air Intake-Intake Manifold Sensor",
+ "systems": "Air Intake",
+ "sub_systems": "Intake Manifold Sensor",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A020125.jpg",
+ "myid": 1007,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0005-Intake Manifold Sensor-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020125.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Heading",
+ "content": "Intake manifold pressure sensor is mounted located at the plenum of the intake manifold. This sensor continuously monitors the variation in intake air pressure. EMS ECU uses this information for fuel correction, EGR control & turbocharger pressure control. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the terminal. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Remove the engine top encapsulation cover. Disconnect boost temperature sensor electrical connector. Using a 8 mm socket spanner, loosen and remove the boost temperature sensor mounting bolt. Torque : 6 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020089.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully remove the sensor from intake manifold. Install in the reverse order of removal. Check for any external cracks, replace if found any. The throttle body is used to control the air flow rate to the engine. The valve actuation in the throttle body depends upon the engine speed and torque demand from driver and is controlled by EMS Using a 10 mm socket spanner, loosen and remove the battery negative terminal Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Remove the engine top encapsulation cover. Disconnect the throttle valve electrical connector. Using a 7 mm socket spanner, loosen intercooler outlet hose clip from throttle valve end. Torque : 6.5 \u00b1 0.6Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020060.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew the throttle body assembly mounting bolts. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020091.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully remove throttle body from intake manifold. Install in the reverse order of removal. Check for any external cracks, replace if found any. The HFM sensor is used to find out the mass flow rate of air entering into fuel injection internal combustion engine. The air mass information is necessary for the ECU to balance and deliver the correct fuel quantity to the engine. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the terminal. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Disconnect the HFM sensor electrical connector. Using a 7 mm socket spanner, loosen the hose clip and detach hose from HFM sensor. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020030.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the HFM sensor mounting bolts. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020031.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020032.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the HFM sensor from the air cleaner assembly. Install in the reverse order of removal. Check for any external cracks, replace if found any. Check for the obstruction of the air flow, if found please replace. The air cleaner element is Non woven +Pleated Media type (Dry Type). Filtration happens in two stages. Coarser particles are filtered in first stage by foam media and fine particles are filtered by Paper media in second stage. The dust and other fine particles which are sucked inside along with air gets trapped in the air cleaner while passing through the filter element. Don\u2019t tap or hit the filter element. Park the vehicle on flat work bay. Open the bonnet and lock it in open position using bonnet stay rod. The air filter element should be inspected and replaced from time to time, when driving under the following conditions: Unpaved road. Dusty air-polluted road. Long-term driving in rainy weather. Using a 5 mm allen key, Unscrew air cleaner top housing mounting allen screws and lift the top housing. Gently take out the air cleaner element from the housing. Clean the inner side of the air cleaner housing using a lint free cloth. Blow the compressed air from the top clean side of filter element. Blow the compress air from the top clean side of filter element (From Paper side). Do not blow the air from bottom dirty side (Foam side). While cleaning, ensure the air pressure should be less than 2 bar. Clean the inner side of the air cleaner housing using a lint free cloth. Gently insert the air cleaner element inside the air cleaner housing. During Installation ensure to keep foam side of the filter element in the bottom side Ensure dust should not fall inside the clean hose area while fitting. Ensure dust should not fall inside the clean hose area while fitting. Always use recommended genuine air filter element. Do not tap or hit the new filter element. Refit the air cleaner top housing and install the mounting allen screws. Torque : 10 Nm ",
+ "file": null,
+ "display_order": 28
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 127,
+ "sys_id": "THAR.LX-0005-en-SM-Wheel & Tyre",
+ "system_name": "Wheel & Tyre",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1014,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 134,
+ "sys_id": "THAR.LX-0005-Wheel & Tyre",
+ "subsys_id": "THAR.LX-0005-Wheel & Tyre-Front Wheel",
+ "systems": "Wheel & Tyre",
+ "sub_systems": "Front Wheel",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A160002.jpg",
+ "myid": 1511,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0005-Front Wheel-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160002.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/56024.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/56025.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 21 mm Wheel spanner/ deep socket spanner, loosen and remove the wheel mounting bolts. Torque :140\u00b110 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the mounting bolts and then remove the wheel. Install in the reverse order of removal. Check for any external damage in the tyre or the rim, if found replace. Check for any foreign material on tyre or rim, remove if found. Using 13 mm socket spanner, loosen and remove the spare wheel carrier mounting bolts. Torque : 50\u00b17.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the spare wheel carrier from the vehicle. Install in the reverse order of removal. Check for any external damage in the spare wheel carrier , if found replace. Using 21 mm socket spanner, loosen and remove the wheel nuts on the spare wheel carrier. Torque :70\u00b110 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the spare wheel from the vehicle. Install in the reverse order of removal. Check for any external damage in the tyre or the rim, if found replace. Check for any foreign material on tyre or rim, remove if found. Position the vehicle on 2 post lift Below illustration shows suggested tyre rotation method: ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Tyres on the front and rear side of vehicles operate at different loads and perform different steering, handling, and braking functions. For these reasons, they wear at unequal rates and develop irregular wear patterns. Rotation will increase tread life. help to maintain mud, snow, and wet traction levels, and contribute to a smooth quiet ride Follow the recommended tyre rotation frequency for your type of driving more frequent rotation is permissible f desired. The reasons for any rapid or unusual wear should be corrected prior to rotation being performed It is recommended to rotate the tyres as per 'Maintenance Schedule'. TPMS Learning needs to be carried out for vehicle models equipped with TPMS(Tyre Pressure Monitoring System), procedure as below. Position the vehicle on a flat surface TPMS Learning - Procedure ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090057.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Press the Scroll Up arrow button on Driver side switch bank and simultaneously turn the ignition ON. Wait for cluster\u2019s tachometer & speedometer self-check rotation and then release the arrow button. Identifying weather the learning is initiated. Infotainment will show popped out screen TPMS Learning screen. TPMS telltale in cluster shall keep blinking. Three vehicle siren chirps will be heard. If failed to enter in to manual learning mode. Try initiating the manual learning once again. Check if reverse gear is engaged, if engaged disengage it. Check MBFM, Infotainment & Cluster software versions. Check if variant coding is done in all three. Check if Scroll Up arrow button on Driver side switch bank button is working fine. TPMS learning procedure must be done in the below sequence: Front left tyre Front right tyre Rear right tyre Rear left tyre Spare tyre Start leaking the air from front left tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If front left tyre is learned 1 siren chirp sound is heard and FL tyre shows learned in infotainment system. Start leaking the air from front right tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If front right tyre is learned 1 siren chirp sound is heard and FR tyre shows learned in infotainment system. Start leaking the air from rear right tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If rear right tyre is learned 1 siren chirp sound is heard and RR tyre shows learned in infotainment system. Start leaking the air from rear left tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If Rear left tyre is learned 1 siren chirp sound is heard and RL tyre shows learned in infotainment system. Start leaking the air from the spare wheel tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If spare tyre is also learned then 1 siren chirp sound is heard and ALL tyres show learned at respective tyre positions and \u2018All tyres Learned successfully\u2019 in the center of the screen. At any point of time during the learning process, if learning takes more than 90 seconds of time for each tyre position then the system shall exit the learning mode and show the \u201cLearning not successful\u201d screen. After tyre rotation or TPMS sensor replacement, TPMS must be learnt, otherwise the system will show TPMS malfunction indicator. TPMS learning need to be carried out whenever : Tyre rotation happens. 2 or more wheels are swapped. TPMS sensor is replaced. MBFM is replaced. The TPMS should not be used as a tyre pressure gauge while adjusting vehicle tyre pressure. No two vehicles should be done with manual learning process at a time in same location with in radius of 20 meters. Post to manual learning all tire should be filled with recommended tyre pressure value. Using chisel Remove the drive shaft mounting nut caulking. Using 36 mm socket spanner, loosen and remove Drive shaft mounting nut by Applying brake. Torque : 240 \u2013 260 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the caliper stem mounting bolts then hang the caliper. Torque : 31 \u2013 38 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Pull the Brake Pad outwards upto pad contact with clip as shown in the illustration. Twist the pad in anti clock wise direction, lift the pad upwards and remove the pad. Using 19 mm socket spanner, loosen and remove the caliper bracket mounting bolts then remove the caliper bracket. Torque : 90 \u2013 100 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using star screw driver, remove the brake disc mounting screw and detach the disc from the front wheel hub. Remove the disc separately. Using 19 mm socket spanner, loosen and remove Hub mounting bolts and remove the hub with carrier plate. Torque : 87 - 90 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160030.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Before assembly clean the mating faces of the front wheel hub and brake disc. Check for any external damage in the wheel hub, if found replace. Check for any wheel hub bearing condition, if found replace. Using 21 mm Wheel spanner/ deep socket spanner, loosen and remove the wheel mounting bolts. Torque :140\u00b110 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the mounting bolts and then remove the wheel. Install in the reverse order of removal. Check for any external damage in the tyre or the rim, if found replace. Check for any foreign material on tyre or rim, remove if found. Tyre Pressure- Inspect & Adjust ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Proper Tyre inflation pressure is essential to the safe and satisfactory operation of your vehicle. Three primary areas are affected by improper Tyre pressure: Safety Economy Ride Comfort and Vehicle Stability Proper Tyre inflation contributes to a comfortable and safe ride. Over inflating produces a jarring and uncomfortable ride. Both under inflation and over inflation affect the stability of the vehicle and can produce a feeling of sluggish response or over responsiveness in the steering. Unequal Tyre pressures can cause erratic and unpredictable steering response or may cause the vehicle to drift left or right. Improper inflation pressures can cause uneven wear patterns to develop across the Tyre tread. These abnormal wear patterns will reduce tread life resulting in a need for earlier Tyre replacement. Under inflation also increases Tyre rolling resistance and results in higher fuel consumption. TYRE PRESSURE LABEL: ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160038.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Tyre Label is located on the driver side inner B-pillar. This label tells you important information about tyre size designed for your vehicle, and the tyre inflation pressures for the front & rear tyres. Never overload the vehicle. Overloading can cause tyre failure, affect vehicle handling, and increase your stopping distance, resulting in an accident and/ or personal injury. Improper inflated tyres can adversely affect vehicle handling or can fail unexpectedly, resulting in an accident and or personal injury. If weight is not equally distributed around the wheel, unbalance centrifugal force by the wheel rotation produces vibration. As the centrifugal force is produced proportional to the square of the rotating speed, the wheel weight should be balanced even at high speed. There are two types of the tire and wheel balancing: static and dynamic. Abnormal vibration may also occur due to unbalanced rigidity or size of tyres Static Balance ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A180032.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "When the free rotation of the wheel is allowed, the heavier part is stopped on the bottom if the wheel weight is unbalanced and this is called 'Static Unbalance' Also, the state at which tyre's stop position is not same is called 'Static Balance' when the wheel is rotated again. If the part A is heavier as shown in the figure, add the \u201cbalance weight\u201d corresponding to unbalanced weight from B to A to maintain the static balance. If the static balance is not maintained, tramping, up and down vibration of the wheels, occurs. Dynamic Balance ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/DBalance.png",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "The static unbalance of the wheel creates the vibration in the vertical direction, but the dynamic unbalance creates the vibration in the lateral direction. As shown in the figure (A) , if two parts, (2) and (3), are heavier when the wheels are under the static balance condition, dynamic unbalance is created, resulting in shimmy, left and right vibration of the wheels, and the torque Fxa is applied in the axial direction. To correct the dynamic unbalance, add the balance weight of a same weight for two points of the circumference of the rim, M1 and M2, as shown in the figure (B) , and apply the torque in the opposite direction to the torque Fxa to offset in order to ensure smooth rotation of the wheel. The wheel should always be balanced and aligned in order to provide: Enhanced tyre life Driving safety and steering control. Better performance of the vehicle. Unbalanced tyre may lead to premature tyre wear and driver fatigue due to vibration. Tyres should always be balanced when they are mounted on wheels for the first time When they are remounted after repair When there are signs of shimmy or vibrations. Deposits of mud, dust must be cleaned from inside of the rim Remove stones from tread, clean the tyre and rim before balancing to achieve better results. Each tyre should be inspected for any damage. The type of balance weights, when used, must be in accordance with the profile of the rim flange. Refer below recommendations for usage of balance weights. For balancing a wheel, follow the manufacturer\u2019s (of balancing machine) manual for balancing instructions, recommendations and any other additional information. Remove the TGS lever assembly . Using 10 mm socket spanner unscrew ATcable grommet mounting bolts. Torque : 13 \u00b1 2.0 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using MST - 0703AAD0009ST (Shifter and selector cable eye end removal tool) detach the shifter cable from gear shifter link ball pin. Detach the abundant from routing bracket and remove the shifter cable from bracket Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Take out the shifter cable. Install in the reverse order of removal. For additional information refer to AT cable setting procedure. ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Notice",
+ "content": "While replacing new TGS lever, Ensure to remove the N position lock. Check for proper shifting of gears in TGS lever and transmission. While refitting gear shifter cable , Ensure the gear shifter link and TGS lever in N (Neutral) position. After installation check the shifter link at various gear positions (PRND). Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. Torque : 6.0 \u00b1 0.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Disconnect AT input speed sensor electrical connector and routing clip. Disconnect the transfercase electrical connector and routing clip. Disconnect AT output speed sensor electrical connector and routing clip. Disconnect AT valve body electrical inter-connector. Disconnect AT Neutral switch electrical connector. Disconnect AT wiring harness interconnector and holding clip and remove the wiring harness. Install in reverse order of removal. Check for any external damage, if found please replace. Remove the radiator LH & RH seal. For additional information refer to the Radiator LH & RH Seal R&R section. Press and disconnect the oil inlet hose quick coupler and routing clips oil cooler end. Press and disconnect the oil outlet hose quick coupler oil cooler end. Using 10 mm socket spanner unscrew AT oil cooler mounting bolts and remove oil cooler. Torque : 5 \u00b1 1 Nm. ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Check and top up the AT oil if required. For additional information refer to AT oil level check and filling procedure. Check for ATF oil leakage and ensure that there are no oil leaks. For additional information refer to ATF Oil leak check procedure section. Check for any external damage, if found please replace. Remove the front grill assembly. Using 10 mm socket spanner unscrew radiator seal LH mounting bolt. Using screw driver remove the radiator seal LH mounting push clip and detach guard from the vehicle. Press and disconnect the oil hose quick coupler and detach routing clips oil cooler end. Press and disconnect the oil hose quick coupler and disconnect the hose at inter connection end. Remove the hose routing to remove hose. Install in reverse order of removal. Check the AT oil level and top up if required. For additional information refer to AToil level inspection and filling procedure. Check for any external oil leakage. Rectify if found. Disconnect the AT oil cooler inlet and outlet hoses thermal bye pass valve end both the sides. Ensure to close the bypass tubes with dummy caps to avoid dust entry Using 10 mm socket spanner unscrew thermal bypass valve bracket mounting bolt from engine oil sump. Torque : 10 \u00b1 2 Nm. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110088.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the thermal bypass valve from the vehicle. Install in reverse order of removal. Check for the AT oil level and top up if required. For additional information refer to AToil level checking and Filling procedure. Check for ATF oil leakage and ensure that there are no oil leaks. For additional information refer to ATF Oil leak check procedure section. Check for any external damage, if found please replace. Make sure to clean dirt, sand or other foreign matter from the Automatic transmission assembly before removing components. Clean components and surrounding area prior to removal. Ensure that all parts are neatly stored in the appropriate container/tray as they removed, failing may leads to difficult while reassemble the components. Do not use cotton gloves or shop rags as frayed strings might get caught in the unit. Thus, work with your bare hands or use plastic gloves. Do not drain the ATF when it is hot, wait until it has cooled down. Recommend to use only Mahindra 'ATF NWS9638' Special Automatic Transmission Fluid and Never mix 2 different oils. Always replace gaskets, 'O' rings and oil seals etc. with new ones. Do not overfill transmission, fluid foaming and shifting problems can result. When connecting the connector, Ensure the connector is fully engaged by connecting it until you hear a click that signals engagement. Keep work areas clean and organized. Pick up tools and use tool cabinets to keep walkways clear and free from clutter. Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery,check for the audible sound of EWP ON. Provide a jack to support to transfer case. Using a 18 mm socket spanner, loosen and remove the transmission bed mount nuts. Using 14 mm & 15 mm socket/Ring spanner unscrew cross member mounting bolts and nuts then remove the cross member. Using 24 mm socket spanner, remove the filler plug from transmission. Using 14 mm socket spanner, remove the drain plug and the gasket. Drain the ATF & Measure Quantity ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W495.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Drain the Automatic transmission fluid and Measure the Drained fluid quantity . Install the drain plug with new gasket and tighten the drain plug with specified torque. Torque : 20 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Caution",
+ "content": "Always replace the drain plug gasket with a new one. Disconnect the AT wiring harness electrical connector from the AT pigtail. Using 10 mm socket spanner, remove transmission oil pan sub-assembly mounting bolts. Remove the oil pan sub-assembly and gasket from the transmission housing. Take sufficient care not to damage the fitting surfaces of the transmission housing and the transmission oil pan sub-assembly. Take sufficient care not to deform the transmission oil pan sub-assembly. Remove the oil cleaner magnets from the oil pan sub-assembly Examine the chips and particles in the oil pan sub-assembly and on the oil cleaner magnet to determine what type of wear has occurred in the Automatic Transmission. Steel (Magnetic) = Bearing, Gear and Plate wear.Brass (Non-magnetic) = Bushing wear.Using 10 mm socket spanner, Remove temperature sensor clamps mounting bolts and pull out the sensors clamp and sensors from the valve body. Disconnect valve body solenoid electrical connectors using small screw driver by pressing the connector location as shown in the illustration. Ensure to smoothly unlock the wiring connector from solenoid by using small screw driver and Take sufficient care not to damage the connectors while remove. Using 10 mm socket spanner, remove transmission WH inter connector mounting bolt and pull out the transmission wiring harness. Take sufficient care not to damage the wiring harness. Take sufficient care not to pull out the harness forcibly. Insert the transmission wiring harness in the housing and Install the transmission WH inter connector mounting bolt and torque tighten the bolt. Always ensure to replace the New 'O' ring of the transmission wire connector while Installation and coat the O ring with ATF while install. Torque : 5.4 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W513.jpg",
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Connect the solenoid electrical connectors. When connecting the connector, Ensure the connector is fully engaged by connecting it until you hear a click noise to ensure proper engagement. Install the oil temperature sensors and sensor clamps to the valve body assembly by the mounting bolts and torque tighten the bolts (A & B) to specified value. Bolt \u201cA\u201d can be used in different lengths \u2013 M6 x 1.0 x 14 mm or M6 x 1.0 x 12 mm. For A = 10 \u00b1 2 Nm For B = 11 \u00b1 1 Nm Install the 4 oil cleaner magnets to the oil pan subassembly. Clean the transmission oil pan subassembly. Clean the oil cleaner magnet before installing. Clean oil from oil pan gasket fitting surface of the housing and the mounting bolt holes. Install a new oil pan gasket on the oil pan subassembly. Always replace the Oil pan gasket with a new one. Ensure to align the gasket in correct position on the oil pan sub assembly as shown in the illustration. Take sufficient care not to damage the fitting surfaces of the Transmission housing and the oil pan subassembly. Take sufficient care not to deform the oil pan subassembly. Install the oil pan sub assembly mounting bolts to the housing. Tighten the bolts to specified torque value. Make sure that there is no oil or foreign matter on the oil pan gasket seal surface and oil pan subassembly contact surface. Install the oil pan gasket properly so that there is no slack in the oil pan gasket, and that the seal surface's entire circumference is level. Make sure that the oil pan gasket drop prevention protrusions are set on the oil pan subassembly. When tightening the oil pan subassembly, make sure that the oil pan gasket is not pinched between the oil pan gasket tightening area's sleeve and the housing seal surface. Torque : 7.4 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Connect the AT wiring harness electrical connector to the AT pigtail. Position & Install the cross member mounting bolts and nut then tighten to specified torque value. Torque: 65 \u00b1 10.0 Nm ",
+ "file": null,
+ "display_order": 83
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Install the transmission bed mount nuts and tighten the nuts to specified torque value. Torque: 110 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 86
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the jack support from transfer case. ATF Refilling ",
+ "file": null,
+ "display_order": 89
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110203.jpg",
+ "display_order": 90
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Refill the ATF (Drained quantity + 0.5 Ltrs) through filling hole by using hose/funnel and tighten the filler plug. Always use the clean hose/funnel for refilling and hose/funnel should be used only for ATF refilling purpose. Always replace the filler plug O ring with a new one. Recommend to use only Mahindra 'ATF NWS9638' Special Automatic Transmission Fluid and Never mix 2 different oils. Do not overfill transmission, fluid foaming and shifting problems can result. Tighten the battery negative cable mounting nut. Torque : 6.0 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Check AT oil level and top-up if required. For additional information refer to AToil level inspection and Filling procedure. Check for oil leak between contact surface of oil pan and housing.. Inspect that shift lever can shift smoothly and accurately when shifting shift lever from 'N' to other range. Inspect that engine can be started with shift lever only 'N' or 'P', but not in other range. Inspect the gear shifter indicator in the instrument cluster be turned on correctly while in P-R-N-D positions. If any of the above conditions are not fulfilled, Kindly check & adjust Selector position switch & Cable. Using 19 mm socket spanner unscrew AT oil cooler oil Inlet hose banjo bolt and remove hose. Torque : 30 \u00b1 3.0 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect the AT oil cooler oil outlet hose thermal bye pass valve end. Ensure to close the bypass tubes with dummy caps. Detach the hose from the routing clip. Install in reverse order of removal. Check the AT oil level and top up if required. For additional information refer to AToil level inspection and filling procedure. Check for any external oil leakage. Rectify if found. Remove the automatic transmission with transfercase. Disconnect the transfercase electrical connector and routing clip from transfercase . Using 12 mm socket spanner unscrew transfercase shifter cable abundant routing bracket mounting bolts. Torque : 25 \u00b1 3.0 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110044.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": " Using 12 mm socket spanner unscrew AT shifter cable routing bracket mounting bolts. Using 12 mm socket spanner unscrew AT shifter cable routing bracket mounting bolts. Torque : 25 \u00b1 3.0 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110041.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": " Using 12 mm socket spanner unscrew transfercase front facing mounting bolts. Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110042.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": " Using 12 mm socket spanner unscrew transfercase rear facing bottom mounting bolt. Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110043.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": " Using 12 mm ring spanner unscrew transfercase rear facing top mounting bolt. Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W459.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": " Remove the transfer case from AT assembly. Using 12 mm socket spanner unscrew AT distance plate mounting bolts and remove distance plate. Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110048.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110053.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": " Disconnect AT input speed sensor electrical connector and routing clip. Disconnect AT output speed sensor electrical connector and routing clip. Disconnect AT Neutral switch selector electrical connector. Disconnect AT valve body electrical connector interconnection end. Disconnect AT Wiring harness interconnector holding clip. Using 12 mm socket spanner unscrew AT shifter cable abundant bracket mounting bolts. Torque : 25 \u00b1 3.0 Nm ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W464.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": " Using 19 mm socket spanner unscrew AT oil cooler oil inlet and outlet hose banjo bolts and remove the hoses. Torque : 30 \u00b1 3.0 Nm ",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W465.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": " Using 13 mm ring spanner unscrew gear shifter link mounting nut and remove the shifter link. Torque : 15 \u00b1 2.0 Nm ",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W466.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": " Install in reverse order of removal. Check the Transmission oil level and topup if needed. For additional information refer to transmission oil level inspection and refilling procedure. Check and ensure that there are no oil leaks. Carry out Service routine (Clear learned data in EEPROM) while replace New AT Assembly. Carry out Initial Learning while replace New AT Assembly. For Additional information refer Initial Learning section. Inspect that shift lever can shift smoothly and accurately when shifting shift lever from 'N' to other range. Inspect that engine can be started with shift lever only 'N or P', but not in other range. Inspect the gear shifter indicator in the instrument cluster be turned on correctly while in P-R-N-D positions. If any of the above conditions are not fulfilled, Kindly check & adjust Selector position switch & shifter cable. Check for any external damage, if found please replace Check for any external oil leakage. Rectify if found. Remove the Transfer Case Assembly. Using a screw driver, remove Rear Housing Oil Seal from transmission. Refit oil seal by using special tool 0701CAJ0002ST - AT Oil Pump/ Rear Housing Oil Seal Installer - 4WD/2WD Coat the Rear Housing Oil Seal with ATF while install. Refit the Transfer Case Assembly. Check AT oil level and top-up if required. For additional information refer to AT oil level inspection and Filling procedure. Inspect the Rear Housing Oil Seal for any damage. Replace if found any. Warm-up ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Raise the ATF temperature by leaving the vehicle idling or performing a drive. Check the ATF temperature using the Diagnostic tool and make sure it is between 65\u00b0C and 80\u00b0C. If the oil temperature is outside this range, need to bring it inside the range. If the automatic transmission or the TCU is replaced, or the TCU software is overwritten, be sure to initialize the learned values and perform initial learning. Do not attempt to raise the oil temperature by stalling the engine. If the fluid temperature is not between 65\u00b0C and 80\u00b0C, initial learning cannot be performed. Before learning, check for shift shock or variable speed shock. Garage shift learning ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "With the vehicle stationary, depress the brake pedal and keep the shift lever in the N position for 3 seconds. Then, move the shift lever from the N position to the D position, and keep the shift lever in the D position for 3 seconds. Repeat this procedure 5 times. Ensure the transmission oil temperature is between 65\u00b0C and 80\u00b0C Gear shift control learning ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "With the shift lever in the D position and the throttle opening amount between 25 and 35%, drive until 6th gear is selected and a vehicle speed of 110 km/h or higher is reached. Then, release the accelerator pedal and let the car coast, and finally bring the vehicle to a stop within 60 seconds. Repeat this procedure 10 times. Check learning results ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Check that variable speed shock and shift shock have decreased compared to the conditions before learning. Check that there are no oil leaks from the contact surfaces between the Auto Transmission and Engine, the housings, extension/adapter and oil pan, each oil seal, and each O ring. Oil leak from contact surface between Auto Transmission and Engine
Check for oil leak to judge whether it is from the Auto Transmission or Engine. If it is from the Auto Transmission, oil may be leaking from the oil pump oil seal or oil pump O ring, If there are any leak found, Replace the required part. Oil leak from contact surface between hoUsingnd case
Check for oil leak from the housing contact surface, If there are any leak found, it is necessary to apply appropriate sealant again. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110206.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": " Oil leak from contact surface between extension/adapter and case
Check for oil leak at the extension/adapter contact surface, If there are any leak found, it is necessary to apply sealant again. Oil leak from contact surface between oil pan and case Check for oil leak between contact surface of oil pan and case, If there are any leak found, it is necessary to replace the gasket. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110208.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3H100163.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": " Oil leak from oil seal
Check for oil leak at the Oil pump oil seal, AT Rear end oil seal or Manual shaft oil seals, If there are any leak found, replace the oil seal with a new one. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110233.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110232.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": " Oil leak from Washers /\"O\" rings
Oil leak from AT Oil cooler & Oil lines
Check for oil leak from the oil lines at Oil cooler/ Automatic transmission banjo bolts & Oil lines, If there are any abnormalities found, replace the required components. ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Do not damage the oil seal lips, housing, case or extension/adapter contact surfaces. Partially detach the TGS leather boot from bezel and fold the boot to top side. Partially detach the bezel from the console. Excessive pull may leads to damage of the electrical connector Disconnect the electrical connector and remove the bezel. Ensure the AT shifter cable end is properly fitted on TGS housing ball pin. Ensure the AT cable abutment is properly fitted on shifter bracket. Position the AT TGS lever at Neutral (N) position. Position the M8 bolt of approx. 60 mm length to the TGS housing hole for ensuring lever in neutral position. Ensure TGS lever position is parallel to Arrow mark shown after inserting M8 bolt. Ensure the ATcable abutment is properly fitted on auto transmission cable bracket. Using 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the shifter cable from gear shifter link ball pin. Position the AT cable link to Neutral (N) position at Automatic transmission assembly as shown below. By fastening M6 bolt for matching shifter link hole with transmission hole and ensure Neutral (N) position. For adjust cable length, move the cable quick adjuster outer cover in forward direction and unlock the QA clip. Adjust the cable length to fix the cable on link ball pin. After adjusting the length, position the quick adjuster body on link ball pin. Once quick adjuster body snap on ball pin, press the QA clip towards arrow mark shown to lock it fully and release the cable quick adjuster outer cover. Ensure the proper locking by confirming/ hearing the click noise while install. After adjustment remove the M6 & M8 bolt from cable link & shifter housing. Inspect that shift lever can shift smoothly and accurately when shifting shift lever from N to other range. Connect the electrical connector on bezel. Attach the bezel on console. Refit the TGS leather boot on bezel. Park the vehicle and Position the TGS lever in N position. Position the AT shifter link to Neutral (N) position at Automatic transmission assembly as shown below By fastening M6 bolt for matching shifter link hole with transmission hole and ensure Neutral (N) position Using 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the shifter cable from gear shifter link ball pin. Using 13 mm socket spanner, remove the shifter link mounting nut and remove the shifter link & M6 bolt. Position the AT gear shifter link and Install M6 bolt for matching shifter link hole with transmission hole and ensure Neutral (N) position. Refit the shifter link mounting nut and torque tight the nut to specified value. Torque : 15 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Attach the shifter cable with gear shifter link. Position the TGS shifter lever in N position & Ensure that the shifter link should be in N position on AT Assy while attach the cable & adjust cable length if needed. Inspect Manual valve lever position for various modes (PRND) at Selector Position Switch are below. Inspect that shift lever can shift smoothly and accurately when shifting shift lever from 'N' to other range. Inspect that engine can be started with shift lever only 'N' or 'P', but not in other range. Inspect the gear shifter indicator in the instrument cluster be turned on correctly while in P-R-N-D positions. If any of the above conditions are not fulfilled, Kindly check & adjust Selector position switch & shifter link. Be sure to perform a function check under the conditions below. Perform after engine inspection and adjustment. Perform with ATF temperature (50-80 \u00b0C) under ordinary driving conditions. The A/C, lights, etc., are turned off. Cruise control is off. In order to prevent sudden start of the vehicle, be sure to lock it before function check Apply the parking brake and chock the wheels. Start the engine. Depress the brake pedal and allow the engine to idle. Move the shift lever from the N position to the D or R position and, Using timer, check how long it takes until a light shift shock is felt. Perform the test at least 3 times and calculate the average. When performing the test wait for 1 minute between the tests. Apply the parking brake and chock the wheels. Start The Engine. Fully depress the brake pedal with your left foot, move the shift lever to the D or R position, fully depress the accelerator pedal with your right foot, and quickly check the maximum engine rpm. Specification Range : 2309 \u00b1 150 rpm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": " As this test causes a sudden rise in the ATF temperature, do not continue the test more than 5 seconds. Perform the test at least 3 times and calculate the average. Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. Torque : 6.0 \u00b1 0.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON,Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Before disconnecting the battery,check for the audible sound of EWP ON. Disconnect the TCU electrical connectors. Using 10 mm socket spanner, unscrew TCU mounting nuts and remove the TCU. Torque : 9 \u00b1 1.0 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Carry out Initial Learning while replace New TCU Assembly. For Additional information refer to Initial Learning section. Check for any external damage, if found please replace. Park the vehicle and Shift the TGS lever to N position. Remove AT gear shifter bezel. For additional information refer to AT gear shifter Bezel - R&R section. Rotate transfercase shifter knob in anticlock wise and remove it from the shifter. Using trim removal tool, carefully remove the floor console top trim with transfer case shifter boot. Disconnect the TGS lever electrical connector. Using 13 mm socket spanner unscrew TGS lever Assembly mounting nuts. Torque : 22.5 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110152.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the cable link from TGS assembly. Carefully remove the shifter cable abundant and remove the TGS assembly. Abutment Clip to be pressed till the cable comes out of Shifter Bracket(Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Install in reverse order of removal. Carry out AT cable settings. For additional information refer to AT cable setting procedure. While replacing new TGS lever, Ensure to remove the N position lock. Check for proper shifting of gears in TGS lever and transmission. While refitting gear shifter cable , Ensure the gear shifter link and TGS lever in N(Neutral) position. After installation check the shifter link at various gear positions (PRND). Inspect the TGS lever assembly for any damage. replace if required. Make sure to clean dirt, sand or other foreign matter from the Automatic transmission assembly before removing components. Clean components and surrounding area prior to removal. Ensure that all parts are neatly stored in the appropriate container/tray as they removed, failing may leads to difficult while reassemble the components. Do not use cotton gloves or shop rags as frayed strings might get caught in the unit. Thus, work with your bare hands or use plastic gloves. Do not drain the ATF when it is hot, wait until it has cooled down. Recommend to use only Mahindra 'ATF NWS9638' Special Automatic Transmission Fluid and Never mix 2 different oils. Always replace gaskets, 'O' rings and oil seals etc. with new ones. Do not overfill transmission, fluid foaming and shifting problems can result. When connecting the connector, Ensure the connector is fully engaged by connecting it until you hear a click that signals engagement. Keep work areas clean and organized. Pick up tools and use tool cabinets to keep walkways clear and free from clutter. Drain the Automatic transmission fluid. Remove the automatic transmission with transfer case. Using 14 mm socket spanner, Remove torque converter holding bracket mounting bolts and remove the bracket. Carefully remove torque converter from the AT assembly. Take sufficient care not to damage the oil pump seal during removal of torque converter. Take sufficient care not to drop the Torque converter assembly Using a screwdriver, position the drive gear on the oil pump assembly in the center and install the Torque converter assembly on the transmission assembly. Take sufficient care not to damage the oil pump oil seal. Take sufficient care not to drop theTorque converter assembly. Take sufficient care not to pinch fingers. Inspect installation position of torque converter assembly. Measure the dimension from the end face of the converter housing to the Torque converter assembly as shown in the figure and check that the Torque converter assembly is installed properly. SPEC : Over than 18.15 mm Refit the Torque converter holding bracket. Refit the automatic transmission with transfer case. Refill the Automatic transmission fluid. Check AT oil level and top-up if required. For additional information refer to AToil level inspection and Filling procedure. Inspect the Torque Converter assembly for any external damage, Replace if required. Using 19 mm socket spanner unscrew AT oil cooler oil outlet hose banjo bolt and remove hose. Torque : 30 \u00b1 3.0 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect the AT oil cooler oil outlet hose thermal bye pass valve end. Ensure to close the bypass tubes with dummy caps. Detach the hose from the routing clip. Install in reverse order of removal. Check the AT oil level and top up if required. For additional information refer to AToil level inspection and filling procedure. Check for any external oil leakage. Rectify if found. Remove the AT Shifter link. Using a screw driver, remove Manual Shaft Oil Seal from transmission. Refit oil seal by using special tool 0701AAJ0017ST - Manual Shaft Oil Seal Installer. Spec : 0 \u00b1 0.5 mm (From the end of the housing). Refit the AT Shifter link. Check AT oil level and top-up if required.For additional information refer to AT oil level inspection and Filling procedure. Inspect the Manual Shaft Oil Seal for any damage. Replace if found any. Remove the Selector Position Switch. Using a screw driver, remove Manual Shaft Oil Seal from transmission. Refit oil seal by using special tool 0701AAJ0017ST - Manual Shaft Oil Seal Installer. Spec : 0 \u00b1 0.5 mm (From the end of the housing). Refit the Selector Position Switch. Check AT oil level and top-up if required.For additional information refer to AT oil level inspection and Filling procedure. Inspect the Manual Shaft Oil Seal for any damage. Replace if found any. ",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 91,
+ "sys_id": "THAR.LX-0005-Automatic Transmission",
+ "subsys_id": "THAR.LX-0005-Automatic Transmission-Troubleshoot - Automatic Transmission",
+ "systems": "Automatic Transmission",
+ "sub_systems": "Troubleshoot - Automatic Transmission",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1460,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0005-Troubleshoot - Automatic Transmission-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Failure Diagnosis Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4674.pdf",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Road Test",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4675.pdf",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Function Check",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Be sure to perform a function check under the conditions below. Perform after engine inspection and adjustment. Perform with ATF temperature (50-80 \u00b0C) under ordinary driving conditions \u2022 The A/C, lights, etc., are turned off. Cruise control is off. In order to prevent sudden start of the vehicle, be sure to lock it before function check Make sure to clean dirt, sand or other foreign matter from the Automatic transmission assembly before removing components. Clean components and surrounding area prior to removal. Ensure that all parts are neatly stored in the appropriate container/tray as they removed, failing may leads to difficult while reassemble the components. Do not use cotton gloves or shop rags as frayed strings might get caught in the unit. Thus, work with your bare hands or use plastic gloves. Do not drain the ATF when it is hot, wait until it has cooled down. Recommend to use only Mahindra 'ATF NWS963' Special Automatic Transmission Fluid and Never mix 2 different oils. Always replace gaskets, 'O' rings and oil seals etc. with new ones. Do not overfill transmission, fluid foaming and shifting problems can result. When connecting the connector, Ensure the connector is fully engaged by connecting it until you hear a click that signals engagement. Keep work areas clean and organized. Pick up tools and use tool cabinets to keep walkways clear and free from clutter. Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Remove the Oil Strainer Assembly. Disconnect the AT wiring harness electrical connector from the AT pigtail. Using 10 mm socket spanner, Remove temperature sensor clamps mounting bolts and pull out the sensors clamp and sensors from the valve body. Disconnect valve body solenoid electrical connectors using small screw driver by pressing the connector location as shown in the illustration Ensure to smoothly unlock the wiring connector from solenoid by using small screw driver and Take sufficient care not to damage the connectors while remove. Using 10 mm socket spanner, remove transmission WH inter connector mounting bolt and pull out the transmission wiring harness. Take sufficient care not to damage the wiring harness. Take sufficient care not to pull out the harness forcibly. Remove the 'O' ring from the transmission wire connector Using 10 mm socket spanner, remove detent spring mounting bolt and remove the cover and detent spring. Using 10 mm socket spanner, remove valve body assembly mounting bolts andremove the valve body. Be careful not to drop the Valve body assembly Remove the transmission housing gaskets. By using Nose plier, remove the brake drum gaskets from the housing. Apply a thin layer of ATF on new brake drum gaskets and install them on the transmission housing. Ensure to fix the drums side shown in the Illustration should be fixed in the case side. Always ensure to replace the New brake drum gaskets while install. Apply a thin layer of ATF on new transmission gaskets and install them on the transmission housing. Always ensure to replace the New transmission gaskets while install. Position the Valve Body assembly and Insert the manual valve lever into the groove on the end of the manual valve. Install the Valve Body assembly with the new bolts to the Transmission housing and torque tighten the bolts to specified value. Always ensure to replace the New Valve Body bolts while install. Ensure to Install the appropriate length bolts as shown in the Illustration M6 x 1.0 x 25 mm M6 x 1.0 x 36 mm M6 x 1.0 x 50 mm Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install the detent spring and detent spring cover with the bolt to the housing and torque tighten the bolt to specified torque. Ensure to align the center of the detent spring roller with the center of the manual valve lever Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W600.jpg",
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Insert the transmission wiring harness in the housing and Install the transmission WH inter connector mounting bolt and torque tighten the bolt. Always ensure to replace the New 'O' ring of the transmission wire connector while Installation and coat the O ring with ATF while install. Torque : 5.4 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W603.jpg",
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Connect the solenoid electrical connectors When connecting the connector, Ensure the connector is fully engaged by connecting it until you hear a click noise to ensure proper engagement. Install the oil temperature sensors and sensor clamps to the valve body assembly by the mounting bolts and torque tighten the bolts (A & B) to specified value.. Bolt \u201cA\u201d can be used in different lengths \u2013 M6 x 1.0 x 14 mm or M6 x 1.0 x 12 mm Torque : For A = 10 \u00b1 2 Nm For B = 11 \u00b1 1 Nm Connect the AT wiring harness electrical connector on the AT pigtail. Refit the Oil Strainer Assembly. Tighten the battery negative cable mounting nut. Torque : 6.0 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Check AT oil level and top-up if required. For additional information refer to AToil level inspection and Filling procedure. Check for oil leak between contact surface of oil pan and housing. Carry out Service routine (Clear learned data in EEPROM) while replace New Valve Body Assembly. Carry out Initial Learning while replace New Valve Body Assembly. For Additional information refer Initial Learning section. Inspect that shift lever can shift smoothly and accurately when shifting shift lever from 'N' to other range. Inspect that engine can be started with shift lever only 'N' or 'P', but not in other range. Inspect the gear shifter indicator in the instrument cluster be turned on correctly while in P-R-N-D positions. If any of the above conditions are not fulfilled, Kindly check & adjust Selector position switch & shifter link. Using 13 mm socket spanner, loosen and remove the electric stone guard mounting bolts. Torque : 4.0 \u00b1 0.5Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove e-disconnect fom the vehicle. Disconnect the oil cooler hose from the intermediate hose cooler end. Disconnect the oil cooler hose from the bypass valve to intermediate hose nd. Detach the hose from the routing clip and remove from the vehicle. Install in reverse order of removal. Check the AT oil level and top up if required. For additional information refer to AToil level inspection and filling procedure.</b</li> Inspect the hose for any crack & damage. Check for any external oil leakage. Rectify if found. Remove the automatic transmission with transfer case. Lock the flex plate using MST(0307ABH0001ST \u2013 Flywheel Locking Tool). Using 19 m socket spanner, unscrew flex plate mounting bolts. Torque : 50 \u00b1 3.0 Nm + 60\u00b0 \u00b1 1\u00b0 ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W469.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110032.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the Flex plate and back plate from crank shaft rear end. Install in reverse order of removal. Check the flex plate for any external damage, if found please replace. Check the back plate for any external damage, if found please replace. Gear Shifter Link Position at Various Modes (PRND) ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110260.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110264.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect & ensure Gear Shifter Link Position at Neutral (N) as shown below By fastening M6 bolt for matching shifter link hole with transmission hole and ensure Neutral (N Mode). Inspect & ensure Gear Shifter Link Position at Drive (D) Mode as shown below Inspect & ensure Gear Shifter Link Position at Reverse (R) Mode as shown below Inspect & ensure Gear Shifter Link Position at Parking (P) Mode as shown below Transmission Oil \u2013 ATF NWS9638 Special Automatic Transmission Fluid. Total Oil Capacity \u2013 9.5 Liters. Top up Oil Quantity \u2013 0.5 Liters. Lack of ATF volume: Oil pump vacuums air and causes lowness of line pressure, causing clutch slipping or lubrication failure of each part, resulting in burning out. Over level ATF volume When driving in this condition, ATF volume rises and ATF may blow off from the breather. Overfilling results in ATF over heating. Shift the TGS lever position to P. Using 5 mm Allen key, remove the over flow plug and confirm for ATF dripping from the over flow hole and tighten the over flow plug to specified torque. Torque : 20 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": " If ATF does not drop, remove the filler plug and fill the additional ATF until ATF drops from the overflow plug. Using 24 mm socket spanner, remove the filler plug and add 0.5L of ATF through filling hole by using Syringe (150ml or 300 ml) with hose and tighten the filler plug with specified torque. Torque : 39 \u00b1 15 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": " Always replace the filler plug O ring with a new one. Recommend to use only Mahindra ATF NWS9638 Special Automatic Transmission Fluid. Never mix 2 different oils. Connect the diagnostic tool and turn the ignition ON. Select THAR from the list of vehicle models and Select the \u201cTHAR_BS6\u201d. From the list of controllers shown, select \u201cTCU\u201d and click on \u201cLIVE DATA\u201d & click \u201cTRANSMISSION\u201d tab for ATF temperature reading (\u201cTransmission Oil temperature\u201d). Start engine and wait until ATF temperature reaches 44\u00b0C Do not raise the temperature by performing a stall test. Shift TGS lever position from P to D and return to P, perform this operation 2 times. Spend more than 2 seconds per each position (P-R-N-D) while shifting from P to D and return. Confirm the ATF temperature between 44 - 54 \u00b0C in diagnostic tool. Using 5 mm Allen key, remove the over flow plug and check ATF drops from the overflow hole and wait until ATF flow becomes drop by drop. If ATF doesn\u2019t drops from the overflow hole then ATF level is low and check for oil leakage/ seepage at AT components and rectify. Refit the overflow plug and tighten the overflow plug with specified torque. Torque : 20 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": " Always replace the overflow plug washer with a new one. Be sure to wipe off spilled ATF completely after tighten overflow plug. If not,it will cause Misjudge of oil leakage. Using 13 mm socket spanner, loosen and remove e-disconnect stone guard mounting bolts. Torque : 4.0 \u00b1 0.5Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110090.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect the oil cooler hose from the bypass valve end. Disconnect the oil cooler hose from the intermediate hose cooler end. Detach the hose from the routing clip and remove from the vehicle. Install in reverse order of removal. Check the AT oil level and top up if required. For additional information refer to AToil level inspection and filling procedure. Check for any external oil leakage. Rectify if found. Inspect the hose for any crack & damage. Park the vehicle and ensure to keep the stransfer case shifting knob in 2H and AT gear shifter lever (TGS) in 'N' position. Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. Torque : 6.0 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery,check for the audible sound of EWP ON. Remove Engine Fead cover. For additional information refer to Engine Fead Cover - R&R section. Using 13 mm socket spanner unscrew starter motor positive cable mounting nut. Torque : 12 \u00b1 2.0 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W452.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": " Using 10 mm socket spanner unscrew starter motor solenoid cable mounting nut. Torque : 2.5 \u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W453.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": " Using 14 mm socket spanner unscrew stater motor mounting bolts and remove starter motor. Torque : 44 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W454.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": " Using 1 4 mm socket spanner unscrew transmission LH top mounting bolt. Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W455.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": " Using 14 mm socket spanner unscrew transmission RH mounting bolts. Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110006.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": " Using 13 mm socket spanner loosen and remove torque convertor mounting bolts. Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Notice",
+ "content": "Rotate the crank pulley using 24 mm ring spanner to access the torque convertor mounting bolts. Ensure to hold the crank pulley while loosen the torque convertor mounting bolts. To access the other torque convertor bolts; rotate the crank pulley to 60 degree respectively. Carefully remove and refit torque convertor mounting bolts, Failing may leads to fall of bolts inside the AT housing. Remove the exhaust intermediate pipe. For additional information refer to Exhaust Intermediate Pipe - R&R section. Remove the exhaust front pipe. For additional information refer to exhaust front pipe - R&R section. Using 13 mm and 16 mm ring and open spanners unscrew rear propeller shaft mounting bolts and nuts rear axle end. Torque : 65 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110008.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using 14 mm ring and open end spanners unscrew rear propeller shaft mounting bolts and nuts transfer case end and remove propeller shaft from the vehicle . Torque : 65 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110009.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": " Using 13 mm combination spanner Unscrew front propeller shaft mounting nuts from transfercase end. Torque : 25 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110010.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": " Using 8 mm socket spanner unscrew front propeller shaft mounting bolts front axle end and remove propeller shaft from vehicle. Torque : 19 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110011.jpg",
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": " Using MST - 0703AAD0009ST (Shifter and selector cable eye end removal tool) detach the shifter cable from gear shifter link ball pin. Detach the abundant from routing bracket and remove the shifter cable from bracket. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Using MST - 0703AAD0009ST (Shifte and selector cable eye end removal tool) detach the transfer case cable from the transfer case ball pins. Detach the transfer case cable abutment from the cable bracket on transmission by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Disconnect the AT wiring harness electrical connector from the inter-connector. Disconnect the AT oil inlet & outlet hoses from thermal bypass valve end. Ensure to close the bypass tubes with dummy caps. Provide a jack to support transmission. Using 14 mm socket spanner unscrew transmission bed mounting bolts. Torque: 70 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110023.jpg",
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": " Using 14 mm & 15 mm socket/Ring spanner unscrew cross member mounting bolts and nuts and remove the cross member. Torque: 65 \u00b1 10.0 Nm ",
+ "file": null,
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110025.jpg",
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": " Using 14 mm socket spanner unscrew AT transmission bottom mounting bolts. Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110026.jpg",
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110212.jpg",
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": " Carefully remove the AT assembly with transfercase. Attach MST 0701FAJ0001ST \u2013 AT Torque convertor Holding Tool with AT to hold torque converter. Install in reverse order of removal. Remove the AT Torque convertor Holding Tool and measure the end face distance. Measure the distance from the end face of the converter housing to the Torque converter assembly as shown in the figure (Distance should be more than 18.15 mm ) and check that the Torque converter assembly is installed properly. Check AT oil level and top-up if required. For additional information refer to AToil level inspection and Filling procedure. Inspect that shift lever can shift smoothly and accurately when shifting shift lever from N to other range. Inspect that engine can be started with shift lever only 'N' or 'P', but not in other range. Inspect the gear shifter indicator in the instrument cluster be turned on correctly while in P-R-N-D positions. If any of the above conditions are not fulfilled, Kindly check & adjust Selector position switch & Cable. Inspect the AT assembly for any external damage, Replace if required. Using 13 mm socket spanner, loosen and remove the e - disconnect stone guard mounting bolts. Torque : 4.0 \u00b1 0.5Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect the AT oil hose quick coupler radiator and interconnector end. Detach the hose routing clip and take out from the vehicle. Install in reverse order of removal. Check the AT oil level and top up if required. For additional information refer to AToil level inspection and filling procedure. Check for any external oil leakage. Rectify if found. Remove the Front Grill Assembly. Press and disconnect the oil hose quick coupler oil cooler side. Press and disconnect the oil hose quick coupler Radiator side. Detach the routing clip and remove hose from the vehicle. Install in reverse order of removal. Check the AT oil level and top up if required. For additional information refer to AToil level inspection and filling procedure. Check for ATF oil leakage and ensure that there are no oil leaks. For additional information refer to ATF Oil leak check procedure section. Check for any external oil leakage. Rectify if found. Perform failure diagnosis by following the steps below. Only the basic procedure is described here. Before performing failure diagnosis, first perform basic steps (1) through (5) to pinpoint the area of the malfunction. Then perform troubleshooting while referring to inspection items. Effective procedures are described for each failure diagnosis item according to the system. Malfunctioning vehicle comes in for service Analyze symptoms of malfunction expressed by customer Check with the customer about the circumstances and conditions at the time of malfunction occurred and capture what, when, where, and in what circumstances the malfunction occurred in detail. In order to perform a correct diagnosis, confirm the symptoms of the malfunction properly without preconceptions. In order to confirm the symptoms of the malfunction properly, it is extremely important to ask the customer about the circumstances at the time the malfunction occurred. Even information such as malfunctions that occurred in the past that are thought to be unrelated or the repair record may be useful sometimes, so it is necessary to gather as much information as possible. Pre-inspection ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using battery voltage tester, inspect the battery voltage with the engine stopped.Specified value (10 to 14 V). Inspect locations that can be visually checked, such as fuse blowout, harness disconnection or short circuit, and the connection state of connectors. Check diagnosis code (Vehicle Data Record) ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Warm up the engine sufficiently. Using Diagnostic tool, check the diagnosis code and Vehicle Data. When a diagnostic code is stored, data (vehicle data) is also stored in the TCU.Record it along with the Diagnostic Code. DTC is shown in the Trouble Code Chart. For additional information refer to Road test procedure section. For additional information refer to Time lag test procedure section. Time lag test procedure section. For additional information refer to stall test procedure section. stall test procedure section. Using Diagnostic tool, delete the diagnosis code and Vehicle Data.Diagnosis code and Vehicle Data cannot be cleared by simply disconnecting the cable from the negative terminal of the battery. Be sure to use the Diagnostic tool to clear them. If no diagnosis code is stored, check for symptoms of the malfunction and then perform a Road Test and Function Check. Use the data obtained at the time of checking for symptoms of the malfunction. Check symptoms of malfunction (recheck diagnosis code) ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Based on the information gathered from the customer and vehicle data, re-create the circumstances and environment in place when the malfunction occurred and check. Troubleshoot by diagnosis code ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": " Referring to Flow Chart of Troubleshooting by Trouble Code, check the content corresponding to the stored diagnosis code and inspect the circuits and parts corresponding to the malfunctioning system. For additional information refer to Diagnosis Manual. Inspect circuits and parts ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": " Referring to Inspection, inspect circuits and parts to pinpoint the location of the malfunction. For additional information refer to Diagnosis Manual. For additional information refer to Diagnosis Manual. Repair malfunction ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": " Conduct repair or replacement to correct the pinpointed location of the malfunction. Completion test ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": " After repair, part replacement, and/or adjustment to correct the location of the malfunction, check for symptoms of the malfunction to make sure the phenomenon does not occur. Using Diagnostic tool, delete the stored diagnosis code and vehicle data. If the TCU or automatic transmission was replaced, be sure to clear the learned values, and perform initial learning. If the TCU or automatic transmission was replaced, be sure to clear the learned values, and perform initial learning. Finished ",
+ "file": null,
+ "display_order": 21
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 59,
+ "sys_id": "THAR.LX-0005-Automatic Transmission",
+ "subsys_id": "THAR.LX-0005-Automatic Transmission-Selector Position Switch Inspection",
+ "systems": "Automatic Transmission",
+ "sub_systems": "Selector Position Switch Inspection",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W446.jpg",
+ "myid": 1173,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0005-Selector Position Switch Inspection-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W446.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Selector Position Switch at Various Modes (PRND) ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect & ensure Selector Position Switch at Neutral (N) Mode as shown below. Manual valve lever angel should be matched with switch projection (Marking) as shown in the figure. Manual valve lever position for various modes (PRND) at Selector Position Switch is below. By using 7 mm Open end spanner rotate the Manual valve lever and ensure P-R-N-D mode positions. Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. Torque : 6.0 \u00b1 0.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery,check for the audible sound of EWP ON. Disconnect the AT WH pigtail interconnector and routing clips. Using 10 mm socket spanner unscrew \u2014 WH grommet mounting bolts on the fire wall side. Torque : 10 \u00b1 1.0 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using screw driver unscrew floor console side trim mounting screw rivets and remove the trim. Disconnect the WH connector from IP WH and routing clips. Detach the WH from vehicle. Install in reverse order of removal. Check for any external damage, if found please replace. Transmission Oil \u2013 ATF NWS9638 Special Automatic Transmission Fluid. Total Oil Capacity \u2013 9.5 Liters. Shift the TGS lever position to P. Lack of ATF volume Oil pump vacuums air and causes lowness of line pressure, causing clutch slipping or lubrication failure of each part, resulting in burning out. Over level ATF volume When driving in this condition, ATF volume rises and ATF may blow off from the breather. Overfilling results in ATF over heating. Using 24 mm socket spanner, remove the filler plug from transmission. Using 14 mm socket spanner, remove the drain plug and the gasket. Drain the Automatic transmission fluid. Install the drain plug with new gasket and tighten the drain plug with specified torque. Torque : 20 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": " Always replace the drain plug gasket with a new one. Refill the ATF (9.5 Ltrs) through filling hole by using hose with funnel. Always use the clean hose/funnel for refilling and hose/funnel should be used only for ATF refilling purpose. Recommend to use only Mahindra ATF NWS9638 Special Automatic Transmission Fluid and Never mix 2 different oils. Do not overfill transmission, fluid foaming and shifting problems can result. Refit the filler plug on transmission, tighten the filler plug with specified torque. Torque : 39 \u00b1 15 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Always replace the filler plug O ring with a new one. Check AT oil level and top-up if required. For additional information refer to AT oil level inspection and Filling procedure. Park the vehicle and Position the TGS lever in N position. Ensure the gear shifter link in Neutral (N) Mode as shown below. By Using M6 size bolt lock the shifter link rod in N position as shown in fig. Disconnect the NSW switch Electrical connector. Unlock the Washer and use a 24 mm socket spanner to remove the switch mounting nut. Torque : 6.9 \u00b1 0.9 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W476.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner unscrew switch mounting bolt from casing. Torque : 12.75 \u00b1 2.95 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W477.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110217.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "By Using screw driver take out the switch from the manual lever and take out from the vehicle. Install in reverse order of removal. Position the Manual lever at N position, lever position should be matched with switch projection(Marking) as shown in the figure. Ensure to lock the washer after fitment of mounting nut. Ensure to remove M6 Bolt mounted on the gear shifter link. Inspect Manual valve lever position for various modes (PRND) at Selector Position Switch are below. Inspect that shift lever can shift smoothly and accurately when shifting shift lever from N to other range. Inspect that engine can be started with shift lever only N or P, but not in other range. Inspect the gear shifter indicator in the instrument cluster be turned on correctly while in P-R-N-D positions. <n>If any of the above conditions are not fulfilled, Kindly check & adjust Selector position switch & shifter link.Inspect the NSW switch for any damage, Replace if required. Make sure to clean dirt, sand or other foreign matter from the Automatic transmission assembly before removing components. Clean components and surrounding area prior to removal. Ensure that all parts are neatly stored in the appropriate container/tray as they removed, failing may leads to difficult while reassemble the components. Do not use cotton gloves or shop rags as frayed strings might get caught in the unit. Thus, work with your bare hands or use plastic gloves. Do not drain the ATF when it is hot, wait until it has cooled down. Recommend to use only Mahindra 'ATF NWS963' Special Automatic Transmission Fluid and Never mix 2 different oils. Always replace gaskets, 'O' rings and oil seals etc. with new ones. Do not overfill transmission, fluid foaming and shifting problems can result. Keep work areas clean and organized. Pick up tools and use tool cabinets to keep walkways clear and free from clutter. Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Remove the AT Oil Pan Assembly. Using 10 mm socket spanner, remove mounting bolts and remove oil strainer from the valve body assembly. Remove the 'O' ring from the oil strainer Apply a thin layer of ATF on new 'O' ring and install on the oil strainer. Always replace the 'O' ring with a new one. Position and Install the oil strainer mounting bolts on valve body assembly, torque tighten the bolts to specified value. Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Refit AT Oil Pan Assembly. Tighten the battery negative cable mounting nut. Torque : 6.0 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Check AT oil level and top-up if required.For additional information refer to AT oil level inspection and Filling procedure. Check for oil leak between contact surface of oil pan and housing. Inspect that shift lever can shift smoothly and accurately when shifting shift lever from 'N' to other range. Inspect that engine can be started with shift lever only N or P, but not in other range. Inspect the gear shifter indicator in the instrument cluster be turned on correctly while in P-R-N-D positions. If any of the above conditions are not fulfilled, Kindly check & adjust Selector position switch & Cable. Remove the Torque Converter. Using a screw driver, remove Oil Pump Oil Seal from transmission. Refit oil seal by using special tool 0701CAJ0002ST - AT Oil Pump/ Rear Housing Oil Seal Installer - 4WD/2WD. Refit the Torque Converter. Check AT oil level and top-up if required.For additional information refer to AT oil level inspection and Filling procedure. Inspect the Oil Pump Oil Seal for any damage. Replace if found any. Check that there is no foreign matter in ATF. In case of surplus metal powder or lining powder, it is considered wear-out of internal automatic transmission components. Check that ATF does not change color. In a case of becoming clouded, especially, it is possible that water is mixed in,so inspect cooling system. The purpose of the road test is to accurately grasp the symptoms of the malfunction and to check completion after repairs are finished. Be sure to perform a road test under the conditions below. Perform after engine inspection and adjustment. Perform with ATF temperature (50-80\u00b0C) under ordinary driving conditions. The A/C, lights, etc., are turned off. Cruise control is off. When performing a road test on public roads, first check the safety of the road.Road Test Procedure. Make sure to clean dirt, sand or other foreign matter from the Automatic transmission assembly before removing components. Clean components and surrounding area prior to removal. Ensure that all parts are neatly stored in the appropriate container/tray as they removed, failing may leads to difficult while reassemble the components. Do not use cotton gloves or shop rags as frayed strings might get caught in the unit. Thus, work with your bare hands or use plastic gloves. Do not drain the ATF when it is hot, wait until it has cooled down. Recommend to use only Mahindra 'ATF NWS9638' Special Automatic Transmission Fluid and Never mix 2 different oils. Always replace gaskets, 'O' rings and oil seals etc. with new ones. Do not overfill transmission, fluid foaming and shifting problems can result. Keep work areas clean and organized. Pick up tools and use tool cabinets to keep walkways clear and free from clutter. Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affe dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Provide a jack to support to transfer case. Using a 18 mm socket spanner, loosen and remove the transmission bed mount nuts. Using 14 mm & 15 mm socket/Ring spanner unscrew cross member mounting bolts and nuts then remove the cross member. Using 24 mm socket spanner, remove the filler plug from transmission. Using 14 mm socket spanner, remove the drain plug and the gasket. Drain the ATF & Measure Quantity ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W618.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Drain the Automatic transmission fluid and Measure the Drained fluid quantity. Install the drain plug with new gasket and tighten the drain plug with specified torque. Torque : 20 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Caution",
+ "content": "Always replace the drain plug gasket with a new one. Using 10 mm socket spanner, remove transmission oil pan sub-assembly mounting bolts. Remove the oil pan sub-assembly and gasket from the transmission housing. Take sufficient care not to damage the fitting surfaces of the transmission housing and the transmission oil pan sub-assembly. Take sufficient care not to deform the transmission oil pan sub-assembly. Remove the oil cleaner magnets from the oil pan sub-assembly. Examine the chips and particles in the oil pan sub-assembly and on the oil cleaner magnet to determine what type of wear has occurred in the Automatic Transmission. Steel (Magnetic) = Bearing, Gear and Plate wear.Brass (Non-magnetic) = Bushing wear.Install the 4 oil cleaner magnets to the oil pan subassembly Clean the transmission oil pan subassembly. Clean the oil cleaner magnet before installing. Clean oil from oil pan gasket fitting surface of the housing and the mounting bolt holes. Install a new oil pan gasket on the oil pan subassembly Always replace the Oil pan gasket with a new one. Ensure to align the gasket in correct position on the oil pan sub assembly as shown in the illustration. Take sufficient care not to damage the fitting surfaces of the Transmission housing and the oil pan subassembly. Take sufficient care not to deform the oil pan subassembly. Install the oil pan sub assembly mounting bolts to the housing. Tighten the bolts to specified torque value. Torque : 7.4 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Make sure that there is no oil or foreign matter on the oil pan gasket seal surface and oil pan subassembly contact surface. Install the oil pan gasket properly so that there is no slack in the oil pan gasket, and that the seal surface's entire circumference is level. Make sure that the oil pan gasket drop prevention protrusions are set on the oil pan subassembly. When tightening the oil pan subassembly, make sure that the oil pan gasket is not pinched between the oil pan gasket tightening area's sleeve and the housing seal surface. Position & Install the cross member mounting bolts and nut then tighten to specified torque value. Torque: 65 \u00b1 10.0 Nm ",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install the transmission bed mount nuts and tighten the nuts to specified torque value. Torque: 110 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the jack support from transfer case. ATF Refilling ",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110203.jpg",
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Refill the ATF (Drained quantity + 0.5 Ltrs) through filling hole by using hose/funnel and tighten the filler plug. Always use the clean hose for refilling and hose should be used only for ATF refilling purpose. Always replace the filler plug O ring with a new one. Recommend to use only Mahindra 'ATF NWS9638' Special Automatic Transmission Fluid and Never mix 2 different oils.Recommend to use only Mahindra 'ATF NWS9638' Special Automatic Transmission Fluid and Never mix 2 different oils. Do not overfill transmission, fluid foaming and shifting problems can result. Tighten the battery negative cable mounting nut. Torque : 6.0 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Check AT oil level and top-up if required. For additional information refer to AToil level inspection and Filling procedure. Check for oil leak between contact surface of oil pan and housing. Inspect that shift lever can shift smoothly and accurately when shifting shift lever from 'N' to other range. Inspect that engine can be started with shift lever only 'N' or 'P', but not in other range. Inspect the gear shifter indicator in the instrument cluster be turned on correctly while in P-R-N-D positions. If any of the above conditions are not fulfilled, Kindly check & adjust Selector position switch & shifter link. Remove the Instrumental Panel Assembly. Using a star driver,loosen and remove the IP driver side switch bank mounting screws. Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270121.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Detach the IP driver side switch bank from the Instrumental Panel Assembly Install in the reverse order of removal. Inspect the IP driver side switch bank condition, if required replace. By using Trim Removal tool, remove the bezel rest from front door RH. Disconnect the electrical connector from the bezel. Using flat screw driver detach the switch from the bezel. Install in the reverse order of removal. Check the mounting clips condition to avoid rattling and falling down. Check the switch condition. If required replace. Remove the IP center switch bank assembly. Using a star driver, loosen and remove the center switch mounting screws. Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270005.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the center switch from IP center switch bank assembly. Install in the reverse order of removal. Check the mounting clips condition to avoid rattling and falling down. Check the switch condition. If required replace. Remove front grill assembly. Pull the lock disconnect head lamp electrical connectors. Using 10 mm socket spanner, loosen and remove the head lamp mounting bolts. Torque : 6 \u00b11Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270022.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the head lamp assembly separately. Install in the reverse order of removal. Inspect the head lamp for any damage, crack and glass fading. Inspect the bulbs. Using a star screw driver, Unscrew front splash shield lower mounting screws. Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts. Torque : 6.5 \u00b10.7Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield. Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270037.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the electrical connector. Using hand, Push the side marker lamp assembly from the cladding and remove. Remove the Side Marker Lamp from vehicle. Install in the reverse order of removal. Inspect the side marker lamp assembly for any physical damage/crack etc. Inspect the glass for fading. Inspect the condition of bulbs. Inspect the connectors for proper fitment. Using a star screw driver, Unscrew front splash shield lower mounting screws (Front side screws). Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nut. Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the front side of shield to access front turn indicator and DRL. Disconnect the front turn indicator and DRL electrical connectors. Using a 10 mm socket spanner loosen and remove the front turn indicator and DRL mounting bolts. Torque : 4\u00b11 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270112.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully remove front turn indicator and DRL. Refit in the reverse order of removal. Inspect the front turn indicator and DRL for any damage, replace if required Remove tail lamp cover from tail lamp. Using 10 mm socket spanner unscrew tail lamp mounting bolts. Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270044.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect tail lamp electrical connector. Remove and turn the backup lamp bulb socket in the direction of the arrow. Remove the reverse lamp bulb from holder. Install in the reverse order of removal. Check the bulb condition to avoid rattling and falling down. Check the bulb condition. If required replace. Using a star screw driver, Unscrew front splash shield lower mounting screws. Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts. Torque : 6.5 \u00b10.7 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield. Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270047.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Rotate the bulb holder in anti clock wise direction and remove the holder with bulb. Remove the bulb from the holder. Install in the reverse order of removal. Check the bulb condition to avoid rattling and falling down. Check the bulb condition. If required replace. Remove tail lamp cover from tail lamp. Using 10 mm socket spanner unscrew tail lamp mounting bolts. Torque :4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270044.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Disconnect tail lamp electrical connector. Remove the bulb from holder by turning the bulb in counter clock wise direction. Gently pull out the bulb from holder. Install in the reverse order of removal. Check the bulb condition to avoid rattling and falling down. Check the bulb condition. If required replace. Using a star screw driver, Unscrew front splash shield lower mounting screws. Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts Torque : 6.5 \u00b1 0.7 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield. Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270058.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect parking lamp electrical connector. Rotate and remove the bulb holder from vehicle. Remove bulb from holder by turning the bulb in counter clock wise direction. Detach the bulb from holder. Install in the reverse order of removal. Check the bulb condition to avoid rattling and falling down. Check the bulb condition. If required replace. Vehicle & head lamp aiming board should place on the same level surface Check and ensure all four tyre pressures as per specification. Head lamp levelling switch position is on zero (0). Vehicle needs to be parked 10 meters or 3 meters away from the aiming board. (L = 10 meters / 3 meters which is the distance from starting point of front tyre to the aiming board as shown in illustration below).Select the aiming board according to the value of \u201cL\u201d. Refer illustration for \u201cL= 10 Meters\u201d ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10713.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270086.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Refer illustration for \u201cL= 3 Meters\u201d. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270091.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Heading",
+ "content": "Refer the illustration for the head lamp adjustment arrangement - ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270087.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270088.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Heading",
+ "content": "Refer the illustration for the head lamp aiming board dimensions of Head Lamps - ",
+ "file": null,
+ "display_order": 12
+ }
+ ]
+ },
+ {
+ "procedure_name": "Low Beam Setting Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270089.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270090.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Refer below illustration for the head lamp aiming board dimensions of Head Lamps : ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Low beam & high beam aiming settings are common. Hence if adjust low beam, high beam will also get aligned with low beam. Using 5 mm socket spanner, rotate the adjusting screw on motor to vary the Low beam cut-off pattern in vertical direction. Clockwise rotation \u2013 Downwards. Anti-clockwise rotation \u2013 Upwards. Using star screw driver, rotate the RH side lamp adjusting screw to vary the low beam cut-off pattern in horizontal direction. Clockwise rotation \u2013 Left side. Anti-clockwise rotation \u2013 Right side. RH & LH Head lamps are common for New THAR vehicle. Using star screw driver, rotate the LH side lamp adjusting screw to vary the low beam cut-off pattern in horizontal direction. Clockwise rotation \u2013 Right side. Anti-clockwise rotation \u2013 Left side. Check the function of system, by operating the switch from '0' to '3' and observe the cutoff pattern movement in downward direction accordingly. At zero position of switch, the cut- off should come at \u201ch\u201d heights 833 mm (For L= 10,000 mm) & 924 mm (For L=3,000 mm) on screen. Low beam & high beam aiming settings are common. Hence if adjust low beam, high beam will also get aligned with low beam. RIGHT TURN INDICATOR ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "For inspection, push the lighting control stalk clockwise (to stop position B) to indicate a right turn. The instrument cluster arrow lamp pointing towards the right flashes along with the right side turn signal lamps with chime indicating your intention of turning towards right After you have completed your right turn, the stalk will automatically return to the neutral position. Both the right turn lamp and the right turn signal lamp switch OFF. LEFT TURN INDICATOR ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "For inspection, push the lighting control stalk anti-clockwise (to stop position A) to indicate a left turn. The instrument cluster arrow lamp pointing towards the left flashes along with the left side turn signal lamps with chime indicating your intention of turning towards left.</li</ul> LAMPS OFF ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "For inspection, rotate the outer rotary switch on the lighting control stalk aligning the \u2018Arrow\u2019 on the switch to \u2018O\u2019 on the stalk to switch OFF all lamps. LANE CHANGING ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "For inspection of signal a lane change, move the light control stalk clockwise or anti-clockwise to the limit point of free movement of the lever and release. The turn signals will flash three times and stop. PARKING LAMPS ON ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "For inspection, rotate the outer rotary switch on the lighting control stalk aligning the \u2018arrow\u2019 on the switch to the \u20181st d\u00e9tente\u2019 position on the stalk to switch ON the parking lamps. HEAD LAMP ON ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "For inspection, rotate the outer rotary switch on the lighting control stalk aligning the \u2018Arrowt\u2019 on the switch to the \u20182nd d\u00e9tente\u2019 position on the stalk to switch ON the head lamps. HEAD LAMP HIGH BEAM/LOW BEAM ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "For inspection, with the head lamp ON, push the lighting control stalk down (away) from steering wheel to switch ON the head lamp high beam. The head lamp high beam tell-tale lamp in the instrument cluster illuminates indicating high beam option selected. With the head lamp high beam ON, pull the lighting control stalk up towards the steering wheel to switch ON the head lamp low beam. HEAD LAMP FLASH ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "For inspection, pull the lighting control stalk (from the head lamp low beam position) towards the steering wheel to instantaneously flash the head lamp high beam. The head lamp flash works even when the head lamp is OFF. FOG LAMPS OFF ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "For inspection, align the inner rotary switch on the lighting control stalk to the fog lamp off \u2018dot\u2019 on the inner fixed stalk as shown to switch OFF the fog lamps. FRONT FOG LAMPS ON ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "To inspect the front fog lamps, switch ON the ignition and the parking lamps. Turn the inner rotary switch on the lighting control stalk to align to the fog lamp symbol on the inner fixed stalk as shown. The front fog lamp indicator in the instrument cluster indicates the operation status. HAZARD WARNING LAMP ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "For inspection, press the hazard switch ON, All the turn signal lamps flash. To turn OFF, press the switch again. CENTER ROOF LAMP ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "The Roof lamp switch has three operation modes to choose from; The lamp remains permanently ON in this position irrespective of the door open status The lamp remains permanently OFF in this position The lamp remains in AUTO mode in this position. WIPER CONTROL STALK ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "Wiper Off ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "For inspection, move the wipe stalk in neutral position (B). Wiper remains OFF. Flick-Wipe (Mist) ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "For inspection, push the wipe control stalk to position A for a flick-wipe, hold to operate the wipe continuously (simultaneously lift the wiper stalk towards the steering wheel to operate the wash). The stalk automatically comes back to position B when released. Intermittent (INT) Mode ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "For inspection, push down the stalk down to position C. In the INT mode, the wiper operates on preset intervals. Low Speed Wiping ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "For inspection, push the wipe control stalk up to the position D to operate the wiper at a fixed low speed. High Speed Wiping ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "For inspection, push the wiper control stalk up to position E to operate the wiper at a fixed high speed. FRONT WIPE/WASH ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "For inspection, pull/lift the wiper control stalk towards the steering wheel from any position to activate the front wipe/wash function. Washer fluid is sprayed on the front windshield and the wipers wipe the windshield 3 times after the washer spray is stopped and wipe once after 4 sec. Hold the stalk in position for continuous spray of washer fluid. HORN ",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "For inspection, press the pad on the steering wheel to sound the horn. The horn functions even when the ignition has been switched OFF. STOP LAMP/HIGH MOUNTED STOP LAMP ",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "For inspection, Press the brake pedal and the Stop Lamp /high mounted stop lamp will illuminate. REVERSE LAMP ",
+ "file": null,
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "For inspection, Engage the reverse gear and the reverse lamp will illuminate. Remove the switch bank driver side . Remove the aiming switch lock by using flat screw driver. Insert the screw driver one side to release lock & release other side. Detach the IP driver side switch bank from the vehicle. Install in the reverse order of removal. Inspect the aiming switch condition, if required replace. Using star screw driver unscrew the panel assembly floor console RH screvits and detach the panel from vehicle Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290031.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console LH screvits and detach the panel from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290034.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew vertical ascent RH mounting screw and detach the vertical ascent RH from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290033.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew vertical ascent LH mounting screw and detach the vertical ascent LH from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290035.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290036.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270129.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "partially detach the switch bank assembly and remove electric connector to take out from the vehicle. Install in the reverse order of removal. Inspect the center switch for any physical damage. Replace if found. Using a star screw driver, Unscrew front splash shield lower mounting screws. Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts. Torque :6.5\u00b10.7 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield. Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270033.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect front indicator electrical connector. Rotate and remove the bulb holder from vehicle. Remove bulb from holder by turning the bulb in counter clock wise direction. Install in the reverse order of removal. Check the bulb holder condition to avoid rattling and falling down. Check the bulb condition. If required replace. Pull and remove the tail lamp cover from vehicle. Using 10 mm socket spanner, loosen and remove tail lamp mounting bolts and partially detach it. Torque : 4 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270044.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect tail lamp electrical connector. Remove tail lamp from vehicle. Install in the reverse order of removal. Inspect the tail lamp/ rear lamp assembly for any physical damage/crack etc. Inspect the glass for fading. Inspect the condition of bulbs. Inspect the connectors for proper fitment. Remove the Convertible Soft top Canopy. Remove the support centre Rexine rivets other side. Remove the Support Side Rexines rivets RH & LH. Using star screw driver, loosen and remove the Bow 1 Injection Mould mounting screws (locate 1 screw at bottom side of centre rexine support). Using star screw driver, loosen and remove the Latch mounting screws. Remove the Bow 1 Injection mould from front side bow and remove the Convertible Soft top Frame Complete assembly. Refit in the reverse order of removal. Inspect the Convertible Soft top Frame Complete assembly for any crack or damage. Replace if any. Remove Side window RH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window Remove Side window LH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window Unzip the tail gate window, detach the tail gate bar locking from rear RH & LH belt rails remove the tailgate window. Unhook the \u2018C\u2019 pillar cover from rear RH & LH belt rails and fold the cover at top of the soft top. Slide the Sun visors and Remove the Footman's loops from front header. While unlock the Footman loop hook from the front header metal bracket, ensure to press & move the softtop assembly slightly in forward direction and release the hook from the bracket. Slide back the convertible top from front header to rear and roll up properly. Properly Roll up the convertible soft top assembly in the rear side as shown in fig . Unlock two Quick release knuckle RH & LH from main pivot brackets . Lift the convertible soft top assembly upwards (both sides) , silding towards rear and take out assembly from the vehicle. Lift the convertible soft top assembly upwards (both sides), sliding towards front and position on the vehicle as shown. Align the convertible soft top assembly both sides & Lock the two Quick release knuckle to RH & LH main pivot brackets . Properly open rolled convertible soft top assembly from the rear side. Slide convertible top from rear end to front header and position on front header properly. Lock the Footman's loops to the front header and slide the Sun visors. Lock the Footman loop hook on the front header metal bracket & press the loop handle While locking ensure top plastic support project on top of the header metal bracket for proper locking as shown. Unfold and Hook the \u2018C\u2019 pillar cover to rear RH & LH belt rails . Attach the tail gate bar locking to rear RH & LH belt rails and zip tailgate window. Position and hook LH side window to the vertical and horizontal belt rail. Zip the window and refit the LH Side window Velcro . Position and hook RH side window to the vertical and horizontal belt rail. Zip the window and refit the RH Side window Velcro . Check the Convertible Soft Top Assembly for any damage, replace if required. Remove the Spare Wheel Carrier. Remove the air extractor from the vehicle. Refit in the reverse order of removal. Inspect the air extractor for any crack or damage. Replace if any. Remove Front Roof caps using trim remover and Using a T30 socket spanner, loosen and remove the roof front top mounting bolts. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A250210.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A250213.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A250211.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A250212.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Rear Roof caps using trim remover and Using a T30 socket spanner, loosen and remove the roof rear top mounting bolts. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A250214.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A250215.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A250216.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A250217.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a trim remover pull out center bow trim and disconnect roof lamp electrical connector. Ensure to use trim remover while removing centre roof bow trim, and avoid the press clip damage. Replace the press clip for proper fixing, if it is damaged. Remove the centre bow trim from the vehicle. Using a T30 socket spanner, loosen and remove the roof top mounting bolts inside bow trim. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A250219.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "By Using T30 Torx Socket Spanner remove the RH & LH roof side upper frame mounting bolts. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A250102.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A250103.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "By Using T30 Torx Socket Spanner remove the RH & LH roof side lower frame mounting bolts Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A250104.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A250104.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "By Using T30 Torx Socket Spanner remove the RH & LH rear lower bracket mounting bolts. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A250206.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A250207.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a T30 socket spanner, loosen and remove the roof top mounting bolts from roll cage. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A250208.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A250209.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Disconnect the HMSL electrical connector. Insert and split the panel with trim remover, in between Hard-Top and frame mounting plate. Lift and Carefully remove the hard top assembly from the vehicle with sufficient manpower and keep it in Trolly bench or flat working bay. Use the recommended safety equipment\u2019s; Safety goggles, Cotton gloves, Safety shoes etc. while lifting the Hard-Top. Prepare the Hard-Top assembly for installation Remove the dust & strain marks by Steel wire brush. (as shown in illustration) Clean with degreaser cloth for silicon sealant application. Don't use ordinary solvent for HardTop cleaning. (it may result some undefined problems in Hard-Top) Inspect the Hard-Top windshield upper frame Seal and replace if needed when the seal loses its softness or if found any damages. Follow the below steps for replacement of Hard-Top windshield upper frame Seal Remove the X-mas tree clips by trim remover from over the roof rail outer frame. Then pull the seal by manually, due to this seal has fixed with two-way pasting tape. Clean the surface by degreaser cloth. Peel the sticker label sheet from the new Seal, then paste on the roof rail outer frame followed by press the X-mas tree clips. The Seal must be replaced along with X-mas tree clips, when the seal loses its softness or if found any damages, don't reused the X-mas tree clips. This seal is for preventing the water leakage and wind noise only. Seal coming with Two-way pasting tape. Before Installation, Apply the silicon sealant on inner side edges of Hard-Top by manual Sealant gun. A triangular V- shaped notch will provide the optimal bead shape. (Height 4 mm/ width 5 mm). After sealant application, immediately fix the Hard-Top assembly, with help of sufficient manpower. Silicon sealant must be applied for water leakage and wind noise prevention. Refit in the reverse order of removal. While Installation hand tighten all the Hard top mounting bolts first for proper positioning and finally torque tighten all the bolts. Don\u2019t over tighten the screws to avoid the thread slipping and other damages. While Installation properly position the Hard top dowels in the body for proper positioning & fitment. Inspect the hard top assembly for any damage. Replace if found. Using 12 mm socket and 13 mm combination spanner, Unscrew front bracket mounting bolt and nut. Using 12 mm socket and 13 mm combination spanner, Unscrew front centre bracket mounting bolt and nut. Using 13 mm socket combination spanner, Unscrew rear bracket mounting bolt. Remove the front foot step assembly from vehicle. Front extreme portion of foot step is not to stand, Since front portion is aesthetic part to merge the design theme with cladding. Refit in the reverse order of removal. Check for any damages or crack in foot step assembly. Replace if found. Pull out cover cap from the wiper arm. Using a 13mm socket spanner, loosen and remove the Wiper arm mounting nuts. Torque : 15 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250008.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the wiper arms from vehicle. Using a star screw driver, loosen and remove the Scuttle Grill mounting screws . Torque : 1.9\u00b10.5Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250011.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the Scuttle Grill mounting Scrivets . Remove the Scuttle Grill from the vehicle. Refit in the reverse order of removal. Inspect the Scuttle grill for any damage. Replace if found. Inspect the mounting push buttons, replace if required. Using a star screw driver, loosen and remove the front splash shield mounting screw rivets from both the sides of vehicle. Remove the front splash shield both the sides from vehicle . Using a 10 mm socket spanner, loosen and remove the front stone guard front mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250032.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen and remove the rear stone guard rear mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250064.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the stone guard mounting screw rivets. Remove the stone guard from the vehicle. Disconnect the fog lamp electrical connectors LH & RH sides. Pull and remove the front bumper top panel trim clips and remove the panel. Using a 10 mm socket spanner, Unscrew front bumper mounting nuts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290003.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290004.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "using a 13 mm socket spanner, Unscrew front bumper bottom mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290005.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew front bumper top side mounting bolts. Using a star screw driver, Unscrew front bumper top centre mounting screw rivets. Remove the front bumper assembly from the vehicle. Using a 13 mm socket spanner, Unscrew front bumper center bracket mounting bolts and remove the front bumper center mounting bracket. Torque : 10.0\u00b11 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290010.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the front grill mounting screw rivets. Using a star screw driver, loosen and remove the bottom side front grill mounting screw rivets. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290011.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the front grill mounting bolts. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250061.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Remove the front grill assembly from the vehicle. Using star screw driver, Remove centre grill mounting screws and locking clips from front facia. Remove the centre grill from front facia. Refit in the reverse order of removal. Inspect the front bumper assembly for any crack or damage, Replace if found any. Check the front grill assembly for any external cracks, replace if found any. Remove the Soft top canopy. Using a 10 mm socket spanner, loosen and remove the rear side cover LH mounting bolts. Using a 10 mm socket spanner, loosen and remove the rear side cover RH mounting bolts. Carefully remove the rear side covers LH and RH sides. Using a 10 mm socket spanner, loosen and remove the rear side member RH mounting bolts. Carefully remove the rear side member RH from vehicle. Using a 10 mm socket spanner, loosen and remove the rear side member LH mounting bolts. Carefully remove the rear side member LH from vehicle. Using a 10 mm socket spanner, loosen and remove the rear centre panel assembly mounting bolts. Using a T40 torx socket spanner, loosen and remove the rear structure frame mounting torx bolts. Remove the rear structure frame from vehicle. Refit in the reverse order of removal. Check the rear structure frame for any external cracks and damages, replace if found any. Remove the convertible soft top assembly Using a star screw driver, loosen and remove Canopy mounting screws from the front side bow assembly RH and LH. Remove the lock from the RH and LH Front side bow assembly. Using star screw driver, loosen and remove Canopy mounting screws from Front side bow assembly inner side. Remove the Canopy from the front side bow assembly. Detach or unlock the spring from the Bow 2 Pivot assembly & remove Canopy from Bow 2 Pivot assembly . Using star screw driver, loosen and remove the canopy mounting screws from bow 2 pivot assembly and detach canopy. Using star screw driver, loosen and remove the canopy mounting screws from bow 3 assembly and detach canopy. Remove the Center Support Rexine Rivets. Remove the Canopy from the Frame. Remove the Cable with Spring from the Canopy (RH &LH). Refit in the reverse order of removal. While Installation, Insert the cable from bracket side to Spring side (Insert spring inside from top) Inspect the convertible soft top canopy for any crack or damage. Replace if any. Using 10 mm socket spanner, loosen and remove the mounting nuts from the ORVM. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files//W4A250274.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the ORVM from the vehicle completely. Refit in the reverse order of removal. Inspect the ORVM for any crack or damage. Replace if any. Remove front lateral trim. Remove Roof Speaker trim assembly Open the top cover and Using a 14 mm socket spanner, loosen and remove the seat belt upper mounting bolt. Torque :38 \u00b16 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210079.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210080.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the seat belt lower mounting bolt. Torque :38 \u00b16 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210081.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the hand support belt. Remove the floor mate partially from the vehicle. Using a 13mm socket spanner, loosen and remove the roller gage bar rear mounting bolt. Torque : 25 \u00b1 4Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250025.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 13mm socket spanner, loosen and remove the roller gage bar front mounting bolt. Torque : 25 \u00b1 4Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250026.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 13mm socket spanner, Unscrew roller gage bar side mounting bolts. Torque : 25 \u00b1 4Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250027.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the roller gage bar from vehicle. Remove the roller bar cover and separate roller gage bar. Refit in the reverse order of removal. Check for any damages or crack in roller gage bar assembly. Replace if found. Using a 10 mm socket spanner, loosen and remove the rear mounting tube pipe structure mounting bolts. Remove the welcro from the rear tubes . Remove the side cover from window bracket LH and RH sides. Using a 10 mm socket spanner, loosen and remove the front mounting tube pipe structure mounting bolts. Remove the welcro from the front tubes . Using a star screw, loosen and remove the canopy front LH and RH screw rivets. Using a 10mm socket spanner, Unscrew canopy front end mounting bolts. Remove the Canopy from the vehicle. Refit in the reverse order of removal. Check the canopy assembly for any external cracks, replace if found any. Recover the AC gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. Remove the Air Cleaner Assembly. Remove the Steering Lower Intermediate Shaft. Using 12 mm open end spanner, Remove suction and discharge hose mounting nut from compressor. Torque Value: 14.0+1.0 Nm Remove the AC/water pump belt. For additional information refer to AC/Water Pump Belt - R&R. Disconnect the AC compressor electrical connector. Using 12 mm socket spanner, Remove the compressor mounting nuts from the crank case. Torque : 25 \u00b1 3 Nm ",
+ "file": "",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A200096.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the compressor from the vehicle. Install in the reverse order of removal. Refit the Steering Lower Intermediate Shaft. For additional information refer to Steering Lower Intermediate Shaft - R&R. Refit the Air Cleaner Assembly. Remove the AC/water pump belt. For additional information refer to AC/Water Pump Belt - R&R. Recharge the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. During installation, fix the new O-ring into both liquid tube and discharge hose mounting joints without any damage. Damage to the O-ring may cause A/C refrigerant leakage which leads to A/c failure. Inspect the compressor for any physical damage. Replace if found. Inspect the clutch pulley for any damage. Replace if found. Inspect the drive belt and Pulley for any physical damage. Replace if found. Remove the HVAC Mode Actuator. Using star screw driver, Unscrew plate mode main link mounting screws and remove the link. Remove the lever sub assembly and lever foot from the plate mode main link. Install in the reverse order of removal. Inspect the plate mode main link for any damage. Replace if found. Using screw driver, remove the floor console RH panel assembly scrivet and detach the panel from the vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": "",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A220006.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A220007.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the floor console LH panel assembly scrivet and detach the panel from vehicle Torque : 2.5\u00b1 0.2 Nm ",
+ "file": "",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A220008.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W749.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the RH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": "",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A220010.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W750.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the LH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": "",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A290036.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Partially detach bezel HAVC control panel assembly and disconnect electrical connectors. Disconnect Heater, Mode selection control cables from the HAVC control panel. Disconnect the cable routing clips and take out the bezel Assembly with HVAC control panel. By using star screw driver, remove the HVAC control panel mounting screws and remove the panel from the bezel assembly. Torque : 1.5\u00b1 0.5 Nm ",
+ "file": "",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the HVAC Control Panel Assembly for any damage. Replace if found. Do not release the refrigerant into the atmosphere. Use approved recovery/ recycling equipment to capture the refrigerant whenever the air conditioning System is discharged. Always wear eye and hand protection (goggles and gloves) when working with any Refrigerant or air conditioning system. Close the high pressure and low pressure refrigerant lines with dust caps to avoid air entry and/or contamination. ",
+ "file": "",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Recover AC gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. Remove Front Grill Assembly. Using 12 mm Combination Spanner, Unscrew the AC pipe compressor side mounting nut. Torque : 14.0+1.5 Nm ",
+ "file": "",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A200071.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew radiator LH seal mounting bolt and remove the seal. Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": "",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A200069.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Remove HVAC pipe condenser side mounting nut. Torque : 6.0+1.0 Nm ",
+ "file": "",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both pipe ends mounting joints without any damage. Damage to the Oring may cause A/C refrigerant leakage which leads to A/c failure. Remove the HVAC pipe assembly from the vehicle. Install in the reverse order of removal. Recharge the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. Inspect the AC pipe for any damage. Replace if found.
Check the blower motor fan blade for damage. Replace the blower motor if necessary
",
+ "file": "",
+ "display_order": 12
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 203,
+ "sys_id": "THAR.LX-0005-Heating, Ventilation And Air Conditioning (HVAC)",
+ "subsys_id": "THAR.LX-0005-Heating, Ventilation And Air Conditioning (HVAC)-Self Diagnostic Procedure \u2013 Electronic Temperature Control (ETC)",
+ "systems": "Heating, Ventilation And Air Conditioning (HVAC)",
+ "sub_systems": "Self Diagnostic Procedure \u2013 Electronic Temperature Control (ETC)",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1312,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0005-Self Diagnostic Procedure \u2013 Electronic Temperature Control (ETC)-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Over Voltage/ Under Voltage",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Whenever over voltage/under voltage situation will occur over ignition Line. These voltages will get sense by MCU and based on these sense voltages panel functionality will disabled or in case of under/over Voltage system will not detect any switch command. It is a kind of Security over connector Pins except Power supplies Pins. If any shorting occur on connector pin either short to battery or short to ground there should be no damage to control panel or circuitry. Over Current/Short to Ground: Face Indicator on off with Frequency 1000 mSec Interval. Short to Battery/ Actuator Stuck: Face Indicator on off with Frequency 500 mSec Interval Over Current/Short to Ground: Air Intake Indicator on off with Frequency 1000 mSec Interval. Short to Battery/ Actuator Stuck: Air Intake Indicator on off with Frequency 500 mSec Interval. Over Current/Short to Ground: Defrost Indicator on off with Frequency 1000 mSec Interval. Short to Battery/ Actuator Stuck: Defrost Indicator on off with Frequency 500 mSec Interval. AC Indicator Blink with 500 mSec Frequency. Do not release the refrigerant into the atmosphere. Use approved recovery/ recycling equipment to capture the refrigerant whenever the air conditioning System is discharged. Always wear eye and hand protection (goggles and gloves) when working with any Refrigerant or air conditioning system. Close the high pressure and low pressure refrigerant lines with dust caps to avoid air entry and/or contamination. Recover the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. Remove the Radiator LH & RH seal. For additional information refer to the Radiator LH & RH Seal R&R section. Using 10 mm socket spanner, Unscrew HVAC Suction and return pipe mounting nuts. Torque : 6.0+1.0 Nm ",
+ "file": "",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both pipes mounting joints without any damage. Damage to the O-ring may cause A/C refrigerant leakage which leads to A/c failure. Using 10 mm socket spanner, Unscrew condenser mounting bolts from radiator end. Torque : 5 \u00b11 Nm ",
+ "file": "",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A200186.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A200074.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Remove the radiator bottom seal mounting bolts and detach it. Torque : 7\u00b10.5 Nm ",
+ "file": "",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A200076.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Detach the ambient temperature sensor from the routing clip. Carefully remove the condenser from vehicle. Install in the reverse order of removal. Refit the Radiator LH & RH seal. For additional information refer to the Radiator LH & RH Seal R&R section. Recharge the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. Inspect the condenser for any physical damage, leakages etc. Replace if found any. Inspect for any foreign materials on condenser. Clean if found. Check and ensure free flow of condenser Using screw driver, remove the floor console RH panel assembly scrivet and detach the panel from the vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": "",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A220006.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A220007.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the floor console LH panel assembly scrivet and detach the panel from vehicle Torque : 2.5\u00b1 0.2 Nm ",
+ "file": "",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A220008.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A220009.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the RH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": "",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A220010.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A220011.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the LH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": "",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A290035.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A200152.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A200153.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Partially detach HAVC control panel bezel and remove the mode cable from HVAC control panel end and routing clip. Remove the driver side IP panel assembly Disconnect the mode cable from HVAC unit end. Remove the cable from the vehicle. Install in the reverse order of removal. Inspect the HVAC mode cable for any damage, Replace if required. Inspect the Mode Cable locks for any damage, Replace if required. The Airbag ECU is installed on the floor panel under the floor console. It deploys the proper Airbag according to the signals from the impact sensors. This ECU communicates with other ECU\u0092s through CAN directly. Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Before disconnecting the battery, check for the audible sound of EWP ON Torque : 6.0\u00b10.6 Nm ",
+ "file": "",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Front console assembly. For additional information refer to Front Console Assembly R&R section. Using star screw driver remove the Airbag ECU Cover screw from airbag ECU. Disconnect the SRS/ Airbag ECU electrical connectors. Using a 10 mm socket spanner, loosen the SRS/ Airbag ECU mounting nuts on the floor panel. Torque :8\u00b11.2 Nm ",
+ "file": "",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A210053.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A210054.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the SRS/ Airbag ECU from the body. Install in the reverse order of removal. Inspect the airbag ECU for any damage, replace if found any. Inspect the airbag ECU connectors for any damage.
Check and clean the connector pins for sulphation and deposits.
",
+ "file": "",
+ "display_order": 13
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 219,
+ "sys_id": "THAR.LX-0005-Heating, Ventilation And Air Conditioning (HVAC)",
+ "subsys_id": "THAR.LX-0005-Heating, Ventilation And Air Conditioning (HVAC)-Heater Core",
+ "systems": "Heating, Ventilation And Air Conditioning (HVAC)",
+ "sub_systems": "Heater Core",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/Heater Core.PNG",
+ "myid": 1328,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0005-Heater Core-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/Heater Core.PNG",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/Heater Core1.PNG",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Evaporator Assembly",
+ "file": "",
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0005,1018,1327",
+ "file": "",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A200221.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A200209.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Carefully remove the heater core \nassembly.",
+ "file": "",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": "",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Refit the Evaporator Assembly",
+ "file": "",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Link",
+ "content": "THAR.LX-0005,1018,1327",
+ "file": "",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Recharge the AC Gas",
+ "file": "",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Link",
+ "content": "THAR.LX-0005,1018,1327",
+ "file": "",
+ "display_order": 12
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the IP lower panel from the vehicle. Disconnect the mode actuator electrical connector. Using star screw driver, Unscrew mode actuator mounting screws. Remove the mode actuator . Install in the reverse order of removal. Inspect the actuator for mechanical damage. Check and clean the connector pins for sulphation and deposits. Before going to performance test, ensure following points are taken care \u0096 AC Filters \u0096 Clean if necessary. AC gas \u0096 Use only R134a A/C gas and only from recommended suppliers. Ensure correct amount of A/C gas is filled in the system. Ensure cleanliness of the condenser surface at regular interval. Ensure proper function of condenser fan. For A/C System testing use only approved Tools & Equipment. This A/C performance test is only to check mechanical performance of the HVAC system and not the flow or circulation related complaints. Park the vehicle on level work bay Open the left front door. Open the glow box and detach the stopper by pressing it. Disengage the glow box from the assembly. Press and remove the HVAC particulate filter cover from HVAC unit. Remove the HVAC particulate filter. Install the HVAC particulate filter on HVAC unit. Install the HVAC particulate filter cover. Engage the glow box stopper and refit the glow box in its position. While installing the filter take sufficient care to prevent bent, damage etc. Close the co-driver door. Use only genuine filter element. Never clean and reuse the HVAC particle filter element. Using screw driver, remove the floor console RH panel assembly scrivet and detach the panel from the vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": "",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A220006.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A220007.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the floor console LH panel assembly scrivet and detach the panel from vehicle Torque : 2.5\u00b1 0.2 Nm ",
+ "file": "",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A220008.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W747.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the RH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": "",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A220010.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W748.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the LH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": "",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A290035.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A200156.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A200157.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Partially detach HAVC control panel bezel and remove the heater cable from HVAC control panel end and routing clip. Open the glove box and remove the glove box by removing the glove box lock. Disconnect the heater cable from the HVAC unit end. Remove the cable from the vehicle. Install in the reverse order of removal. Inspect the HVAC heater cable for any damage, Replace if required. Inspect the heater Cable locks for any damage, Replace if required. Position the vehicle on 2 post lift/ 4 post lift. Check the HVAC drain pipe locking grommet fitment condition on BIW. Ensure that pipe is straight downwards. Do not pull the water drain pipe excessively. Remove the Cross Car Beam (CCB) Assembly. Recover the AC gas. For additional information refer to AC gas recovery procedure. Using 10 mm open end spanner, Remove the HVAC Pipe mounting nut from expansion valve end. Torque : 8.0+1.0 Nm ",
+ "file": "",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both liquid tube and discharge hose mounting joints without any damage. Damage to the O-ring may cause A/C refrigerant leakage which leads to A/c failure. Detach heater inlet and outlet hose quick couplers. Do not open the degassing tank cap when the coolant is hot. Failure to follow this instruction will lead to personal injury. Before removing the heater core hoses, open the degassing tank cap for releasing the coolant pressure. Coolant will leak, while removing the heater core hoses, as a result drain the coolant into a container. Using 10 mm Socket Spanner, Unscrew the HVAC unit assembly mounting bolt and nuts. Torque : 7 \u00b11 Nm ",
+ "file": "",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 5\u00b11 Nm ",
+ "file": "",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 7 \u00b11 Nm ",
+ "file": "",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 7 \u00b11 Nm ",
+ "file": "",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A200104.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm Socket Spanner, Remove the HVAC earth cable mounting nut. Torque : 5\u00b11 Nm ",
+ "file": "",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A200102.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A200103.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the HVAC unit assembly from vehicle. Install in the reverse order of removal. Refit the Cross Car Beam. Recharge the Refrigerant. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. Start the engine, check the coolant level. Refill if required. Check the coolant leak when engine is started. Check the A/C system cooling and operation. Inspect the HVAC assembly for any physical damages. Repair if found. Inspect the kinematics for proper functioning. Inspect the actuators / cables for proper operation. Inspect the filter element and clean/replace if required. Disconnect air fresh and recirculation actuator electrical connector. Using star screw driver, Unscrew the actuator mounting screws. Remove the air fresh and recycling actuator . Install in the reverse order of removal. Inspect the actuator for mechanical damage. Check and clean the connector pins for sulphation and deposits. Do not release the refrigerant into the atmosphere. Use approved recovery/ recycling equipment to capture the refrigerant whenever the air conditioning System is discharged. Always wear eye and hand protection (goggles and gloves) when working with any Refrigerant or air conditioning system. Close the high pressure and low pressure refrigerant lines with dust caps to avoid air entry and/or contamination. ",
+ "file": "",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Recover the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. Remove the Front Grill Assembly. Remove the Air Cleaner Assembly. Using 10 mm open end spanner, Liquid pipe pipe mounting nut from expansion valve end. Torque : 8.0+1.0 Nm ",
+ "file": "",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A200062.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Remove Liquid pipe routing bracket mounting nut from the vehicle. Torque : 8.0+1.0 Nm ",
+ "file": "",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A200063.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A200129.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen and remove the suction hose routing bracket mounting nut. Torque : 8.0+1.0 Nm ",
+ "file": "",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 8.0+1.0 Nm ",
+ "file": "",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A200064.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect the pressure switch electrical connector. Using 10 mm socket spanner, Unscrew radiator LH seal mounting bolt and detach it. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": "",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A200067.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew Liquid pipe mounting nut from condenser end. Torque : 6.0+1.0 Nm ",
+ "file": "",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both end of liquid tube mounting joints without any damage. Damage to the O-ring may cause A/C refrigerant leakage which leads to A/c failure. Remove the liquid pipe from the vehicle. Install in the reverse order of removal. Refit the Air Cleaner Assembly. Refit the Front Grill Assembly. Recharge the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. Inspect the suction hose assembly for any physical damage, leakages etc. Replace if found any. Inspect for any foreign materials on condenser. Clean if found. Check and ensure free flow of condenser. Remove the HVAC control panel. Remove the Glove Box Assembly. Remove the driver side IP panel assembly. Remove the wiring harness routing clips from the HVAC assembly. Disconnect the fresh air actuator, mode actuator, blower motor, blower resistor, evaporator temperature sensor and blower switch Connectors. Carefully remove the HVAC wiring harness from the IP assembly. Install in the reverse order of removal. Inspect the electrical connectors for mechanical damage. Replace if found. Check and clean the connector pins for sulphation and deposits. Remove the IP Centre Switch Bank Assembly. Using a star screw driver, Unscrew HVAC control unit mounting screws. Torque : 1.5\u00b1 0.5 Nm ",
+ "file": "",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A200083.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the HVAC Control panel. Install in the reverse order of removal. Inspect the HVAC Control Panel Assembly for any damage. Replace if found. By using screw driver remove the TVD screw. Make aligning marks on the flange, UJ and propeller shaft before removal. Torque : 14 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130031.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 14 mm ring and socket spanners unscrew rear propeller shaft mounting bolts and nuts from transfer case end. Torque : 55 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130032.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W315.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W316.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the TVD assembly from vehicle and hang the Rear propeller shaft aside. Install in the reverse order of removal. Inspect the Torsional Vibration Damper (TVD) for any damage, if found replace the TVD assembly. Inspect the propeller shaft for any bend, crack, twisting and stone penetration, if foun replace the propeller shaft assembly. Check the propeller shaft for any flyweights missing. Replace the propeller shaft if found. Clean the propeller shaft if any foreign materials like dirt found. If the propellers shaft unbalance is suspected then it can be verified by the following procedure, removing & rendering the propeller shaft by 180\u00b0 may eliminate some vibrations. Clean all the foreign material from propeller shaft and the universal joint. Ensure that the propeller shaft is not worn, are properly installed and are correctly aligned with the propeller shaft. Check the companion flange mounting bolts. Raise the vehicle and remove rear wheels & tyres. Install the wheel nuts to lock the brake drum. Mark & number the shaft 6 inches from pinion end at four positions 90\u00b0 apart. Run and accelerate the engine until vibration occurs. Note the intensity & the speed at which the vibration occurs. Install a screw clamp at position \u201c1\u201d Start the engine and recheck for vibrations. If there is little vibration or no change in vibrations then move the clamp to the other 3 positions. If there is no difference in vibration at the other position then the vibration is not due to the propeller shaft imbalance. If the vibration decreases, install a second clamp and repeat the test. If the clamps cause an additional imbalance, separate the clamp (\u00bc inch above & below the mark). Repeat the vibration test. Increase the distance between the clamps until the vibration is at the lowest level. At this position bend the slack end of the clamp so that it does not loosen. Install the wheel & tyres. Lower the vehicle. If the amount of the vibration remains unacceptable then repeat the exercise at the gearbox end. After completing above procedure, if vibration is reduced, which indicates there is some imbalance in the propeller shaft. Replace the propeller shaft. Tyres that are out of round or wheels that are out of balance causes a low frequency vibration. \u2022 Brake drums that are unbalanced cause a harsh low frequency vibration. Drive line vibrations can also result from loose or damaged engine mountings Propeller shaft vibrations will keep on increasing as the vehicle speed increase. The propeller shaft does not cause a vibration that is present only in a narrow speed range. Refer below chart for various symptoms, causes and their remedial actions \u2013 ",
+ "file": null,
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Component Inspection and Testing Table",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10325.jpg",
+ "display_order": 4
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 102,
+ "sys_id": "THAR.LX-0005-Propeller Shaft",
+ "subsys_id": "THAR.LX-0005-Propeller Shaft-Propeller Shaft Run out \u2013 Check",
+ "systems": "Propeller Shaft",
+ "sub_systems": "Propeller Shaft Run out \u2013 Check",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A130007.jpg",
+ "myid": 1216,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0005-Propeller Shaft Run out \u2013 Check-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the propeller shaft from vehicle. Remove dirt, rust, paint & undercoating from the propeller shaft surface. Keep the propeller shaft on surface plate along with \u2018V\u2019 block at both ends. The dial indicator must be installed perpendicular to the shaft surface. Measure the run out at the center and at the ends by rotating propeller shaft assembly by hand \u2013 away from the weld. Replace the propeller shaft if the run out is beyond the specified limit. Position the vehicle on 2 post lift/ 4 post lift. Inspect the inboard and outboard joint RH side drive shaft boots, clamps for cut, nick, loose, bend, crush or abrasion. Replace if necessary. Rotate Steering wheel from one end to other for better visualization of boots. Inspect the RH side drive shaft condition for cracks or damage. Replace if necessary. Inspect the inboard and outboard joint LH side drive shaft boots, clamps for cut, nick, loose, bend, crush or abrasion. Replace if necessary. Rotate Steering wheel from one end to other for better visualization of boots. Inspect the LH side drive shaft condition for cracks or damage. Replace if necessary. Start the engine and place the wheels at straight ahead direction. For additional information refer to Steering straight ahead setting procedure. Turn the steering wheel until the tyres starts to move and measure the free play on the circumference of the steering wheel. Free Play Value \u00b1 5\u00b0 If the free play is out of the specified value, check the free play in steering column shaft connection and steering linkage. Replace or repair if necessary. The rack and pinion design is a simple design. However it is still susceptible to various problems in particular to leaks. If the bellows are ripped or are unable to keep the contaminant\u2019s away then it can cause damage to oil seal and subsequent leaks. One complaint, which can be present, is that the steering may be stiff and jerky when the unit is cold and as the vehicle is driven and it warms up the power assist gradually comes back. This normally indicates that grooves have worn into the bore of the pinion aluminum housing by control valve seals which may have hardened due to ageing. Wear in the centre housing causes the fluid to leak around the rack piston. Causing either steering wander or lack of straight- ahead stability. Another cause of steering wander and erratic control often accompanied by clumping, thunking noise is the deterioration of rack mounting bushings. Fluid leaks can be hard to locate. Sometimes you will see a low level in the pump reservoir but no evidence of escaping fluid. Squeeze the bellows and you will probably find that they are full of fluid. To confirm if that side of the rack is the root cause, then remove the both the bellows, clean the rack housing and then operate the system to observe the seepage directly. A rusty input shaft U joint or deteriorated flexible textile coupling could imitate rack problems Check the tyre pressure. Check the accessory drive belt for any damage. Check the Tie-rod ends for bend or damage. Check ball joint rubber boots for signs of cracking or deterioration Check inner and outer ball joints for excessive wear Inspect all the steering bushes for signs of wear and deterioration Check the steering oil level in the reservoir. If the level is below \u201cMIN\u201d mark, top up steering fluid. Check the steering gear assembly for any external damage or steering fluid leakage. Check the power steering pressure lines for fluid leakage and deterioration. Check the power steering pump and the reservoir for fluid leakage. Check the steering gear rubber bellows for cuts, cracks, deterioration and oil traces. If the cause is not visually evident, verify the symptom and refer to the Troubleshooting Chart Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Before disconnecting the battery, check for the audible sound of EWP ON Remove the Driver Airbag. Disconnect the electrical connection from steering switches. Using a star screw driver, loosen and remove the steering switches mounting screw then remove the steering switches from the vehicle. Install in the reverse order of removal. Inspect for any external damage or bent, if found replace. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Remove the steering wheel. Disconnect the ignition key barrel electrical connector. Disconnect the combination switch & clock spring electrical connectors. Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft bottom mounting bolts and detach the intermediate shaft bottom from the steering column. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190039.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering column mounting nuts then remove the steering column from the vehicle. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190120.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190111.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the grommet mounting bolts then remove the grommet from vehicle . Torque : 22 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190133.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Ensure to fit the Grommet Projection should face driver side. Ensure Shaft to Grommet clearance is 5 mm in top side. Ensure to install Upper & Lower I shaft connector according to the marking. Inspect for grommet any external damage or cracks, if found replace. Place the front wheel on a turning radius measuring tool. Turn the steering wheel to the its both ends and measure the maximum steering angle. If the steering angle is out of the specified value, check and adjust the toe. Using a Small chisel or punch hit and unscrew the mounting screw of ignition switch barrel with support of hammer.
Position the vehicle on 2 post lift/ 4 post lift. Check the steering rack assembly RH side boots, clamps for cut, nick or abrasion, replace if necessary. Check the steering rack assembly LH side boots, clamps for cut, nick or abrasion, replace if necessary. Check the steering rack assembly RH side linkage condition (Without removing boots) for play, damage, replace if necessary. Rotate Steering wheel from one end to other for better visualization of boots. Check the steering rack assembly LH side linkage condition (Without removing boots) for play, damage, replace if necessary. Rotate Steering wheel from one end to other for better visualization of boots. Disconnect the RPAS sensor electrical connectors. Unlock the RPAS sensors from the cover. Detach the sensors from vehicle. Check sensor, wiring, connector for any damage. Check for mud on sensor, clean gently if found. Remove selective diesel particulate filter (SDPF). Using a 10 mm socket spanner, loosen and remove the OCFM side Mounting bolt. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050190.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the OCFM routing bracket bolt. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050140.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a hose clip plier, loosen and remove the EGR quick coupler from the engine . Using a hose clip plier, loosen the Dosing Module inlet hose clip and remove the hose. Remove the pipe takeout from the vehicle. Install in the reverse order of removal. Check inlet pipe for any damage, cracks, kinks and degradation found replace the inlet pipe with a new one Check inlet pipe mounting for proper tightness and damages, replace the inlet pipe if required. Remove the thermostat valve from the thermostat housing. Thermostat and thermometer bulb should be suspended in water. If they touch bottom or the sides then temperature in which thermostat / thermometer operate will not be correct and wrong diagnosis will take place. Insert the thermostat valve in to a container filled with water. Heat the container and measure the temperature of water by Using digital thermometer. Keep track of water temperature and respective valve opening/ travel. Thermostat should start opening at 88 \u00b1 2 \u00b0 C (0.1 mm travel) . Once temperature reaches 96 \u00b1 2\u00b0 C valve should be fully open , at this moment, valve travel will be approximately 8 mm . In case thermostat valve behavior does not confirm to above specifications, it should be replaced. Disconnect the electrical connectors from resistor. Using screw driver, loosen the resistor mounting screw and remove the resistor. Install the reverse order of removal. Check the resistor for any damages, if found then replace it . Coolant flow within the cooling system is shown in the above mentioned schematic diagram. Typical sign of failed water pump is leakage through the seal and bearings. If the water pump is leaking replace the pump as soon as possible. Water pump failure can be confirmed by below steps: Remove the drive belt Rotate the water pump pulley and check for free rotation. Replace the water pump, if necessary. For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 7 mm socket spanner, Loosen the mounting hose clip and detach the radiator outlet hose OCFM end. Torque : 6.5 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the turbo oil return pipe routing bracket mounting bolt. Torque : 25 \u00b1 3Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the coolant inlet pipe bolts then remove the coolant inlet pipe from OCFM. Torque : 11\u00b11Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A05008536aa24.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external damage, if found please replace. Check coolant inlet pipe hose clamps for proper tightness and damages, replace the clamps if required. Using 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially remove the degassing tank (Without disconnecting the hoses). Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050052.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect radiator fan electrical connector. Using a 10 mm socket spanner, loosen and remove fan mounting bolts. Torque : 6.5\u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050058.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050057.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the shroud holder clips from radiator and fan then remove the clips (Top & Bottom). Using 7 mm socket spanner, loosen the hose clamp and disconnect the intercooler inlet hose from the intercooler assembly. Torque : 6.5 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050186.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050130.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Detach the fan assembly from radiator bottom seating and remove the radiator fan assembly. While Installing ensure the fan bottom seating are properly seated on radiator. Install the reverse order of removal. Check electric fan blades for any damages. Position the vehicle on 2 post lift/ 4 post lift. Open the bonnet and lock it in open position using bonnet stay rod. Coolant \u2013 Mahindra 'MAXIMILE ULTRA COOL' Genuine Long Life Coolant (READY TO USE COOLANT. NO NEED TO MIX WATER).Refilling Capacity \u2013 ~5.0 Litres.Coolant Level And Leak Inspection Procedure: ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the degassing tank pressure cap for any damage or coolant leakage. Rectify the leakage if found. Check the coolant level in the degassing tank, it should be between MAX and MIN marks. Check the coolant level when the engine is cold. If found below MIN mark then top it up with MAHINDRA 'MAXIMILE ULTRA COOL' (ready to use coolant. no need to mix water). Inspect the degassing tank to radiator vent hose for any coolant leakages, also check the mounting spring band clamp for any damage. If found any damage or leak, rectify Inspect the engine to T connection vent hose for any coolant leakages, also check the mounting spring band clamp for any damage. If found any damage or leak,rectify. Inspect the degassing tank outlet hose assembly at every joints such as degassing tank end, T-connector connections, EWP inlet and outlet sides, OCFM side for any coolant leakage, also check the mounting spring band clamp for any damage. If found any damage or leak, rectify. Inspect the radiator inlet hose at radiator and engine block for coolant leakage, rectify the leakage if found. Also inspect the mounting spring band clamp for any damage, replace the mounting spring band clamp if found damaged or loose. Inspect the radiator inlet hose at radiator and engine block for coolant leakage, rectify the leakage if found. Also inspect the mounting spring band clamp for any damage, replace the mounting spring band clamp if found damaged or loose. Inspect the heater inlet & outlet hoses for any coolant leakage at the heater core side, EGR module side, coolant outlet pipe side and coolant nipple heater inlet side, also check the mounting spring band clamp for any damage. If found any damage or leak, rectify. Inspect the Dosing Module inlet hose, Dosing Module outlet hose also check the mounting spring band clamp and bolts for any damage. If found any damage or leak, rectify. Inspect the Coolant Inlet & outlet pipes bolts at OCFM for any damage. If found any damage or leak, rectify. Never remove the degassing tank cap when the engine is hot. Brand Specific. Don't use other Coolants / Water for top up. In case of emergency, Coolant meeting JIS K2234 Specification should be used (30% Concentration Diluted with Distilled water) and coolant change period has to be reduced as 30,000 KM Never mix MAHINDRA MAXIMILE ULTRA COOL with water Using hose clamp plier, release the radiator vent hose spring band clamp and disconnect the hose. Never work with cooling system when the engine is hot. failing to this may cause personal injury. Using hose clamp plier, Release the degassing tank outlet hose spring band clamp and detach hose degassing tank end . Using 10 mm socket spanner, Unscrew degassing tank mounting bolts. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050129.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully remove the degassing tank. Install in the reverse order of removal. Inspect the degassing tank for any damages or blockages, replace if found replace the degassing tank. Inspect the hoses for any damages, cracks or kinks, if found replace the hose assembly inspect the coolant hoses clamps for proper fitment, if found loose then replace the clips. Position the Vehicle on 2 post lift/ 4 post lift. Open the bonnet and lock it using bonnet retaining lever. Place a tray under vehicle for collecting the coolant. Coolant \u2013 Mahindra 'MAXIMILE ULTRA COOL' Genuine Long Life Coolant (READY TO USE COOLANT. NO NEED TO MIX WATER).Refilling Capacity \u2013 ~5.0 Litres.Switch OFF the Ignition and allow Engine to cool down. Never remove the degassing cap when the engine is hot Open the degassing tank cap. Using star screw driver, remove the front stone guard screvits. Using a 10 mm & 13 mm socket spanner, loosen the front & rear mounting bolts and remove the front stone guard. Remove the radiator drain plug and allow the entire coolant to get drained. Place a tray beneath the drain plug to collect coolant drained. Start filling the recommended coolant in degassing tank. While filling, open the drain Plug & wait for the coolant to drop & close drain Plug. Check coolant level in degassing tank, add coolant to MAX level and close the degassing cap. Check all the hoses and clips for leakage and correct fitment. Start the engine and run at 3000 rpm for about 10 minutes. (For Thermostat Opening). Maintain Coolant level at MAX level always and ensure coolant never goes below MIN level. Switch OFF the Ignition and allow the engine to cool down, Check coolant level in degassing tank and add coolant to MAX level. Refit the front stone guard screvits & mounting bolts, torque tighten the bolts to specified value. Torque: 4.0 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Inspect the coolant circuit for any leakages. ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": "Never remove the degassing cap when the engine is hot. Never mix MAHINDRA MAXIMILE ULTRA COOL genuine coolant with water. Brand Specific. Don't use other Coolants / Water for top up. In case of emergency, Coolant meeting JIS K2234 Specification should be used (30% Concentration Diluted with Distilled water) and coolant change period has to be reduced as 30,000 KM Do not overfill the system; allow free space in the degassing tank for expansion of the fluid. Using a hose clamp plier, release electric water pump inlet hose spring band clamp and disconnect the hose. Using a hose clamp plier, release electric water pump outlet hose spring band clamp and disconnect the hose. Disconnect the EWP electrical connector. Using a 10 mm socket spanner, Unscrew EWP clamp mounting bolts and remove the EWP. Install in the reverse order of removal. Check EWP for any damage, cracks, kinks and degradation. If found replace the EWP with a new one. Check EWP hose clamps for proper tightness and damages, replace the clamps if required. Using a 7 mm socket spanner, loosen hose clip and detach radiator outlet hose OCFM end. Torque : 6.5 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050084.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the turbocharger oil return pipe routing bracket mounting bolt. Torque : 25\u00b13Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050085.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove coolant inlet pipe bolts and remove coolant inlet pipe OCFM end. Torque : 11\u00b11Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050087.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050162.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Check thermostat valve opening and closing temperatures, if found deviation from specified value, replace the thermostat. Check travel of thermostat valve, if found deviation from specified value, replace the thermostat. Remove the selective diesel particulate filter (SDPF) . Using a 10 mm socket spanner, loosen and remove the Turbocharger oil drain pipe bottom mounting. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050142.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the Turbocharger oil drain pipe routing bracket. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050143.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the outlet pipe mounting bolt at OCFM end. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050144.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the pipe routing bracket bolt. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050145.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a hose clip plier, loosen and remove Heater outlet hose clamp and detach the hose. Using a hose plier, loosen and remove the EGR quick coupler from the engine . Remove the Pipe EGR Cooler Outlet. Install in the reverse order of removal. For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 26
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check outlet pipe for any damage, cracks, kinks and degradation. If found replace the outlet pipe with a new one. Check outlet pipe mounting for proper tightness and damages, replace the outlet pipe if required. Remove the front grill assembly. Using 10 mm socket spanner, Unscrew the LH and RH radiator seal mounting bolts. Torque : 4.5 \u00b10.5Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050048.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver, loosen and remove the LH and RH radiator seal mounting screw rivets. Torque : 4.5 \u00b10.5Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050134.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the both LH and RH radiator seal from the vehicle. Install the reverse order of removal. Check for any external cracks, replace if found any Check for the obstruction of the air flow, if found please replace. The radiator assembly is a cooler located at the front of the vehicle. The radiator is a heat exchanger that removes the excess heat from the coolant passing through it. The coolant flows inside the radiator from RH to LH. The cool ambient air flows through the fins of the radiator. The heat exchange happens between the coolant to air. Drain Cock is located in the bottom of the Radiator and used to Drain the engine coolant. Drain the engine coolant. For additional information refer into coolant draining and refilling procedure. Remove the Intercooler assembly. Remove the Degassing Tank assembly. Using 10 mm socket spanner, Unscrew degassing tank mounting brackets mounting bolts LH & RH. Torque : 10 \u00b1 0.5Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050179.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect radiator fan electrical connector. Using 10 mm socket spanner, loosen and remove cooling fan mounting bolts. Torque : 6.5\u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050058.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050057.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect the shroud holder clips from radiator and fan then remove the clips (Top & Bottom). Detach the fan assembly from radiator bottom seating and remove the radiator fan assembly. While Installing ensure the fan bottom seating are properly seated on radiator. Using Hose clamp plier, release radiator inlet and outlet hose spring band clamps and disconnect the hoses radiator end. Using hose plier, release vent hose spring band clamp and disconnect hose radiator end. Using 13 mm socket spanner, Unscrew radiator mounting bolts. Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050035.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050036.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew radiator LH & RH seal mounting bolts. Torque : 4.5 Nm ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050033.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050034.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050187.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew condenser mounting bolts and partially detach the condenser from the radiator. Torque : 5 \u00b11Nm ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050032.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Remove the radiator from the vehicle. Install in the reverse order of removal. Carry-out coolant filling and de-aeration process. For additional information refer to Coolant filling and de-aeration section. Check the radiator fins for damage, replace if found any. Check the radiator for coolant leakage, refill if found any. Check the radiator for dust accumulation, clean with compressed air if dust accumulation is noticed. Check for free flow of water from radiator top to bottom. Check the radiator drain plug for any leakage. Refer below chart for various symptoms, causes and there remedial actions - Position the Vehicle on 4 post lift. Inspect and ensure the following nuts/bolts are with proper torque as recommended: Front shock absorber assembly on chassis (LH/RH). Torque value: 40 \u00b1 5Nm Torque Wrench Type - Open end Torque Wrench Front shock absorber mounting bolt on LCA (LH/RH). Torque value: 120 \u00b1 12 Nm Front stabilizer bar mounting bracket bolts. Torque value: 50 \u00b1 5 Nm Front stabilizer bar link mounting bolts on LCA (LH/RH). Torque value: 90 \u00b110 Nm Front upper control arm pivot mounting bolts on chassis (LH/RH). Torque value: 97\u00b1 10 Nm Front Lower arm mounting bolts on chassis (LH/RH). Torque value: 250 \u00b1 20 Nm Ensure to do the torquing in the nut side and holding the bolt while torquing. Knuckle bottom mounting bolts LHS & RHS. Torque value: 140 \u00b1 10 Nm Torque Wrench Type - Open end Torque Wrench Rear stabilizer bar mounting on Rear Axle (RH/LH). Torque value : 70 \u00b1 7 Nm Rear stabilizer bar link rod mounting on chassis (LH/RH). Torque value : 90 \u00b110 Nm Torque Wrench Type - Open end Torque Wrench Rear lower link mounting on chassis and axle (LH&RH). Torque value: 230 \u00b1 20 Nm Torque Wrench Type - Open end Torque Wrench for LH chassis side While torquing axle side, hold the nut by open end spanner & do the torquing in the bolt side. Rear upper link mounting on chassis and axle (LH&RH). Torque value: 230 \u00b1 20 Nm Torque Wrench Type - Open end Torque Wrench for LH chassis & axle side Rear shock absorber bottom mounting on Rear axle (LH&RH). Torque value : 110\u00b111 Nm Torque Wrench Type - Open end Torque Wrench Rear shock absorber top mounting on chassis (LH&RH). Torque value : 65\u00b110Nm Pan hard rod mountings on axle & chassis. Torque value: 230 \u00b1 20 Nm DOC upstream temperature sensor (T4) is located at the top of oxidation catalyst (DOC). T4 temperature used here is of PTC type. EMS ECU uses signal from T4 mainly for: Closed loop control of exhaust gas treatment system Understand the engine out exhaust gas temperature For calculating the oxidation catalyst efficiency Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON Torque :6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010903.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect temperature sensor (T4) electrical connector. Using 17 mm open end spanner, Unscrew temperature sensor T4 mounting on SDPF Torque :35\u00b15 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach T4 sensor from routing clip and remove it Install in the reverse order of removal. Yellow colour tape provided on T4 Sensor wiring pigtail and engine wiring harness connector for easy identification while refit and ensure to properly connect the T4 Sensor wiring pigtail connector with engine wiring harness Mismatch connection of wiring connectors may leads to affect the engine performance and occur engine trouble. Check for any external cracks, replace if found any Position the vehicle on a 2 post / 4 post lift. Check the insulators of the exhaust front pipe, exhaust intermediate pipe with muffler and exhaust tail pipe, Replace if found elongated or damaged. Check the joint between exhaust tail pipe with intermediate pipe, if found leakage then replace the gasket and torque tighten the nuts to specified value. Check the joint between exhaust intermediate pipe with front pipe for any leakage, if found leakage then replace the gasket and torque tighten the nuts to specified value. Check the joint between exhaust front pipe with SDPF for any leakage, if found leakage then replace the gasket and torque tighten the nuts to specified value. Do not work when the exhaust system is hot. Failure to follow this instruction will result in personal injury. Check all the exhaust joints for leakage and correct fittings. If leakage is found, check the exhaust pipe gasket. Replace if required. The exhaust after treatment system uses SCR (Selective Catalytic Reduction) technology which requires Diesel Exhaust Fluid (DEF) for reduction of NOx in order to enable the vehicle to comply with emission regulations. DEF is a NOx reduction agent. It is recommended to use MaxiCLEAN DEF meeting IS 17042 (or) ISO 22241 specification. It is basically an aqueous urea solution, having a urea content of 32.5% and remaining 67.5% of water. DEF is a nonflammable, non-toxic, colorless and water-soluble liquid. DEF is stored in vehicle in a tank and provision is provided to refill it as per requirements. To enable SCR system to work efficiently and to ensure emission conformance, DEF meeting quality requirements of IS 17042 (or) ISO 22241 standard is mandatory. Even when DEF of correct specification is filled, it\u2019s useful life remain limited depending upon extent of exposure of storage tank/vehicle to varying environmental temperature conditions. Refilling DEF is part of regular maintenance service. DEF consumption is highly dependent on driving conditions/pattern. It may be necessary to refill DEF reservoir in-between the scheduled service, Need to monitor DEF Indicator Tell Tale and symbols/ Alert messages displayed on Cluster screen. It is unlawful to tamper with or remove any component of the after treatment system. It is also unlawful to use a DEF that does not meet the specification provided or to operate the vehicle without DEF. The exhaust after treatment system uses SCR (Selective Catalytic Reduction) technology which requires Diesel Exhaust Fluid (DEF) for reduction of NOx in order to enable the vehicle to comply with emission regulations. DEF is a NOx reduction agent. It is recommended to use MaxiCLEAN DEF meeting IS 17042 (or) ISO 22241 specification. It is basically an aqueous urea solution, having a urea content of 32.5% and remaining 67.5% of water. DEF is a nonflammable, non-toxic, colorless and water-soluble liquid. DEF is stored in vehicle in a tank and provision is provided to refill it as per requirements. To enable SCR system to work efficiently and to ensure emission conformance, DEF meeting quality requirements of IS 17042 (or) ISO 22241 standard is mandatory. Even when DEF of correct specification is filled, it\u2019s useful life remain limited depending upon extent of exposure of storage tank/vehicle to varying environmental temperature conditions. Refilling DEF is part of regular maintenance service. DEF consumption is highly dependent on driving conditions/pattern. It may be necessary to refill DEF reservoir in-between the scheduled service, Need to monitor DEF Indicator Tell Tale and symbols/ Alert messages displayed on Cluster screen. It is unlawful to tamper with or remove any component of the after treatment system. It is also unlawful to use a DEF that does not meet the specification provided or to operate the vehicle without DEF. Do not hold the Supply Module while carry DEF tank. Do not handle Supply Module using connectors, complete housing to be held to avoid any type of damages. Handle Dosing Module using housing and not on connectors to avoid any type of damages. Avoid painting or application of other coatings on Dosing Module (DM) & Supply Module (SM) to ensure lifetime & functionality. Always remove (manually) protection caps of DM & SM just before assembly of its mating pipes/cables, to avoid contamination of the system. Only use recommended tools for remove & Installation of DM & SM. After removing, cover the openings with protective caps to prevent the entry of contaminants. The entry of contaminants in the interfaces of the DM must be prevented during Installation & removing of DM. Storage Guidelines ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Storage Guidelines",
+ "content_type": "Description",
+ "content": "Dosing Module (DM) & Supply Module (SM) should not be handled as bulk goods, as it can damage the parts. If a part falls down, it must be scrapped, even if it looks visually ok, to avoid any latent damages leading emission issues Parts have to be stored in original M&M packaging Parts needs to be protected against rain, snow, heat sources and dust Max. storage period of DM & SM should be not more than 4 years Avoid any damages to Supply Module while storing DEF tank The DEF tank is the reservoir to store and supply the DEF to the dosing module.
The supply module is welded along with the DEF tank and consists of the following parts
Integrated DEF filter with filtering size upto 20 microns Supply Pump : Solenoid operated plunger pump - Supplies DEF on DemandBack Flow Pump : Solenoid operated plunger pump - Regulate the pressure and empties the DEF supply line to avoid crystallizationTemperature Sensor : NTC type sensor used to measure the temperature of the DEF inside the tankDEF Level Sensor : Ultrasonic level sensor accurately detects the quantity of DEF available in tank. The ultrasonic sensor sends ultrasonic waves from the bottom of the tank. The waves are reflected back to the sensor from the highest level of the DEF present in the tank. The sensor then converts the ultrasonic signal to level and sends it to the EMS ECU multiplexed as a PWM signal. EMS ECU decodes the PWM signal & converts the level to height of DEF present in the tank.Both the supply and back flow pump is integrated as one unit - DEF Pump is a serviceable part and is screwed to supply module ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W729.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "DEF storage",
+ "content_type": "Description",
+ "content": "DEF is stored in vehicle in a tank and provision is provided to refill it as per requirements. For refilling DEF, Filler and Vent Pipe Assembly is provided in the vehicle. DEF filler lid is located in the RH side of Quarter panel, while DEF Tank is located underbody.
The DEF is required to be pumped from DEF tank to the Dosing Module at required rate and under specified range of pressure. Fluid level inside storage tank needs to be monitored. To enable these functions, DEF Supply Module is integrated with the DEF Tank.
Even when DEF of correct specification is filled, it\u2019s useful life remain limited depending upon extent of exposure of storage tank/vehicle to varying environmental temperature conditions.
",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Primary Function",
+ "content_type": "Description",
+ "content": "To store DEF in sufficient quantity for specified period so that the customer can refill and maintenance at specified intervals. To assist filling, venting and draining of DEF from tank at specified rate. To enable dynamic venting while preventing dust, foreign particles, moisture or water from getting inside the tank. To enable integration of DEF Supply module and assist in pumping, level sensing. To enable uninterrupted DEF supply when vehicle is negotiating longitudinal grades and side slopes. To contain vibration levels of DEF Supply module below specified limit. To contain fluid sloshing noise to acceptable levels. Always ensure to refill the DEF greater than or equal to the \u2018Minimum Refill Quantity\u2019 DEF level monitoring system will not detect the refill which is lower than the \u2018Minimum Refill Quantity\u2019. The DEF is available under MaxiCLEAN brand. MaxiCLEAN is available in 10 lit, 6 lit & 2 lit packs. DEF can be filled up to the filler neck, if filled very slowly towards the end. Ensure that the maximum refill quantity is calculated so that the available SKUs are used fully. In the event of requirement of less quantity than the full SKU, use a clean measuring can for calculating the billing amount to the customer. The measuring can should be for the exclusive use of DEF only and should not be used to measure any other fluids like Engine oil or Coolant. MDW/DMS accepts \u201cDecimal\u201d billing It is always recommended to fill the Maximum qty to maximise the range of vehicle operation. The Electric-Variable Geometry Turbocharger (e-VGT) system variably controls the passages of the turbine housing to regulate the flow rate of the exhaust gas. The actuator for e-VGT has been changed from traditional vacuum actuator to DC motor actuator (E-Actuator), thereby enabling to achieve more fast and precise control The engine ECU controls the E-actuator electronically as follows: At low speed: Narrows the flow passage for the exhaust gas, resulting in increasing the flow speed of the exhaust gas and running the turbine quickly and powerfully.At high speed: Expands the flow passage for the exhaust gas, resulting in increasing the mass flow of the exhaust gas.eVGT Learning: At the end of every driving cycle when ignition is switched OFF, EMS ECU triggers a learning on the eVGT. In the learning EMS ECU will move turbocharger actuator to the open & close end positions. At the end positions, the eVGT position sensor will read and store the signal voltage. At the end of every driving cycle, EMS ECU will read, store & compare the value with the stored value from the previous driving cycle & an absolute value.Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury. Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. For removing any SCR hydraulic connections carry out below \u201cSCR ROUTINES\u201d by using i-SMART. For additional information refer Diagnosis Manual. -EMPTYING of SCR SystemAfter removal of supply hose, Cover the DEF tank & Dosing Module with dust caps to avoid entry of dust and Contamination of the DEF. Torque :6.0\u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Remove Diesel Exhaust Fuel(DEF) tank. Turn over the DEF tank and position the tank to face bottom side to access Supply Module Using T30 Torx spanner, Unscrew DEF supply Pump Mounting torx screws Firmly release the supply pump from Module & take out from DEF tank. Install in the reverse order of removal. Avoid painting or application of other coatings on Supply Module (SM) to ensure lifetime & functionality Always remove (manually) protection caps of SM just before assembly of its mating pipes/cables, to avoid contamination of the system Only use recommended tools for remove & Installation of SM. After removing, cover the openings with protective caps to prevent the entry of contaminants Do not hold the Supply Module while carry DEF tank Do not handle Supply Module using connectors, complete housing to be held to avoid any type of damages. The Number of Supply Pump Remove & Refit from Supply Module limited to 3 times. If remove & refit beyond 3 times it can affect the torquing of screws leading to un tight assembly of pump with module. Failing to do may affect the supply module performance Always use new Dampers & Sleeves while replace new Supply Pump. Clean Supply Pump seating area on module thoroughly before insert the pump. For New DEF Supply Pump Replacement carry out below \u201cSCR ROUTINES\u201d by using i-SMART. For additional information refer Diagnosis Manual. DEF First Filling DEF Pressure Preparation DEF Leak Test DEF metered dosing test EMPTYING of SCR System For New DEF Supply Pump Replacement carry out \u201cComponent Replacement Procedures \u2014 DEF Pump Replacement\u201d by using i-SMART. For additional information refer Diagnosis Manual. Check for any external damage, replace if found any. SCR Routines assist in checking the functionality of the SCR system components (DEF supply pump, DEF back flow pump, Dosing module, leaks in system) and also to initialize some SCR system components after replacement. There are 10 routines that can be performed using i- SMART. They are represented in the below table along with serviceable components. Numbers in the cell indicate the order in which a routine has to be done after the respective component replacement. To access these routines Open i-SMART \u2192THAR\u2192THAR_BS6\u2192 EMS \u2192 ROUTINES \u2192SCR ROUTINES. PRE-CONDITIONS FOR SCR ROUTINES: ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/101.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "All SCR routines have certain pre-conditions which have to be met before they can be performed. Pre-conditions for the routines will be displayed in i-SMART along with actual and acceptable values. SCR routines will not proceed, if even one pre-condition is not met. DEF first filling test when actuated by i-SMART will fill this air gap with DEF. Performing this routine is mandatory on tank / pump replacement to ensure SCR system performance. WHEN TO DO ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "If DEF tank or DEF pump module is replaced. Refer Diagnostic manual for DEF First Filling SCR ROUTINE Procedure. Pressure preparation routine will build up a moderate pressure in the DEF supply hose and vent any air in the supply hose when actuated by i-SMART. Performing this routine is mandatory when any hydraulic component (DEF pump module, DEF tank, supply hose) is removed and re-fitted. WHEN TO DO ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "If DEF tank or DEF pump module is replaced. If DEF supply hose is replaced. Refer Diagnostic manual for DEF Pressure Preparation SCR ROUTINE Procedure. SCR system emptying routine when actuated by i-SMART will purge / suck the DEF from the supply line back to the DEF tank using the backflow pump. This routine can be done during diagnosis process before removing and SCR system hydraulic connections. WHEN TO DO ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Before removing any SCR hydraulic connections. Refer Diagnostic manual for EMPTYING of SCR System SCR ROUTINE Procedure. DEF leak test is a smart test that can indicate if there could be any DEF leaks. WHEN TO DO ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "When diagnosing for any DEF pressure DTCs. After refitting any SCR system hydraulic connectors to check for leaks. Refer Diagnostic manual for DEF Leak Test SCR ROUTINE Procedure. DEF dosing module spray test is a smart test that simulates the spray pattern of DEF dosing. The dosing module has 7 holes through which DEF is sprayed into the exhaust. WHEN TO DO ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "When diagnosing for Dosing module stuck DTC. To check dosing module functioning. After refitment of new dosing module. Refer Diagnostic manual for Dosing Module Spray Test SCR ROUTINE Procedure. Dosing module dry actuation test is a smart test that can indicate if the dosing module is not opening or is stuck. WHEN TO DO ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "When diagnosing for Dosing module stuck DTC. Refer Diagnostic manual for Dosing Module Dry Actuation Test SCR ROUTINE Procedure. DEF metered dosing test when actuated by i-SMART will build up DEF pressure and dose DEF through the dosing module. This routine can be done to test the dosing module. WHEN TO DO ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "After replacing a new dosing module. Refer Diagnostic manual for DEF Metered Dosing Test SCR ROUTINE Procedure. DEF static dosing test when actuated by i-SMART will build up DEF pressure and dose DEF through the dosing module. This routine can be done to test the dosing module. This routine is intended to simulate high mass flow rate dosing. WHEN TO DO ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "After replacing a new dosing module. Refer Diagnostic manual for DEF Static Dosing Test SCR ROUTINE Procedure. DEF static dosing test when actuated by i-SMART will build up DEF pressure and dose DEF through the dosing module. This routine can be done to test the dosing module. This routine is intended to simulate low mass flow rate dosing. WHEN TO DO ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "After replacing a new dosing module. Refer Diagnostic manual for DEF Dynamic Dosing Test SCR ROUTINE Procedure. The SDPF is a combination of Selective Catalytic Reduction (SCR) and Diesel Particulate Filter (DPF). The DOC assembly connected to turbocharger as input and SDPF as output, the SDPF output connect with exhaust pipes. DOC treated exhaust gaseous enters mixer zone where a multiple plate like structure is constructed in such a way it promotes swirl The SDPF functions to reduce particulates and NOx values from the engine out emissions. The Particulate filter filters the particulate emissions coming from the engine and the NOx in the engine out is reduced using the Diesel Exhaust Fluid (DEF) dosed into the exhaust. The SDPF consists of Parallel channels with alternate cells closed in the form of a honeycomb structure and this enables the filtration of the particulates coming from the engine by forcing them through the porous walls of the filter. The SDPF is coated with Zeolite that helps to retain the Diesel Exhaust Fluid (DEF) dosed into the exhaust system thereby helpful for conversion of NOx conversion. Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury. For removing any SCR hydraulic connections carry out below \u201cSCR ROUTINES\u201d by using i-SMART. For additional information refer Diagnosis Manual. \u2014 EMPTYING of SCR SystemAfter removal of supply hose, Cover the DEF tank & Dosing Module with dust caps to avoid entry of dust and Contamination of the DEF Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Using 15 mm combination and ring spanner, Unscrew exhaust front pipe mounting nuts SDPF end. Using 12 mm socket spanner, Unscrew SDPF front bottom bracket mounting bolt Using 12 mm socket spanner, Unscrew SDPF rear bracket mounting bolt. Using 12 mm socket spanner, Unscrew SDPF mounting bolts cylinder head end. Using 12 mm socket spanner, Unscrew SDPF mounting bolt fire wall end. Using 10 mm socket spanner, Unscrew turbo heat shield mounting bolts. Using 13 mm socket spanner, Loosen Turbocharger and SDPF coupling V Clamp mounting nut. Carefully remove SDPF Assembly from engine compartment. Take at most care not to damage Turbo oil return hose and HVAC pipe lines while take out SDPF from vehicle Check for any external damage, replace if found any Position SDPF assembly inside the engine compartment. Install SDPF supporting bracket mounting bolts on the engine head. Position the SDPF over Turbocharger housing and pre-engage the V Clamp over the joint. INITIAL TORQUE 7 Nm <n>FINAL TORQUE 13.5\u00b11 Nm ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030191.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Follow the refitment sequence as instructed in the upcoming steps carefully, false installation can lead to effect the SDPF performance. Always use new V band clamp & Gasket once removed. V Clamp Gasket to be positioned over EATS by aligning the gasket lug with marking on V Clamp as shown in the image V Clamp to be fully opened and put over Turbine Housing before position the SDPF Install DOC bracket mounting bolts on the engine head . Install SDPF bottom front & rear bracket mounting bolts on the crank case. Torque tighten Turbocharger - SDPF Coupling V clamp to the specified torque value. Initial Torque : 7 Nm <n>Final Torque : 13.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Ensure to fit the clamp in proper position for easy accessing of clamp in subsequent removal. Torque tighten the SDPF supporting bracket bolts to the specified value. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Torque tighten the DOC bracket mounting bolts to the specified value.",
+ "file": null,
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": "Torque tighten the SDPF bottom front & rear bracket mounting bolts to the specified value. Torque : 25\u00b13 Nm <n>Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030038.jpg",
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Install exhaust front flexi pipe mounting nuts. Tighten the nuts to specified torque value. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Refit turbocharger heat shield and install the mounting bolts. Tighten the nuts to specified torque value. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Refit the Differential Pressure (DPF) Pipes Assembly. For additional information refer to Differential Pressure (DPF) Pipes Assembly - R&R section Refit the e Temperature Sensor (T4). Refit the e Temperature Sensor (T5). Refit the DEF Dosing Module. Reconnect battery negative cable and torque tighten it to the specified value . Torque :6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 84
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Check and top up the engine coolant if required For New SDPF Replacement replacement carry out \u201cComponent Replacement Procedures \u2014 SDPF Replacement\u201d by using i-SMART. For additional information refer Diagnosis Manual. After refitting DEF Dosing Module carry out below \u201cSCR ROUTINES\u201d by using iSMART. For additional information refer Diagnosis Manual Pressure preparation test DEF Leak Test Dosing Module Dry Actuation Test Dosing Module Spray Test DEF static metered dosing test DEF dynamic metered dosing test EMPTYING of SCR System 2 post lift/ 4 post lift.
Diesel Exhaust Fuel (DEF) - Mahindra MaxiCLEAN Genuine Diesel Exhaust Fluid.20 Liters.Minimum Refill Quantity - 6 Liters.DOC Downstream Temperature Sensor (T5) is located at the bottom side of the oxidation catalyst (DOC). T5 temperature used here is of PTC type. EMS ECU uses signal from T5 mainly for Closed loop control of exhaust gas treatment system DPF inlet exhaust gas temperature For calculating the oxidation catalyst efficiency Connect the i-SMART diagnostic testerand turn the ignition ON. Launch the i-SMART application. Select Dearborn Electronics India Pvt Ltd. \u2013 Garuda and then click START. Select THAR from the list of vehicles displayed as in following window then select the THAR_ BS6 . Select EMS from the ECU List Select the LIVE DATA tab. In the menu drop down list select DEF Tank level and Temperature and Water Pump Relay and click Proceed . The volume of DEF in the tank is to be read from the label\u201dFiltered DEF in-tank volume\u201d only . Convert the \u201cFiltered DEF in-tank volume\u201d from mL to Litres The Filtered DEF in-tank volume indicates the volume of the DEF left out in the DEF tank. With the tank volume of 20 liters, by doing the following calculation, the DEF Refill quantity can be arrived: DEF Refill Volume = 20 Liters - Filtered DEF in -tank volume.For Example, Filtered DEF in-tank volume = 12560 mL = 12.5 Liters Then DEF Refill Volume = 20 \u2014 12.5 = 7.5 Liters Refill the required quantity of DEF in the tank, follow the below Refill procedure. Select the suitable combination of SKUs of MaxiCLEAN available in stock. Always fill the Diesel Exhaust Fluid (DEF) in ignition OFF condition. Turn OFF the Ignition. Using vehicle key open the fuel filler door. Remove the DEF filler cap. Open the Container Pack (Bucket) and fix the filling pipe. The filling pipe supplied with the bucket is to be fitted on the bucket spout. Filling pipe fitment procedure below, Avoid using any funnel or unclean containers for filling. Do not keep container open after use. Fill DEF as required. Maximum Storage capacity is 20 litres. Overfilling DEF more than 20 litres may result in system /component failure. DEF is corrosive against paint and metal surface - Don\u2019t spill DEF on the vehicle, it may damage/ corrode the paint or colour change. If the DEF spills on the metal or plastic or rubber parts, wipe off immediately with a wet cloth or wash it with plain water. This will avoid corrosion. Place DEF filler cap back on DEF filler neck and tighten it moderately by turning it clockwise, then close the DEF filler lid. Close and lock the fuel filler door. Remove the vehicle Key. Turn the ignition ON If Diesel fuel is accidentally filled in the DEF tank, then the following components need to be replaced as the diesel fuel impacts the seals and other components inside the DEF tank. DEF tank along with Supply module sDPF needs to be replaced on further analysis of the vehicle data. Contact your Tekliner for further assistance. Use Genuine DEF MaxiCLEAN always. In case of genuine Diesel Exhaust Fluid (DEF) non-availability, DEF confirming to IS 17042 or ISO 22241 specification only can be used. Overfilling DEF more than 20 litres may result in system /component failure. Don\u2019t expose the DEF or DEF filler container to sun light. By exposing to warm condition or sun light the water gets evaporated from the DEF Solution and results in concentration mismatch or crystallization deposit. The DEF is non toxic and non flammable fluid. DEF is non corrosive to Fabric and humans, but it is recommended to wash immediately on spillage to avoid any stain or allergy. DEF is corrosive against paint and metal surface. Don\u2019t spill DEF on the vehicle, it may damage/ corrode the paint or colour change. If the DEF spills on the metal or plastic or rubber parts, wipe off immediately with a wet cloth or wash it with plain water. This will avoid corrosion. Make sure that no dirt or other foreign matter is allowed to contaminate the DEF. If the DEF is stored in a sealed container for more than a year, before utilizing the DEF perform the following Check the Urea concentration using a refractometer. If it is with in the recommended limit, use the DEF. Check for crystallization deposits. If found discard the DEF. DEF will not deteriorate, if it is stored in sealed container at ambient conditions. It can be used up-to one year. The DEF is available under MaxiCLEAN brand. MaxiCLEAN is available in 10 lit, 6 lit & 2 lit packs. DEF can be filled up to the filler neck, if filled very slowly towards the end. Ensure that the maximum refill quantity is calculated so that the available SKUs are used fully. In the event of requirement of less quantity than the full SKU, use a clean measuring can for calculating the billing amount to the customer. The measuring can should be for the exclusive use of DEF only and should not be used to measure any other fluids like Engine oil or Coolant. MDW/DMS accepts \u201cDecimal\u201d billing. It is always recommended to fill the Maximum qty to maximise the range of vehicle operation. Connect the i-SMART and ensure the Filtered DEF in-tank volume is 20 liters (20000 mL) . Verify for any warning related to DEF level low in the Infotainment System. If present, then drive the vehicle for 4 to 5 kms. If the warning is still present in the Infotainment System, then connect iSMART and check for any error codes (DTCs\u2019) in \u201cENGINE MANAGEMENT SYSTEM\u201d. Refer the Diagnostic Manual for more details. Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable Torque :6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON Disconnect temperature sensor (T5) electrical connector. Using 17 mm open end spanner, Loosen temperature sensor T5 mounting on SDPF. Torque : 35\u00b15 Nm ",
+ "file": null,
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove T5 sensor from routing clip and remove from SDPF. Detach T5 sensor from routing clip and remove it Install in the reverse order of removal. Green colour tape provided on T5 Sensor wiring pigtail and engine wiring harness connector for easy identification while refit and ensure to properly connect the T5 Sensor wiring pigtail connector with engine wiring harness Mismatch connection of wiring connectors may leads to affect the engine performance and occur engine trouble. Check for any external cracks, replace if found any DOC Downstream Temperature Sensor (T5) is located at the bottom side of the oxidation catalyst (DOC). T5 temperature used here is of PTC type. EMS ECU uses signal from T5 mainly for Closed loop control of exhaust gas treatment system DPF inlet exhaust gas temperature For calculating the oxidation catalyst efficiency Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable Torque :6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Warning",
+ "content": "Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON Disconnect temperature sensor (T5) electrical connector. Using 17 mm open end spanner, Loosen temperature sensor T5 mounting on SDPF. Torque : 35\u00b15 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove T5 sensor from routing clip and remove from SDPF. Detach T5 sensor from routing clip and remove it Install in the reverse order of removal. Green colour tape provided on T5 Sensor wiring pigtail and engine wiring harness connector for easy identification while refit and ensure to properly connect the T5 Sensor wiring pigtail connector with engine wiring harness Mismatch connection of wiring connectors may leads to affect the engine performance and occur engine trouble. Check for any external cracks, replace if found any Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury Remove selective diesel particulate filter(SDPF). Remove DPF assembly without removing T4 sensor, T5 sensor mountings and DEF dosing module from SDPF assembly. Using 7 mm socket spanner, Loosen air intake clean hose clip turbo end and detach hose Using 7 mm socket spanner, Loosen turbo outlet hose clip and detach hose . Using 14 mm socket spanner, Unscrew turbocharger oil inlet tube mounting banjo bolt . Torque : 17.5\u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew turbo oil return tube mounting bolts crank case end. Torque : 11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew turbo oil return tube routing bracket mounting bolt Torque :25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect eVGT electrical connector Using 13 mm socket spanner, Unscrew exhaust manifold mounting bolts. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Notice",
+ "content": "Always use new metal gasket onceremoved. check for any leakages. While installing, Molykote to be applied on both sides of stud on exhaust manifold- turbocharger. Torquing to be done immediately after application of molykote sealant. Nuts to be re torque after initial tightening in the same sequence Using 10 mm socket spanner, Unscrew turbo oil outlet pipe mounting bolt from turbocharger. Torque :11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030165.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Check Engine Oil level & Topup the engine oil. Check oil return tube for any external damage, replace if found any. Drain the coolant. For additional information refer to Coolant draining section. Remove pipe EGR module to intake manifold. Disconnect EGR electrical connector. Disconnect EGR cooler bypass actuator electrical connector. Disconnect Vacuum hose EGR module end. Using 12 mm socket spanner, Unscrew engine wiring routing bracket bolt intake manifold end. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew EGR module mounting bolts. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew EGR cooler mounting bolt. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Disconnect EGR cooler inlet and outlet hose quick couplers. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Disconnect coolant temperature sensor electrical connection. Remove EGR assembly from the vehicle. Install in the reverse order of removal. Always use new gasket once removed. Refill the Coolant. For additional information refer to Engine coolant filling and de-aeration Procedure. Check for any external damage, replace if found any. Conditions to Diesel Exhaust Fuel (DEF) Draining & Filling ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030127.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "If vehicle covers less than 10,000 kms in 2 years then replace DEF in 2nd year end. Place the vehicle on a 2/4 post lift. Switch the ignition OFF. Using vehicle key open the fuel filler door. Remove the DEF filler cap. Using star screw driver, remove DEF tank bottom protection cover scrivets and detach the cover Remove DEF drain hose quick coupler and drain the DEF Refit drain hose quick coupler Position protection cover and install DEF tank bottom cover scrivets Fill DEF Maximum Storage capacity 20 liter Always fill the Diesel Exhaust Fluid (DEF) in ignition OFF condition. Overfilling DEF more than 20 litres may result in system /component failure. DEF is corrosive against paint and metal surface - Don\u2019t spill DEF on the vehicle, it may damage/ corrode the paint or colour change. If the DEF spills on the metal or plastic or rubber parts, wipe off immediately with a wet cloth or wash it with plain water. This will avoid corrosion. Place DEF filler cap back on DEF filler neck and tighten it moderately by turning it clockwise, then close the DEF filler lid. Close and lock the fuel filler door. Remove the vehicle Key Turn the ignition ON Connect the i-SMART and ensure the \u201cFiltered DEF in-tank volume\u201d is 20 liters (20000 mL). Verify for any warning related to DEF level low in the Infotainment System. If present, then drive the vehicle for 4 to 5 kms. If the warning is still present in the Infotainment System, then connect iSMART and check for any error codes (DTCs\u2019) in \u201cENGINE MANAGEMENT SYSTEM\u201d. Refer the Diagnostic Manual for more details. Use Genuine DEF MaxiCLEAN always. In case of genuine Diesel Exhaust Fluid (DEF) non-availability, DEF confirming to IS 17042 or ISO 22241 specification only can be used. Overfilling DEF more than 20 litres may result in system /component failure Don\u2019t expose the DEF or DEF filler container to sun light. By exposing to warm condition or sun light the water gets evaporated from the DEF Solution and results in concentration mismatch or crystallization deposit. The DEF is non toxic and non flammable fluid. DEF is non corrosive to Fabric and humans, but it is recommended to wash immediately on spillage to avoid any stain or allergy DEF is corrosive against paint and metal surface. Don\u2019t spill DEF on the vehicle, it may damage/ corrode the paint or colour change. If the DEF spills on the metal or plastic or rubber parts, wipe off immediately with a wet cloth or wash it with plain water. This will avoid corrosion Make sure that no dirt or other foreign matter is allowed to contaminate the DEF. If the DEF is stored in a sealed container for more than a year, before utilizing the DEF perform the following Check the Urea concentration using a refractometer. If it is with in the recommended limit, use the DEF Check for crystallization deposits. If found discard the DEF DEF will not deteriorate, if it is stored in sealed container at ambient conditions. It can be used up-to one year The DEF is available under MaxiCLEAN brand. MaxiCLEAN is available in 10 lit, 6 lit & 2 lit packs DEF can be filled up to the filler neck, if filled very slowly towards the end Ensure that the maximum refill quantity is calculated so that the available SKUs are used fully In the event of requirement of less quantity than the full SKU, use a clean measuring can for calculating the billing amount to the customer. The measuring can should be for the exclusive use of DEF only and should not be used to measure any other fluids like Engine oil or Coolant MDW/DMS accepts \u201cDecimal\u201d billing It is always recommended to fill the Maximum qty to maximise the range of vehicle operation Using 10 mm socket spanner, Unscrew SDPF heat shield mounting bolts and remove the heat shield. Torque :11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew SDPF heat shield mounting bolt. Torque :25\u00b1 3 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, Unscrew SDPF heat shield top mounting Struds. Torque :11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, Unscrew turbocharger oil inlet tube mounting banjo bolt turbo end.. Torque : 17.5\u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, Unscrew turbocharger oil inlet tube mounting banjo bolt OCFM end Torque : 17.5\u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove turbocharger oil inlet tube Install in the reverse order of removal. Check Engine Oil level & Topup the engine oil. Check for any external damage, replace if found any Conditions to Diesel Exhaust Fuel (DEF) Flushing ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "If any contamination or the concentration level of stored DEF not met with the recommended value. For additional information on DEF Concentration Measurement by using Refractometer & Usage guidelines, Refer to DEF Refractometer Session. If alert message of \u201cWrong DEF Detected\u201d display in the infotainment system. If Diesel fuel is accidentally filled in the DEF tank, then the following components need to be replaced as the diesel fuel impacts the seals and other components inside the DEF tank . DEF tank along with Supply module. sDPF needs to be replaced on further analysis of the vehicle data. Contact your Tekliner for further assistance. Place the vehicle on a 2/4 post lift. Switch the ignition OFF. Using vehicle key open the fuel filler door. Remove the DEF filler cap. Using star screw driver, remove DEF tank bottom protection cover scrivets and detach the cover. Remove DEF drain hose quick coupler and drain the DEF. Refit drain hose quick coupler. Fill 2 litres of DEF for flushing and close the DEF filler cap. Always fill the Diesel Exhaust Fluid (DEF) in ignition OFF condition. Remove DEF drain hose quick coupler and drain the 2 Liters of DEF from tank. Refit drain hose quick coupler. Position protection cover and install DEF tank bottom cover scrivets. Fill DEF Maximum Storage capacity 20 litre. Always fill the Diesel Exhaust Fluid (DEF) in ignition OFF condition. Overfilling DEF more than 20 litres may result in system /component failure. DEF is corrosive against paint and metal surface - Don\u2019t spill DEF on the vehicle, it may damage/ corrode the paint or colour change. If the DEF spills on the metal or plastic or rubber parts, wipe off immediately with a wet cloth or wash it with plain water. This will avoid corrosion. Place DEF filler cap back on DEF filler neck and tighten it moderately by turning it clockwise, then close the DEF filler lid. Close and lock the fuel filler door. Remove the vehicle Key. Connect the i-SMART and ensure the Filtered DEF in-tank volume is 20 liters(20000 mL) . Verify for any warning related to DEF level low in the Infotainment System. If present, then drive the vehicle for 4 to 5 kms. If the warning is still present in the Infotainment System, then connect iSMART and check for any error codes (DTCs\u2019) in \u201cENGINE MANAGEMENT SYSTEM\u201d. Refer the Diagnostic Manual for more details. Use Genuine DEF MaxiCLEAN always. In case of genuine Diesel Exhaust Fluid (DEF) non-availability, DEF confirming to IS 17042 or ISO 22241 specification only can be used. Overfilling DEF more than 20 litres may result in system /component failure. Don\u2019t expose the DEF or DEF filler container to sun light. By exposing to warm condition or sun light the water gets evaporated from the DEF Solution and results in concentration mismatch or crystallization deposit The DEF is non toxic and non flammable fluid. DEF is non corrosive to Fabric and humans, but it is recommended to wash immediately on spillage to avoid any stain or allergy. DEF is corrosive against paint and metal surface. Don\u2019t spill DEF on the vehicle, it may damage/ corrode the paint or colour change. If the DEF spills on the metal or plastic or rubber parts, wipe off immediately with a wet cloth or wash it with plain water. This will avoid corrosion. Make sure that no dirt or other foreign matter is allowed to contaminate the DEF. If the DEF is stored in a sealed container for more than a year, before utilizing the DEF perform the following Check the Urea concentration using a refractometer. If it is with in the recommended limit, use the DEF. Check for crystallization deposits. If found discard the DEF DEF will not deteriorate, if it is stored in sealed container at ambient conditions. It can be used up-to one year. The DEF is available under MaxiCLEAN brand. MaxiCLEAN is available in 10 lit, 6 lit & 2 lit packs. DEF can be filled up to the filler neck, if filled very slowly towards the end. Ensure that the maximum refill quantity is calculated so that the available SKUs are used fully. In the event of requirement of less quantity than the full SKU, use a clean measuring can for calculating the billing amount to the customer. The measuring can should be for the exclusive use of DEF only and should not be used to measure any other fluids like Engine oil or Coolant. MDW/DMS accepts \u201cDecimal\u201d billing It is always recommended to fill the Maximum qty to maximise the range of vehicle operation. DEF is a NOx reduction agent. It is recommended to use MaxiCLEAN DEF meeting IS 17042 (or) ISO 22241 specification. It is basically an aqueous urea solution, having a urea content of 32.5% and remaining 67.5% of water. Recommend to check the Urea concentration in the DEF Using Refractometer SCR system is an integral part of the Engine Exhaust System, and any contaminants or impurities in the DEF could cause the SCR system to malfunction or fail. Thus, it is important to maintain quality of the DEF as defined in ISO 22241-1 standard. If the DEF is stored in a sealed container for more than a year, before utilizing the DEF perform the following. Check the Urea concentration Using refractometer. If it is with in the recommended limit, use the DEF. Check for crystallization deposits. If found discard the DEF. DEF will not deteriorate, if it is stored in sealed container at ambient conditions. It can be used up-to one year. Press READ button to START the refractometer. Calibration Add 2-3 drops of Distilled water on the prism. Press CAL button for 2 to 3 seconds till see CAL flashing Press CAL button again during CAL flashing to end calibration process - End will be displayed for 2 to 3 seconds on the screen as notification After calibration completes clean and dry the prism using soft tissue paper. Add 2-3 drops of Distilled water on the prism. Press CAL button for 2 to 3 seconds till see CAL flashing Press CAL button again during CAL flashing to end calibration process - End will be displayed for 2 to 3 seconds on the screen as notification After calibration completes clean and dry the prism using soft tissue paper. DEF Concentration Measurement: ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Collect small quantity of DEF from the DEF Tank. Add 2-3 drops of DEF on the prism Ensure that there are no air bubbles present in the DEF droplets. Press READ button once & wait for about 15 seconds to get Concentration of DEF Ensure that the Scale should be \u201cS 01\u201d. If not, then press the Scale button again till the scale changes to \u201cS 01\u201d DEF concentration will get displayed on the screen The DEF Concentration acceptance range \u2014 31.8 to 33.2 % Post Measurement: ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Completely clean and dry the prism using soft tissue paper. SCR or selective catalytic reduction is an exhaust after-treatment technology to reduce NOx emissions in diesel vehicles. The technology involves the use of Diesel Exhaust Fluid (DEF) which is an aqueous urea solution (AUS32). The DEF is pressurised and injected into the exhaust gases at the SCR catalyst to reduce the NOx at the tail pipe. So in case of any malfunction in the SCR system, DEF not available in the tank or if any other fluid (not meeting AUS32) is used in the DEF tank, the SCR system will not function as intended. The inducement strategy is a legally mandated warning system to alert the driver if the system is not functioning as intended. In the Thar, the inducements are displayed on the Cluster screen. The EMS will enter into a inducement (warning message) when certain emission or functional DTCs are detected. Every inducement always comes with a DTC & the SCR warning lamp in the Cluster. The aim of each inducement is to ensure that the root cause of any malfunction in the SCR system is identified & fixed. So for the inducement to stop the DTC causing the inducement has to be tested again and healed. Inducement will not stop by clearing the DTC using i-SMART For the inducement to stop the DTC will have to be healed, i. e. The root cause identified & then tested. Only when the EMS tests for the DTC again & detects that the DTC is healed inducement stops displaying in the Cluster. If any inducement causing DTC is present in i-SMART, DO NOT CLEAR THE DTC without ensuring that the issue is fixed & tested again. Always generate DTC report in i-SMART at the start of diagnosis of a DTC. There are 3 different inducement messages for Low DEF level, malfunction in DEF dosing system and incorrect DEF present in the system. Each inducement then has 5 levels. At the final inducement (level 5), vehicle will not be allowed to start unless root cause for the inducement (warning message) is fixed. When DEF level in tank fall below pre-defined values, warning lamp turns ON and Alert messages are flashed in five stages in the Cluster. These five warning stages are explained below: If the DEF warning lamp turns on due to the DEF level, refill the DEF tank. Failure to refill may cause the engine start restriction. Overfilling DEF more than 20 litres may result in system /component failure. In absence of DEF level low warning, refilling is not recommended. If SCR system detects quality of DEF inside the tank is not meeting IS 17042 (or) ISO 22241 specification, warning lamp turns ON and Alert messages are flashed in five stages in the Cluster. These four warning stages are explained below: If filled with water /incorrect DEF (With different concentration), the complete tank content needs to be drained off and to be flushed with correct DEF. If Diesel fuel is accidentally filled in the DEF tank, then the following components need to be replaced as the diesel fuel impacts the seals and other components inside the DEF tank. DEF tank along with Supply module Dosing unit pipes and hoses sDPF Assembly SDPF needs to be replaced on further analysis of the vehicle data. Contact your Tekliner for further assistance. If the DEF warning lamp turns on due to the DEF quality, see contamination/ incorrect fluid for corrective action. Failure to correct may cause the engine start restriction. If SCR system detects any malfunction due to failures in components or tampering, warning lamp turns ON and Alert messages are flashed in five stages in the Cluster. These five stages are explained below: If the DEF warning lamp turns on due to dosing malfunction, refer diagnostic manual for more information. Failure to repair the system may cause the engine start restriction. DEF inducement extension is an option to increase the drive range of a vehicle by 50 kms only if Level 5 DOSING MALFUNCTION or INCORRECT DEF inducement is active. This option can be used for Driving the vehicle to service center if vehicle is shut off. Testing and healing certain DTCs that may cause DOSING MALFUNCTION or INCORRECT DEF inducement. Refer Diagnostic manual for Inducement Extension Procedure. ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "After extension, the Cluster will display 50 kms and reduce when the vehicle is being driven. Once the distance comes to 0 kms in the Cluster, the extension option can be used again to extend by another 50 kms. The distance can be extended only by 50 kms at a time. Clicking Reset in i-SMART multiple times will not extend the drive distance more than 50 kms.",
+ "file": null,
+ "display_order": 31
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 367,
+ "sys_id": "THAR.LX-0005-Exhaust & Emission Control",
+ "subsys_id": "THAR.LX-0005-Exhaust & Emission Control-Troubleshoot - Exhaust & Emission Control",
+ "systems": "Exhaust & Emission Control",
+ "sub_systems": "Troubleshoot - Exhaust & Emission Control",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1452,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0005-Troubleshoot - Exhaust & Emission Control-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Symptom Possible Causes",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/314.pdf",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Component Inspection and Action Table",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/315.pdf",
+ "display_order": 2
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 362,
+ "sys_id": "THAR.LX-0005-Exhaust & Emission Control",
+ "subsys_id": "THAR.LX-0005-Exhaust & Emission Control-Pipe EGR",
+ "systems": "Exhaust & Emission Control",
+ "sub_systems": "Pipe EGR",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A030055.jpg",
+ "myid": 1030,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0005-Pipe EGR-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/files_VST-0063_EGR Module Installation.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030055.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/306.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/307.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010903.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew EGR pipe mounting bolts EGR cooler end. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew EGR pipe mounting bolts intake manifold side. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew EGR pipe routing bracket mounting bolts and remove the pipe. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030118.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Always use new metal gasket once removed. Check for any external cracks, replace if found any. The oil filter is located after the oil pump and before the oil starts getting distributed. Any impurity whose size can cause breakdown of lubrication film and cause metal to metal contact are entrapped in the oil filter element\u2019s filtration medium. Position the vehicle on ground level/ 2 post lift/ 4 post lift and turn engine OFF. Open the bonnet and lock it in open position using bonnet stay rod. Using a 27 mm 12 point doublehexagonal socket spanner, Loosen the engine oil filter cap. To access Oil filter cap mounting slightly move the Intercooler hose (without removing) and Carefully remove the damaging the hose. Remove the engine oil filter with cap from engine assembly. Ensure gasket isn\u2019t in casting housing and element assembly should come along with filter cap. Carefully rotate the oil filter element in clockwise direction, pull upward and remove the filter element. Remove the filter element carefully, with no damage to the plastic snaps. Pay attention not to damage the oil bypass valve while removing the oil filter element. Smear a layer of fresh oil on new oil filter O-ring and Position the O-ring on filter cap. Replace the O-ring with new one when replacing the oil filter element. Ensure no damage to O-ring during assembly, with no sharp edges damaging O-ring or element. Ensure to fix the oil bypass valve in proper position on oil filter cap. Place the oil filter in the bowl projection, push the filter inside and rotate the filter in anti-clockwise direction to lock it. Install the element carefully , with no damage to snaps. Position the oil filter cap with filter on the oil cooler surface. Tighten the oil filter cap in clockwise direction and torque tighten cap to the specified value. Torque :25 - 30 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Don\u2019t apply improper torque which leads to damage in threads. Check the engine oil level. Start the engine and check for Oil leakage/ seepage at: Oil pan & crankcase joint. Oil pan drain plug. Oil filter joint. Recommend to use only the Mahindra genuine oil filter for better engine protection and lubricant life. Make sure for all the subassembly and components going into engine assembly should be clean and away from foreign material. Remove the timing case cover. For additional information refer to Timing Case Cover - R&R Section. Remove MST 0307ABH0001ST - Flywheel Locking Tool - Eagle mounting bolts and detach it. Position engine front lifting hook and hand tighten the mounting bolts. Using 18 mm socket spanner, unscrew engine mounting bracket nuts (Both RH & LH). Provide engine support beam to support engine. Lift the engine with care, don\u2019t over lift since chances of damaging parts are high Ensure none of the components are effected or damaged during lifting. Using 14 mm combination spanner and socket spanner , unscrew LH engine mounting bracket mounting bolts and remove the LH bracket. Using 6 mm square socket spanner, loosen and remove TDC locking dummy from crankcase. Refit damper pulley and install damper pulley mounting bolt on crankshaft. Lock the crankshaft by Inserting the TDC locking pin (MST\u2013 0312ABH0001ST). Ensure the crankshaft locking tool is seated properly into the slot on crankshaft and ensure the TDC locking pin insert upto Red mark in the pin as shown. Check and ensure the 1st cylinder piston position to TDC. Ensure that correct TDC locking tool is used. TDC locking hole is near crankcase left side below intake manifold (Near Engine LH Mounting bracket). If not able to position the MST in proper position into crankshaft, Slightly rotate damper pulley and align the crankshaft to insert MST:- 0312ABH0001ST Crankshaft Locking Tool - TDC Pin on crankshaft. Install the (MST \u2013 0310ABH0001ST Cam Shaft locking tool) on the front side of cylinder head as the location shown below using appropriate bolts. The Cam shaft 2D Matrix must be on the top side for both Intake and Exhaust camshaft. Crank Sprocket Key must be at 12\u2019O Clock Position. Ensure that locking tool is seated properly on Cam shaft. If the tool is not properly seat on the cam shaft slot then the engine is not in proper timing and follow the below steps for Engine timing adjustment . Using T55 socket spanner, loosen exhaust Cam sprocket mounting bolt. The Exhaust Camshaft Sprocket mounting bolt must be loosened first and then the Intake camshaft Sprocket Mounting bolt to be loosened. Using 15 mm socket spanner, loosen intake CAM sprocket mounting bolt. Loosen (MST\u2013 0310ABH0001ST Cam Shaft locking tool) mounting bolt and adjust cam shaft till MST locking properly at camshaft slot, then tighten MST mounting bolts. Follow below Sequence and procedure for Torque tightened the Intake & Exhaust Cam shaft sprocket bolts. Place the MST203 - Companion Flange Holding Tool into the Primary Chain Intake Cam shaft sprocket as shown and hold the tool in opposite direction of torqueing. Torque tightened the Intake Cam shaftsprocket bolt to 50\u00b12 Nm + 90\u00b0\u00b15\u00b0 . Holding the MST Tool and Torque tightened the Exhaust Cam shaft sprocket bolt after intake sprocket to 50\u00b12 Nm + 80\u00b0\u00b15\u00b0 . MST : 0301BM011ST (cam chain tensioning tool) can be used instead of MST203 - Companion Flange Holding Tool. Using a suitable tool, loosen and remove the MST- 0310ABH0001ST Alignment Tool Camshaft separately. Remove the TDC locking pin. Refit damper pulley and install damper pulley mounting bolt on crankshaft. Rotate the crankshaft (360?) 4 times towards clockwise direction and check the free rotation. To reconfirming proper cam and crank timing, Once again Insert TDC locking pin and ensure cam shaft locking tool properly seating on the cam shafts position. Remove the cam shaft locking tool & TDC locking pin after confirmation Apply Loctite 574 , Install the TDC locking dummy on crankcase and torque tighten. Torque : 20\u00b12 Nm ",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Remove the damper pulley. Position the engine LH mounting bracket and install the mounting bolts. torque tighten the bolts to specified value. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Detach the engine support beam from engine and remove support beam from vehicle. Install the engine mounting bracket nuts (Both RH & LH) on engine beds and torque tighten the nuts to specified value. Torque : 110\u00b1 10 Nm. ",
+ "file": null,
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1662.jpg",
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Remove the engine front lifting hook. Refit Flywheel locking tool (MST\u2013 0307ABH0001ST) with suitable mounting bolts on crankcase. Refit the timing case cover. For additional information refer to Timing Case Cover \u2013 R&R Section. Remove the crankshaft pulleyFor additional information refer to the Crankshaft Pulley \u2013 R&R section. Using a suitable tool remove the front end oil seal. Remove the seal from the engine. Install in reverse order of removal. The crankshaft oil seals are one time use, should never be reused. Apply thin layer of oil on the new oil seal lip. Follow the below procedure for front oil seal Installation. Position the front oil seal on the timing cover. Place the front oil seal installer (MST\u20130311DBH0001ST) over the oil seal and tighten the torsional vibration damper pulley bolt Tighten the torsional vibration damper pulley bolt till the front oil seal is pushed to the timing cover Visually inspect the oil seal for proper seating. Check & Top-up the engine oil. Check and clean the oil seal seating area thoroughly for any damage. Hydro lock or hydrostatic lock is an abnormal condition in internal combustion engine. This occurs when a volume of liquid (Coolant/water or fuel) greater than the volume of the cylinder at its minimum (end of the piston stroke) enters the cylinder. Since liquids are nearly incompressible the piston cannot complete its travel; either the engine stop rotating or a mechanical failure occurs. When an engine is suspected to be hydrostatically locked, regardless of what caused the problem, the following steps should be used DO NOT use starter motor to rotate the engine, severe damage may occur. Inspect air cleaner, air intake system and intake manifold to ensure system is dry and clear of water and foreign material. Disconnect negative battery cable Place a shop towel around the injectors when removing them from the engine. This will catch any fluid that may possibly be in the cylinder under pressure With all injectors removed, rotate engine crankshaft. Identify the fluid in the cylinder(s) (i.e., coolant, fuel, oil or other). Make sure all fluid has been removed from the cylinders. Inspect engine for damage (i.e., connecting rods, pistons, valves, etc.) Repair engine or components as necessary to prevent this problem from recurring. Squirt approximately one teaspoon of oil into the cylinders, rotate engine to lubricate the cylinder walls to prevent damage on restart. Drain engine oil and remove oil filter. Install a new oil filter. Fill engine with specified amount of approved oil. Connect negative battery cable. Install all Injectors. Start engine and check for any leaks The oil Sump is the reservoir for the oil and also cover for the crank case. It is secured to the engine block by bolts. A liquid sealant is used to provide an leak proof joint. For additional information refer to Electric Disconnect Stone Guard \u2013 R&R Section. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 14 mm ring and 15 mm socket spanner, Unscrew the front cross member mounting bolts and nuts. Torque : 65 \u00b110 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the front cross member from the vehicle Disconnect the front axle electrical connector. Provide jack to support the front axle assembly. Using a 19 mm Socket spanner, loosen and remove the front axle assembly mounting bolts. Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Partially down the front axle assembly . For additional information refer to AC compressor belt - R&R Section.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the AC compressor bottom mounting bolts. Torque : 23 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the transmission bottom mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the oil sump bottom mounting bolts. Torque : 22.5 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a 8 mm socket spanner, loosen and remove the oil sump bottom mounting bolts. Torque : 11 \u00b1 1.0 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Detach engine oil sump from the vehicle . Install in reverse order of removal Clean the sump and sump seating area on bed plate. Gently apply sealant for engine oil sump. Apply sealant as per recommendation and position the sump on crankcase. Please refer Sealant pattern session for sealant apply pattern. Torque tighten the bolts as per below sequence. Refill the engine oil and check for oil leakage. Check the oil sump for any cracks, damage etc, replace if found any. A glow plug is a heating device used to aid in cold starting. In cold weather, high speed diesel engines can be difficult to start because the mass of the cylinder block and cylinder head absorb the heat of compression, preventing ignition due to the higher surface-to-volume ratio. The glow plug is a pencil-shaped piece of metal with a heating element at the tip. This heating element, when electrified, heats due to its electrical resistance and begins to emit light in the visible spectrum, hence the term glow-plug. The heat generated by the glow plugs is directed into the cylinders and serves to warm the engine block immediately surrounding the cylinders. This aids in reducing the amount of thermal diffusion which will occur when the engine attempts to start. The fuel injector spray pattern then impinges directly upon the hot tip of the glow plug during the injection of fuel at top dead center. This enables the fuel to ignite even when the engine is insufficiently hot for normal operation. This reduces the cranking time needed to start the diesel engine. The glow plugs are controlled by the EMS ECU. The ECU decides the actuation of the glow plugs based on operating conditions, engine temperature and environment temperature. Remove the Intake Manifold. Disconnect the glow plug electrical connector. Using 8 mm deep socket spanner, Carefully loosen and remove the glow plug from the cylinder head. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010678.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "Follow the same procedure for all glow plugs. Install in reverse order of removal. Check for any cracks, damage etc, replace if found any. The oil pump circulates the engine oil to lubricate the components such as bearings, piston and valve. The lower chain drives oil pump to lubricate the engine. This oil pump are integrated with the strainer. The oil strainer is the first stage in the filtration of the lubricant. It filters the coarse particles present in the oil before it enters the oil pump. Using a 8 mm allen socket spanner, loosen and remove the engine oil pump tensioner mounting bolt. Torque : 25\u00b1 3 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, Remove engine oil pump mounting bolts. Torque : 26 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the engine oil pump from oil pump chain. Carefully remove the engine oil pump. Install in reverse order of removal. Refill the engine oil and check for oil leakage. Inspect the oil pump for any damage. Replace if found. Inspect the oil pump and strainer for any blockage, clean if found. The camshaft controls the valve opening and closing events. It is driven by the crankshaft through a chain connection. The camshaft rotates at half the speed of the crankshaft to maintain proper timing of the four cycle of combustion. The opening and closing of the valves are done by lobes on the camshaft. The timing of the valve depends on the position of the camshaft and shape of the lobes on it. The valve lift is the distance the valve is lifted off its seat when fully opened. This is determined by the height of the CAM lobe. The valve need enough lift to allow air to flow freely into the cylinder and for exhaust gases to flow out of the cylinder, without interfering with piston or binding the spring. The duration is the length of time the CAM lobe keeps the valve open. It is measured in degrees of camshaft rotation and is determined by the shape of the CAM lobe. Camshaft also drives the fuel pump and vacuum pump. Remove the engine top encapsulation cover. Using nose plier, release engine vent hose clip at T Joint and disconnect the hose. Using 10 mm socket spanner, Unscrew degassing tank mounting bolts and partially detach it (Without detaching the hoses). Using 10 mm socket spanner, loosen and remove the engine fead cover mounting bolts. Remove the engine fead cover from engine compartment. Place the MST 0306GAM0006ST - Stretch Fit Belt Removal Tool on damper pulley side as shown in the image. Using 24 mm socket spanner, rotate the damper pulley to clockwise direction then remove the water pump drive belt and MST separately Using 14 mm ring spanner, turn the hexagon knob in the belt tensioner Anti clockwise direction to release the tension. Remove the alternator drive belt. Using 10 mm socket spanner, Unscrew engine wiring harness carrier mounting stud from Cam cover and detach it partially. Disconnect the Injectors electrical connectors from the injectors. Using 17 mm open end spanner, Unscrew High pressure pipe mounting flare nut from common rail end. Using 19 mm open end spanner, unscrew High pressure pipe flare nut from injection pump end.
",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Notice",
+ "content": "While loosening the high pressure pipes at Injector end, hold the injector pipe connector by 13 mm Open end spanner. ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040093.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040094.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040219.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010050.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": " Remove the high pressure fuel pipes from the engine. Remove injector leak - off pipe lock clip and detach leak off pipes from the injector end. Remove all 4 Injectors from cylinder head. Injector Bore must be covered with lint sfree cloth/Masking tape to avoid foreign objects entering injector bore/cylinder. Plug the fuel inlet and wiring harness connector slot as soon as injector is removed. Store the injector in a neat tray. Never drop the injectors. Never clean the injector using pressurized water. Disconnect fuel inlet tube quick couplers from fuel injection pump & FCU. All are quick fix connectors, press gently and remove it carefully to avoid seal damages. Using nose plier release fuel return hose spring band clamp and detach hoses from fuel injection pump & FCU. Press the lock and disconnect fuel control unit electrical connector. Using 10 mm socket spanner, Unscrew fuel return line 'T' bracket mounting bolts. Using 12 mm socket spanner, Unscrew Cam box mounting bolts and remove the bolts. Rotate the Cam Box Assembly as direction shown in the image to access fuel high pressure pump mounting bolts. Using T30 socket spanner unscrew fuel high pressure pump mounting bolts and detach pump. Remove Cam box assembly along with FCU from engine. While taking out Cam box, ensure to move the tappet in upward direction by hand. Disconnect T4 temperature sensor electrical connector. Disconnect T5 temperature sensor electrical connector. Detach the vacuum hose routing clips from heat shield. Using 14 mm socket spanner, loosen and remove the heat shield mounting studs from Cam cover. Using 10 mm socket spanner, loosen and remove the heat shield mounting bolt from Cam cover and rear engine hook. Using 12 mm socket spanner, loosen and remove the heat shield mounting bolt from SDPF side. Disconnect the dosing module electrical connector. Disconnect the SDPF Sensor electrical connector. Disconnect the Cam phase sensor electrical connector. Disconnect the common rail electrical connector and wiring harnesses routing clip. Using hose clip plier, Unclip oil separator hose spring band clamp and detach hose. Using 10 mm ring spanner, loosen and remove stud mountings from Cam cover. Using 10 mm socket spanner, loosen and remove Cam cover mounting bolts & studs. Using 8 mm socket spanner, loosen and remove the Cam cover mounting bolts. Detach Cam cover from the engine completely. Using nose plier, Release the spring band clamp and disconnect vacuum hose from vacuum pump side. Using 12 mm socket spanner, Unscrew vacuum pump mounting bolts and remove vacuum pump from engine. Using 14 mm socket spanner, Loosen and remove auto tensioner mounting bolt and remove tensioner Using 14 mm socket spanner, Loosen and remove the drive belt idler mounting bolt and remove idler from the engine. Using 14 mm socket spanner, loosen and remove the starter motor mounting bolts. Lock the flywheel by using MST 0307ABH0001ST - Fly wheel Locking tool. Using 24 mm socket spanner, Unscrew damper pulley mounting bolt and remove damper pulley. Using 12 mm socket spanner, Loosen and remove the engine front cover mounting bolts from the Oil sump. Using 12 mm socket spanner, Loosen and remove the AC compressor top mounting bolt. AC compressor top mounting bolt must be removed, failing to remove the bolt will leads to crack the front cover. Using 14 mm socket spanner, loosen and remove engine front cover mounting bolts from cylinder head. Using 12 mm socket spanner, loosen and remove engine front cover mounting bolts from crank case. Using 12 mm socket spanner, loosen and remove engine front cover mounting bolts. Detach engine front cover from engine. Ensure to cover the engine oil sump open space properly by lint free cloth after removal of Front Cover. Make sure for all the subassembly and components going into engine assembly should be clean and away from foreign material. Remove the flywheel locking tool MST\u20130307ABH0001ST. Position engine front lifting hook and hand tighten the mounting bolts. Using 18 mm socket spanner, unscrew engine mounting bracket nuts (Both RH & LH). Provide engine support beam to support engine. Lift the engine with care, don\u2019t over lift since chances of damaging parts are high. Ensure none of the components are effected or damaged during lifting. Using 14 mm combination spanner and socket spanner , unscrew LH engine mounting bracket mounting bolts and remove the LH bracket. Using 6 mm square socket spanner, loosen and remove TDC locking dummy from crankcase. Refit damper pulley and install damper pulley mounting bolt on crankshaft. Lock the crankshaft by Inserting the TDC locking pin (MST\u2013 0312ABH0001ST). Ensure the crankshaft locking tool is seated properly into the slot on crankshaft and ensure the TDC locking pin insert upto Red mark in the pin as shown. Check and ensure the 1st cylinder piston position to TDC. Ensure that correct TDC locking tool is used. TDC locking hole is near crankcase left side below intake manifold (Near Engine LH Mounting bracket). If not able to position the MST in proper position into crankshaft,Slightly rotate damper pulley and align the crankshaft to insert MST:-0312ABH0001ST Crankshaft Locking Tool - TDC Pin on crankshaft. Install the (MST \u2013 0310ABH0001ST Cam Shaft locking tool) on the front side of cylinder head as the location shown below using appropriate bolts. The Cam shaft 2D Matrix must be on the top side for both Intake and Exhaust camshaft. Crank Sprocket Key must be at 12\u2019O Clock Position. Ensure that locking tool is seated properly on Cam shaft. Remove the damper pulley. Using T55 socket spanner, loosen exhaust Cam sprocket mounting bolt. The Exhaust Camshaft Sprocket mounting bolt must be loosened first and then the Intake camshaft Sprocket Mounting bolt to be loosened. Using 15 mm socket spanner, loosen intake Cam sprocket mounting bolt. Using 10 mm socket spanner loosen, and remove the chain hydraulic tensioner mounting bolts. Using 8 mm Allen key, loosen and remove the chain guide bolt and detach guide. Using 10 mm socket spanner, loosen and remove the chain fixed guider bolts and detach guide. Remove and take out the timing chain with intake Cam sprocket from engine. Using 5 mm Allen key/ Socket, loosen and remove the secondary chain tensioner mounting Allen bolts. Remove the exhaust Cam sprocket mounting bolt. Compress the tensioner and remove the camshaft intake and exhaust drive chain and sprockets along with tensioner. Unscrew Cam Shaft Locking (MST\u20130307ABH0001ST) mounting bolts and remove MST. Using 10 mm socket spanner, Loosen and Remove the Intake Cam shaft rear bearing cap mounting bolts. Remove the rear bearing cap from the cylinder head. Using 8 mm socket spanner, Loosen and Remove Cam shaft front bearing cap mounting bolts. Remove the front bearing cap from the cylinder head. Using 8 mm socket spanner, Loosen and Remove the intake and exhaust CAM shaft bearing cap mounting bolts. Remove the intake and exhaust CAM shaft bearing caps. Remove the Intake and Exhaust CAM shafts from the cylinder head. Check the intake camshaft and the exhaust camshaft for any damage and replace it if necessary. Inspect the camshaft bearing journals for scoring or excessive wear. Inspect the camshaft lobes for scoring or excessive wear. Inspect the threaded bolt holes in the front of the camshaft for damaged threads or debris. ",
+ "file": null,
+ "display_order": 205
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " Apply a thin layer of engine oil to the mounting parts of the Cam shafts. ",
+ "file": null,
+ "display_order": 206
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010040.jpg",
+ "display_order": 207
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": " Install the Intake and Exhaust cam shafts. ",
+ "file": null,
+ "display_order": 208
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010041.jpg",
+ "display_order": 209
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": " Line up the timing marks of the intake/exhaust Cam shaft (on the front side) when installing as shown. The Cam shaft 2D Matrix must be on the top side for both Intake and Exhaust camshaft. Crank Sprocket Key must be at 12\u2019O Clock Position. Check and confirm the 1st cylinder piston position at TDC before installation. Apply a thin layer of engine oil on the Cam shafts. ",
+ "file": null,
+ "display_order": 215
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010042.jpg",
+ "display_order": 216
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": " Install the Front, Rear & Cam shafts bearing caps. ",
+ "file": null,
+ "display_order": 217
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010043.jpg",
+ "display_order": 218
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": " Sealant (Loctite 574- 2mm thickness) to be applied on rear bearing cap as per below pattern. Extra sealant to be wiped off after assembly of rear bearing cap. Install the bearing caps mounting bolts and torque tighten the bolts to specified value as per tightening sequence. ",
+ "file": null,
+ "display_order": 221
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010044.jpg",
+ "display_order": 222
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": " Torque for A & B : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 223
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010048.jpg",
+ "display_order": 224
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque for C : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 225
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25246.jpg",
+ "display_order": 226
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": " Install the (MST \u2013 0310ABH0001ST Cam Shaft locking tool) on the front side of cylinder head as the location shown below using appropriate bolts. ",
+ "file": null,
+ "display_order": 227
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010033.jpg",
+ "display_order": 228
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Notice",
+ "content": " The Cam shaft 2D Matrix must be on the top side for both Intake and Exhaust camshaft. Crank Sprocket Key must be at 12\u2019O Clock Position. Ensure that locking tool is seated properly on Cam shaft. Assemble the exhaust and intake camshaft sprocket and Cam chain tensioner.Compress the tensioner and insert the suitable locking pins/allen keys on tensioner. ",
+ "file": null,
+ "display_order": 234
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011144.jpg",
+ "display_order": 235
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": " Install the camshaft intake and exhaust drive chain and sprockets along with tensioner on cam shafts. ",
+ "file": null,
+ "display_order": 236
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011145.jpg",
+ "display_order": 237
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": " Install the secondary tensioner mounting bolts and Torque tighten bolts to specified value. ",
+ "file": null,
+ "display_order": 238
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011146.jpg",
+ "display_order": 239
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": " Torque: 11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 240
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": " Release the tensioner locking pins. ",
+ "file": null,
+ "display_order": 241
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011147.jpg",
+ "display_order": 242
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": " Hand tighten the New exhaust Cam sprocket mounting bolt. ",
+ "file": null,
+ "display_order": 243
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011148.jpg",
+ "display_order": 244
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Caution",
+ "content": " Ensure to replace New Exhaust Cam shaft bolt while Installation. Before Installation of Primary timing chain, Clean the inner and outer surface of the timing chain and timing cover. ",
+ "file": null,
+ "display_order": 246
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": " Position the primary timing chain along with sprocket on Intake Cam shaft. ",
+ "file": null,
+ "display_order": 247
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011153.jpg",
+ "display_order": 248
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": " Align primary chain into primary crank sprocket and engage New Intake camshaft bolt. ",
+ "file": null,
+ "display_order": 249
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011154.jpg",
+ "display_order": 250
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Caution",
+ "content": " Ensure to replace New Intake Cam shaft bolt while Installation. Align the timing chain fixed guide on timing chain and install the mounting bolts.torque tighten the bolts to specified value. ",
+ "file": null,
+ "display_order": 252
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011156.jpg",
+ "display_order": 253
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Torque Value",
+ "content": "Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 254
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011160.jpg",
+ "display_order": 255
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": " Align the timing chain guide on timing chain and install the mounting bolt.torque tighten the bolt to specified value. ",
+ "file": null,
+ "display_order": 256
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011028.jpg",
+ "display_order": 257
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Torque Value",
+ "content": " Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 258
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": " Compress the chain hydraulic tensioner and lock the tensioner by using locking pin. ",
+ "file": null,
+ "display_order": 259
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011032.jpg",
+ "display_order": 260
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": " Refit the New chain hydraulic tensioner by mounting bolts, torque tighten the bolts to specified value. ",
+ "file": null,
+ "display_order": 261
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011178.jpg",
+ "display_order": 262
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Torque Value",
+ "content": "Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 263
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Caution",
+ "content": " Ensure to replace New primary chain hydraulic tensioner while Installation. Follow below Sequence and procedure for Torque tightened the Intake & Exhaust Cam shaft sprocket bolts. Place the MST203 - Companion Flange Holding Tool into the Primary Chain Intake Cam shaft sprocket as shown and hold the tool in opposite direction of torqueing. ",
+ "file": null,
+ "display_order": 265
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011165.jpg",
+ "display_order": 266
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Notice",
+ "content": " MST : 0301BM011ST (cam chain tensioning tool) can be used instead of MST203 - Companion Flange Holding Tool. Torque tightened the Intake Cam shaft sprocket bolt to 50\u00b12 Nm + 90\u00b0\u00b15\u00b0. Holding the MST Tool and Torque tightened the Exhaust Cam shaft sprocket bolt after intake sprocket to 50\u00b12 Nm + 80\u00b0\u00b15\u00b0. Intake and exhaust Cam Shaft sprocket mounting bolts should be torque tightened only after installing the chain guides and hydraulic tensioner. Release the chain hydraulic tensioner locking pin. ",
+ "file": null,
+ "display_order": 271
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011180.jpg",
+ "display_order": 272
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": " Remove the MST Cam Shaft locking tool. ",
+ "file": null,
+ "display_order": 273
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010033.jpg",
+ "display_order": 274
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": " Remove the TDC locking pin. ",
+ "file": null,
+ "display_order": 275
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011167.jpg",
+ "display_order": 276
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": " Refit damper pulley and install damper pulley mounting bolt on crankshaft. ",
+ "file": null,
+ "display_order": 277
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010977.jpg",
+ "display_order": 278
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Rotate the crankshaft (360) 4 times towards clockwise direction and check the free rotation",
+ "file": null,
+ "display_order": 279
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011164.jpg",
+ "display_order": 280
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": " To reconfirming proper cam and crank timing, Once again Insert TDC locking pin and ensure cam shaft locking tool properly seating on the cam shafts position. Remove the cam shaft locking tool & TDC locking pin after confirmation. Apply Loctite 574 , Install the TDC locking dummy on crankcase and torque tighten. ",
+ "file": null,
+ "display_order": 284
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010976.jpg",
+ "display_order": 285
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Torque Value",
+ "content": "Torque : 20\u00b12 Nm ",
+ "file": null,
+ "display_order": 286
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": " Remove the damper pulley. ",
+ "file": null,
+ "display_order": 287
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010977.jpg",
+ "display_order": 288
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": " Position the engine LH mounting bracket and install the mounting bolts.torque tighten the bolts to specified value. ",
+ "file": null,
+ "display_order": 289
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010975.jpg",
+ "display_order": 290
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 291
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": " Detach the engine support beam from engine and remove support beam from vehicle. ",
+ "file": null,
+ "display_order": 292
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010032.jpg",
+ "display_order": 293
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": " Install the engine mounting bracket nuts (Both RH & LH) on engine beds and torque tighten the nuts to specified value. ",
+ "file": null,
+ "display_order": 294
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010973.jpg",
+ "display_order": 295
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Torque : 110\u00b1 10 Nm. ",
+ "file": null,
+ "display_order": 296
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010986.jpg",
+ "display_order": 297
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Description",
+ "content": " Remove the engine front lifting hook. ",
+ "file": null,
+ "display_order": 298
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010972.jpg",
+ "display_order": 299
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "Description",
+ "content": " Refit the flywheel locking tool MST\u2013 0307ABH0001ST. ",
+ "file": null,
+ "display_order": 300
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010971.jpg",
+ "display_order": 301
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "Description",
+ "content": " Install MST 0311DBH0002ST \u2013 Engine front cover guide (1 Set) pins on cylinder block. ",
+ "file": null,
+ "display_order": 302
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010025.jpg",
+ "display_order": 303
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "Caution",
+ "content": " Clean sealant on front cover. Clean sealant & oil between crankcase and front cover mounting surface and ensure sealant not to get inside the oil sump. The thread hole in the front cover at Oil Sump joint to be checked for any sealant present inside. The Sealant must be cleaned completely . Apply the Loctite 5900 (2mm thickness) on the Front cover & Oil sump (Front side) as per below recommended pattern. ",
+ "file": null,
+ "display_order": 306
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010878.jpg",
+ "display_order": 307
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "Caution",
+ "content": " Use only the recommended sealant, failure to follow the instruction may lead to leakages. Install the front cover to the cylinder block, guiding by guide pins. ",
+ "file": null,
+ "display_order": 310
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010026.jpg",
+ "display_order": 311
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "Description",
+ "content": " Remove the front cover installation guide pins. ",
+ "file": null,
+ "display_order": 312
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010027.jpg",
+ "display_order": 313
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "Description",
+ "content": " Refit the engine front cover mounting bolts on cylinder block & cylinder head. ",
+ "file": null,
+ "display_order": 314
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010671.jpg",
+ "display_order": 315
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "Notice",
+ "content": " Visually inspect the oil seal for proper seating. Torque tighten the cover mounting bolts to specified value as per torque tighten sequence. ",
+ "file": null,
+ "display_order": 319
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010870.jpg",
+ "display_order": 320
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25291.jpg",
+ "display_order": 321
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "Description",
+ "content": " Refit the engine front cover mounting bolts on Oil sump and torque tighten to specified value. ",
+ "file": null,
+ "display_order": 322
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010669.jpg",
+ "display_order": 323
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "Torque Value",
+ "content": "Torque : 22.5 \u00b12.5 Nm ",
+ "file": null,
+ "display_order": 324
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "Description",
+ "content": " Refit the AC compressor top mounting bolt and torque tighten to specified value. ",
+ "file": null,
+ "display_order": 325
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011176.jpg",
+ "display_order": 326
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "Torque Value",
+ "content": "Torque : 23 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 327
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "Description",
+ "content": " Position the damper pulley, Install the mounting bolt and torque tighten to specified value. ",
+ "file": null,
+ "display_order": 328
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010668.jpg",
+ "display_order": 329
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "Torque Value",
+ "content": " Torque : 200\u00b120 Nm + 135\u00b0\u00b15\u00b0 ",
+ "file": null,
+ "display_order": 330
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011161.jpg",
+ "display_order": 331
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "Caution",
+ "content": " Ensure to replace New Damper pulley bolt & spacer while Installation. Remove the flywheel locking tool. ",
+ "file": null,
+ "display_order": 333
+ },
+ {
+ "step_name": "Step-40",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010921.jpg",
+ "display_order": 334
+ },
+ {
+ "step_name": "Step-41",
+ "content_type": "Description",
+ "content": " Position the starter motor and install the mounting bolts. torque tighten the bolts to specified value. ",
+ "file": null,
+ "display_order": 335
+ },
+ {
+ "step_name": "Step-41",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010667.jpg",
+ "display_order": 336
+ },
+ {
+ "step_name": "Step-41",
+ "content_type": "Torque Value",
+ "content": "Torque : 44 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 337
+ },
+ {
+ "step_name": "Step-42",
+ "content_type": "Description",
+ "content": " Refit the drive belt idler and install the mounting bolt. torque tighten the bolt to specified value. Torque : 45 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 338
+ },
+ {
+ "step_name": "Step-42",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010666.jpg",
+ "display_order": 339
+ },
+ {
+ "step_name": "Step-43",
+ "content_type": "Description",
+ "content": " Refit auto tensioner and install the mounting bolt. torque tighten the bolt to specified value. ",
+ "file": null,
+ "display_order": 340
+ },
+ {
+ "step_name": "Step-43",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010665.jpg",
+ "display_order": 341
+ },
+ {
+ "step_name": "Step-43",
+ "content_type": "Torque Value",
+ "content": "Torque : 45 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 342
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "Description",
+ "content": " Position the vacuum pump, refit the pump mounting bolts and torque tighten to specified value. ",
+ "file": null,
+ "display_order": 343
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010701.jpg",
+ "display_order": 344
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "Notice",
+ "content": " Replace the Vacuum Pump \u2018O\u2019 ring with a new one when installing. The slot parts of the vacuum pump are parallel to each other as shown in the figure if the engine chain timing marks are lined up. Fit the slots when assembling Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 347
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010468.jpg",
+ "display_order": 348
+ },
+ {
+ "step_name": "Step-45",
+ "content_type": "Description",
+ "content": " Refit the vacuum hose on pump side. ",
+ "file": null,
+ "display_order": 349
+ },
+ {
+ "step_name": "Step-45",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1652.jpg",
+ "display_order": 350
+ },
+ {
+ "step_name": "Step-46",
+ "content_type": "Description",
+ "content": " Follow the below Caution points before Install the Cam Cover. ",
+ "file": null,
+ "display_order": 351
+ },
+ {
+ "step_name": "Step-46",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010058.jpg",
+ "display_order": 352
+ },
+ {
+ "step_name": "Step-46",
+ "content_type": "Caution",
+ "content": " Extra sealant to be wiped off after assembly of rear bearing cap. The Sealant at Cam Bearing Area on Cylinder Head and Cover must be cleaned completely. The Oil on the Cylinder Head Cam Cover Joint Face Area must be cleaned before sealant application and cam cover assembly. Apply Sealant (Loctite 5900 - 2mm thickness) on cylinder head as per below pattern before assembling cam cover. Replace the Cam Cover gaskets with a new one when installing. Ensure the New Cam Cover Rubber Gasket is Properly placed in the Cam Cover Groove. The Gasket Profile and cover groove profile must match especially at Intake Camshaft Rear Main Bearing Cap Location. Position the Cam cover with New Gaskets on engine, refit the studs and mounting bolts on the Cam cover. ",
+ "file": null,
+ "display_order": 358
+ },
+ {
+ "step_name": "Step-47",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010649.jpg",
+ "display_order": 359
+ },
+ {
+ "step_name": "Step-47",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011149.jpg",
+ "display_order": 360
+ },
+ {
+ "step_name": "Step-47",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010693.jpg",
+ "display_order": 361
+ },
+ {
+ "step_name": "Step-48",
+ "content_type": "Description",
+ "content": " Torque tighten the mounting bolts & studs to specified value as per sequence order. ",
+ "file": null,
+ "display_order": 362
+ },
+ {
+ "step_name": "Step-48",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011151.jpg",
+ "display_order": 363
+ },
+ {
+ "step_name": "Step-48",
+ "content_type": "Description",
+ "content": " Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 364
+ },
+ {
+ "step_name": "Step-48",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25313.jpg",
+ "display_order": 365
+ },
+ {
+ "step_name": "Step-49",
+ "content_type": "Description",
+ "content": " Refit the oil separator hose. ",
+ "file": null,
+ "display_order": 366
+ },
+ {
+ "step_name": "Step-49",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010648.jpg",
+ "display_order": 367
+ },
+ {
+ "step_name": "Step-50",
+ "content_type": "Description",
+ "content": " Connect the common rail electrical connector and wiring harnesses routing clip. ",
+ "file": null,
+ "display_order": 368
+ },
+ {
+ "step_name": "Step-50",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010691.jpg",
+ "display_order": 369
+ },
+ {
+ "step_name": "Step-51",
+ "content_type": "Description",
+ "content": " Connect the Cam phase sensor electrical connector. ",
+ "file": null,
+ "display_order": 370
+ },
+ {
+ "step_name": "Step-51",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010688.jpg",
+ "display_order": 371
+ },
+ {
+ "step_name": "Step-52",
+ "content_type": "Description",
+ "content": " Connect the DPF Sensor electrical connector. ",
+ "file": null,
+ "display_order": 372
+ },
+ {
+ "step_name": "Step-52",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010646.jpg",
+ "display_order": 373
+ },
+ {
+ "step_name": "Step-53",
+ "content_type": "Description",
+ "content": " Connect the dosing module electrical connector. ",
+ "file": null,
+ "display_order": 374
+ },
+ {
+ "step_name": "Step-53",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010675.jpg",
+ "display_order": 375
+ },
+ {
+ "step_name": "Step-54",
+ "content_type": "Description",
+ "content": " Position the heat shield and refit the heat shield mounting bolt on DPF side and torque tighten the bolt. ",
+ "file": null,
+ "display_order": 376
+ },
+ {
+ "step_name": "Step-54",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010062.jpg",
+ "display_order": 377
+ },
+ {
+ "step_name": "Step-54",
+ "content_type": "Torque Value",
+ "content": "Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 378
+ },
+ {
+ "step_name": "Step-54",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010920.jpg",
+ "display_order": 379
+ },
+ {
+ "step_name": "Step-55",
+ "content_type": "Description",
+ "content": " Refit the heat shield mounting bolt on Cam cover and rear engine hook and torque tighten the bolts. ",
+ "file": null,
+ "display_order": 380
+ },
+ {
+ "step_name": "Step-55",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010659.jpg",
+ "display_order": 381
+ },
+ {
+ "step_name": "Step-55",
+ "content_type": "Torque Value",
+ "content": "Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 382
+ },
+ {
+ "step_name": "Step-56",
+ "content_type": "Description",
+ "content": " Refit the heat shield mounting studs on Cam cover and torque tighten the studs. ",
+ "file": null,
+ "display_order": 383
+ },
+ {
+ "step_name": "Step-56",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010660.jpg",
+ "display_order": 384
+ },
+ {
+ "step_name": "Step-56",
+ "content_type": "Description",
+ "content": "Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 385
+ },
+ {
+ "step_name": "Step-57",
+ "content_type": "Description",
+ "content": " Attach the vacuum hose on routing clips. ",
+ "file": null,
+ "display_order": 386
+ },
+ {
+ "step_name": "Step-57",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130307.jpg",
+ "display_order": 387
+ },
+ {
+ "step_name": "Step-58",
+ "content_type": "Description",
+ "content": " Connect T5 temperature sensor electrical connector. ",
+ "file": null,
+ "display_order": 388
+ },
+ {
+ "step_name": "Step-58",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010657.jpg",
+ "display_order": 389
+ },
+ {
+ "step_name": "Step-58",
+ "content_type": "Caution",
+ "content": " Green colour tape provided on T5 Sensor wiring pigtail and engine wiring harness connector side for easy identification while refit and ensure to properly connect the T5 Sensor wiring pigtail connector with engine wiring harness. Mismatch connection of wiring connectors may leads to affect the engine performance and occur engine trouble. Connect T4 temperature sensor electrical connector. ",
+ "file": null,
+ "display_order": 392
+ },
+ {
+ "step_name": "Step-59",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010656.jpg",
+ "display_order": 393
+ },
+ {
+ "step_name": "Step-59",
+ "content_type": "Caution",
+ "content": " Yellow colour tape provided on T4 Sensor wiring pigtail and engine wiring harness connector for easy identification while refit and ensure to properly connect the T4 Sensor wiring pigtail connector with engine wiring harness. Mismatch connection of wiring connectors may leads to affect the engine performance and occur engine trouble. Position the Cam box on Intake cam shaft rear end. ",
+ "file": null,
+ "display_order": 396
+ },
+ {
+ "step_name": "Step-60",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011140.jpg",
+ "display_order": 397
+ },
+ {
+ "step_name": "Step-60",
+ "content_type": "Notice",
+ "content": " While Installing Cam box, ensure to move the tappet in upward direction by hand. Ensure to replace New Cam box gasket during Installation. Before Installation of Cam box mounting bolts, Rotate the Cam Box Assembly as direction shown in the image to install fuel high pressure pump mounting bolts. ",
+ "file": null,
+ "display_order": 402
+ },
+ {
+ "step_name": "Step-61",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011133.jpg",
+ "display_order": 403
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "Description",
+ "content": " Position the fuel pump on Cam box and install mounting bolts. Tighten the mounting bolts to the specified torque value. ",
+ "file": null,
+ "display_order": 404
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011135.jpg",
+ "display_order": 405
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "Torque Value",
+ "content": "Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 406
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040214.jpg",
+ "display_order": 407
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "Notice",
+ "content": " While Installing the pump always replace the Gasket with a new one. While torque tighten the Pump mountings, hold the Cam box Assembly by second technician as shown. Install the Cam box mounting bolts. Tighten the bolts to the specified torque value. ",
+ "file": null,
+ "display_order": 412
+ },
+ {
+ "step_name": "Step-64",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011132.jpg",
+ "display_order": 413
+ },
+ {
+ "step_name": "Step-64",
+ "content_type": "Torque Value",
+ "content": " Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 414
+ },
+ {
+ "step_name": "Step-64",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010061.jpg",
+ "display_order": 415
+ },
+ {
+ "step_name": "Step-65",
+ "content_type": "Description",
+ "content": " Install fuel return line 'T' bracket mounting bolts. Tighten the bolts to the specified torque value ",
+ "file": null,
+ "display_order": 416
+ },
+ {
+ "step_name": "Step-65",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040206.jpg",
+ "display_order": 417
+ },
+ {
+ "step_name": "Step-65",
+ "content_type": "Torque Value",
+ "content": "Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 418
+ },
+ {
+ "step_name": "Step-66",
+ "content_type": "Description",
+ "content": " Refit fuel return hoses and lock it by spring band clamp. ",
+ "file": null,
+ "display_order": 419
+ },
+ {
+ "step_name": "Step-66",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040167.jpg",
+ "display_order": 420
+ },
+ {
+ "step_name": "Step-66",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040161.jpg",
+ "display_order": 421
+ },
+ {
+ "step_name": "Step-67",
+ "content_type": "Description",
+ "content": " Connect fuel inlet tube quick coupler at pump end & FCU. ",
+ "file": null,
+ "display_order": 422
+ },
+ {
+ "step_name": "Step-67",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040166.jpg",
+ "display_order": 423
+ },
+ {
+ "step_name": "Step-67",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040160.jpg",
+ "display_order": 424
+ },
+ {
+ "step_name": "Step-68",
+ "content_type": "Description",
+ "content": " Connect the fuel control unit electrical connector. ",
+ "file": null,
+ "display_order": 425
+ },
+ {
+ "step_name": "Step-68",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040159.jpg",
+ "display_order": 426
+ },
+ {
+ "step_name": "Step-69",
+ "content_type": "Description",
+ "content": " Position all 4 Injectors and clamps on cylinder head, refit the injector clamp mounting bolts and torque tighten the bolts to specified value. ",
+ "file": null,
+ "display_order": 427
+ },
+ {
+ "step_name": "Step-69",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040237.jpg",
+ "display_order": 428
+ },
+ {
+ "step_name": "Step-69",
+ "content_type": "Caution",
+ "content": " Always replace the injector O\u2013 ring with new one when ever injector is removed. \u2022 Check the Injector Washer condition, replace if in damaged condition. Torque : 32 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 431
+ },
+ {
+ "step_name": "Step-69",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040234.jpg",
+ "display_order": 432
+ },
+ {
+ "step_name": "Step-70",
+ "content_type": "Description",
+ "content": " Connect the Injector electrical connectors. ",
+ "file": null,
+ "display_order": 433
+ },
+ {
+ "step_name": "Step-70",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011175.jpg",
+ "display_order": 434
+ },
+ {
+ "step_name": "Step-71",
+ "content_type": "Description",
+ "content": " Refit injector leak - off pipe lock clips on the injector end. ",
+ "file": null,
+ "display_order": 435
+ },
+ {
+ "step_name": "Step-71",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011174.jpg",
+ "display_order": 436
+ },
+ {
+ "step_name": "Step-72",
+ "content_type": "Description",
+ "content": " Position the Fuel HP pipe and tighten the mounting on Common rail end to the specified torque value. ",
+ "file": null,
+ "display_order": 437
+ },
+ {
+ "step_name": "Step-72",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040089.jpg",
+ "display_order": 438
+ },
+ {
+ "step_name": "Step-72",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 439
+ },
+ {
+ "step_name": "Step-73",
+ "content_type": "Description",
+ "content": " Position the Fuel HP pipe and tighten the mounting on FIP end to the specified torque value. ",
+ "file": null,
+ "display_order": 440
+ },
+ {
+ "step_name": "Step-73",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040090.jpg",
+ "display_order": 441
+ },
+ {
+ "step_name": "Step-73",
+ "content_type": "Torque Value",
+ "content": "Torque : 30 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 442
+ },
+ {
+ "step_name": "Step-74",
+ "content_type": "Description",
+ "content": " Refit the engine wiring harness carrier mounting studs on Cam cover and torque tighten the studs. ",
+ "file": null,
+ "display_order": 443
+ },
+ {
+ "step_name": "Step-74",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010658.jpg",
+ "display_order": 444
+ },
+ {
+ "step_name": "Step-74",
+ "content_type": "Torque Value",
+ "content": "Torque : 8 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 445
+ },
+ {
+ "step_name": "Step-75",
+ "content_type": "Description",
+ "content": " Position the high pressure pipes on common rail side and injector side and torque tighten the mountings to specified value. ",
+ "file": null,
+ "display_order": 446
+ },
+ {
+ "step_name": "Step-75",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040093.jpg",
+ "display_order": 447
+ },
+ {
+ "step_name": "Step-75",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 448
+ },
+ {
+ "step_name": "Step-75",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040094.jpg",
+ "display_order": 449
+ },
+ {
+ "step_name": "Step-76",
+ "content_type": "Description",
+ "content": " Position the drive belt and Using 14 mm ring spanner, swing the auto-tensioner in Anti clock-wise direction and install the belt. ",
+ "file": null,
+ "display_order": 450
+ },
+ {
+ "step_name": "Step-76",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010932.jpg",
+ "display_order": 451
+ },
+ {
+ "step_name": "Step-77",
+ "content_type": "Description",
+ "content": " Place the MST 0306GBH0001ST - Stretch Fit Belt Installation Tool on damper pulley as shown in the image. ",
+ "file": null,
+ "display_order": 452
+ },
+ {
+ "step_name": "Step-77",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011101.jpg",
+ "display_order": 453
+ },
+ {
+ "step_name": "Step-78",
+ "content_type": "Description",
+ "content": " Using 24 mm socket spanner, rotate the damper pulley in anticlockwise direction. ",
+ "file": null,
+ "display_order": 454
+ },
+ {
+ "step_name": "Step-78",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010931.jpg",
+ "display_order": 455
+ },
+ {
+ "step_name": "Step-79",
+ "content_type": "Description",
+ "content": " By rotating pulley, belt started getting into pulley groove and once belt installed properly on pulley, then remove the MST and spanner ",
+ "file": null,
+ "display_order": 456
+ },
+ {
+ "step_name": "Step-79",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010930.jpg",
+ "display_order": 457
+ },
+ {
+ "step_name": "Step-79",
+ "content_type": "Caution",
+ "content": " Ensure proper engagement of belt teeth in all the pulley grooves after Installation. Refit the engine fead cover on engine, torque tighten the bolts to specified value. ",
+ "file": null,
+ "display_order": 459
+ },
+ {
+ "step_name": "Step-80",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011173.jpg",
+ "display_order": 460
+ },
+ {
+ "step_name": "Step-80",
+ "content_type": "Torque Value",
+ "content": "Torque : 11\u00b1 1Nm ",
+ "file": null,
+ "display_order": 461
+ },
+ {
+ "step_name": "Step-80",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011070.jpg",
+ "display_order": 462
+ },
+ {
+ "step_name": "Step-81",
+ "content_type": "Description",
+ "content": " Refit the degassing tank and install the mounting bolts on the bracket. Torque tighten the bolts to specified value. ",
+ "file": null,
+ "display_order": 463
+ },
+ {
+ "step_name": "Step-81",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011171.jpg",
+ "display_order": 464
+ },
+ {
+ "step_name": "Step-81",
+ "content_type": "Torque Value",
+ "content": " Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 465
+ },
+ {
+ "step_name": "Step-82",
+ "content_type": "Description",
+ "content": " Refit the engine vent hose on T connection. ",
+ "file": null,
+ "display_order": 466
+ },
+ {
+ "step_name": "Step-82",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011170.jpg",
+ "display_order": 467
+ },
+ {
+ "step_name": "Step-83",
+ "content_type": "Description",
+ "content": " Check engine coolant level and top-up. ",
+ "file": null,
+ "display_order": 468
+ },
+ {
+ "step_name": "Step-84",
+ "content_type": "Description",
+ "content": " Check engine oil level and top-up if needed. ",
+ "file": null,
+ "display_order": 469
+ },
+ {
+ "step_name": "Step-85",
+ "content_type": "Description",
+ "content": " Run the Engine in Idle condition for few minutes, check for oil & coolant leakage and ensure proper functioning of engine. ",
+ "file": null,
+ "display_order": 470
+ },
+ {
+ "step_name": "Step-86",
+ "content_type": "Description",
+ "content": " Refit the engine top encapsulation cover. ",
+ "file": null,
+ "display_order": 471
+ },
+ {
+ "step_name": "Step-86",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010904.jpg",
+ "display_order": 472
+ },
+ {
+ "step_name": "Step-87",
+ "content_type": "Description",
+ "content": " Connect iSmart, Check and clear DTC if any. ",
+ "file": null,
+ "display_order": 473
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 7,
+ "sys_id": "THAR.LX-0005-Engine",
+ "subsys_id": "THAR.LX-0005-Engine-Oil Cooler Assembly",
+ "systems": "Engine",
+ "sub_systems": "Oil Cooler Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A011082.jpg",
+ "myid": 1089,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0005-Oil Cooler Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011082.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30204.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30205.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the engine coolant.For additional information refer to coolant drain Procedure.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the OCFM - degassing tank outlet pipe . For additional information refer to OCFM-Degassing Tank Outlet Pipe - R&R.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Recover the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew air cleaUsing a 12 mm socket spanner, loosen and remove the AC compressor suction and discharge pipes mounting nuts from compressor. Torque : 14.0+1.0 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using T45 Torx spanner, loosen and remove the Oil Cooler Mounting torx Bolts. Remove the oil cooler from the engine. Replace New O ring while refitting. Ensure to clean the Engine oil spillages Install in reverse order of removal. Refill the engine oil and check for the oil leakage. Refill the engine coolant and carry-out deaeration procedure. Check and clean the oil cooler thoroughly for any damage. Remove the engine oil sump. Using a 8 mm Allen socket spanner, loosen and remove the engine oil pump tensioner mounting bolt. Torque : 25\u00b1 3 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the starter motor mounting bolts. Torque : 44\u00b15 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using MST\u2013 0307ABH0001ST lock the flywheel. Using a 14 mm socket spanner, loosen and remove the sprocket nut from the sprocket. Torque : 40\u00b15 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the sprocket from the chain and take out from the vehicle. Install in reverse order of removal Ensure to match the Sprocket slot projection to Oil pump shaft slot. Refill the engine oil and check for oil leakage. Inspect the engine oil pump chain for any physical damage. If found replace Using a screw driver, remove the crankshaft rear end oil seal. Install the rear end oil seal by using MST 0302ABH0001ST - Engine Rear End Oil Seal Installer on the crankshaft. Always use new oil seal while installation. Install in reverse order of removal. Check & Top-up the engine oil. Check for any cracks, damage etc, replace if found any. Detach the wiring routing clip from the water pump. Using a 13 mm socket spanner, Unscrew water pump mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1557.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully remove the water pump from the engine. Remove the O ring from the water pump. Install in reverse order of removal. Always replace the O ring new one once removal of water pump. Refill the engine coolant and carry-out de-aeration procedure. Check for coolant seepage and any oil seepage on the engine and transmission. Replace if any traces found. Inspect the water pump for any damage or leakage or noise. Replace if found. Inspect the impeller for any damage, Replace if found. Using 10 mm socket spanner, loosen the battery negative cable mounting nut disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Remove the transmission with transfer case. For AT Variant : ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove Automatic Transmission with Transfer Case. ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Link",
+ "content": "THAR.LX-0005,1004,1088",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect the AT oil cooler hoses from thermal bye pass valve end. Ensure to close the bypass tubes with dummy caps to avoid dust entry. Using 10 mm socket spanner unscrew thermal bypass valve bracket mounting bolt from engine oil sump. Torque : 6.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the clean side hose. For additional information refer to Clean Side Hose Assembly - R&R section.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the Hose Turbocharger to Intercooler. For additional information refer to Hose Turbocharger To Intercooler - R&R section.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the Intercooler Outlet Hose. For additional information refer to Intercooler Outlet Hose - R&R section.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Remove the Degassing tank. ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Link",
+ "content": "THAR.LX-0005,1004,1088",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Disconnect the boost pressure sensor electrical connector. Using a 13 mm Socket Spanner, Unscrew the Intercooler mounting bolts and remove the intercooler. Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020090.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Press and release the dosing module DEF supply quick coupler. Using a 7 mm socket spanner, loosen the coolant hose mounting clamp and detach the coolant inlet hose from Dosing Module end. Using a hose clip piler, release vacuum hose spring band clamp and detach the vacuum hoses from EGR module and vacuum pump end. Detach the vacuum hose from the routing clip and keep aside. Using a 7 mm socket spanner, loosen the radiator outlet hose clamp and detach radiator outlet hose. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Using a hose clip plier, release the spring band clamp and detach degassing tank Outlet hose OCFM end. Using a 7 mm socket spanner, loosen the radiator inlet hose clamp and detach radiator inlet hose engine end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Using a hose clip plier, release the spring band clamp and detach the Vent hose pipe end. Using a hose clip plier, release the spring band clamp and detach heater outlet hose heater outlet pipe end. Using a hose clip plier, release the spring band clamp and detach the heater inlet hose from cylinder head side. Using a 13 mm socket spanner, loosen and remove alternator positive cable mounting nut. Torque : 15 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen starter motor positive cable mounting nut and detach cable from starter motor end. Torque : 12\u00b12 Nm ",
+ "file": null,
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Using a 8 mm socket spanner, Unscrew starter motor solenoid switch electrical connector. Torque : 2.5\u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Remove AC compressor suction and discharge pipes mounting nuts and detach the pipes. Torque : 14.0+1.0 Nm ",
+ "file": null,
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Description",
+ "content": "Disconnect the fuel pipe quick coupler metering unit end. Press and disconnect the quick coupler carefully to avoid seal damages. Using a hose clip plier, unclip the spring band clamp detach fuel return hose from T joint Using a hose clip plier, unclip the spring band clamp detach the fuel line metering unit to return T- Joint hose. Disconnect ECU electrical connector and & routing clip. Using a 10 mm socket spanner, loosen and remove the engine wiring harness carrier mounting struds and detach partially. Disconnect fuel filter electrical connector. Using 15 mm combination spanner, Remove exhaust front pipe mounting nuts SDPF end. Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "Description",
+ "content": "Using 17 mm open end spanner, Remove the power steering pump to steering gear box oil line mounting power steering pump side. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 85
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "Description",
+ "content": "Remove radiator air guide.",
+ "file": null,
+ "display_order": 86
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "Link",
+ "content": "THAR.LX-0009,1004,1088",
+ "file": null,
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the front top cross member mounting bolts. Torque : 25 \u00b1 4.0 Nm ",
+ "file": null,
+ "display_order": 90
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the front top cross member mounting bolts Torque : 10.50 \u00b1 1.5Nm ",
+ "file": null,
+ "display_order": 93
+ },
+ {
+ "step_name": "Step-40",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew degassing tank mounting brackets mounting bolts LH & RH. Torque : 10 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-40",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050043.jpg",
+ "display_order": 97
+ },
+ {
+ "step_name": "Step-40",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050044.jpg",
+ "display_order": 98
+ },
+ {
+ "step_name": "Step-41",
+ "content_type": "Description",
+ "content": "Provide jack support to the engine with the supporting of floor crane. Improper tie-up of the lifting rope chain will cause damage to the vehicle and the persons involved. Using a 19 mm socket spanner, loosen and remove the engine mounting nut from the vehicle. Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 104
+ },
+ {
+ "step_name": "Step-43",
+ "content_type": "Description",
+ "content": "Jack up the crane and take out the engine from the vehicle Improper tie-up of the lifting rope chain will cause damage to the vehicle and the persons involved. Disconnect AC compressor electrical connector. Disconnect engine oil pressure switch electrical connector. Disconnect alternator electrical connector Disconnect EGR unit electrical connectors. Disconnect throttle body electrical connector. Disconnect fuel injection pump electrical connector. Disconnect temperature T4, T5 sensor electrical connectors. Yellow colour tape provided on T4 Sensor wiring pigtail and engine wiring harness connector for easy identification while refit and ensure to properly connect the T4 Sensor wiring pigtail connector with engine wiring harness. Mismatch connection of wiring connectors may leads to affect the engine performance and occur engine trouble. Green colour tape provided on T5 Sensor wiring pigtail and engine wiring harness connector side for easy identification while refit and ensure to properly connect the T5 Sensor wiring pigtail connector with engine wiring harness. Mismatch connection of wiring connectors may leads to affect the engine performance and occur engine trouble. Disconnect EVGT unit electrical connector and routing clip. Disconnect Dosing Module electrical connector Disconnect common rail electrical connector Disconnect coolant temperature sensor electrical connector. Disconnect glow plug electrical connector. Disconnect boost pressure sensor electrical connector Disconnect fuel injector electrical connector. Disconnect differential pressure sensor electrical connector and remove the routing tag from the engine compartment. Disconnect CAM phase sensor electrical connector. Detach the routing clips and remove the wiring harness from the engine assembly Remove the SDPF mounting bolts and Turbo-SDPF Coupling V clamp and detach SDPF. While Installation, Firmly keep the SDPF Assy on th turbo and Take at most care not to damaging SDPF & near by components. Always use new V band clamp & Gasket once removed V Clamp Gasket to be positioned over EATS by aligning the gasket lug with marking on V Clamp as shown in the image. V Clamp to be fully opened and put over Turbine Housing before position the SDPF. Ensure to fit the clamp in proper position for easy accessing of clamp in subsequent removal. Using 12 mm socket spanner loosen and remove clutch cover assembly mounting bolts and remove it. Torque : 25 \u00b1 5.0 Nm (Step Torque : 5,15,25) ",
+ "file": null,
+ "display_order": 157
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011111.jpg",
+ "display_order": 158
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "Notice",
+ "content": "Install the MST : 0307ABH0001ST \u2013 Flywheel locking tool and lock the flywheel rotation. Insert MST \u2013 0801BUA0001ST \u2013 Master clutch plate assembly, before loosening the clutch cover bolts to prevent clutch plate falling down and getting damage. While Installation, the projected part of clutch disc should come towards transmission side only, fails may result in clutch disc damage. Install in reverse order of removal. Refit the battery -negative cable Check & Top-up the engine oil. Check for coolant seepage and any oil seepage on the engine and transmission.Replace if any traces found. Check the accessory drive belt for any cracks, damage etc, replace if found any. Check SMF face-out and run-out. Check SMF Surface thermal cracks condition. Check the flywheel ring gear for worn-out or damage, Refer SMF Inspection procedures for more details.
",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010638.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Preliminary Activities/Conditions",
+ "content_type": "Description",
+ "content": "Position the Vehicle on level ground and turn engine OFF. Open the bonnet and lock it in open position using bonnet stay rod. Wait for about 10 minutes for oil in circulation to drain down. Pull out the dip stick gauge and wipe it clean with a cloth/paper. Insert the dip stick gauge into the dip stick guide fully till the end. Pull out the dip stick slowly and check for the oil level mark between Maximum and Minimum level - if found below minimum level, top up with recommended oil. Insert the dip stick back and fix properly. Start the engine and check for oil leakage/ seepage at: Oil sump & crankcase joint. Oil sump drain plug. Oil filter joint. Always use MAHINDRA 'MAXIMILE ULTRA'Gen-NXT Technology GENUINE ENGINE Fluid. This is specially developed for your engine\u2019s efficiency. In extreme cases of emergency and non-availability of above oil, we suggest to use 'Maximile Feo' engine oil, take the vehicle to nearest Mahindra Authorised Service centre and replace the oil with 'MAXIMILE ULTRA'. No other brand / grade oil recommended. Remove the air cleaner assembly. Disconnect engine oil pressure switch electrical connector. Using a 24 mm deep socket spanner, loosen and remove engine oil pressure switch from the vehicle. Torque : 17 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010680.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Check engine oil level and Top up engine oil. Refill the engine oil and check for oil leakage. Check oil pressure switch for any cracks, damage etc, replace if found any. The cylinder head gasket failure can be easy to determine. A large stream of white smoke blowing from the exhaust and an overheating engine are sure signs. However, more suitable cylinder head gasket failure signs may be more difficult to diagnose. The engine may experience mysterious coolant loss, or only lose coolant when the engine is driven under heavy load. You may even experience a rough running engine when you first start the vehicle. An initial inspection of cooling system components and a comprehensive test drive may be necessary to confirm the customer's complaint of coolant loss or overheating. Check for the presence of white steam/smoke coming from the exhaust. Steam coming out of the exhaust may smell slightly sweet as the steam gently dissipates into the surrounding air. Another sign that the head gasket may be leaking is the presence of oil in the cooling system. Check for oil residue in the coolant reservoir. It is important to confirm actual engine running temperature and accuracy of the temperature gauge. This can be verified by using a non-contact infrared heat detection gun. It is a non intrusive method used by most repair shops to verify temperature gauge accuracy and actual engine running temperature. Pressurizing the cooling system (to eliminate coolant leaks as being the source of coolant loss), checking for proper operation of the cooling fan, and checking radiator efficiency are important before jumping to the conclusion that the head gasket is defective. Cylinder to Cylinder Leakage Test ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the cylinder compression pressure as already explained. Leakage between cylinders will be result in drop of compression pressure by nearly 50 to 70% in the affected cylinders. Cylinder to Water jacket Leakage Test ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the degassing pressure cap Warm up the engine and allow it to warm up until the engine thermostat opens. If large combustion pressure leak exist, bubbles will be visible in coolant If bubbles are not visible, install a pressure tester and pressurize the cooling circuit. If a cylinder is leaking combustion pressure into the water jackets then the tester\u2019s needle will pulsate with every combustion stroke of the cylinder. This vehicle is equipped with one autotensioner to maintain the accessory drive belt tension for Alternator and Power steering pump drive belt. It is mandatory to maintain belt tension through out the belt life in-order to have maximum efficiency and life. A tensioner is a device that applies a force to create or maintain recommended belt tension. Position the vehicle on ground level/ 2 post lift/ 4 post lift and turn engine OFF. Open the bonnet and lock it in open position using bonnet stay rod Using a 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially detach it (Without detaching the hoses). Torque : 4.5\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the engine fead cover mounting bolts. Torque : 11 \u00b1 1Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the engine fead cover from engine compartment. Using a 24 mm socket spanner, rotate the crank pulley 360? till belt completes one full rotation to check belt condition and confirm following belt appearances if any. Random Cracking Across the Ribs ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010286.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Small yet visible cracks along the length of a rib or ribs. Causes: ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Continuous exposure to high temperatures and the stress of bending around the pulleys leads to cracking. Cracks begin at the rib top and grow to the cord line. As a rule, if cracks appear 1 or 2 cm apart, 80% of the life is gone and the belt should be replaced. Chunk-Out ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010287.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Pieces or chunks of rubber material have come off the belt. When chunk-out has occurred, a belt can fail at any moment. Belt should be replaced immediately Causes: ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Chunk-out can happen when several cracks in one area move parallel to the cord line. Heat, age and stress are the primary contributors. Pilling ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Belt material wears off from the ribs and builds up in the belts grooves. Causes: ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "There are a number of causes, including misalignment, new belt on worn pulleys, lack of tension or a combination of these factors. Gravel Penetration ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W309.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Small pinholes are visible on the backside of the belt. Bumps may be visible and fabric around the holes can be frayed. Causes: ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Granular gravel or pebble gravel is wedged between the belt groove(s) and pulley ridge(s). Damaged Outermost Ribs ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010290.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Sidewalls of the belt may appear glazed or the edge-cord may become frayed and ribs removed. A noticeable noise may result. Causes: ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Pulley misalignment is a common cause of premature belt failure. Misalignment forces the belt to twist while running, causing premature wear. Oil Contamination ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010291.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "The belt surface is flaky, sticky or swollen. Causes: ",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Oil and grease are a rubber compound\u2019s worst enemies, weakening the compound\u2019s bonds and making the belt soft and spongy. Eventually, such a belt will slip, create heat and fail. Abrasion ",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W310.jpg",
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "The backside of the belt appears very shiny or glazed. In advance stages, the fabric or even the cord becomes exposed and gets damaged. Causes: ",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "When in motion, the belt makes contact with the foreign objects in its path such as a flange or bolt. This may be caused by improper belt tension or by belt flutter (vibrations) on longer span lengths between two pulleys. Rib Separation ",
+ "file": null,
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010293.jpg",
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "The belt rib shears off or begins to separate from the belt base. Causes: ",
+ "file": null,
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "The belt is not correctly positioned. One of the belt ribs is placed outside the pulley groove, causing a belt rib to run without a supporting or aligning pulley groove. Uneven Rib Wear ",
+ "file": null,
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010294.jpg",
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Wear that is more severe on one rib than on the others or one rib that exhibits a different wear pattern than the others. A thumping or grinding noise may also be heard. Causes: ",
+ "file": null,
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "A foreign object \u2014 such as a pebble \u2014 in the pulley will cause uneven wear and cut into the belt and break the tensile cords. Broken Belt ",
+ "file": null,
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010295.jpg",
+ "display_order": 72
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "A large foreign object between the belt and pulley can cut into the belt and break the tensile cords. Tensile break may occur but go unnoticed when the belt is forced or pried on during installation. Other possible causes may be severe shock loads or a blocked pulley and/or accessory. Belt Noise ",
+ "file": null,
+ "display_order": 77
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010296.jpg",
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Run the engine and inspect for Chirping, squealing. tapping, ticking or grinding noise coming from the belt. It is recommended to remove & check the drive belts thoroughly if any abnormality noticed Check belt tension as per procedure mentioned below: ",
+ "file": null,
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011102.jpg",
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Turn ON belt tension gauge Select reading mode in hertz (Hz) and hold the probe approximately 5mm distance in front of the belt. Do not touch the probe to the belt, this can damage the probe. Belt tension needs to be checked at the green points shown in illustration. Between Crank pulley & water pump pulley Between water pump pulley & AC Compressor Pulley Tap on the belt near the probe Note the reading, if the reading is within 195 \u2013 228 Hz, belt tension is OK. If the reading is not within the above limit, check & replace the belt if required. Position the vehicle on ground level/ 2 post lift/ 4 post lift and turn engine OFF. Open the bonnet and lock it in open position using bonnet stay rod. Position the vehicle on ground level/ 2 post lift/ 4 post lift and turn engine OFF. Open the bonnet and lock it in open position using bonnet stay rod. Using 10 mm socket spanner, socket spanner, loosen and remove the degassing tank mounting bolts and partially detach it (Without detaching the hoses). Torque : 4.5\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the engine fead cover mounting bolts. Torque : 11 \u00b1 1Nm ",
+ "file": null,
+ "display_order": 99
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the engine fead cover from engine compartment. Using a 24 mm socket spanner, rotate the crank pulley 360? till belt completes one full rotation to check belt condition and confirm following belt appearances if any Random Cracking Across the Ribs ",
+ "file": null,
+ "display_order": 104
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010286.jpg",
+ "display_order": 105
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 106
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Small yet visible cracks along the length of a rib or ribs. Causes: ",
+ "file": null,
+ "display_order": 108
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Continuous exposure to high temperatures and the stress of bending around the pulleys leads to cracking. Cracks begin at the rib top and grow to the cord line. As a rule, if cracks appear 1 or 2 cm apart, 80% of the life is gone and the belt should be replaced. Chunk-Out ",
+ "file": null,
+ "display_order": 110
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010287.jpg",
+ "display_order": 111
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 112
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Pieces or chunks of rubber material have come off the belt. When chunk-out has occurred, a belt can fail at any moment. Belt should be replaced immediately Causes: ",
+ "file": null,
+ "display_order": 114
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Chunk-out can happen when several cracks in one area move parallel to the cord line. Heat, age and stress are the primary contributors. Pilling ",
+ "file": null,
+ "display_order": 116
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010288.jpg",
+ "display_order": 117
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 118
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Belt material wears off from the ribs and builds up in the belts grooves. Causes: ",
+ "file": null,
+ "display_order": 120
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "There are a number of causes, including misalignment, new belt on worn pulleys, lack of tension or a combination of these factors. Gravel Penetration ",
+ "file": null,
+ "display_order": 122
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W309.jpg",
+ "display_order": 123
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 124
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Small pinholes are visible on the backside of the belt. Bumps may be visible and fabric around the holes can be frayed. Causes: ",
+ "file": null,
+ "display_order": 126
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Granular gravel or pebble gravel is wedged between the belt groove(s) and pulley ridge(s). Damaged Outermost Ribs ",
+ "file": null,
+ "display_order": 128
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010290.jpg",
+ "display_order": 129
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 130
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Sidewalls of the belt may appear glazed or the edge-cord may become frayed and ribs removed. A noticeable noise may result. Causes: ",
+ "file": null,
+ "display_order": 132
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Pulley misalignment is a common cause of premature belt failure. Misalignment forces the belt to twist while running, causing premature wear. Oil Contamination ",
+ "file": null,
+ "display_order": 134
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010291.jpg",
+ "display_order": 135
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 136
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "The belt surface is flaky, sticky or swollen. Causes: ",
+ "file": null,
+ "display_order": 138
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Oil and grease are a rubber compound\u2019s worst enemies, weakening the compound\u2019s bonds and making the belt soft and spongy. Eventually, such a belt will slip, create heat and fail. Abrasion ",
+ "file": null,
+ "display_order": 140
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W310.jpg",
+ "display_order": 141
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 142
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "The backside of the belt appears very shiny or glazed. In advance stages, the fabric or even the cord becomes exposed and gets damaged. Causes: ",
+ "file": null,
+ "display_order": 144
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "When in motion, the belt makes contact with the foreign objects in its path such as a flange or bolt. This may be caused by improper belt tension or by belt flutter (vibrations) on longer span lengths between two pulleys. Rib Separation ",
+ "file": null,
+ "display_order": 146
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010293.jpg",
+ "display_order": 147
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 148
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "The belt rib shears off or begins to separate from the belt base. Causes: ",
+ "file": null,
+ "display_order": 150
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "The belt is not correctly positioned. One of the belt ribs is placed outside the pulley groove, causing a belt rib to run without a supporting or aligning pulley groove. Uneven Rib Wear ",
+ "file": null,
+ "display_order": 152
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010294.jpg",
+ "display_order": 153
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 154
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Wear that is more severe on one rib than on the others or one rib that exhibits a different wear pattern than the others. A thumping or grinding noise may also be heard. Causes: ",
+ "file": null,
+ "display_order": 156
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "A foreign object \u2014 such as a pebble \u2014 in the pulley will cause uneven wear and cut into the belt and break the tensile cords. Broken Belt ",
+ "file": null,
+ "display_order": 158
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010295.jpg",
+ "display_order": 159
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 160
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 161
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 162
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "A large foreign object between the belt and pulley can cut into the belt and break the tensile cords. Tensile break may occur but go unnoticed when the belt is forced or pried on during installation. Other possible causes may be severe shock loads or a blocked pulley and/or accessory. Belt Noise ",
+ "file": null,
+ "display_order": 164
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010296.jpg",
+ "display_order": 165
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Heading",
+ "content": "Inspection: ",
+ "file": null,
+ "display_order": 166
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Run the engine and inspect for Chirping, squealing. tapping, ticking or grinding noise coming from the belt. It is recommended to remove & check the drive belts thoroughly if any abnormality noticed Inspect the auto-tensioner carefully for symptoms such as cracked arms, excessive vibration during idle speeds, looseness, noise (clatter or rattling) and sticking or seized operation. These all can be signs that roller needs replacement. Rust bleed and cracks ",
+ "file": null,
+ "display_order": 171
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S2B010321.jpg",
+ "display_order": 172
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 173
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S2B010322.jpg",
+ "display_order": 174
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Rust bleeding between arm and base or dripping from the tensioner. Also, check the tensioner for cracks or damage to arm, housing and bracket. Causes: ",
+ "file": null,
+ "display_order": 176
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Rust bleeding or dripping is a sign of internal component wear. Most common crack damage occurs at tensioner \u201cStops\u201d and mounting bolts. Solution: ",
+ "file": null,
+ "display_order": 178
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Replace the auto-tensioner. Pulley bearing wear ",
+ "file": null,
+ "display_order": 180
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S2B010323.jpg",
+ "display_order": 181
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 182
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "If any abnormality noticed, remove the belt and manually rotate the pulley. If you notice, resistance or roughness, the problem is likely to be pulley bearing wear. Causes: ",
+ "file": null,
+ "display_order": 184
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Defective bearing and/or pulley. Solution: ",
+ "file": null,
+ "display_order": 186
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Replace the complete tensioner. Do not attempt to replace a worn pulley in a used tensioner assembly but always replace the entire tensioner assembly, as part failure will inevitably follow quickly. TENSIONER ASSEMBLY MISALIGNMENT ",
+ "file": null,
+ "display_order": 188
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S2B010324.jpg",
+ "display_order": 189
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 190
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S2B010325.jpg",
+ "display_order": 191
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Abnormal belt tracking on tensioner pulley.. Causes: ",
+ "file": null,
+ "display_order": 193
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Bent or misaligned mounting bracket,improper tensioner installation or corrosion/ contamination between tensioner base and mounting surface. A small amount of contamination results in a large amount of at tensioner pulley Tensioner Noise ",
+ "file": null,
+ "display_order": 195
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 196
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Squeaks and rattles coming from the tensioner. Causes: ",
+ "file": null,
+ "display_order": 198
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Failure of bearings or pivot are will cause excessive noise. Solution: ",
+ "file": null,
+ "display_order": 200
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Replace the tensioner assembly The crankshaft speed sensor is an inductive type sensor. It measures the speed of the trigger wheel mounted on the crankshaft. During engine cranking and running, the EMS ECU receives the output signal from crankshaft speed sensor. Remove the wheel (front LH). Disconnect Engine Speed Sensor electrical connector. By using 8 mm socket spanner, Universal Joint and proper extension rod, Unscrew Engine Speed Sensor mounting bolt and remove it. Torque : 11\u00b11.0 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1560.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "Take sufficient care not to damage the sensor while removing. Ensure correct torque value is given to sensor mounting bolt. Else chances of sensor malfunction is high. Install in reverse order of removal. Inspect the sensor and connector for any physical damage. Replace if found. EMS (Engine Management System) ECU is an electronic control unit which is used to ensure optimal engine performance. It does this by analyzing values or signals from various sensors and other ECU\u2019s and adjusting the actuators accordingly. EMS ECU is mounted on engine compartment LH apron. ECU electrical connector should be disconnected before carrying out any welding activities in the vehicle. Using 10 mm socket spanner, Loosen battery negative terminal mounting nut and disconnect the terminal. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Open the lock and gently pull-out and disconnect EMS ECU electrical connector. Using 10 mm socket spanner remove MS ECU mounting bolts. Torque : 6\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011053.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. For New EMS ECU replacement carry out \u201cComponent Replacement Procedures \u2014 EMS ECU replacement\u201d by using i-SMART. For additional information refer Diagnosis Manual. ECU electrical connector should be disconnected before carrying out any welding activities in the vehicle. Check for any external damage, if found replace. Remove the cylinder head assembly. Place the cylinder head on clean flat work table. Using an appropriate tool, compress and hold the valve spring and then remove the valve spring lock studs. Remove the upper retainer and valve spring. Incase of reusing the same valves spring, make necessary marking according to the respective cylinder. Remove the valve stem seal. The valve should be identified, so that in case the valves are being reused they can be used. Failure to do so may increase the probability of compression leak through the valve after the engine is rebuilt. Check the valve spring lock for any internal and external damage. Check the valve spring height. Check the valve guide bore diameter. Check the valve guide for any damages. Check the valve for any damages. Using a micrometer measures the diameter of the valve stems. If the measurements are not to specification, install a new valve. Check the valves for bend - especially if the engine has suffered water entry into combustion chamber. Clean the cylinder head assembly thoroughly, if any cracks or damages are found replace the cylinder head. Check the Cylinder Head for external damages. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. Check the valve seat area for leakages. Check the Cylinder Head bottom face for distortion. Check the cylinder head flatness, if any misalignment or bend found replace the cylinder head assembly. Check the cylinder head for warpage. Check the length of the Cylinder Head bolts. Using a micrometer measure the diameter at 90\u00b0 intervals to determine if the journals are out-of-round. Measure at two different points on the journal to determine if there is any tapering. Check the camshaft for any damage and replace it if necessary. Inspect the rocker arm for wear or damage. Replace as necessary. Do not dis-assemble the HLLA, as it is not a serviceable component. Incase of a failure of a HLLA, replace the complete assembly. Camshaft Surface Inspection ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1563.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Inspect the camshaft lobes for pitting or damage in the active area. Minor pitting is acceptable outside the active area. Using suitable tool refit new valve stem seal Never use old valve stem seal, always use a new one. Insert the respective valve spring and top retainer. Using a suitable tool, compress the valve spring carefully insert the locking pins and lock it properly. Install the cylinder head assembly. Clean the cylinder head assembly thoroughly, if any cracks or damages are found replace the cylinder head. Replace the cylinder head gasket with a new one. Failure to follow this will lead to compression failure. The cylinder head mounting bolts cannot be reused. Always use new bolts during installation. Start the engine. Run at idle for 5 minutes. Observe for leaks. Drive the vehicle at 50% of the maximum speed in each gear for about 10 to 30 kms each (Approx.) Hand over the vehicle to customer to drive with speed limitation for 2000 kms. Do not run the engine without load for hours for bedding in. This process only harms the engine Running the engine without load cause ring fluttering and damage to rings as well as liners. Running the engine at idle for prolonged time has serious consequences on major engine components. Engine Oil \u2013 MAHINDRA 'MAXIMILE ULTRA' Gen-NXT Technology Genuine Engine Fluid.Capacity \u2013 6.0 Liters.Engine should be hot while draining the oil. Position the vehicle on ground level/ 2 post lift/ 4 post lift and turn engine OFF. Open the bonnet and lock it in open position using bonnet stay rod. Remove the engine top encapsulation cover. Remove the engine oil filler cap. Using 22 mm ring/ socket spanner, Unscrew engine oil drain plug located under the oil sump. Torque value: 33\u00b12 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Allow the entire oil to get drained. Place a tray under the drain plug to collect the oil. Refit the drain plug with a new copper washer and tighten the drain plug to specific torque. Torque : 33\u00b1 2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Always replace the copper washer with a new one. Fill fresh recommended oil to specified quantity. Refit the engine oil filler cap. Refit the engine encapsulation cover. Wait for about 10 minutes for oil in circulation to drain down Pull out the dip stick gauge and wipe it clean with a cloth/paper. Insert the dip stick gauge into the dip stick guide fully till the end. Pull out the dip stick slowly and check for the oil level mark between Maximum and Minimum level - if found below minimum level, top up with recommended oil. Insert the dip stick back and fix properly. Start the engine and check for oil leakage/ seepage at: Oil sump & crankcase joint. Oil sump drain plug. Oil filter joint. Always use MAHINDRA 'MAXIMILE ULTRA'Gen-NXT Technology GENUINE ENGINE Fluid. This is specially developed for your engine\u2019s efficiency. In extreme cases of emergency and non-availability of above oil, we suggest to use 'Maximile Feo' engine oil, take the vehicle to nearest Mahindra Authorised Service centre and replace the oil with 'MAXIMILE ULTRA'. No other brand / grade oil recommended. The engine oil becomes hot and has to be cooled to increase its life and performance. Heat is transferred from oil to coolant in the oil filter module. The oil cooler and filtration (OCFM) module consists of oil cooler, oil filter, thermostat and coolant pipes. For additional information refer to the turbocharger with exhaust manifold - R&R.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the AC/water pump belt.For additional information refer to AC/water pump belt - R&R.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the OCFM to turbo oil inlet banjo bolt. Torque : 17.5+2.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the EGR cooler inlet pipe routing bracket mounting bolt from the OCFM . Torque :11\u00b11 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew EGR cooler outlet pipe mounting bolt at OCFM end. Torque :11\u00b11 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the turbo oil return pipe routing bracket bolt. Torque :25\u00b13 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 7 mm socket spanner, loosen and remove the radiator outlet hose clamp OCFM pipe end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the degassing to OCFM pipe mounting bolt. Torque :11\u00b11 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the wiring harness routing bracket bolts from the water pump and OCFM. Torque :11\u00b11 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1570.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque : 10\u00b11 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the OCFM mounting bolts from engine. Torque :25\u00b13 Nm ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Caution",
+ "content": "Replace New rubber gasket while refitting Remove OCFM from the vehicle Using a 10 mm socket spanner, Unscrew water pump pulley mounting bolts and remove pulley from water pump. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Notice",
+ "content": "Using a suitable tool hold the pulley then remove the water pump pulley. Using a 13 mm socket spanner, Unscrew water pump mounting bolts and remove the water pump from the OCFM. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010267.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Refill the engine oil and check for the oil leakage. Refill the engine coolant and carry-out de-aeration procedure. Check the OCFM for any external cracks, replace if found any. This vehicle is equipped with one autotensioner to maintain the accessory drive belt tension for Alternator and Power steering pump drive belt. It is mandatory to maintain belt tension through out the belt life in-order to have maximum efficiency and life. A tensioner is a device that applies a force to create or maintain recommended belt tension. Position the vehicle on ground level/ 2 post lift/ 4 post lift and turn engine OFF. Open the bonnet and lock it in open position using bonnet stay rod Using 10 mm socket spanner, Unscrew degassing tank mounting bolts and partially detach it (Without detaching the hoses). Torque : 4.5\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen and remove the engine fead cover mounting bolts. Torque : 11 \u00b1 1Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the engine fead cover from engine compartment Place the MST 0306GAM0006ST - Stretch Fit Belt Removal Tool on damper pulley side as shown in the image. Using a 24 mm socket spanner, rotate the damper pulley to clockwise direction then remove the water pump drive belt and MST separately Place the MST 0306GBH0001ST - Stretch Fit Belt Installation Tool on damper pulley as shown in the image. Using a 24 mm socket spanner, rotate the damper pulley in anticlockwise direction. By rotating pulley, belt started getting into pulley groove and once belt installed properly on pulley, then remove the MSTand spanner Ensure proper engagement of belt teeth in all the pulley grooves after Installation. Check the Belt tension. Refer Belt Tension Checking Procedure session. Refit the engine fead cover on engine compartment, torque tighten the bolts to specified value Torque : 11\u00b1 1Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011070.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit the degassing tank mounting bolts on the bracket and Torque tighten the bolts to specified value. Torque : 4.5\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Refit the new auto-tensioner assembly . Torque tighten the mounting bolt to specified value. Torque : 45 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010933.jpg",
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 14 mm ring spanner, swing the auto-tensioner in counter clock-wise direction and install the belt. Refit AC Compressor /Water Pump Stretch Fit Belt. For additional information refer to Accessory Drive Belt (AC Compressor /Water Pump) \u2013 Replace section. Check belt tension as per procedure mentioned below: ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011102.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Run the engine for few minutes. Turn ON belt tension gauge. Select reading mode in hertz (Hz) and hold the probe approximately 5mm distance in front of the belt. Do not touch the probe to the belt, this can damage the probe Belt tension needs to be checked at the green points shown in illustration. Between Crank pulley & water pump pulley Between water pump pulley & AC Compressor Pulley Tap on the belt near the probe Note the reading, if the reading is within 195 \u2013 228 Hz, belt tension is OK. Position the vehicle on ground level/ 2 post lift/ 4 post lift and turn engine OFF. Open the bonnet and lock it in open position using bonnet stay rod. Using 14 mm ring spanner, turn the hexagon knob in the belt tensioner Anti clockwise direction to release the tension. Using 14 mm socket spanner, remove the alternator/power steering auto tensioner mounting bolt and remove the tensioner. The cylinder compression test is performed to determine the compression pressure of individual cylinders. The test is performed in two stages. Dry Test. Wet Test The results of the cylinder compression test can be utilized to diagnose several engine malfunctions. Before carrying out the compression test ensures that the battery is in good working condition. Otherwise the indicated pressures may not be valid for diagnostic purpose Check engine oil level and add oil if necessary. Drive the vehicle until engine reaches normal operating temperature. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Remove the respective injector whose compression pressure need to check. Fit the dummy injector and connect it with the compression gauge. Disconnect the cam phase sensor and crank shaft sensor (for safety) electrical connector. Crank the engine for 10\u201315 seconds. Note down the max value the gauge indicates Repeat the procedure for all the other cylinders. Tabulate the results Refer to the specification for the value. Spray 10 to 20 ml of engine oil inside the bore through the injector port with the help of an oil can. Fit the dummy injector and connect it with the compression gauge. Disconnect the cam phase sensor and crank shaft sensor (for safety) electrical connector. Crank the engine. Note the maximum value the gauge indicates. Repeat the procedure for all the other cylinders. Tabulate the results. Refer to the specification for the value. Compare both the dry and the wet values with the specifications. The wet test values should always be higher than the dry test values. If the reading does not change during wet test this can hint towards compression leakage from cylinder head or through the valves. If the wet and dry test values vary considerably between cylinders then the piston rings can be suspected. Remove the engine top encapsulation cover. Using nose plier, release engine vent hose clip at T Joint and disconnect the hose. Using 10 mm socket spanner, Unscrew degassing tank mounting bolts and partially detach it (Without detaching the hoses). Using 10 mm socket spanner, loosen and remove the engine fead cover mounting bolts. Remove the engine fead cover from engine compartment. Place the MST 0306GAM0006ST -Stretch Fit Belt Removal Tool on damper pulley side as shown in the image. Using 24 mm socket spanner, rotate the damper pulley to clockwise direction then remove the water pump drive belt and MST separately. Using 14 mm ring spanner, turn the hexagon knob in the belt tensioner Anticlockwise direction to release the tension. Remove the alternator drive belt. Using 10 mm socket spanner, Unscrew engine wiring harness carrier mounting stud from Cam cover and detach it partially. Disconnect the Injectors electrical connectors from the injectors. Using 17 mm open end spanner,Unscrew High pressure pipe mounting flare nut from common rail end. Using 19 mm open end spanner,unscrew High pressure pipe flare nut from injection pump end. Using 17 mm open end spanner loosen the high pressure pipe flare nuts at common rail side and injector side. While loosening the high pressure pipes at Injector end, hold the injector pipe connector by 13 mm Open end spanner. Remove the high pressure fuel pipes from the engine. Remove injector leak - off pipe lock clip and detach leak off pipes from the injector end. Using 8 mm Allen socket spanner, Unscrew the injector clamp mounting bolts. Remove all 4 Injectors from cylinder head. Injector Bore must be covered with lint free cloth/Masking tape to avoid foreign objects entering injector bore/cylinder. Plug the fuel inlet and wiring harness connector slot as soon as injector is removed Store the injector in a neat tray. Never drop the injectors. Never clean the injector using pressurized water. Disconnect fuel inlet tube quick couplers from fuel injection pump & FCU. All are quick fix connectors, press gently and remove it carefully to avoid seal damages. Using nose plier release fuel return hose spring band clamp and detach hoses from fuel injection pump & FCU. Press the lock and disconnect fuel control unit electrical connector. Using 10 mm socket spanner, Unscrew fuel return line 'T' bracket mounting bolts. Using 12 mm socket spanner, Unscrew Cam box mounting bolts and remove the bolts. Rotate the Cam Box Assembly as direction shown in the image to access fuel high pressure pump mounting bolts. Using T30 socket spanner unscrew fuel high pressure pump mounting bolts and detach pump. Remove Cam box assembly along with FCU from engine. While taking out Cam box, ensure to move the tappet in upward direction by hand. Disconnect T4 temperature sensor electrical connector. Disconnect T5 temperature sensor electrical connector. Detach the vacuum hose routing clips from heat shield. Using 14 mm socket spanner, loosen and remove the heat shield mounting studs from Cam cover. Using 10 mm socket spanner, loosen and remove the heat shield mounting bolt from Cam cover and rear engine hook. Using 12 mm socket spanner, loosen and remove the heat shield mounting bolt from SDPF side. Disconnect the dosing module electrical connector. Disconnect the dosing module electrical connector. Disconnect the Cam phase sensor electrical connector. Disconnect the common rail electrical connector and wiring harnesses routing clip. Using hose clip plier, Unclip oil separator hose spring band clamp and detach hose. Using 10 mm ring spanner, loosen and remove stud mountings from Cam cover. Using 10 mm socket spanner, loosen and remove Cam cover mounting bolts & studs. Using 8 mm socket spanner, loosen and remove the Cam cover mounting bolts. . Detach Cam cover from the engine completely. Using nose plier, Release the spring band clamp and disconnect vacuum hose from vacuum pump side. Using 12 mm socket spanner, Unscrew vacuum pump mounting bolts and remove vacuum pump from engine. Using 14 mm socket spanner, Loosen and remove auto tensioner mounting bolt and remove tensioner Using 14 mm socket spanner, Loosen and remove the drive belt idler mounting bolt and remove idler from the engine. Using 14 mm socket spanner, loosen and remove the starter motor mounting bolts. Lock the flywheel by using MST0307ABH0001ST - Fly wheel Locking tool. Using 24 mm socket spanner, Unscrew damper pulley mounting bolt and remove damper pulley. Using 12 mm socket spanner, Loosen and remove the engine front cover mounting bolts from the Oil sump. Using 12 mm socket spanner, Loosen and remove the AC compressor top mounting bolt. AC compressor top mounting bolt must be removed, failing to remove the bolt will leads to crack the front cover Using 14 mm socket spanner, loosen and remove engine front cover mounting bolts from cylinder head. Using 12 mm socket spanner, loosen and remove engine front cover mounting bolts from crank case. Using 12 mm socket spanner, loosen and remove engine front cover mounting bolts. Detach engine front cover from engine. Ensure to cover the engine oil sump open space properly by lint free cloth after removal of Front Cover. Make sure for all the subassembly and components going into engine assembly should be clean and away from foreign material. Remove the flywheel locking tool MST\u2013 0307ABH0001ST. Position engine front lifting hook and hand tighten the mounting bolts. Using 18 mm socket spanner, unscrew engine mounting bracket nuts (Both RH & LH). Provide engine support beam to support engine. Lift the engine with care, don\u2019t over lift since chances of damaging parts are high. Ensure none of the components are effected or damaged during lifting. Using 14 mm combination spanner and socket spanner , unscrew LH engine mounting bracket mounting bolts and remove the LH bracket. Using 6 mm square socket spanner, loosen and remove TDC locking dummy from crankcase. Refit damper pulley and install damper pulley mounting bolt on crankshaft. Lock the crankshaft by Inserting the TDC locking pin (MST\u2013 0312ABH0001ST). Ensure the crankshaft locking tool is seated properly into the slot on crankshaft and ensure the TDC locking pin insert upto Red mark in the Check and ensure the 1st cylinder piston position to TDC. Ensure that correct TDC locking tool is used. TDC locking hole is near crankcase left side below intake manifold (Near Engine LH Mounting bracket). If not able to position the MST in proper position into crankshaft, Slightly rotate damper pulley and align the crankshaft to insert MST:- 0312ABH0001ST Crankshaft Locking Tool - TDC Pin on crankshaft. Install the (MST \u2013 0310ABH0001ST Cam Shaft locking tool) on the front side of cylinder head as the location shown below using appropriate bolts. The Cam shaft 2D Matrix must be on the top side for both Intake and Exhaust camshaft. Crank Sprocket Key must be at 12\u2019O Clock Position. Ensure that locking tool is seated properly on Cam shaft. Remove the damper pulley. Using T55 socket spanner, loosen exhaust Cam sprocket mounting bolt. The Exhaust Camshaft Sprocket mounting bolt must be loosened first and then the Intake camshaft Sprocket Mounting bolt to be loosened. Using 15 mm socket spanner, loosen intake Cam sprocket mounting bolt. Using 10 mm socket spanner, loosen and remove the chain hydraulic tensioner mounting bolts. Using 8 mm Allen key, loosen and remove the chain guide bolt and detach guide. Using 10 mm socket spanner, loosen and remove the chain fixed guider bolts and detach guide. Remove and take out the timing chain with intake Cam sprocket from engine. Using 5 mm Allen key/ Socket, loosen and remove the secondary chain tensioner mounting Allen bolts. Remove the exhaust Cam sprocket mounting bolt. Compress the tensioner and remove the camshaft intake and exhaust drive chain and sprockets along with tensioner. Unscrew Cam Shaft Locking (MST\u2013 0307ABH0001ST) mounting bolts and remove MST. Using 10 mm socket spanner, Loosen and Remove the Intake Cam shaft rear bearing cap mounting bolts. Remove the rear bearing cap from the cylinder head. Using 8 mm socket spanner, Loosen and Remove Cam shaft front bearing cap mounting bolts. Remove the front bearing cap from the cylinder head. Using 8 mm socket spanner, Loosen and Remove the intake Cam shaft bearing cap mounting bolts. Remove the intake Cam shaft bearing caps. Remove the Intake Cam shaft from the cylinder head. Apply a thin layer of engine oil to the mounting parts of the Intake Cam shaft. Install the New Intake Cam shaft. Line up the timing marks of the intake/ exhaust Cam shaft (on the front side) when installing as shown. The Cam shaft 2D Matrix must be on the top side for both Intake and Exhaust camshaft. Crank Sprocket Key must be at 12\u2019O Clock Position. Check and confirm the 1st cylinder piston position at TDC before installation. Apply a thin layer of engine oil on the Intake Cam shaft. Install the Front, Rear & Intake Cam shaft bearing caps. Sealant (Loctite 574 - 2mm thickness) to be applied on rear bearing cap as er below pattern. Extra sealant to be wiped off after assembly of rear bearing cap. Install the bearing caps mounting bolts and torque tighten the bolts to specified value as per tightening sequence. Tightening Sequence ",
+ "file": null,
+ "display_order": 220
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010048.jpg",
+ "display_order": 221
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque for A & B : 11\u00b11 Nm <n>Torque for C : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 222
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20758.jpg",
+ "display_order": 223
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install the (MST \u2013 0310ABH0001ST Cam Shaft locking tool) on the front side of cylinder head as the location shown below using appropriate bolts. The Cam shaft 2D Matrix must be on he top side for both Intake and Exhaust camshaft. Crank Sprocket Key must be at 12\u2019O Clock Position. Ensure that locking tool is seated properly on Cam shaft. Assemble the exhaust compress the tensioner and insert the suitable locking pins/allen keys on tensioner. Install the camshaft intake and exhaust drive chain and sprockets along with tensioner on cam shafts. Install the secondary tensioner mounting bolts and Torque tighten bolts to specified value. Torque: 11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 237
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Release the tensioner locking pins. Hand tighten the New exhaust Cam sprocket mounting bolt. nsure to replace New Exhaust Cam shaft bolt while Installation. Before Installation of Primary timing chain, Clean the inner and outer surface of the timing chain and timing cover. Position the primary timing chain along with sprocket on Intake Cam shaft. Align primary chain into primary crank sprocket and engage New Intake camshaft bolt. Ensure to replace New Intake Cam shaft bolt while Installation. Align the timing chain fixed guide on timing chain and install the mounting bolts. torque tighten the bolts to specified value. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 251
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011160.jpg",
+ "display_order": 252
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Align the timing chain guide on timing chain and install the mounting bolt. torque tighten the bolt to specified value. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 255
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Compress the chain hydraulic tensioner and lock the tensioner by using locking pin. Refit the New chain hydraulic tensioner by mounting bolts, torque tighten the bolts to specified value. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 260
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Caution",
+ "content": "Ensure to replace New primary chain hydraulic tensioner while Installation. Follow below Sequence and procedure for Torque tightened the Intake & Exhaust Cam shaft sprocket bolts. Place the MST203 - Companion Flange Holding Tool into the Primary Chain Intake Cam shaft sprocket as shown and hold the tool in opposite direction of torqueing. Torque tightened the Intake Cam shaft sprocket bolt to 50\u00b12 Nm + 90\u00b0\u00b15\u00b0 . Holding the MST Tool and Torque tightened the Exhaust Cam shaft sprocket bolt after intake sprocket to 50\u00b12 Nm + 80\u00b0\u00b15\u00b0 . MST : 0301BM011ST (cam chain tensioning tool) can be used instead of MST203 - Companion Flange Holding Tool. Intake and exhaust Cam Shaft sprocket mounting bolts should be torque tightened only after installing the chain guides and hydraulic tensioner. Release the chain hydraulic tensioner locking pin. Remove the MST Cam Shaft locking tool. Remove the MST Cam Shaft locking tool. Refit damper pulley and install damper pulley mounting bolt on crankshaft. Rotate the crankshaft (360?) 4 times towards clockwise direction and check the ree rotation. To reconfirming proper cam and crank timing, Once again Insert TDC locking pin and ensure cam shaft locking tool properly seating on the cam shafts position. Remove the cam shaft locking tool & TDC locking pin after confirmation. Apply Loctite 574 , Install the TDC locking dummy on crankcase and torque tighten. Torque : 20\u00b12 Nm ",
+ "file": null,
+ "display_order": 283
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Remove the damper pulley. Position the engine LH mounting bracket and install the mounting bolts. torque tighten the bolts to specified value. Torque :45\u00b15 Nm ",
+ "file": null,
+ "display_order": 288
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Detach the engine support beam from engine and remove support beam from vehicle. Install the engine mounting bracket nuts (Both RH & LH) on engine beds and torque tighten the nuts to specified value. Torque : 110\u00b1 10 Nm. ",
+ "file": null,
+ "display_order": 293
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1619.jpg",
+ "display_order": 294
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Description",
+ "content": "Remove the engine front lifting hook. Refit the flywheel locking tool MST\u20130307ABH0001ST. Install MST 0311DBH0002ST \u2013 Engine front cover guide (1 Set) pins on cylinder block. Clean sealant on front cover Clean sealant & oil between crankcase and front cover mounting surface and ensure sealant not to get inside the oil sump. The thread hole in the front cover at Oil Sump joint to be checked for any sealant present inside. The Sealant must be cleaned completely . Apply the Loctite 5900 ( 2mm thickness) on the Front cover & Oil sump (Front side) as per below recommended pattern. Use only the recommended sealant,failure to follow the instruction may lead to leakages. Install the front cover to the cylinder block, guiding by guide pins. Remove the front cover installation guide pins. Refit the engine front cover mounting bolts on cylinder block & cylinder head. Visually inspect the oil seal for proper seating. Torque tighten the cover mounting bolts to specified value as per torque tighten sequence. Refit the engine front cover mounting bolts on Oil sump and torque tighten to specified value. Torque : 22.5 \u00b12.5 Nm ",
+ "file": null,
+ "display_order": 321
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "Description",
+ "content": "Refit the AC compressor top mounting bolt and torque tighten to specified value. Torque : 23 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 324
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "Description",
+ "content": "Position the damper pulley, Install the mounting bolt and torque tighten to specified value. Torque : 23 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 327
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011161.jpg",
+ "display_order": 328
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "Caution",
+ "content": "Ensure to replace New Damper pulley bolt & spacer while Installation. Remove the flywheel locking tool. Position the starter motor and install the mounting bolts. torque tighten the bolts to specified value. Torque : 44 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 334
+ },
+ {
+ "step_name": "Step-42",
+ "content_type": "Description",
+ "content": "Refit the drive belt idler and install the mounting bolt. torque tighten the bolt to specified value. Torque : 45 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 337
+ },
+ {
+ "step_name": "Step-43",
+ "content_type": "Description",
+ "content": "Refit auto tensioner and install the mounting bolt. torque tighten the bolt to specified value. Torque : 45 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 340
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "Description",
+ "content": "Position the vacuum pump, refit the pump mounting bolts and torque tighten to specified value. Replace the Vacuum Pump \u2018O\u2019 ring with a new one when installing. The slot parts of the vacuum pump are parallel to each other as shown in the figure if the engine chain timing marks are lined up. Fit the slots when assembling. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 345
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1629.jpg",
+ "display_order": 346
+ },
+ {
+ "step_name": "Step-45",
+ "content_type": "Description",
+ "content": "Refit the vacuum hose on pump side. Follow the below Caution points before Install the Cam Cover. Extra sealant to be wiped off after assembly of rear bearing cap. The Sealant at Cam Bearing Area on Cylinder Head and Cover must be cleaned completely The Oil on the Cylinder Head Cam Cover Joint Face Area must be cleaned before sealant application and cam cover assembly. Apply Sealant (Loctite 5900 - 2mm thickness) on cylinder head as per below pattern before assembling cam cover. Replace the Cam Cover gaskets with a new one when installing \u2022 Ensure the New Cam Cover Rubber Gasket is Properly placed in the Cam Cover Groove. The Gasket Profile and cover groove profile must match especially at Intake Camshaft Rear Main Bearing Cap Location. Position the Cam cover with New Gaskets on engine, refit the studs and mounting bolts on the Cam cover. Torque tighten the mounting bolts & studs to specified value as per sequence order. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 362
+ },
+ {
+ "step_name": "Step-48",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20824.jpg",
+ "display_order": 363
+ },
+ {
+ "step_name": "Step-49",
+ "content_type": "Description",
+ "content": "Refit the oil separator hose. Connect the common rail electrical connector and wiring harnesses routing clip. Connect the Cam phase sensor electrical connector. Connect the DPF Sensor electrical connector. Connect the dosing module electrical connector. Position the heat shield and refit the heat shield mounting bolt on DPF side and torque tighten the bolt. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 376
+ },
+ {
+ "step_name": "Step-54",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010920.jpg",
+ "display_order": 377
+ },
+ {
+ "step_name": "Step-55",
+ "content_type": "Description",
+ "content": "Refit the heat shield mounting bolt on Cam cover and rear engine hook and torque tighten the bolts. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 380
+ },
+ {
+ "step_name": "Step-56",
+ "content_type": "Description",
+ "content": "Refit the heat shield mounting studs on Cam cover and torque tighten the studs. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 383
+ },
+ {
+ "step_name": "Step-57",
+ "content_type": "Description",
+ "content": "Attach the vacuum hose on routing clips. Connect T5 temperature sensor electrical connector. Green colour tape provided on T5 Sensor wiring pigtail and engine wiring harness connector side for easy identification while refit and ensure to properly connect the T5 Sensor wiring pigtail connector with engine wiring harness. Mismatch connection of wiring connectors may leads to affect the engine performance and occur engine trouble. Connect T4 temperature sensor electrical connector. Yellow colour tape provided on T4 Sensor wiring pigtail and engine wiring harness connector for easy identification while refit and ensure to properly connect the T4 Sensor wiring pigtail connector with engine wiring harness. Mismatch connection of wiring connectors may leads to affect the engine performance and occur engine trouble. Position the Cam box on Intake cam shaft rear end. While Installing Cam box, ensure to move the tappet in upward direction by hand. Ensure to replace New Cam box gasket during Installation. Before Installation of Cam box mounting bolts, Rotate the Cam Box Assembly as direction shown in the image to install fuel high pressure pump mounting bolts. Position the fuel pump on Cam box and install mounting bolts. Tighten the mounting bolts to the specified torque value. While Installing the pump always replace the Gasket with a new one. While torque tighten the Pump mountings, hold the Cam box Assembly by second technician as shown. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 406
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1644.jpg",
+ "display_order": 407
+ },
+ {
+ "step_name": "Step-63",
+ "content_type": "Description",
+ "content": "Rotate the Cam Box Assembly direction as shown in the image to original position. Install the Cam box mounting bolts.Tighten the bolts to the specified torque value. Tightening Sequence ",
+ "file": null,
+ "display_order": 412
+ },
+ {
+ "step_name": "Step-64",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010061.jpg",
+ "display_order": 413
+ },
+ {
+ "step_name": "Step-64",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 414
+ },
+ {
+ "step_name": "Step-65",
+ "content_type": "Description",
+ "content": "Install fuel return line 'T' bracket mounting bolts. Tighten the bolts to the specified torque value Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 417
+ },
+ {
+ "step_name": "Step-66",
+ "content_type": "Description",
+ "content": "Refit fuel return hoses and lock it by spring band clamp. Connect fuel inlet tube quick coupler at pump end & FCU. Connect the fuel control unit electrical connector. Position all 4 Injectors and clamps on ylinder head, refit the injector clamp mounting bolts and torque tighten the bolts to specified value. Always replace the injector O\u2013 ring with new one when ever injector is removed. Check the Injector Washer condition,replace if in damaged condition. Torque : 32 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 430
+ },
+ {
+ "step_name": "Step-69",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040234.jpg",
+ "display_order": 431
+ },
+ {
+ "step_name": "Step-70",
+ "content_type": "Description",
+ "content": "Connect the Injector electrical connectors. Refit injector leak - off pipe lock clips on the injector end. Position the Fuel HP pipe and tighten the mounting on Common rail end to the specified torque value. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 438
+ },
+ {
+ "step_name": "Step-73",
+ "content_type": "Description",
+ "content": "Position the Fuel HP pipe and tighten the mounting on FIP end to the specified torque value. Torque : 30 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 441
+ },
+ {
+ "step_name": "Step-74",
+ "content_type": "Description",
+ "content": "Refit the engine wiring harness carrier mounting studs on Cam cover and torque tighten the studs. Torque : 8 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 444
+ },
+ {
+ "step_name": "Step-75",
+ "content_type": "Description",
+ "content": "Position the high pressure pipes on common rail side and injector side and torque tighten the mountings to specified value. Torque : 25 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 447
+ },
+ {
+ "step_name": "Step-75",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040094.jpg",
+ "display_order": 448
+ },
+ {
+ "step_name": "Step-76",
+ "content_type": "Description",
+ "content": "Position the drive belt and Using 14 mm ring spanner, swing the auto-tensioner in Anti clock-wise direction and install the belt. Place the MST 0306GBH0001ST - Stretch Fit Belt Installation Tool on damper pulley as shown in the image. Using 24 mm socket spanner, rotate the damper pulley in anticlockwise direction. By rotating pulley, belt started getting into pulley groove and once belt installed properly on pulley, then remove the MST and spanner Ensure proper engagement of belt teeth in all the pulley grooves after Installation. Refit the engine fead cover on engine, torque tighten the bolts to specified value. Torque : 11\u00b1 1Nm ",
+ "file": null,
+ "display_order": 460
+ },
+ {
+ "step_name": "Step-80",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1647.jpg",
+ "display_order": 461
+ },
+ {
+ "step_name": "Step-81",
+ "content_type": "Description",
+ "content": "Refit the degassing tank and install the mounting bolts on the bracket. Torque tighten he bolts to specified value. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 464
+ },
+ {
+ "step_name": "Step-82",
+ "content_type": "Description",
+ "content": "Refit the engine vent hose on T onnection. Check engine coolant level and top-up. Check engine oil level and top-up if needed. Run the Engine in Idle condition for few minutes, check for oil & coolant leakage and ensure proper functioning of engine. Refit the engine top encapsulation cover. Connect iSmart, Check and clear DTC if any. The cylinder head contains valves, fuel injectors, camshafts, glow plugs, vacuum pump, intake manifold, exhaust manifold and Fuel pump. In the diesel engine cylinder head performs several functions. It provide as the top seal for the cylinders bore. The cylinder head even consists of ports which are used to allow air in to the combustion chamber and allows the exhaust gases to move out. The cylinder is made by gravity casting and integrated with water jacket. The cylinder oil passage is drilled and sealed by Expansion plug or steel ball. The Camshafts bearing cap is also made by casting and installed on the cylinder head. Remove the turbocharger with exhaust manifold. Remove the intake manifold. Using a 12 mm ring spanner, loosen and remove common rail mounting bolts. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the CAM shaft lower bearing caps from cylinder head. Disconnect the electrical connectors from the glow plug. Using a 8 mm deep socket spanner, loosen and remove the glow plugs from the cylinder head. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 19 mm socket spanner, loosen and remove the coolant temperature sensor. Torque : 20 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the heater inlet pipe mounting bolt and detach from cylinder head. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the engine rear hanging hook mounting bolts. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a 17 mm socket spanner, loosen and remove the cylinder head mounting bolts. Torque : 90\u00b110 Nm + 2x90\u00b0\u00b15\u00b0 ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Remove the cylinder head from engine. Using a 6 mm Allen spanner, loosen and remove engine coolant vent pipe mounting banjo bolt Install in reverse order of removal. Always replace the mounting bolts New ones while installing head assembly. Replace the cylinder head gasket with a new one. Failure to follow this will lead to compression failure. When fitting the cylinder head with it fitted to the glow plug, be careful not to damage the glow plug, since the broken pieces may enter inside the cylinder and damage the engine if the glow plug is exposed to an impact, which results in breakage of it. Check & Top-up the engine oil. Check for coolant seepage and any oil seepage on the engine and transmission. Replace if any traces found. Clean the cylinder head assemblies thoroughly, replace it if any cracks or damages are found. Check the Cylinder Head for external damages. Check the cylinder head height and if not meeting the specified value, replace the cylinder head assembly. Check the Cylinder Head bottom face for distortion. Using 10 mm Allen key, loosen and remove rear axle filler plug. Using 10 mm Allen key, remove rear axle drain plug and drain the entire oil. Wait till the entire oil get drained. Place a tray beneath the rear axle for collecting the oil while draining. Using 13 mm and 16 mm ring and open end spanners unscrew rear propeller shaft mounting bolts and nuts rear axle end. Torque : 65 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "By using Special tool MST 203\u2013Companion Flange Holding Tool, hold the companion flange and Using 32 mm deep socket spanner loosen and remove the companion flange mounting nut Remove the companion flange using mallet. If companion flange shows wear in the area of seal contact, it should be replaced. Remove the pinion oil seal by using screw driver. Ensure not to damage the oil seal mating surface while remove the Oil seal. Inspect t the pinion oil seal for any damage. Replace if found. Inspect t the companion flange for any damage. Replace if found. Using MST 0502AUA0004ST Rear Axle Pinion Oil Seal Installer, Place and Press New oil seal uniformly on banjo gear carrier housing. Apply a light coat of oil to the lip of oil seal before installation. Install the dust cap into the companion flange. Install the companion flange on the banjo housing and Install the new mounting nut with washer. Always use new flange mounting nut once it removed. Hold the companion flange Using MST203 Companion Flange Holding Tool and torque tighten the companion flange mounting nut. Tighten nut to Initial torque as 270 Nm Measure the Pinion Rotational Torque (PTTR), It should be within 2.5 - 3.5Nm. If measured Pinion Rotational Torque (PTTR) not within 2.5 - 3.5 Nm, Then tighten nut to incremental torque from 270 Nm onwards to 330 Nm until specified PTTR (Pinion torque to rotate) is achieved. Measure and ensure the Final Pinion Rotational Torque (PTTR), It should be within 2.5 - 3.5 Nm. PTTR SPEC : 2.5 to 3.5 Nm Attach the propeller shaft to the rear axle with mounting nuts, torque tighten it to the specified value. Torque : 65 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refit the drain plug and torque tighten tospecified value. Clean the drain plug and differential housing with a clean cloth before refitting. Torque : 47 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Refill specified quantity of recommended differential oil into differential assembly Never reuse drained oil. Always use recommended oil only. Never mix different types of oil and use. Clean filler plug area properly using acloth before filling the oil. Check the oil level and ensure its up to the level. Ensure that the oil level is up to lower most point of the filler plug. Refit the filler plug back and torque tighten to mounting plug specified value. Clean the filler plug with a clean cloth before refitting. Torque : 29 \u00b1 5Nm ",
+ "file": null,
+ "display_order": 57
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 126,
+ "sys_id": "THAR.LX-0005-Rear Axle",
+ "subsys_id": "THAR.LX-0005-Rear Axle-Troubleshoot - Rear Axle",
+ "systems": "Rear Axle",
+ "sub_systems": "Troubleshoot - Rear Axle",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1464,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0005-Troubleshoot - Rear Axle-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Trouble Shooting",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Certain rear axle and driveline trouble symptoms are also common to the engine, transmission, tyres and other parts of the vehicle. For this reason be sure that the cause of the trouble is in the rear axle before adjusting, repairing or replacing any of the axle parts. Basic characteristics in a rear axle are more difficult to diagnose and repair than mechanical failures. Slight axle noise heard only at certain speed or under particular conditions must be considered normal. Axle noise tend to peak or be more pronounced at particular speeds and the noise is in no way a sign of the trouble in the vehicle. Where noise is present in objectionable form (Loud and/ or at all speeds) the first effort should be to isolate the noise. Isolation of noise in any one unit requires care and experience and an attempt to eliminate a slight noise may baffle even the most experienced mechanic/ technician. The most important characteristic of the gear noise is that it is usually sensitive to accelerator position. E.g. noise audible under drive condition will often disappear under coast condition (i.e. driving in neutral with the clutch released and engine running) at the same vehicle speed and vice versa. Axle gear noise whine will always occur at the same road speed and throttle setting i.e. drive or coast (i. e. driving in neutral with the clutch released and engine running). Gear whine is usually a fairly high pitched pure tone as opposed to a low-pitched rumble caused by a spalled bearing. Some noises, which can be confused with axle gear whine, are: - Whine from an engine component; this will always occur at the same engine speed irrespective of which transmission gear is used. Whine from an indirect transmission gear (e. g. 5th gear on some vehicles produces a whine comparable with axle whine) however this will disappear when the direct transmission ratio is selected. Whine from tyres or wind noise from a rack or aerial. These noise generally occur over a very broad speed range and do not change with driving mode i. e. drive or coast (i.e. driving in neutral with the clutch released and engine running). Before diagnosing the whine as axle gear noise, ensure that the whine:Occurs in direct transmission ratio (4th gear). Changes with throttle/ accelerator variations (drive and coast) (i.e. driving in neutral with the clutch released and engine running). Always occur at the same road speed and not engine speed. Occurs over a limited vehicle speed. (This can vary over a wide band should the axle be in extremely bad condition.). ",
+ "file": null,
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Bearing Noise",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Bearing noise is inclined to be less throttle sensitive than gear noise and frequently occurs over a wide speed range. Bad cases of faulty bearings can, in fact be detected from walking speed, building up in pitch as speed increases and is not directly affected by changing from drive to coast (i. e., driving in neutral with the clutch released and engine running) and vice versa. Rear wheel bearing noise tends to be low pitched grumble, which can normally be detected and confirmed when driving on a smooth road at constant speed, with the noise most audible while swerving sharply from left to right. If the noise increases or a decrease as the car is swerved, it is probable that a wheel bearing is faulty. Driving close to a wall or a curb at a suitable speed can carry out a further check for wheel bearing noise. Differential bearing noise is usually similar to in pitch to wheel bearing noise but is not affected by the swerve check referred to previously. Pinion bearing noise is normally at a higher pitch than wheel or differential bearings and is often slightly sensitive to throttle position, although not to the same extent as gear noise. A further condition, which can exist, is due to a worn bearing that allows the gear set to move out of its correct mesh cause gear noise. This condition is usually throttle sensitive, with the noise frequently disappearing on a \u201cdrive\u201d condition. Any amount of or end play in either the pinion bearings or differential carrier bearings are detrimental to the gears and bearings and will cause axle noise. A high spot sometimes occur on either the ring gear or the drive pinion; this shows up as a ticking or light knocking noise over a restricted range of throttle position. The frequency of the noise will indicate whether the high spot is on the pinion (drive shaft frequency) or on the ring gear. The severity of the noise indicates the size of the defect. A light \u201ctick\u201d is seldom detrimental and usually occurs in new axle and will normally disappears once the axle has been run in. Louder noise usually indicates a more serious defect and a knock occurring in an axle which was previously free from this type of noise must always be investigated. Remove the rear axle shaft RH. Using circlip plier, remove the toner wheel circlip. By using hydraulic press, remove toner wheel along with Rear bearing carrier assembly. Take sufficient care not to damage the toner ring while removing. Remove the bearing from Rear bearing carrier. Replace the toner ring and bearing assembly once removed. Using a suitable tool, Remove the oil seal from Rear bearing carrier. Replace the outboard oil seal once removed. Refit in the reverse order of removal. Check differential oil level, top up the oil if required. Carry out Parking Brake Adjustment. Inspect the axle shaft outer oil seal & bearing for any damage, Replace if necessary. Detach the hand brake cable from brake shoe. Remove the hand brake cable lock clip and detach the hand brake cable from backplate. Using 11 mm open end spanner, Loosen brake bundy tube flare nut wheel cylinder end. Torque : 16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 17 mm socket spanner, loosen and remove axle shaft mounting nuts. Torque : 35 \u2013 50 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using MST 0505AAA0001ST puller rear axle shaft banjo remove rear axle shaft, dust shield with brake liner assembly from vehicle. To avoid the back plate falling down,using a plastic tag tie it with any other fixed member before the shaft is pulled out. Clean sealant on the axle housing flange, Back Plate and apply new sealant on the housing. Apply Locktite Sealant 5060 during Installation and Ensure that sealer bead is on the inside of screw holes as shown above. Bead must be 3 to 6mm high and 3 to 6mm wide. Refit in the reverse order of removal. Check differential oil level, top up the oil if required. Carry out Parking Brake Adjustment. Inspect the axle shaft for any damage, crack or bend. Inspect the toner ring for any damage. Inspect the rear wheel bearing for any damage. Inspect the back plate for any damage. RearAxleOil \u2013Mahindra MAXIMILEELITE NewGenerationGenuineDifferentialFluid.Position the vehicle on 2 post lift/ 4 post lift. Rear Axle Oil \u2013 Mahindra 'MAXIMILE ELITE' New Generation Genuine Differential Fluid.Capacity \u2013 2.0 Litres.using 10 mm allen key, loosen and remove rear axle filler plug. Using 10 mm allen key, remove rear axle drain plug and drain the entire oil. Wait till the entire oil get drained. Place a tray beneath the rear axle for collecting the oil while draining. Refit the drain plug and torque tighten to specified value. Clean the drain plug and differential housing with a clean cloth before refitting. Torque:47\u00b17 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refill specified quantity of recommended differential oil into differential assembly Never reuse drained oil. Always use recommended oil only. Never mix different types of oil and use. Clean filler plug area properly using a cloth before filling the oil. Check the oil level and ensure its up to thelevel. Ensure that the oil level is up to lower mostpointofthefillerplug. Refit the filler plug back and torque tightentomountingplugspecifiedvalue. Clean the filler plug with a clean cloth beforerefitting. Torque:29\u00b15 Nm ",
+ "file": null,
+ "display_order": 24
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 125,
+ "sys_id": "THAR.LX-0005-Rear Axle",
+ "subsys_id": "THAR.LX-0005-Rear Axle-Rear Axle Carrier Assembly Overhaul",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Axle Carrier Assembly Overhaul",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A140074.jpg",
+ "myid": 1238,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0005-Rear Axle Carrier Assembly Overhaul-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Removal & Installation Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/VST-0076_Rear Axle Differential Overhaul.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/53595.pdf",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Disassembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the Rear axle oil.For additional information refer to Rear axle oil draining procedure.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Rear Axle Carrier Assembly. Mount the Rear Axle carrier assembly on a suitable stand. Liquid sealant is used to seal carrier section with banjo beam. Clean the sealant on the carrier facing Using a 17 mm socket spanner, loosen and remove the bearing cap mounting bolts and then remove the bearing caps. Using a Mallet, tap and detach the bearing caps. Identification marks are punched on bearing cap; this is to ensure correct bearing cap is installed on correct side. Ensure correct bearing caps used While reassembly. Pry out differential case from carrier with help of (MST 0502AAA0001ST - Tommy Bars) as shown in the illustration. Remove the shims from both the sides of differential case. Backlash shims are not to be interchanged during assembly If Backlash shims are damaged, replace with new shims during assembly. There is no identification provided on the shim, Needs to be measured by micro meter. Remove the bearing caps from both the ends. Mount the (MST 0502AUA0013ST - R Axle Diff Case Bearing Puller Adapter) and (MST 0502AUA0012ST - Axle Bearing Puller) on side bearing cone as steps shown below. Remove the side bearing cone by tightening the screw rod using 24 mm ring spanner and remove the bearing cone from the differential case. Hold the top plate using 36 mm open end spanner while tightening. It is always preferred to replace side bearings, but one can confirm free rolling of bearings and reuse if they are defect free. Similarly remove ring gear other side bearing cone as steps shown below. Using 14 mm socket spanner remove the ring gear mounting bolts. Ring gear mounting bolts are opposite threaded. Loosen in clock wise direction. Tap ring gear with a mallet to free it from case If required and remove. Follow Steps 15 to 18 to remove Side Gears & Pinion Mate Gears for Open Differential. Using MST 0502AUA0033ST - Front Axle Diff Case Pin Remover&Installer and hammer remove the differential gear locking pin. Using hammer and punch, Remove the differential shaft from differential case as shown in illustration. To remove side gears and pinion mate gears, rotate the side gears, this will allow the pinion mate gears to turn to opening of the case. To remove side gears and pinion mate gears, rotate the side gears, this will allow the pinion mate gears to turn to opening of the case. Check the differential gear condition, any damage replaces it Inspect cross pin for excessive wear, replace it if necessary Always replace differential pinion gears and side gear both along with washer as a complete set. Do not mix new gears with old gears, as this may cause uneven wear and short gear life. Position the carrier assembly on the suitable stand to facing the companion flange side. Hold the companion flange using (MST 203\u2013 Companion Flange Holding Tool) and Using 32 mm deep socket spanner loosen and remove the companion flange mounting nut. Using mallet tap and remove the companion flange, washer and dust cup. If companion flange shows wear in the area of seal contact, it should bereplaced. Using a mallet, tap the pinion assembly and remove the pinion assembly from the differential housing. Fit a nut of pinion before tapping to avoid thread damage. Hold the pinion with hand to avoid falling. Gear teeth have sharp edges. Handle gears carefully to avoid injury. . Remove the collapsible Washer. Discard collapsible spacer. New one is required to be used during assembly. Assemble (MST 0502AUA0014ST - R Axle Pinion Inner Bearing Puller Adapter) and (MST 0502AUA0012ST - Axle Bearing Puller) as shown in the illustration. Tighten the screw rod using 24 mm ring spanner to remove the pinion inner bearing. Hold the top plate using 36 mm open end spanner while tightening. Remove the pinion head bearing & remove the shims from the pinion. Collect shims and keep them togetherg. Replace shims if found damaged. Remove the pinion oil seal by using screw driver. Ensure not to damage the oil seal mating surface while remove the Oil seal. Gently pull-out and remove the pinion outer bearing. Using suitable punch and hammer remove the outer bearing cap. Using suitable punch and hammer remove the inner bearing cap. Ring gear and pinion is supplied as a set. They are matched with each other during manufacture. Matching numbers on both pinion and ring gear are etched for verification. Refer Fig. A or Fig. B for more details. If a new gear set is used, verify numbers on pinion and ring for matching before proceeding with assembly. Standard mounting distance from center line of ring gear to back face of pinion is 109.525 mm. This dimension is controlled by selecting shims, which are positioned between the inner pinion bearing and pinion shoulder. Best running position of gear set is achieved by proper shim selection. On the bottom face of pinion, a number is etched. It can be a plus (+) number, a minus (-) number or Zero (0). Required pinion shim selection is achieved with help of this number. Pinion offset always in thou (1 thou = 0.0254 mm). Fig. A shows ring and pinion etched with inch identification.Fig. B shows ring and pinion etched with metric identificationIf no offset on pinion face then assume it zero. If no offset on pinion face then assume it zero. Position the rear axle housing on a suitable stand. Position the (MST 0502AUA0016ST -Rear Axle Pinion Height Master Block) over the inner bearing cup seating area as shown. Position the (MST 0502AUA0016ST -Rear Axle Pinion Height Master Block)/b<> over the inner bearing cup seating area as shown. Using feeler gauge measure the distance between the MST\u2019s as shown and the value assumed as \u2018A\u2019 . For example consider the value obtained as 1.51 mm. Convert the obtained value in \u201cmm\u201d into \u201cThou\u201d (1.51x39 = 59 Thou). Now see the etched value on pinion, the value assumed as \u2018B\u2019 (For example consider the offset value as +4) Now to get the final shim size, the formula is Shim thickness (In Thou) = A \u2013 (+B or \u2013 B).i.e, (59 \u2013 4 = 55 Thau) Convert the Thou value to mm ( 55 x 0.0254 = 1.40 mm) , which is the final shim thickness required. Mount the pinion positioning shim pack on pinion Select shim pack based on Pinion Shim Selection Procedure to position the pinion at correct mounting distance as per value etched on pinion stem for best running position Position the pinion inner bearing on pinion & press the bearing by using (MST 0502AUA0017ST - R Axle Pinion Inner Brg Press Dolly) . Insert a new collapsible spacer Collapsible spacer should rest in between pinion inner and outer bearing and it can be fitted in any direction. Always use new collapsible spacer,never use old one Install the Inner bearing cup by using (MST 0502AUA0018ST - Pinion Inner bearing cup installer) and (MST 0707BBA0003ST - Universal mandrel) on banjo gear carrier housing. Install the Outer bearing cup by using (MST 0502AUA0019ST - Pinion outer bearing cup installer) and (MST 0707BBA0003ST - Universal mandrel) on banjo gear carrier housing. Install the pinion on the axle banjo housing and provide a support for pinion in the bottom. Using (MST 0502AUA0017ST - R Axle Pinion Inner Brg Press Dolly) and hammer press the pinion outer bearing. Place oil slinger on pinion outer bearing cone Place and Press oil seal on banjo gear carrier housing using (MST 0502AUA0004ST - Rear Axle Pinion Oil Seal Installer) Apply a light coat of oil to the lip of oil seal . Install the dust cap into the companion flange. Install the companion flange on the banjo housing.. Install the companion flange mounting nut. Hold the companion flange using (MST203 - Companion Flange Holding Tool) and torque tighten the companion flange mounting nut. Tighten nut to Initial torque as 270 Nm Measure the Pinion Rotational Torque (PTTR), It should be within 2.5 - 3.5 Nm. If measured Pinion Rotational Torque (PTTR) not within 2.5 - 3.5 Nm, Then tighten nut to incremental torque from 270 Nm onwards to 330 Nm until specified PTTR (Pinion torque to rotate) is achieved. Excessive care must be taken during bearing preload torque adjustment. Do not over tighten, loosen and then retighten nut. Do not exceed specified bearing preload torque. If preload torque is exceeded, a new collapsible spacer must be installed and torquing sequence as above to be repeated. Follow Steps 17 to 20 to Install Side Gears & Pinion Mate Gears for Open Differential. Assemble both side gears and thrust washers, hold them in place with one hand and then assemble the pinion mate gears with thrust washer to hold the side gears in place. An easy way to assemble the side gears and pinion mate gears is to have all parts lubricated before assembly. Rotate the side gears until the holes of the spherical washers and pinion mate gears line up with the holes in the case by the help of engaging the splines of axle shaft to side gears. When both the cross bore hole matched and insert the differential shaft.. Use a drift to line holes of the gears up with case. Assemble differential shaft and pull out drift. Be sure vertical lock pin hole is lined up with that of the case, and that pinion mate washers are in place and lined up with gear and case Align the differential shaft hole, insert the lock pin and fix using (0502AUA0033ST - Differential gear lock pin removal tool) and hammer. Assemble ring gear to the differential case using mounting bolts. Tighten the bolts to specified torque value in recommended sequence.. Torque : 90 - 105 Nm ",
+ "file": null,
+ "display_order": 182
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140174.jpg",
+ "display_order": 183
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Notice",
+ "content": "Always use new ring gear bolts. Ring gear mounting bolts have LH threads. While Installation torque in anti-clocking direction Assemble (MST 0502AUA0020ST - Rear Axle Dummy Bearing) on to differential case Place differential case assembly into housing. Push the differential case assembly towards the pinion side and insert the shims pack on the LH side (Back to ring gear) and Insert the shims pack on the RH side (Teeth side). Remove the shims (6 Thou) from LH Side and add to RH Side for backlash tolerance. Install dial gauge and locate tip of indicator on the surface of one of the ring gear teeth and measure the backlash at three equally spaced points (Each 120 degree rotation space), confirm the Backlash tolerance is (0.15 to 0.25 mm) Fix the Dial Gauge on Housing, Set the Dial Indicator 0 on Ring gear teeth as shown. Hold the pinion flange at the bottom side. Rotate the ring gear by using ring spanner & measure the backlash. Backlash variation at three points should not more than 30% . These corrections are made by switching shims from one side of differential case to other High backlash is corrected by moving ring gear closer to pinion (Move Shims from RH to LH). Low backlash is corrected by moving ring gear away from pinion (Move Shims from LH to RH). Remove dial gauge and take out diff case & remove the dummy differential bearings. Press bearing on Differential case assembly by using (MST 0502AUA0021ST - R Axle Diff Case Brgs Pressing tool). Repeat the same procedure for installation of bearing on other side. Install the Differential bearing caps on both the sides. Install differential case assembly into carrier with the help of mallet. Carelessness while installing differential case assembly may result in injury.. Install the shims on both the sides of differential case Backlash shims are not to be interchanged during assembly. If Backlash shims are damaged, replace with new shims during assembly Assemble bearing caps using mounting bolts. Ensure correct fitment of caps by matching letters on caps and carrier on either side. Tight the bearing cap bolts to specified value. Torque : 90 - 110 Nm ",
+ "file": null,
+ "display_order": 222
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "Description",
+ "content": "Install dial gauge and locate tip of indicator on the surface of one of the ring gear teeth and measure the ring gear and pinion backlash at three equally spaced points (Each 120 degree rotation space),confirm the Backlash tolerance is (0.15 to 0.25 mm). Fix the Dial Gauge on Housing, Set the Dial Indicator 0 on Ring gear teeth as shown. Hold the pinion flange at the bottom side. Rotate the ring gear by using ring spanner & measure the backlash. Backlash variation at three points should not more than 30% . These corrections are made by switching shims from one side of differential case to other. High backlash is corrected by moving ring gear closer to pinion (Move Shims from RH to LH). Low backlash is corrected by moving ring gear away from pinion (Move Shims from LH to RH). If backlash is as per specification, check ring gear and pinion tooth contact pattern. If backlash is as per specification, check ring gear and pinion tooth contact pattern as below. Apply Locktite RTV Sealant 5060 to flat surface of banjo beam Flat face of the carrier assembly and flat surface of the banjo beam must be free of any oil film or foreign material. Ensure that sealer bead is on the inside of bolt holes. Bead must be 3 to 6 mm high and 3 to 6 mm wide. Refit the Differential Carrier Assembly. For additional information refer to Differential carrier assembly R&R section. Fill the differential fluid. For additional information refer to Differential fluid filling procedure. Using 0502CAA0012ST \u2014Puller Oil Seal Pinion /Flange Inbord-X ,remove the inboard oil seal. Refit in the reverse order of removal. Use a MST (0502BUA0001ST \u2014 Rear Axle Shaft Inboard Oil Seal Installer, during Installation. Check differential oil level, top up the oil if required. Carry out Parking Brake Adjustment. Inspect t the axle inboard for any damage. Rectify if found. Remove the Rear Axle Shaft Assembly LH . Remove the Rear Axle Shaft Assembly RH. Using 14 mm socket spanner, Unscrew rear propeller shaft mounting bolts and detach propeller rear end and properly hang the shaft. Torque : 65 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrewgear carrier to banjo housing mounting bolts. Torque : 35 - 50 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 17 mm socket spanner, Unscrew rear stabilizer bar bracket mounting bolts and detach the bracket partially. Torque tightening should be done without load and with the tyres on level ground. Ensure to add washer only for bottom mounting of stabilizer bar. Torque : 70 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 5 mm allen key, hold the rear stabilizer bar link bottom mounting then using a 18 ring spanner, loosen and remove the top mounting nut from stabilizer bar. Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140038.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on levelground. Remove the rear axle gear carrier from vehicle. Clean the sealant on the gear carrier Refit in the reverse order of removal. Apply Locktite Sealant 5060 during Installation and Ensure that sealer bead is on the inside of screw holes and pattern as shown below Bead must be 3 to 6 mm high and 3 to 6 mm wide. Refill the rear axle oil. Check the gear carrier, cracks, damage, wear or distortion, replace it if necessary. Check the axle case for yield, deformation or cracks, replace if necessary. Remove the rear axle shaft assembly. Using circlip plier, remove the toner wheel circlip. By using hydraulic press, remove toner wheel along with Rear bearing carrier assembly & dust shield. Take sufficient care not to damage the toner ring while removing. Replace the toner ring and bearing once removed. Refit in the reverse order of removal. Check differential oil level, top up the oil if required. Inspect the toner wheel for any damage, Replace if necessary. Inspect the Rear bearing carrier assembly for any damage, Replace if necessary. For additional information refer to Rear brake drum LH and RH - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Detach the hand brake cable both the sides(LH&RH)from brake shoes. Remove the hand brake cable lock clips from both the sides (LH & RH) and detach the hand brake cables from back plate. Remove the hand brake holding spring on the axle from LH & RH side. Remove the bundy tube rear hose to LH wheel. For additional information refer to Bundy Tube Rear Hose to LH Wheel - R&R section. Remove the bundy tube rear hose to RH wheel. For additional information refer to Bundy Tube Rear Hose To RH WheeL - R&R section. Remove the flexible hose LH & RH side locking from the axle. Using a 10mm socket spanner,Unscrew wheel speed sensor mounting bolts and detach the sensors. Torque:9\u00b11Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140015.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Provide a jack to support the rear axle assembly. Remove the rear propeller shaft. For additional information refer to Rear Propeller Shaft - R&R section. Remove the stabilizer bar rear. For additional information refer to Stabilizer Bar Rear-R&Rsection. Using a 24 mm socket spanner, loosen and remove the upper link mounting bolt/nut. Torque : 230 \u00b1 20 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170029.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 21mm ring spanner. Torque tightening should be done without load and with the tyres on level ground. Using a 24 mm socket spanner, loosen and remove the lower arm mounting bolt/nut. While loosening the nut, hold the bolt using 21mm ring spanner. Torque tightening should be done without load and with the tyres on level ground. Torque:230\u00b120Nm ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using a 17 mm socket spanners, loosen and remove the both rear shock absorbers bottom side mounting bolts and nuts. Torquevalue:110\u00b111Nm Torque Wrench Type - Open end Torque Wrench ",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. While loosening the nut, hold the bolt using15mmringspanner. Remove the rear coil spring and pad securelyfromvehicle. Pay attention while Installation Locking lug to be matched with hole on Rear Coil spring dome bracket of Chassis. Yellow coloured PU sleeve should be on chassis side while assembling the coil spring ashown in illustration. Carefully remove the rear axle assembly from vehicle. Refit in the reverse order of removal. Check differential oil level,top up the oil if required. All Suspension Torque tightening should be done without load and with the tyres on level ground. Check the axle shaft for straightness, cracks, damage, wear or distortion, replace it if necessary. Check the axle case for yield,deformation or cracks,replace if necessary. Inspect rear axle for any oil leakage,seepage. The ignition key barrel consists of ignition switch and steering lock. It is located on the steering column. The ignition barrel when switched ON by the mechanical key,switches the power supply to all controllers. Using a 10 mm combination spanner,loosen battery negative cable mounting nut and disconnect cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON Should not remove the battery connection when the EWP is ON,Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Remove Combination switch. Disconnect the ignition switch electrical connection. Using a Small sizzle and hammer, hit and remove the key barrel screws. Use new screw while installing key barrel. Remove the Ignition key with ICU from the vehicle. Using a star screw driver, loosen and remove the ICU mounting screws then remove the ICU from the key barrel. Insert the key and turn the key into AC position. Cut the micro switch routing tag and detach the connector holding clip from the ICU. Install in reverse order of removal. Always use new mounting bolts while installing the Ignition Switch Assembly clamping unit. Inspect ignition key for crack or damage. Replace if found any. Inspect ICU for crack or damage. Replace if found any. This test can only be performed with starter motor removed from vehicle. Remove Starter Motor from vehicle. Disconnect wire from solenoid field coil terminal. Check for continuity between solenoid terminal and solenoid field coil terminal with a continuity tester. There should be continuity. If OK, go to Step 4. If not OK, replace faultystarter motor. Check for continuity between solenoid terminal and solenoid case. There should be continuity. If not OK, replace faulty starter motor. The starter relay is an electromechanical device that switches battery current to the starter solenoid when the ignition switch is turned to the Start position. The starter relay is made of two separate circuits The control circuit which includes the electromagnet The power circuit which includes the contact blade. Remove the relay from fuse box Give 12 volt supply to pin number 86 and earth pin number 85Once supply is given sound can be noticed which indicated control circuit is perfect If sound is not noticed, replace the relay Using multi-meter, check continuity between pin number 30 & 87. (Power given to pin number 86 and earth given to pin number 85).If continuity is there, which indicates that the power circuit is perfect. If Continuity is not there then replace the relay Using multi-meter, check for continuity between pin numbers 30 and 87 (No power given to pin number 86 and no earth given to pin number 85). If continuity is there which indicates power circuit is NOT OK (Short internally). Replace the relay. If continuity is not there, Relay is OK The cranking voltage test measures the voltage available for ignition while the starting motor cranks the engine. Turn off the ignition, connect a voltmeter across the battery and crank the engine. Note the voltage reading. If the starting motor cranks normally and the voltmeter reads 9 volts or higher, cranking voltage is normal. Slow cranking with the voltage above 9 volts indicates high resistance in the motor circuit or starting motor. Low cranking speed and low voltage may indicate a discharger battery. If the battery is charger, look for trouble in the starter motor or engine. Immobilizer control unit (ICU) is fitted on the ignition lock barrel. The following are the functions of ICU: Supplies power to antenna. Receives and analyses signal from the key via antenna. Conveys the key status information to EMS ECU thru CAN. The transponder ring is fitted in the ignition socket, when the ignition key inserted in the key cylinder, the ignition key transponder which is configured with Mahindra specific codes will send a radio frequency (RF) signal to transponder ring. The transponder ring securely communicates the code to the immobilizer ECU Using a 10 mm combination spanner,loosen battery negative cable mounting nut and disconnect cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON Should not remove the battery connection when the EWP is ON,Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Remove Combination switch. Disconnect the ignition switch electrical connection. Using a star screw driver, loosen and remove ICU mounting screws then remove ICU from the key barrel. Install in reverse order of removal. Ensure the wheels are straight ahead. Also the steering rack should be in center. Check and ensure both the front wheels for straight ahead position while fitting the steering wheel and also after fitting. Carefully install the clock spring without damaging the locks. When installing the DAB, make sure that all electrical connectors are fixed in proper position. When installing the driver airbag into steering wheel, make sure the horn pad buttons are fixed properly and correct position. Inspect the ICU for any physical damage. Replace if found any. Inspect ICU connector for any damage or loose connection. Rectify if found. The following operation will require a voltmeter accurate to 1/10 (0.10) volt. The battery should be fully-charged. Engage the parking brake. Position the gearshift selector lever in the neutral position and lock the clutch pedal in the fully depressed position. Verify that all lamps and accessories are turned off. In-order to avoid the engine from starting, remove the starter relay. Connect the positive lead of the voltmeter to the battery negative terminal post and then connect the negative lead of the voltmeter to the battery negative cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery negative cable terminal clamp and the battery negative terminal post. Connect the positive lead of the voltmeter to the battery positive terminal post. Connect the negative lead of the voltmeter to the battery positive cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery positive cable terminal clamp and the battery positive terminal post. Connect the voltmeter to measure between the battery positive cable terminal clamp and the starter solenoid terminal stud.Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt. Clean and tighten the battery positive cable eyelet terminal connection at the starter solenoid terminal stud. Repeat the test. If the reading is still above 0.2 volt,replace the faulty battery positive cable. Connect the voltmeter to measure between the battery negative cable terminal clamp and ground on the transmission. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery negative cable eyelet terminal connection to the engine block. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery negative cable. The starting motor is a device that converts electric energy into mechanical energy to generate rotational power, and transfers the energy required for starting the engine initially with this power. The starter motor is composed of three parts, which are: The solenoid, which moves the starter pinion by means of a fork and at the same time closes the power circuit to feed the electric motor. The direct current electric motor, which cranks the engine. The fork and pinion assembly, which makes the connection between the starter motor and the ring gear on the flywheel. Using a 10 mm combination spanner,loosen battery negative cable mounting nut and disconnect cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before disconnecting the battery, check for the audible sound of EWP ON Should not remove the battery connection when the EWP is ON,Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance Using a 13 mm socket spanner, loosen and remove the battery positive cable mounting nut on starter motor end. Torque : 12\u00b12 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 8 mm socket spanner, loosen and remove the starter motor solenoid switch mounting nut on starter motor end. Torque : 2.5\u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen and remove the starter motor mounting bolts and remove starter motor from vehicle. Torque : 44\u00b15 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090046.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect battery negative cable for crack or damage. Replace if found any. Check the starter motor external crack or damage. Replace if found any. Check the starter motor internal gear crack or damage. Replace if found any. Using a 10 mm socket spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work Should not remove the battery connection when the EWP is ON,Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Glove Box Assembly. Remove the IP grab handle cover. Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220024.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting screws. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220025.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle. Partially detach the door edge beading and using a trim removal tool, remove the IP LH side cover. By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt. Torque : 8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220066.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220077.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector. Take out the IP LH side top cover with Passenger air bag from the IP. Using a 10 mm ring spanner, loosen and remove the air bag mounting bolt from IP top cover. Torque :4.5\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210047.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210048.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Expand the PAB module holder both sides using screw driver and detach the PAB separately from IP top cover. Using a star screw driver, Unscrew LH side AC vent mounting screws. Carefully release the vent locking clips from the cover and detach the vent. Check for any external damages or damaged locking clips, Replace if necessary. Inspect the PAB module for any damage. Replace if found any. Inspect the PAB module connector for any damage. Inspect the PAB module trim for any damage. Remove the Combination Switch. Remove the A Pillar Upper Trim LHS & RHS. Remove the Glove Box Assembly. Using a trim removal tool, Remove the cluster bezel.. Partially detach the door edge beading and using a trim Removal tool, Remove the IP side trim RH side. Using star screw driver, Unscrew Driver side top cover mounting screw and remove the cover. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220072.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew the cluster mounting screws. Torque : 2 \u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220071.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Partially Detach Cluster and disconnect the electrical connector. Remove the Instrument Cluster. Remove the Floor Console Assembly. For additional information refer to Floor Console Assembly \u2013 R&R Section. Using trim removal tool, Remove IP side vertical trim LHS And RHS partially detach the switch bang assembly and remove electric connector to take out from the vehicle. Detach the USB Docking station bezel and disconnect the electrical connectors. Disconnect Driver switch bank electrical connector. Remove the IP grab handle cover. Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts. Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220024.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting bolts. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220025.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle. Partially detach the door edge beading and using a trim removal tool , remove the IP side trim LH side. By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt. Torque : 8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220066.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220077.jpg",
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector. Remove IP Speaker Grill from LH and RH Sides.. Disconnect speaker electrical connectors from both the sides. Using a trim removal tool Detach the infotainment trims. Using a star screw driver, Unscrew the infotainment mounting screws. Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220086.jpg",
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Partially detach infotainment and disconnect the electrical connectors Remove the infotainment from Instrument panel. Using 10 mm socket spanner, Unscrew instrument panel mounting bolts. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 84
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220096.jpg",
+ "display_order": 85
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "Description",
+ "content": "Carefully remove the instrument panel from vehicle. Install in the reverse order of removal. Check for any external damages or damaged locking clips, Replace if necessary. Using trim removal tool remove the cluster bezel. Using a trim removal tool, remove the IP panel assembly driver side. Partially detach the door edge beading and using a trim removal tool, remove the IP RH side cover. Using star screw driver, Unscrew driver side IP cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220019.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the driver side IP cover. Using star screw driver, Unscrew AC vent mounting screws. Remove the RH side AC vent. Carefully release the vent locking clips from the cover and detach the vent. Install in the reverse order of removal. check for any external damages or damaged locking clips, Replace if necessary. Remove the Instrument Panel Assembly. Using a star screw driver, Unscrew the Instrument Panel AC & defroster Duct mounting screws and remove the ducts. Using a star screw driver, Unscrew IP driver switch bank mounting screws. Torque : 1.5 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270121.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the Driver Switch bank from Instrument Panel Using a star screw driver, Unscrew IP centre air vent mounting screws. Remove the Centre Air Vents from Instrument Panel. Install in the reverse order of removal. check for any external damages or damaged locking clips, Replace if necessary. Using trim removal tool remove the cluster bezel. Using a trim removal tool, remove the IP panel assembly driver side. Partially detach the door edge beading and using a trim removal tool, remove the IP RH side cover. Using star screw driver, Unscrew driver side IP cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220019.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the driver side IP cover. Using star screw driver, Unscrew AC vent mounting screws. Remove the IP AC Vent RH. Carefully release the vent locking clips from the cover and detach the vent. Install in the reverse order of removal. check for any external damages or damaged locking clips, Replace if necessary. Using star screw driver unscrew the panel assembly floor console RH screvits and detach the panel from vehicle Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W322.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220007.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console LH screvits and detach the panel from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220036.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220037.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Loosen and Remove Gear Knob and Transfer case shifter knobs Remove the gear shifter cover with trim Remove the rummier mat from the cup holder For AT Variants top trim removal follow (Steps 6\u2013 11) : Pull and fold the gear shifter boot from gear shifter bezel. Partially detach the bezel from the console. Excessive pull may leads to damage of the electrical connector Disconnect the AT gaiter electrical connector from the bezel. Carefully remove the bezel trim from the TGS lever. Handle bezel assembly carefully to prevent it from damage or scratches. Using trim removal tool, carefully remove the floor console top trim with transfer case shifter boot Using 10 mm socket spanner, Unscrew floor console LH and RH side mounting bolts Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220050.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220049.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew floor console LH and RH side mounting screws Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220043.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Remove the bottle holder rubber mat Using 10 mm socket spanner, Unscrew floor console mounting bolts Using 10 mm socket spanner, Unscrew floor console LH and RH side mounting bolts Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220053.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Lift the floor console and disconnect the floor console electrical connector Remove the floor console from vehicle. Remove the power window switch assembly from floor console. Install in the reverse order of removal. Check floor console assembly for any damage, replace if found any. Unlock glove box lock and remove the glove box assembly from IP Using star screw driver, remove the handle mounting screws Remove the glove box handle from the glove box assembly Install in the reverse order of removal. Check the glove box for damage, replace if necessary. Using a 10 mm socket spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Glove Box Assembly. Remove the IP grab handle cover. Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts. Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220024.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting screws. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220025.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle. Partially detach the door edge beading and using a trim removal tool, remove the IP LH side cover. By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt. Torque : 8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220066.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220077.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector. Take out the IP LH side top cover with Passenger air bag from the IP. Using a star screw driver, Unscrew LH side AC vent mounting screws. Remove the IP AC Vent LH. Carefully release the vent locking clips from the cover and detach the vent. Check for any external damages or damaged locking clips, Replace if necessary. Disconnect the TMC electrical connector then detach from the routing clips. Using 13 mm open end spanner, loosen and remove the TMC to EHCU Primary & Secondary bundy tubes from TMC side flare nuts. Torque :16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using hose clip plier, release brake fluid reservoir tank to clutch TMC hose clip then detach the hose. Using 12 mm combination spanner, Unscrew TMC mounting nuts and remove the TMC assembly from the brake booster. Torque : 16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130187.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Check and top up the brake fluid, If required. Check for master cylinder external damage, if found replace. Using 14 mm socket spanner, loosen and remove the brake hose banjo bolt then detach the brake hose. Torque :24 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Replace the banjo bolt washers with new ones always while installation, else brake fluid leakage may happen. Using 19 mm socket spanner, loosen and remove the caliper assembly mounting bolts. Torque : 95 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the caliper assembly from the vehicle. Install in the reverse order of removal. Check and top up the brake fluid, If required. Inspect the caliper for any physical damage. Replace if found any. Carefully refit the rubber seal. Clean all the internal parts thoroughly with fresh brake fluid or alcohol. Do not use mineral oil like kerosene, petrol, diesel etc. If the piston does not move smoothly, remove it and examine the sealing ring for correct seating in its groove. Fit the other end of the piston boot on to the caliper housing Refit the front caliper assembly. Using trim removal tool, remove the IP panel trim driver side. Using Nose plier, remove the R-clip and the clevis pin from the pedal shank. Using 12 mm socket spanner, loosen and remove the pedal box top mounting bolt. Torque :25 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the pedal box mounting nuts then remove the brake pedal box assembly. Torque :25\u00b15.0 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Brake Pedal Assembly (AT Variant) - R&R.PNG",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the brake pedal assembly for any physical damage. Replace if found any. Using 13 mm open end spanners, loosen and remove the TMC to primary and secondary bundy tubes flare nuts on EHCU side. Torque :16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130026.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 11 and 13 mm open end spanners, loosen and remove the EHCU to FL,FR,RL, RR output bundy tubes flare nuts on EHCU side. Torque : 16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Carefully detach the bundy pipe without any bend. if the bundy tube bends, Constant pressure will not be maintained. Disconnect the EHCU electrical connector. Using 12 mm socket spanner, Unscrew air cleaner housing mounting bolts to partially detach and keep aside. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanners, Unscrew EHCU mounting bolts and remove the EHCU assembly with EHCU mounting bracket. Torque : 23 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner , Unscrew EHCU mounting nuts from the bracket. Torque : 8 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130196.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "After removing the bundy tubes from EHCU, seal each port of ECHU with dummy plugs to avoid dust entry. Do not give any impact to hydraulic unit and take at most care not to allow dust to enter the hydraulic unit. Do not place hydraulic unit on its side or upside down. Handling it in inappropriate way will affect its original performance. Take sufficient care while installation and ensure correct bundy is connected to the specified inlet port. Use colour code for identification. Install in the reverse order of removal. Check and top up the brake fluid, If required. Check the EHCU for any external damage, if found replace. Disconnect battery negative connector. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Disconnect the wheel speed senor electrical connector. Detach the wheel speed sensor cable from the routing clips. Using 10 mm socket spanner, loosen and remove the wheel speed sensor mounting bolt then remove the sensor. Torque :9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130035.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the sensor for any physical damage. Replace if found any. Inspect the sensor for foreign particles segregation. Clean if found. Inspect the sensor connector for any damage. Remove the floor console assembly. Using 10 mm open end spanner, loosen and remove the parking brake adjusting nut. Detach the parking brake cable from parking brake lever. Disconnect the parking brake switch electrical connector. Using 12 mm socket spanner, Unscrew parking brake lever assembly mounting nuts. Torque :25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the parking brake switch from parking brake lever assembly. Install in the reverse order of removal. Inspect the park brake lever for any physical damage. Replace if found any. Remove the front caliper assembly. Blow dry compressed air into the caliper gradually through the inlet port connected to banjo bolt, to gradually move the piston out of the caliper. Remove the piston from the caliper housing. Remove the dust cover from the caliper housing. Remove the rubber seal from the groove in the caliper housing. Piston Outer surface should be free from nicks, score or rust and should feel smooth to touch. Do not use emery paper on piston surface, Replace if found any. Caliper Housing bores should be free from score, pitting, and corrosion, Replace if found any. Carefully refit the rubber seal. Clean all the internal parts thoroughly with fresh brake fluid or alcohol. Do not use mineral oil like kerosene, petrol, diesel etc. If the piston does not move smoothly, remove it and examine the sealing ring for correct seating in its groove. Fit the other end of the piston boot on to the caliper housing. Refit the front caliper assembly. Press the lock and disconnect the electrical connector from the brake switch. Place the brake pedal in release position. Turn the brake switch in anti-clock wise direction to get the brake switch free from adjuster lock. Insert the brake switch (A) in adjuster (B) till the switch plunger get completely pressed against brake pedal (at this point switch body will rest on brake pedal). Ensure no play between adjuster and the mounting bracket . Replace the adjuster if play is observed. While replacing new Switch with adjuster - Adjuster is to be snapped on mounting bracket. Ensure no play between the adjuster and mounting. Rotate the brake switch in clock wise direction till the switch gets locked. After locking the switch, the gap between the switch body and brake pedal will set to 1\u00b10.15mm. Connect the brake switch electrical connector. It is connected to brakes booster push rod. Brake pedal switch is mounted on the brake pedal. When the brake pedal is depressed by the driver based on brake pedal travel, brake pedal ratio and vacuum assist booster ratio, hydraulic pressure is generated in the master cylinder. Also brake switch gets released to activate brake lamps/stop lamps and high mount stop lamp at the rear of the vehicle. Disconnect the brake switch electrical connector. Rotate the brake switch in anti-clockwise direction and remove the brake switch. Install in the reverse order of removal. Carry out brake switch adjustment setting. Inspect the brake switch for any damage. Replace if required. Inspect the connector for any damage. Check proper fitment of connector. Brake Fluid - Mahindra 'Maximile DOT 4' Genuine brake fluid. Capacity - 1.75 Liters (Including bleeding quantity). Entire bleeding operation should be done with engine ON condition. In case of fluid reservoir or brake fluid replacement, bleeding of brake circuit is required. Always use recommended fluid and do not mix different brand fluids. Always use fresh and clean fluid from a sealed container. Do not pump the brake pedal at any time while bleeding (i. e. when the bleeding screw is opened). Air in the system will be further compressed into small bubbles and distributed throughout the hydraulic system and will result in additional bleeding operations. Do not reuse the drained fluid. Fluid level in the reservoir must be at MAX level at the start of bleeding and should be checked after bleeding each brake circuit and top up as required. Position the vehicle on 2 post lift/ 4 post lift. Open the bonnet and lock it in open position using bonnet stay rod. Open brake fluid reservoir cap. Pull-out the bleeding nipple dust cap from both front & Rear (RH and LH) bleeding nipple. Connect a transparent tube into rear LH side bleeding nipple and using a 9 mm ring spanner, loosen the brake fluid nipple then allow the brake fluid to drain. Press the brake pedal gently to drain the fluid completely. Collect the brake fluid in the container and tighten the brake fluid nipple then detach the hose from bleeder nipple. Connect a transparent tube into rear RH side bleeding nipple and using a 9 mm ring spanner, loosen the brake fluid nipple then allow the brake fluid to drain. Press the brake pedal gently to drain the fluid completely. Collect the brake fluid in the container and tighten the brake fluid nipple then detach the hose from bleeder nipple. Connect a transparent tube into front LH side bleeding nipple and using a 8 mm ring spanner, loosen the brake fluid nipple then allow the brake fluid to drain out completely. Press the brake pedal gently to drain the fluid completely. Collect the brake fluid in the container and tighten the brake fluid nipple then detach the hose from bleeder nipple. Connect a transparent tube into front RH side bleeding nipple and using a 8 mm ring spanner, loosen the brake fluid nipple then allow the brake fluid to drain. Press the brake pedal gently to drain the fluid completely. Collect the brake fluid in the container and tighten the brake fluid nipple then detach the hose from bleeder nipple. Hand tighten all the bleeding nipples. Fill recommended brake fluid up to \u201cMAX\u201d mark on the brake fluid reservoir. Press and release brake pedal gently several times, so that brake fluid will get circulated throughout the circuit. For vehicles equipped with ABS/ESP, brake circuit air bleeding needs to be carried out in 3 steps as mentioned below: Manual bleeding. Bleeding the EHCU with the use of diagnostic Tool. Final manual bleeding. During the bleeding process, it has to be ensured that the fluid level in the reservoir does not drop below minimum. Refer the below illustration for the bleeding sequence. Manual Bleeding Procedure ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130236.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Connect a transparent tube into Rear LH side bleeding nipple and insert the other end of tube in a transparent container. Ensure other end of tube is submerged in liquid, else chances for air entry is high. Always use transparent tube for better visibility of air bubbles. Press and release the brake pedal 3 - 4 times gently to the full stroke and hold the pedal in depressed condition. Ensure proper quantity of brake fluid in the reservoir throughout the bleeding procedure. Using a 9 mm ring spanner, loosen the brake fluid nipple and allow the brake fluid to drain. Air bubbles will escape from brake circuit to container through transparent pipe and the bubbles will be clearly visible. Tighten the bleeder screw as soon as there is no air bubbles visible in the transparent tube. Continue procedure steps 2 - 4 till there is no air bubbles visible in the transparent tube. Remove the transparent tube and firmly tighten the brake fluid nipple. Follow steps from 1\u2013 6 for Rear RH side brake. Refit the bleeding nipple dust cap on both REAR RH and LH bleeding nipples. Connect a transparent tube into Front LH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Ensure other end of tube is submerged in liquid, else chances for air entry is high. Always use transparent tube for better visibility of air bubbles. Press and release the brake pedal 3 - 4times gently to the full stroke and hold the pedal in depressed condition. Ensure proper quantity of brake fluid in the reservoir throughout the bleeding procedure. Using a 8 mm ring spanner, loosen the brake fluid nipple and allow the brake fluid to drain. Air bubbles will escape from brake circuit to container through transparent pipe and the bubbles will be clearly visible. Tighten the bleeder screw as soon as there is no air bubbles visible in the transparent tube. Continue procedure Steps 10 \u2013 12 till there is no air bubbles visible in the transparent tube. Remove the transparent tube and firmly tighten the brake fluid nipple. Follow steps from 9 \u2013 14 for Front RH side brake. Refit the bleeding nipple dust cap on both Front RH and LH brake bleeding nipples. Maintain recommended brake fluid up to MAX mark on the brake fluid reservoir. Refit the brake fluid reservoir cap. Connect i-SMART diagnostic tester and turn the ignition \u201cON\u201d . During the tool-bleeding process, ensure that the fluid level in the reservoir does not drop below minimum. Launch i-SMART Select ABS ECU and Navigate to Write Data . Routine screen will appear. Click on \u201cROUTINE SELECTION\u201d drop down list and select \u201cREPAIR BLEEDING\u201d . Click on \u201cSTART ROUTINE\u201d to initiate the tool bleeding. Ensure the fluid level in brake fluid reservoir is at \u201cMAX\u201d mark. Connect a transparent tube into rear LH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Loosen and open the rear LH bleeding screw and then press \u201cOK\u201d button Click on \u201cYES\u201d button to proceed for \u201cBleeding phase I\u201d. Ensure other end of tube is submerged in liquid, else chances for air entry is high. After pressing \u201cYES\u201d button, Press and hold the brake pedal for 3 seconds and then release for 0.5 seconds. Continue above procedure till \u201cBleeding phase I \u201d ends Connect a transparent tube into front LH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Loosen and open the front LH bleeding screw and then press \u201cOK\u201d button. Click on \u201cYES\u201d button to proceed for \u201cBleeding phase II\u201d. Ensure other end of tube is submerged in liquid, else chances for air entry is high. After pressing \u201cYES\u201d button, Press and hold the brake pedal for 3 seconds and then release for 0.5 seconds. Continue above procedure till \u201cBleeding phase II \u201d ends. Close the front LH bleeding nipple once the above mentioned pop up window appears. Connect a transparent tube into front RH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Loosen and open the Front RH bleeding screw and then press \u201cOK\u201d button. Ensure other end of tube is submerged in liquid, else chances for air entry is high. Click on \u201cYES\u201d button to proceed for \u201cBleeding phase III\u201d. After pressing \u201cYES\u201d button, Press and hold the brake pedal for 3 seconds and then release for 0.5 seconds. Continue above procedure till \u201cBleeding phase IV\u201d ends. In bleeding phase IV\u201d, pump motor switches ON and OFF in a pre defined intervals. While pump motor is ON, brake pedal pulsations can be felt along with the motor operating sound. Connect a transparent tube into Rear RH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Loosen and open the Rear RH bleeding screw and then press \u201cOK\u201d button. Ensure other end of tube is submerged in liquid, else chances for air entry is high. Click on \u201cYES\u201d button to proceed for \u201cBleeding phase IV\u201d. After pressing \u201cYES\u201d button, Press and hold the brake pedal for 3 seconds and then release for 0.5 seconds. Continue above procedure till \u201cBleeding phase IV\u201d ends. In bleeding phase IV, pump motor switches ON and OFF in a pre defined intervals. While pump motor is ON, brake pedal pulsations can be felt along with the motor operating sound. Once again carry-out mechanical bleeding. For additional information refer to Manual bleeding section . Check brake pedal for sponginess. If found spongy, repeat the entire procedure of bleeding. Check and ensure there is no leakage from pipes and joints. Do not spill brake fluid on the vehicle, it may damage the paint, if the brake fluid does contact the paint, wash it off immediately with water. Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. The fluid reservoir cap/ container should not be opened with dirty hands. Avoid direct water spray on reservoir while washing engine compartment. If Maximile DOT 4 Brake fluid is not used and in emergency conditions, use brake Fluid Meeting SAE J1703 FMVSS NO.116 DOT 4 OR IS 8654 TYPE-2 Specification and change it at 30,000 kms or 2 years whichever is earlier. During the bleeding operation ensure the container and pipe used is of transparent for better visual. At all times during the bleeding process, it has to be ensured that the fluid level in the reservoir does not drop below minimum. Brake and Clutch Fluid: - Mahindra Maximile DOT 4 Genuine Brake fluid.Brake and Clutch Fluid: - 1.75 Liters .Position the vehicle on level ground/ 2 post lift /4 post lift. Open the bonnet and lock it in open position using bonnet stay rod. Check Brake fluid reservoir fluid level, if found less than MIN mark, top up to MAX mark. Check the reservoir for leakage and check the level of fluid, if found less top up till MAX mark. Always maintain fluid level at MAX mark on reservoir Check for brake fluid leakage at master cylinder primary & secondary bundy tubes. Check for brake fluid leakage at EHCU primary, secondary and outlets bundy tubes. Check for brake fluid leakage or seepage from front LH/RH flexible hose. Check for brake fluid leakage or seepage from EHCU front bundy tubes to front LH/RH flexible hose joints. Check for brake fluid leakage at front bleeding nipple (both LH & RH side). Check for brake fluid leakage or seepage from front and rear bundy tube joints shown in illustration. Check for brake fluid leakage or seepage from rear brakes bundy tubes (Both LH & RH side) to rear RH/LH flexible hoses joints. Check for brake fluid leakage or seepage from rear both LH/RH wheel cylinder joints. Check for brake fluid leakage or seepage from rear both LH/RH wheel cylinder bleeding nipples. Use recommended fluid & do not mix different brand fluids. In case fluid reservoir replaced, brake and clutch system needs bleeding. Brake/Clutch fluid level & leak check to be done at every service interval (Excludes fluid replacement intervals). Use the same brand fluid for top up; do not top up brake fluid from used and unsealed brake fluid container. The brake/clutch fluid reservoir cap container should not be opened with dirty Avoid direct water spray on reservoir while washing engine compartment. Always use Mahindra Maximile DOT 4 genuine brake fluid. Using trim removal tool, remove the IP panel trim driver side. Using Nose plier, remove the R-clip and the clevis pin from the pedal shank. Using 12 mm socket spanner, loosen and remove the pedal box top mounting bolt. Torque :25 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the pedal box mounting nuts then remove the brake pedal box assembly. Torque :25\u00b15.0 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130330.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the brake pedal assembly for any physical damage. Replace if found any. Position the vehicle on 2 post lift. Using a 21 mm wheel spanner, remove wheel mounting nuts and then remove the front wheel. For vehicles with Alloy wheels,measuring can be done without removing the wheels. Insert the Brake pad gauge between caliper housing and edge of brake pad backing plate and contact Tip of tool housing (A) on rotor machined surface as shown. Brake pad gauge should be in perpendicular to rotor surface while measuring. Push the Rear barrel (E) of tool inward and rotate the barrel to rotate Probe tip (B) of the tool as shown Release the barrel (E) outward upto the probe tip (B) in contact with surface of brake pad back plate as shown Rotate Knurled ring (D) of rear measuring barrel in same direction to view quick reference color pattern (C) and find actual brake pad thickness (In mm). Refer Brake Pad Thickness Vs Quick reference colors table mentioned below Wear Limits: ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "If Measured pad thickness is 1 mm or less, it has to be replaced. New pad thickness: 11.35 mm. Useful Pad thickness: 10.35 mm. Follow the Step 2 to 7 for measuring thickness of Inboard Brake Pad. Inspect the disc thickness at different points. Actual thickness of disc: 30mm. Minimum Useful disc thickness: 28 mm. Refit the front wheel back with the help of mounting nuts and torque tighten it to specified torque value. Follow the above procedure for front other side wheel brake pad and disc inspection. Remove and inspect the brake pads if the vehicle is reported for the following concerns. Brake Shudder. Brake Noise. Brake Squeal and any other brake related concerns. If any one pad is worn out (inboard /outboard) then replace both the pads. If pads on one wheel only are worn, even then replace the other wheels also. Rotate the disc and make sure it is free to rotate. If it is not free to rotate, inspect and rectify. The Pads in the Pad kit should be replace on the respective caliper i.e. assemble < RH > marked pads on RH Caliper and < LH > marked pads on LH Caliper. If the pads are to be reused make sure they are assembled back in the same position as they were when removed i.e., inboard pad on to the piston side and outboard pad to the wheel side. This is possible only when at the time of removal these pads are marked for their positions and kept aside. Never lubricate the pad seating areas as it may lead to jamming. Never polish pad lining with sandpaper. If lining is polished with sandpaper, hard particles of sandpaper will be deposited in lining and may damage disc. When pad lining requires correction, replace it with a new one. After assembly of pads, apply brake pedal 5 - 6 times in static condition in order to make the pads align properly. It is recommended to apply light braking during the road test and avoid heavy and continuous braking during the initial 200kms of run or until the new pads are performing satisfactorily. Never lubricate the pad seating areas as this may lead to jamming. Always ensure that the anti rattle pad clips (small low abutment clip \u2013 sLAC) are replaced whenever the pads are replaced. Always ensure the grease (Wolfracote) between clip & carrier whenever the sLAC clips are removed/replaced. Don\u2019t overload or pull the retraction loop during pad assembling. Don\u2019t use deformed clips & don\u2019t damage the clips during pad insertion. Using hose clip plier detach the vacuum hose clip and remove hose from the brake booster. Disconnect the brake booster electrical connector and detach from the routing clips. Using hose clip plier, release the brake fluid reservoir tank to clutch TMC hose clip then detach the hose. Using cutting plier, remove the R-clip then remove the clevis pin. Using 12 mm socket spanner, Unscrew brake booster mounting nuts and remove the brake booster with TMC. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130024.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Carry out brake switch adjustment setting. Check and top up the brake fluid, If required. Check for the booster diaphragm if found check & replace the assembly. Disconnect battery negative terminal. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Disconnect the wheel speed senor electrical connector. Detach the wheel speed sensor cable from the routing clips. Using 10 mm socket spanner, loosen and remove the wheel speed sensor mounting bolt then remove the sensor. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130227.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the sensor for any physical damage. Replace if found any. Inspect the sensor for foreign particles segregation. Clean if found. Inspect the sensor connector for any damage. Position the vehicle on 2 post lift. Using a 21 mm wheel spanner, Loosen and remove the rear LH wheel. Using a star screw driver, Loosen and remove drum mounting screw. Clean the brakes by blowing compressed air. Check the wheel cylinder for oil leakage.(It is recommended to check the oil seepage from wheel cylinder by lifting the dust boots.) Check the brake lining for wear/cracks. Measure the brake lining thickness by using Vernier caliper. The minimum usable thickness of the rear brake liner is 4.6 mm. Replace when thickness falls Minimum thickness of lining below 1 mm. The brake shoe must be replaced before the rib starts touching the drum. Measure the wear of the brake lining at the maximum worn out place. Place the drum in its position and install the mounting screw. Refit the LH wheel and torque tighten the nuts to specified value. Whenever the brake shoes are replaced, replace both RH & LH assemblies as a set to prevent car from pulling to one side when braking. If there is significant difference in the thickness of the liner on the left and right sides, check parking brake operation/ wheel cylinders piston for free movement. Position the vehicle on a 2 post lift. Parking Brake Operation \u2013 Check & Adjust ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130296.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Apply and release the parking brake 5 times to condition the cables for normal use and Put the parking brake lever into the released position. Check both the rear wheels for free rotation. Position the parking brake lever at 5th notch position . Check both the rear wheels for free rotation, if the wheels are rotate then tighten the adjusting nut 14 mm till the rear wheels can no longer be rotated using hands. Apply and release the parking brake 5 times. Set the parking brake lever into the released position. The rear wheels must be able to turn freely. If not, loosen the adjusting nut gradually until the wheel can turn freely. Brake pads convert the kinetic energy of the car to thermal energy by friction. Two brake pads are contained in the brake caliper with their friction surfaces facing the brake disc which are pressed together against the rotating disc to slow/stop the vehicle. Using 21 mm wheel spanner remove mounting nuts and remove the front RH wheel. Remove front caliper lower mounting bolt using 12 mm socket spanner. Lift the caliper upwards as shown in the illustration. Pull the Brake Pad outwards upto pad contact with clip as shown in the illustration. Twist the pad in anti clock wise direction, lift the pad upwards and remove the pad. Follow Step 4 & 5 for remove another pad. While inserting the pads between the carrier and disc care should be taken that the friction material should be towards the disc. Rotate the disc and make sure it is free to rotate. If it is not free to rotate, inspect andrectify. Before inserting the pads ensure that caliper is returned fully to its position. (Push the caliper inside if necessary). Never polish pad lining with sandpaper. If lining is polished with sandpaper, hard particles of sandpaper will be deposited in lining and may damage disc. When pad lining requires correction, replace it with a new one. While fitting the guide pin ensure that the straight portion of the pin matches with the ear of the calliper body. The Pads in the Pad kit should be replace on the respective caliper i.e. assemble RH marked pads on RH Caliper and LH marked pads on LH Caliper. If the pads are to be reused make sure they are assembled back in the same position as they were when removed i.e., inboard pad on to the piston side and outboard pad to the wheel side. This is possible only when at the time of removal these pads are marked for their positions and kept aside. Never lubricate the pad seating areas as it may lead to jamming. After assembly of pads, apply brake pedal 5 - 6 times in static condition in order to make the pads align properly. It is recommended to apply light braking during the road test and avoid heavy and continuous braking during the initial 200 kms of run or until the new pads are performing satisfactorily. Never lubricate the pad seating areas as this may lead to jamming. Always ensure that the anti rattle pad clips (small low abutment clip \u2013 sLAC) are replaced whenever the pads are replaced. Always ensure the grease (Wolfracote) between clip & carrier whenever the sLAC clips are removed/replaced. Ensure that the sLAC clips are placed properly and fitted in correct direction in the caliper bracket as shown in the illustration. Ensure that the sLAC clips are replaced/swapped diagonally as shown in the illustration. Ensure that no damage or no deformation of retraction loop in the sLAC clips before fitment. Don\u2019t overload or pull the retraction loop during pad assembling. Don\u2019t use deformed clips & don\u2019t damage the clips during pad insertion. Ensure the proper fitment of all the small low abutment clip (sLAC) . Replace sLAC clips with a new one if found any damage or crack. Refit the brake pad by pushing the pad inside the clips in angled approach as shown in the illustration. Rotate the pad in clockwise direction to vertical position and push the pad inside to caliper. Ensure pad touching the clip retraction. Move the caliper downwards and bring back to its original position. For easy movement, pull the caliper outwards a bit and move it down. Chances for piston seal damage is high, so take adequate precaution while moving the caliper downwards. If the pads are changed with a new one, push both the pistons inside before moving the caliper downwards. Refit the caliper bottom mounting bolt and torque tighten to specified torque value. Ensure the sliding pins are greased well, whenever removed or replaced. Torque : 31 \u2013 38 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit the front RH wheel back with the help of mounting nuts and torque tighten it to specified torque value. Torque : 140\u00b110 Nm ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Follow the same procedure for front LH brake pad and caliper inspection. If any one pad is worn out (inboard /outboard) then replace both the pads. If pads on one wheel only are worn, even then replace the other wheels also. Position the vehicle on 2 post lift. Using 21 mm wheel spanner, Loosen and remove the rear LH wheel. Using star screw driver, Loosen and remove drum mounting screw. Using flat screw driver, slide the parking brake retaining lever and Using plier, remove the parking brake cable. Disconnect the parking brake cable connection from the liner assembly. Using plier, remove the liner spring holder. Gently expand and remove the liner assembly carefully. Remove the auto-adjuster and adjuster lever. Using flat end screw driver detach the top shoe return spring and the bottom shoe return spring and remove the liners. Assemble the Liner kit.
Align the shoes and fit bottom return spring. Refit the auto-adjuster and auto-adjuster lever. Refit the top shoe return spring. Refit the liner kit assembly. Refit the liner spring holder. Using plier slide the parking brake retainer lever & fix the parking cable. Refit the brake drum with the help of mounting screw. Refit the LH wheel and torque tighten the nuts to specified value. Whenever the brake shoes are replaced, replace both RH & LH assemblies as a set to prevent car from pulling to one side when braking. If there is significant difference in the thickness of the liner on the left and right sides, check parking brake operation/ wheel cylinders piston for free movement. Remove the hand brake cable lock clip and detach the hand brake cable from back plate. Using 11 mm open end spanner, Loosen brake bundy tube flare nut wheel cylinder end. Torque : 16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew Wheel cylinder mounting bolts and remove the cylinder. Using 17 mm socket spanner, loosen and remove axle shaft mounting nuts. Torque : 90 \u2013 100 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using MST (0505AAA0001ST puller rear axle shaft banjo) remove rear axle shaft, dust shield with brake liner assembly from vehicle To avoid the back plate falling down, using a plastic tag tie it with any other fixed member before the shaft is pulled out. Clean sealant on the axle housing flange, Back Plate and apply new sealant on the housing. Apply Locktite Sealant 5060 during Installation and Ensure that sealer bead is on the inside of screw holes as shown above Bead must be 3 to 6 mm high and 3 to 6 mm wide. Remove Back plate from vehicle. Install in the reverse order of removal. Check and top up the brake fluid, If required. Check the brake back plate any external damage & also check the brake back plate usable thickness, if required replace. Remove the Front stabilizer bar assembly. For additional information refer to Front Stabilizer Bar \u2013 R&R section. Using 24 mm socket spanner, loosen and remove the front lower control arm mounting nuts on chassis. While loosening the nut, hold the bolt using 24 mm ring spanner. Torque tightening should be done without load and with the tyres on level ground. Torque value: 250 \u00b1 20 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 19 mm socket spanner, loosen and remove strut fork mounting bolt. Torque tightening should be done without load and with the tyres on level ground. Ensure to insert the washer before Install the bolt. Torque : 120 \u00b1 12 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a cutting plier, remove the cotter pin from the ball joint Never reuse the split pin, always replace with a new one. Using a 24 mm socket spanner, loosen and remove lower arm ball joint mounting nut. Torque : 130 \u2013 150 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Using a 22 mm socket spanner, loosen and remove knuckle bracket mounting bolts,remove the knuckle lower half. Torque value: 140 \u00b1 10 Nm <n>Torque Wrench Type - Open end Torque Wrench ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Using a hammer, tap strut fork and release it from lower arm. Remove the lower control arm mounting bolts from the vehicle frame. Torque value: 250 \u00b1 20 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the lower control arm from the vehicle Install in reverse order of removal. Pay attention while Installation Torque tightening should be done without load and with the tyres on level ground. LH and RH identification sticker available on part for orientation. Camber and caster bolt marking position required at center Camber and caster bolt should be fitted in the direction of Arrow shown in illustration Inspect the lower control arm for any external damage or bent, if found replace. Inspect the lower control arm ball joint and bushes for any damage. Place the Pan hard on suitable base block. Place the suitable dolly on the Pan hard bush One end. Using a hydraulic press or hammer remove the Pan hard bush one end. Place the Pan hard other end on base block and place the dolly on Pan hard bush. Using a hydraulic press or hammer remove the Pan hard bush other end. Place the Pan hard one end on base block and place the bush installer MST:0401BAA0043ST).on the bush. Using a hydraulic press or hammer, Install the Pan hard bush One end. Panhard bush should be fitted in center of panhard and ensure to maintain equal distance on both side of panhard as shown. Dimensions are in mm. Place the Pan hard other end on base block and place the bush installer (MST:0401BAA0043ST).on the bush. Using a hydraulic press or hammer, Install the Pan hard bush other end. Remove the Front Lower Control Arm. Place the base block (MST:0401BAA0033ST) and place the collar support (MST: 0401BAA0037ST) . on the base block. Place the upper arm one end on the base block. Place the upper arm bush remover(MST: 0401BAA0040ST) on the bottom bush. Place the Pin cage (MST:0401BAA0041ST) & the support cage (MST: 0401BAA0013ST) as shown. Using a hydraulic press remove the upper arm one side (bottom) bush. Place the upper arm other end on the base block (MST: 0401BAA0033ST) and collar support (MST: 0401BAA0037ST) . Place the upper arm bush remover (MST: 0401BAA0040ST) on the bush. Place the upper arm dummy bush (MST:0401BAA0042ST) on the upper side bush seating hole. Place the upper arm pin cage (MST:0401BAA0041ST) & the support cage (MST:0401BAA0013ST) as shown. Using a hydraulic press remove the other side bush. Place the Upper arm on the base block (MST: 0401BAA0033ST) & collar support (MST: 0401BAA0037ST) and place the bush over the upper arm. Place the bush installer (MST:0401BAA0043ST) on the bush. Using a hydraulic press, Install the upper arm one side bush. Place the Upper arm other side on the base block (MST: 0401BAA0033ST) & collar support (MST: 0401BAA0037ST) and place the bush over the upper arm. Place the bush installer (MST:0401BAA0043ST) .on the bush. Using a hydraulic press, Install the upper arm bush. Refit the Front Upper Control Arm. Using a 24 mm socket spanner, loosen the mounting bolt and nut in the chassis end then remove nut from the link. Torque : 230 \u00b1 20 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 21 mm ring spanner. Torque tightening should be done without load and with the tyres on level ground. Torque Wrench Type - Open end Torque Wrench for LH chassis & axle ends. Using a 24 mm socket spanner, loosen and remove the link mounting nut from the axle end. Torque : 230 \u00b1 20 Nm <n>Torque Wrench Type - Open end Torque Wrench for LH chassis & axle ends ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 21 mm ring spanner. Torque tightening should be done without load and with the tyres on level ground. Using a appropriate jack support slightly lift the rear axle. Using a 17 mm socket spanners, loosen and remove the both rear shock absorbers bottom side mounting bolts and nuts. Torque value : 110\u00b111 Nm <n>Torque Wrench Type - Open end Torque Wrench ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. While loosening the nut, hold the bolt using 15 mm ring spanner. Remove the respective side coil spring. Jack up the rear axle slightly. Remove the rear upper link chassis end mounting bolt then remove the front and rear upper link from the vehicle. Pay attention while Installation Bolt should be fitted in the direction of Arrow shown in illustration Inspect the upper link for any damage, crack or twisting. Replace if found any. Inspect the upper link bushes for any damage, crack or material deterioration. Replace the bushes if found any. Remove the Rear Lower Link. Place the base block (MST:0401BAA0033ST) & place the Rear Lower and Upper Link Coller (MST :0401BDD0001ST) . Place the Lower link one end on the base block. Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) on the lower link one end bush. Using a hydraulic press, remove the lower link one end bush. Place the Lower link other end on the base block. Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) on the lower link other end bush. Using a hydraulic press, remove the lower link other end bush. Place the Lower link one end on then base block and place the bush over the lower link. Place the Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press While Installation ensure to maintain Bush Void at 45\u00b0 angle as shown. Ensure to Install the Bush with Void end should be fitted in Chassis end on vehicle. Place the Lower link other end on the base block and place the bush over the lower link. Place the Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press. Refit the Rear Lower Link. Using a 13 mm socket spanner , loosen and remove the brake hose routing bracket mounting nut. Using a 19 mm socket spanner , loosen and remove the strut fork mounting bolt at lower arm end and detach it. Torque : 120 \u00b1 12 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Using hammer, tap strut fork graduall and release strut fork from lower arm. Using a 17 mm ring spanner, loosen and remove the strut top mounting nuts from chassis. Torque value: 40 \u00b1 5Nm <n>Torque Wrench Type - Open end Torque Wrench ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Detach Wheel speed sensor routing clips from upper control arm. Using 14 mm socket spanner and 18 mm open end spanner, unscrew upper arm bolt and nut and detach partially. Torque value: 97\u00b1 10 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170137.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Remove front strut assembly from front suspension. LH and RH identification sticker available on part for orientation. Using a 17 mm socket spanner and 19mm open end spanner, loosen the fork ounting bolt and nut and remove fork from strut assembly. Install in reverse order of removal. Check for the coil spring for any damage, crack etc. Check for oil leakage from the shock absorber. Remove the Rear Upper Link. Place the base block (MST:0401BAA0033ST) & Place the Rear Lower and Upper Link Coller (MST : 0401BDD0001ST) . Place the upper link one end on the base block. Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) on the lower link one end bush. Place the upper link other end on the base block. Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) on the upper link other end bush and Using a hydraulic press, remove the bush. Place the upper link one end on then base block and place the bush over the upper link. Place the bush & Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press While Installation ensure to maintain Bush Void at 90\u00b0 angle as shown. Place the upper link other end on the base block and place the bush over the upper link. Place the bush & Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press. Refit the Rear Upper Link. Using a appropriate jack support and slightly lift the rear axle. Using a 24 mm deep socket spanner,loosen and remove the pan hard rod mounting nut and bolt from chassis side. Torque : 230\u00b1 20 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt with the help of 21 mm deep socket. Torque tightening should be done without load and with the tyres on level ground. Using a 21 mm socket spanner, loosen and remove the pan hard rod mounting bolt from axle side. Torque : 230\u00b1 20 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Remove pan hard rod separately. Yellow color all round marking added on Pan hard rod to identify chassis end. Install in reverse order of removal. After installation of pan hard rod remove the jack support. Pay attention while Installation. Bolt should be fitted in the direction of Arrow shown in illustration. While Installation, ensure to refit the Anti Rotation Bracket in the axle end bold side. Inspect the pan hard rod for any external damage/bend or crack, if found replace. Preliminary Activities/Conditions ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": " Position the Vehicle on 4 post lift. Check lower control arm front and rear bush condition (both LH & RH) for wear & tear, cracks & shift. Replace if necessary. Check upper control arm front and rear bush condition (both LH & RH) for wear & tear, cracks & shift. Replace if necessary. Check the ball joint boots for damage, cracks, replace if necessary. Check shock absorber bushes, shock absorber dust boot, stabilizer bar bushes,stabilizer bar link boots, bump stop for wear & tear, cracks and shift, replace if necessary. Check the lower link, pan hard rod, Upper link, stabilizer bar and stabilizer bar links bushes for any damage/crack or deterioration. Replace the bushes if found any. Check shock absorber bushes, dust boot & bump stop for wear, crack and shift. Preliminary Activities/Conditions ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " Position the Vehicle on 4 post lift. Inspect front suspension lower control arm for any bend, damage or crack. Inspect front suspension upper control arm for any bend, damage or crack. Inspect front suspension stabilizer bar for any bend, twisting, damage or crack. Inspect rear suspension lower link for any bend, damage or crack. Inspect rear suspension upper link for any bend, twisting, damage or crack. Inspect rear suspension panhard rod for any bend, twisting, damage or crack. Inspect rear suspension stabilizer bar for any bend, twisting, damage or crack. Inspect front & rear suspension stabilizer bar link for any bend, twisting, damage or crack. While tightening the link & torquing ensure that wheels are resting on the ground/ 4post lift. If it is not done, the ride quality will get adversely affected. Remove the Front Lower Control Arm. Place the base block (MST:0401BAA0033ST) and place the Front Lower Arm Big End Bush Collar (MST: 0401BBB0001ST) . on the base block. Place the Lower arm big bush end over the fixture. Place the LCA big bush remover (MST: 0401BAA0038ST) and Front Lower Arm Bushs Support tool (MST: 0401BBB0002ST) on the big end bush. Place the Pin cage (MST:0401BAA0019ST) & the support cage (MST:0401BAA0013ST) as shown. Using a hydraulic press, remove the lower arm big end bush. Place the LCA small bush end on the base block (MST: 0401BAA0033ST) and LCA small bush collar support (MST : 0401BAA0036ST) . Place the Lower arm small bush end over the fixture. Place the LCA small bush remover (MST: 0401BAA0039ST) & Front Lower Arm Bushs Support tool (MST :0401BBB0002ST) over the lower arm bush. Place the dummy bush (MST:0401BAA0016ST) on the big end bush seating hole. Place the Pin cage (MST:0401BAA0019ST) & support cage (MST:0401BAA0013ST) as shown. Using a hydraulic press, remove the LCA small bush. Place the lower arm on the base block (MST: 0401BAA0033ST) . Place the bigger end bush on the lower arm & place the bush installer (MST: 0401BAA0044ST) on the bush. Lower arm big end bush has Void profile and While Installation ensure to maintain Bush Void at appropriate angle as shown. Using a hydraulic press, Install the lower arm big end bush. Place the lower arm small end on the base block (MST: 0401BAA0033ST) Place the lower arm small end bush & the installer (MST: 0401BAA0045ST) . Using a hydraulic press, Install the lower arm small end bush. Refit the Lower Upper Control Arm. Support the rear axle using the appropriate hydraulic jack. Using a 17 mm socket spanners, loosen and remove the both rear shock absorbers bottom side mounting bolts and nuts. Torque value : 110\u00b111 Nm <n>Torque Wrench Type - Open end Torque Wrench ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. While loosening the nut, hold the bolt using 15 mm ring spanner. Remove the rear coil spring and pad securely from vehicle. Install in reverse order of removal. Pay attention while Installation Locking lug to be matched with hole on Rear Coil spring dome bracket of Chassis Yellow coloured PU sleeve should be on chassis side while assembling the coil spring ashown in illustration. Inspect the coil spring for any damage, crack. Replace if found. Inspect the coil spring pad for any damage. Replace if found. Remove the Front strut assembly. Using a spring compressor compress the strut coil spring. Ensure that the spring compressor is tightened with the spring, else expansion of the spring cause severe injury. Using a 6 mm open end spanner hold the shock absorber & using a 16 mm ring spanner remove the mounting nut. Remove the shock absorber washer & bush. Remove the bracket coil spring guide assembly. Remove the coil spring seat. Remove the compressed coil spring. Remove the shock absorber bush. Remove the bump stopper cap. Remove the shock absorber dust seal. Remove the front bump stopper. Remove the shock absorber. Inspect shock absorber for oil leak. Inspect the dust seal for damage, if found replace. Check the bush condition, if worn out please replace. Install the front bump stopper on the shock absorber. Install the shock absorber dust seal. Install the bump stopper cap. Install the shock absorber bush. Install the compressed spring. Install the coil spring seat. Install the coil spring bracket. Install the shock absorber washer & bush. Install the mounting nut. Install the top mounting nut. Torque tighten the nut to specified value. Torque : 40 \u2013 45 Nm <n>Torque Wrench Type - Open end Torque wrench ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the spring compressor tool. Using a cutting plier, remove the cotter pin from the ball joint Never reuse the split pin, always replace with a new one. Using a 24 mm socket spanner, loosen and remove the upper control arm ball joint nut. Torque : 90 \u2013 110 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Detach the wheel speed sensor routing clips from the upper control arm. Using a 18 mm ring spanner, hold the mounting nut & using an 14 mm socket spanner loosen the bolt, remove the bolts & nuts. Torque : 97 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Detach and remove the upper control arm. Install in reverse order of removal. Pay attention while Installation Bolt should be fitted in the direction of Arrow marks shown in illustration Inspect the upper control arm for any external damage or bent, if found replace. Remove the rear shock absorber. Place the rear shock absorber one end on the suitable base block. Place the suitable dolly on the rear shock absorber. Using a hydraulic press or hammer remove the rear shock absorber bush. Place the rear shock absorber one end on then base block and place the bush over the rear shock absorber. Place the bush & Installer rear shock absorber End Bush (MST) over the bush and Refit the bush by loading the hydraulic press Refit the rear shock absorber, Support the rear axle using the appropriate hydraulic jack and lift the vehicle to compress the coil springs. Using a 17 mm socket spanners, loosen and remove the bottom mounting bolts and nuts of rear shock absorbers from the rear axle. Torque value : 110\u00b111 Nm <n>Torque Wrench Type - Open end Torque Wrench ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. While loosening the nut, hold the bolt using 15 mm ring spanner. Using a 14 mm socket spanner, loosen and remove the top mounting bolts of both rear shock absorbers from the chassis. Torque value : 65\u00b110Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Remove the shock absorber from the vehicle. Install in reverse order of removal. Pay attention while Installation Bolt should be fitted in the direction of Arrow shown in illustration Ensure the arrow on Rear Shock absorber should be on rear side of vehicle. Inspect the shock absorber for any damage or oil leakage, replace if found any. Inspect the shock absorber bushes for any damage. Wheel alignment (adjustment of Camber, Caster and Toe) is part of standard automobile maintenance that consists of adjusting the angles of the wheels so that they are set to the specification. The purpose of these adjustments is to reduce tyre wear, and to ensure that vehicle travel is straight and true (without pulling to one side). Wheel alignment consists of adjusting the angles of the wheels so that they are perpendicular to the ground and parallel to each other. The purpose of these adjustments is maximum tyre life and a vehicle that tracks straight and true when driving along a straight and level road. The symptoms of a vehicle that is out of alignment are: Uneven or rapid tyre wear, Pulling or drifting away from a straight line, Wandering on a straight level road, Spokes of the steering wheel off to one side while driving on a straight and level road. Before doing wheel alignment, ensure front and rear tyre pressure are as per specifications.Vehicle to be run for some distance before starting the wheel alignment. This will settle the load on each tyre. Ensure that the turn table & roller plate move freely to avoid suspension block & no rocking of turn tables. Check for any damage of the rims or bushes & suspension joints/ wheel end for play. Ensure that the front turntables & rear plates are at the same level. Do the setting of steering wheel for Straight Ahead Position (SAP) and lock the steering column rotation. Refer the wheel alignment specification chart for the front Suspension. Refer decision tree for wheel alignment: Wheel Alignment Sequence <n>Run Out Compensation ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U3A130002.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": " If above sequence is not followed, it will lead to incorrect wheel alignment even though individual adjustments are done correctly. Park the vehicle on 4 post wheel alignment equipment to do the run-out compensation. Refer wheel alignment equipment manufacturer's guide lines while doing run-out compensation. Steering Straight Ahead Position Setting ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": " Keep the wheels on turntables of the wheel alignment machine. Rotate the steering wheel to LHS lock position. From LHS lock position, rotate steering wheel to RHS Lock position. Count the number of turns of steering wheel from LHS to RHS lock position. From RHS lock position, rotate steering wheel exactly half the number of turns towards LHS. Lock the steering wheel. If the steering straight ahead does not match the wheel straight ahead, then adjust the OBJ of the desired side. Ensure that the silent bushes in the front suspension are in satisfactory condition. Ensure that the front suspension fasteners are tightened to specified torque. Ensure that there is no play in steering linkages and suspension ball joints. Follow instruction manual of wheel aligning system manufacturer. Wheel Alignment - Check & Adjust <n>Specification for Wheel Alignment <n>Front Suspension ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20183.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": " Wheel alignment consists of adjusting the angles of the wheels so that they are parallel to each other and perpendicular to the ground, thus maximizing tyre life and ensures straight and true tracking along a straight and level road. Front Suspension <n>Steering Angle Parameters ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20184.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Wheel alignment procedure to be done in vehicle unladen condition only Do wheel alignment only according to manufacturer's specifications. Front tyre should have uniform wear and inflated to recommended pressure. Ensure that hub play is correct. Ensure that the front suspension fasteners are tightened to specified torque. Ensure that there is no play in steering linkages and suspension ball joints. Camber is defined as the inward or outward tilt of the top of the wheel as viewed from the front. While adjusting camber angle vehicle should be unladen and nobody should sit inside. The camber values should be within: 0\u00e2\u0081\u00b0 \u00b1 0.2\u00e2\u0081\u00b0. The difference between two wheels should be within: 0\u00e2\u0081\u00b0\u00b1 0.4\u00e2\u0081\u00b0. Using a 24 mm socket spanner, loosen the camber bolt locking nut. While loosening hold the bolt with the help of a 24 mm ring spanner. To adjust camber angle, rotate the camber bolt using 24 mm ring/socket spanner, to clockwise or anti clockwise direction. Clockwise rotation will reduce the camber angle and anti-clockwise rotation will increase the camber angle. After adjusting camber angle tighten the camber bolt locking nut and recheck the camber angle. The angle between the vertical line and king pin, which fixes the steering knuckle and front axle, (steering column which connects the top and bottom ball joints in the independent axle type) when viewed the tyres from the side is called caster angle. While adjusting caster angle vehicle should be unladen. The values should be within: 4.2\u00b0 \u00b10.4\u00b0. The difference between two wheels should be within: 0\u00b0 \u00b1 0.4\u00b0 Adjust caster bolt until red zone becomes green. (Only if wheel alignment is out of specs). Using a 24 mm socket spanner, loosen the caster bolt locking nut. While loosening the nut, hold the bolt using 24 mm ring spanner. To adjust castor angle, rotate the caster bolt to clockwise or anti clockwise direction using 24 mm socket spanner. Clockwise rotation will decrease the caster angle and anti-clockwise rotation will increase the caster angle. Toe is the difference of measured distances between the front ends of the tyres (A) and the rear ends of the tyres (B) along the same axle when viewed the wheels from the top. Front Toe In to be adjusted individually on LH and RH side tie rod ends. The values should be within: 4.2\u00b0 \u00b10.4\u00b0. Front Total toe between two wheels should be within: 0.23\u00e2\u0081\u00b0 \u00b1 0.1\u00e2\u0081\u00b0. Using a 19 mm open end spanner, hold tie rod end first and then loosen tie rod end lock nut with the help of 19 mm open end spanner. Using a 14 mm open end spanner, Toe-in is adjusted by varying the length of tie rods. While adjusting toe-in, adjust the length of both the tie rods by rotating them in the same direction such that their lengths remain equal at all times. Perform steering angle sensor (SAS) calibration if steering wheel is removed and adjusted during straight ahead position setting and procedure as below. After adjusting the length of tie rods, recheck toe in and then hold tie rod end with 19 mm open end spanner and then tightening locknut with 19 mm open end spanner. Ensure the Steering Wheel is at center and the front wheels are straight. Connect the i-SMART diagnostic tester and turn the ignition ON . Launch i-SMART Select ABS ECU and Navigate to Write Data . Select the WRITE DATA tab. Click on \u201cROUTINE SELECTION\u201d drop down list and select \u201cSteering Angle Sensor Calibration\u201d . Click on \u201cSTART ROUTINE\u201d to initiate the SAS Calibration. Ensure the Steering Wheel is at center and the front wheels are straight. The following pop up window appears once the SAS Calibration completed. Press \u201cOK\u201d button to complete SAS Calibration through i-SMART. Refer wheel alignment equipment manufacturer's guide lines for wheel turning angle check. Ride height is to be measured from wheel arch center (Bottom Surface) to ground for both front and rear in unladen condition. Front ride height : Front wheel arch center (Bottom Surface) to ground.Rear ride height : Rear wheel arch center (Bottom Surface) to ground.R16 SF 6S - Rim Size 16, Side Facing 6 SeaterR16 FF 4S<M</b> - Rim Size 16, Front Facing 4 Seater R18 FF 4S - Rim Size 18, Front Facing 4 SeaterCorrect Wheel alignment values. Recommended Tyre pressure. DEF tank filled full. Fuel tank filled 90%. Spare Wheel mounted. Correct tyre pressure. Coil spring damage. Loosened suspension mounting bolts. Rubber bushes of UCA and LCA. Position the vehicle on a 2 post lift and Raise the vehicle. Prior to inspect the ball joint, inspect the wheel bearings for any play. Check 1 On Vehicle. Inspect the ball joint for relative movement by, grasp the top and bottom of the wheel and rock it in and out along the wheel\u2019s vertical axis. Observe any relative movement between the wheel knuckle and ball joints. Ensure wheel nuts/bolts are not in loosen condition while checking, as that may cause movement when rocking the wheel. If relative movement play is little or no play then the ball joint is in good condition. If relative movement play that seems excessive or noises, then Visual check the ball joints. Any noises or play heard towards the top are most likely indicative of a problem with the upper ball joint, while, any play or noise coming from the bottom of the wheel are probably indicative of a problem with the lower ball joint. Check 2 (On Vehicle) ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Take a pry bar and place it between the lower control arm and the steering knuckle, the two parts that are connected together by the ball joint and attempt to pry them apart. Loose ball joints will have an excessive amount of play and movement when you pry on them, may even make knocking or clicking sounds. Check 3 On Vehicle \u2013 Visual Inspection ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170172.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Inspect the ball joints for any signs of rust, damage to the dust boot, grease leakage, or other potential problems that may indicate a need for replacement. Check the looseness of ball joints in Control arms. Remove the Ball joints from Vehicle. Refer Respective Ball Joints R&R Section. Check 4 Off Vehicle ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Check the ball joint for free rotational torque by rotate the ball pin through the periphery of ball joint cup for checking the movement. Replace the ball joint only if movement is found jerky during rotation. Check the Axial lift by holding the ball Joint and lifting the ball pin in upward direction. If the play was observed more than 0.5 mm replace the ball joint. Lift the ball pin by one hand & hold the lower end of ball joint grounded by other hand. Refer the procedure given below for SAP setting ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Keep the wheels on turntables of the wheel alignment machine. Rotate the steering wheel to LHS lock position. From LHS lock position, rotate steering wheel to RHS Lock position. Count the number of turns of steering wheel from LHS to RHS lock position. From RHS lock position, rotate steering wheel exactly half the number of turns towards LHS. Lock the steering wheel. If the steering straight ahead does not match the wheel straight ahead, then adjust the OBJ of the desired side. Ensure that the silent bushes in the front suspension are in satisfactory condition. Ensure that the front suspension fasteners are tightened to specified torque. Ensure that there is no play in steering linkages and suspension ball joints. Follow instruction manual of wheel aligning system manufacturer. Using a 24 mm socket spanner loosen and remove the rear lower link front and rear mounting nuts and bolts. Torque value: 230 \u00b1 20 Nm <n>Torque Wrench Type - Open end Torque Wrench for LH chassis side ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 21 mm ring spanner. Torque tightening should be done without load and with the tyres on level ground. Detach the rear wheel speed sensor routing from the lower link Remove the rear lower link from the vehicle. Install in reverse order of removal. Pay attention while Installation Bolt should be fitted in the direction of Arrow shown in illustration Inspect the rear lower link for any damage. Replace if found. Inspect the rear lower link bushes for any damage. If found replace Using 10 mm socket spanner, unscrew glass channel mounting nuts and detach the run channel beading from the channel and take out the channel from door. Torque :5\u00b11 Nm ",
+ "file": "",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the door latch electrical connector. Detach the mounting link from latch to exterior door handle. Detach link from the handle lever. Using a 5 mm Allen key, Unscrew the latch to door mounting Allen screws. Torque : 7 Nm ",
+ "file": "",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the front door latch assembly separately. Install in the reverse order of removal. Inspect the latch assembly for any damage, replace if found. Inspect the linkages for any damage or bend. Open the bonnet and lock it using bonnet stay rod. Using a star screw driver, loosen and remove both side front splash shield mounting screw rivets. Remove both front splash shields from vehicle. Using a 10 mm socket spanner, loosen and remove the front stone guard front mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen and remove the rear stone guard rear mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the stone guard mounting screw rivets. Remove the stone guard from the vehicle. Disconnect the fog lamp electrical connectors LH & RH sides. Pull and remove the front bumper top panel trim clips and remove the panel. Using a 10 mm socket spanner, Unscrew front bumper mounting nuts. Torque : 4.0\u00b10.5Nm ",
+ "file": "/files/W4A290004.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, Unscrew front bumper bottom mounting bolts. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew front bumper top side mounting bolts. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front bumper top centre mounting screw rivets. Remove the front bumper assembly from the vehicle. Using a 13 mm socket spanner, Unscrew front bumper center bracket mounting bolts and remove the front bumper center mounting bracket. Torque : 10.0\u00b11 Nm ",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the front grill mounting screw rivets. Using a star screw driver, loosen and remove the bottom side front grill mounting screw rivets. Using a 10 mm socket spanner, loosen and remove the front grill mounting bolts. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Remove the front grill assembly from the vehicle. Using a 10 mm socket spanner, Unscrew hood catcher mounting nuts both the sides. Torque : 7 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380105.jpg",
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Remove the hood catchers from the vehicle. Install in the reverse order of removal. Inspect the hood catcher for any damages. Replace if found any. Disconnect the front door window glass motor electrical connector. Using a 10 mm socket spanner, loosen and remove the front door window glass mechanism to door mounting nuts. Torque : 10.50 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the front door window glass mechanism separately. Install in the reverse order of removal. Inspect the glass for any damage. Replace if found. Inspect the regulator for any damages, Replace if found any. Using a star screw drive, unscrew tail door handle top mounting screw and remove the cover. Carefully pull and detach the outer door handle from tail door. Using a star screw driver, unscrew handle inside support mounting screw from the tail gate. Torque : 1.3 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal. Inspect the rear door exterior handle for any damages. Replace if found any. Pull out the bonnet latch cable and open the bonnet. Lock it using bonnet stay rod. Disconnect cable guide and link from latch. Detach cable from routing clips. Press the lock and pull lever to detach bonnet cable lever with cable and take out the cable from the vehicle. Install in the reverse order of removal. Inspect the bonnet cable for any damage, replace if found. For Softtop Variants, For additional information refer to Tail Door Inner Handle - R&R Section. Disconnect tail door latch electrical connector. Disconnect latch lever from the key lock and handle. Using a 5mm allen key, unscrew the tail door latch mounting screw. Torque : 7 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully detach tail door latch. Install in the reverse order of removal Inspect the latch assembly for any damage, replace if found. Remove the Front Door Window Glass Regulator LH. Using a T20 torx socket spanner, unscrew the regulator motor mounting screws. Torque : 2.5 to 3 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380081.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the glass for any damage. Replace if found. Inspect the regulator for any damages, Replace if found any. Disconnect cable guide and link from latch. Using a 10 mm socket spanner, unscrew bonnet latch mounting nuts. Torque : 10.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the bonnet latch from hood. Install in the reverse order of removal. While Installation, hand tighten the latch mounting nuts first and align the latch in appropriate position. And ensure smooth locking of latch in holding bracket , finally torque tighten the mounting nuts. Inspect the bonnet latch for any damage, replace if found. Remove the wiper washer nozzles. For additional information refer to the Wiper Washer Nozzle Front - R &R; section. Remove the stay rod. For additional information refer to the Stay Rod - R &R; section. Remove the wiper hose routing clips from the bonnet. Remove the bonnet rubber beading from the bonnet. Using 12 mm socket spanner, loosen and remove the bonnet catcher bracket mounting bolts (Both sides). Torque : 13.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260054.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260053.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using T40 socket spanner, loosen and remove the bonnet mounting bolts. Torque : 24\u00b14 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260061.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the bonnet from the vehicle. Install in the reverse order of removal. Inspect the bonnet hinges for any crack or damage. Replace if found. Remove Side window RH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Remove Side window LH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Unzip the tail gate window, detach the tail gate bar locking from rear RH & LH belt rails remove the tailgate window. Unhook the \u2018C\u2019 pillar cover from rear RH & LH belt rails and fold the cover at top of the soft top. Using a T30 socket spanner, loosen and remove the belt rear rail Mounting bolts and remove the belt rail from the vehicle. Follow the same procedure for LH side. Remove the seal from the body. Install in the reverse order of removal. Inspect the tail door half seal for any damage or wears. Replace if found any. Remove Front Door Trim RH. For additional information refer to Front Door Trim RH- R &R; Section. Detach the key handle lever from the key lock set. Detach lock holding bracket and remove key lock from the vehicle. Install in the reverse order of removal. Remove Tail Door Trim. For additional information refer to Tail Door Trim RH- R &R; Section. Detach the key handle lever from the key lock set. Detach lock holding bracket and remove key lock from the tail door. Install in the reverse order of removal. Remove Glove Box Assembly. Using Screw driver, remove Glove box Latch mounting screws and remove the latch from the glove box. Using Screw driver, Remove Lock from Latch by pressing lock locking clips. Install in the reverse order of removal. Using vehicle key open the fuel filler door. Using Screw driver, detach lock holding bracket and remove key lock from the fuel lid door. Install in the reverse order of removal. Inspect the key locks for any damage or wears. Replace if found any. Lift and open the tail gate glass. Using a screw driver carefully lift and open the gas strut lock at both the ends. Carefully remove tail gate glass gas strut. Install in the reverse order of removal. Inspect the gas strut assembly for any damage, replace if found. Pull the door outer handle and slowly close the door with outer door handle pulled in condition. Check and feel for the condition of latch fouling with striker. If the latch fouling with the striker then loosen the striker mounting screws and align the striker so that there is no fouling. Tighten the striker mounting screws to specific torque Torque : 23.5 \u00b1 2.5 ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "Ensure that door closing should be smooth and latch is not foul on the striker Follow the same procedure for other doors. Lower the window glass to prevent from damage. Disconnect door accessory electrical connector. Protect the electrical connectors to avoid water entry, which may leads to short circuit. Detach the wiring harness bunch from holding bracket \u2018A\u2019 Pillar end. Using 12 mm socket spanner, Unscrew door stopper mounting bolts BIW end. Using T40 Torx Socket, Unscrew door hinge pin at bottom of the hinge. Carefully lift and remove the door assembly from vehicle. Refit in the reverse order of removal. Key IN Reminder & Park Lamp Reminder will not function in case of driver door is removed. Roof lamp will not work with respect to door status Lock & Unlock functions will not work through Master Actuator in case of driver door is removed Hinge pin can break if overtightened during door reinstall \u2014 Max. Torque 10 Nm. Doors are heavy, Take at most care when removing the doors, Failing to this may cause personal injury After Door removal vehicle will be left with only IRVM (as ORVM\u2019s fitted on doors) In such scenario driving the vehicle on road is not permitted as per regulations. Do not drive your vehicle on public roads with the doors removed as you will lose the protection they can provide. This procedure is furnished for use during off-road operation only All occupants must wear seat belts during off-road operation with doors removed. Disconnect the Door wiring harness electrical connector and detach WH bunch from \u2018A\u2019 pillar lower. Using 12 mm socket spanner, Unscrew door stopper mounting bolt BIW side. Torque : 23.5 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260006.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew door hinge mounting bolts from body. Torque : 50 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260041.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the door assembly from vehicle. Support the door while removing the bolts. Using star screw driver , Unscrew door hinge mounting screw door end. Torque : 24\u00b1 4.0 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Before tightening the bolts align the door assembly correctly, else door operation won\u2019t be smooth.. Refit in the reverse order of removal. Do the door alignment, if required. Inspect the door hinge for any damage. Replace if required. Remove the tail door trim. For additional information refer to the Tail Door Trim- R&R; section. Remove the tail door electrical connector and remove the wiring routing clips from the tail door. Using a screws driver, loosen and remove the mounting screws from the hinges. Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260018.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, loosen and remove the stopper mounting bolt from the Body. Torque : 23.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260119.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the hinge mounting bolts inside tail door. Torque : 50\u00b15 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260033.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Ensure to hold the tail door with spare wheel properly while remove, failing will lead door falling down which may lead to personal injuries. Using 12 mm socket spanner, loosen and remove the Hinge Mounting bolts from body. Torque :27\u00b14 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the tail door hinges for any physical damage, replace if found. Remove the spare wheel carrier. Remove the tail door trim. For additional information refer to the Tail Door Trim - R &R; section. Remove the tail door latch. Remove the tail door inner handle . For additional information refer to the Tail Door Inner Handle - R &R; section. Remove the tail door outer handle . Remove the tail door Stopper. For additional information refer to the tail door Stopper section. Remove the tail door lock. For additional information refer to the Tail Door Lock section. Remove the tail door weather strip from the tail door. Remove the tail door electrical connector and remove the wiring routing clips from the tail door. Using a Screws driver, loosen and remove the mounting screws from the hinges. Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260018.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, loosen and remove the Stopper Mounting bolt from the Body. Torque : 50\u00b15 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260119.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, loosen and remove the hinge mounting bolts inside tail door. Torque : 50\u00b15 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260016.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Remove the tail door from vehicle. Install in the reverse order of removal. Inspect the tail door for any physical damage, replace if found Disconnect the demister electrical connectors. Using 4 mm Allen key, Unscrew glass hinge mounting screws. Torque : 2.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260077.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260076.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260118.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using the screw driver Unlock the strut to detach the strut and remove the glass. Ensure to hold the Rear Windshield glass while detach the struts, failing to hold leads to glass falling. Using 10 mm socket spanner, Unscrew strut bracket mounting bolts from glass. Torque : 5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Ensure not to over tigthen the strut bracket mounting bolts while Installation. Remove strut mounting grommet and cap nuts from the glass. Install in the reverse order of removal. Inspect the rear windshield glass for any damage or wears. Replace if found any. Remove the hard top assembly. Remove the seal from the body. Install in the reverse order of removal. Inspect the tail door half seal for any damage or wears. Replace if found any Remove the scuttle grill. Using T40 socket spanner, loosen and remove the bonnet mounting bolts. Torque : 24\u00b14 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260058.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the bonnet hinge mounting bolts from the body and detach hinge. Torque : 24\u00b14 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260055.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the hood hinge from the bonnet. Install in the reverse order of removal. Inspect the bonnet hinges for any crack or damage. Replace if found. For additional information refer to Front LH wheel Hub \u2014 R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-0006,1014,1245",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Front Stabilizer Bar. For additional information refer to Front Stabilizer Bar \u2014 R&R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front LH wheel speed sensor mounting bolt and remove the sensor.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150026.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": " Torque : 9 \u00b1 1 Nm",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the wheel speed sensor routing clips from the upper control arm.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170123.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using cutting plier, remove upper arm ball joint cotter pin.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150027.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Never reuse the cotter pin, always replace with a new one.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 24 mm socket spanner, unscrew upper arm ball joint mounting nut.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150028.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": " Torque : 90 \u2013 110 Nm",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using suitable lever, partially detach the knuckle and remove the drive shaft.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150029.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Pull the drive shaft downwards and remove it.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150030.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150031.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 24
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Move the joint up, down, left, right, and in axial direction. Check for any rough movement or significant looseness.Remove Front LH drive shaft. Using 10 mm socket spanner, Unscrew electric disconnect housing mounting bolts Replace the Inboard Oil Seal once removed. For additional information refer to E-Disconnect stone guard \u2013 R &R section. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect E \u2013 Disconnect electric connector. Using 10 mm socket spanner, Unscrew electric disconnect housing mounting bolts and Carefully remove the E-Disconnect Housing with Fork . Torque : 17\u00b12 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150265.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using circlip plier remove the intermediate shaft circlip from housing. Tool should not damage the splines on the axle shaft this affects disconnect operation. Pull out the axle shaft from wheel end side of e-disconnect housing. Using MST 0502AUA0008ST Front Axle Tube Needle Bearing Puller, remove the Needle bearing from e-disconnect housing LH side. By using MST 0502AUA0007ST - F Axle Tube Needle Bearing Dolly, Install the LH Side needle bearing In the disconnect housing. Clean and Insert the axle shaft through wheel end side of the disconnect housing. Align the shifter sleeve on the intermediate shift through disconnect housing window and Install the circlip on the axle shaft with the help of circlip tool. Ensure there should not be excessive play between two shafts this affects the disconnect. Install the new cover gasket while locating in the dowel on the disconnect housing. Ensure to use New Gasket while Installation. Ensure the cleanliness of disconnect housing cover face and cover resting face. Do not bent the wrap the Gasket while installing. Gasket orientation is fixed by dowel on the disconnect housing hence it will fit in one direction only. Bent or warped cover gasket may lead to leak during running. Locate the disconnect cover on the dowel and install the bolts. Tighten the mounting bolts to specified torque value. Ensure to use New bolts while Installation. Apply locktite sealant on the bolts while installing, this avoid the leakthrough cover. Torque : 17\u00b12 Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Connect e-Disconnect electrical connector. For additional information refer to E-Disconnect stone guard \u2013 R &R section. ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, refit the Oil seal on the housing. Refit Front LH drive shaft. Inspect the Front axle Tube Needle Bearing for any damage, Replace if necessary Remove Front LH drive shaft. Using MST 0502AUA0002ST Front Axle Shaft Inboard Oil Seal Puller, remove the Oil seal from the housing. Replace the Inboard Oil Seal once removed. Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, refit the Oil seal on the housing. Refit Front LH drive shaft. Inspect the axle shaft Inboard Oil Seal for any damage, Replace if necessary. Remove Front RH drive shaft. Position the Special tool support piece inside the axle housing and using MST 0502AUA0002ST Front Axle Shaft Inboard Oil Seal Puller, remove the Oil seal from the housing. Replace the Inboard Oil Seal once removed. Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, refit the Oil seal on the housing. Refit Front RH drive shaft. Inspect the axle shaft Inboard Oil Seal for any damage, Replace if necessary. Using 8 mm socket spanner, Unscrew front propeller shaft mounting bolts/nuts at front axle end. Torque : 19\u00b13 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Front LH drive shaft. Drain the front differential oil. For additional information refer to Front differential oil draining and filling procedure. Remove Front RH Wheel Hub. Using 10 mm socket spanner, Unscrew front RH wheel speed sensor mounting bolt and remove the sensor. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Detach the wheel speed sensor from routing bracket. Using cutting plier, Remove upper arm ball joint cotter pin. Never reuse the cotter pin, always replace with a new one. Using 24 mm socket spanner, unscrew upper arm ball joint mounting nut and remove the ball joint. Torque tightening should be done without load and with the tyres on level ground. Torque : 90 \u2013 110 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove E-Disconnect stone guard. For additional information refer to E-Disconnect stone guard \u2013 R &R; section. Disconnect E \u2013 Disconnect electric connector. Provide a jack to support front axle. Using 19 mm socket spanner, unscrew front axle mounting bolts and partially remove the axle downwards. Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Partially detach the knuckle an remove the drive shaft by using a suitable lever. Pull the drive shaft downwards and remove it. Remove the front axle assembly from Vehicle. Install in the reverse order of removal. Refill the front axle oil upto Max level. For additional information refer to Front differential oil draining and filling procedure. Check the axle shaft for straightness, cracks, damage, wear or distortion, replace it if necessary. Check the axle case for yield, deformation or cracks, replace if necessary. Inspect front axle for any oil leakage, seepage. Drain the Front Differential Oil. For additional information refer to Front differential oil draining and filling procedure. Remove the Front Axle Assembly. Mount the Front Axle Assembly on a suitable stand. Using 15 mm socket spanner, Unscrew front axle RH bracket mounting bolts and remove the RH bracket. Using 13 mm socket spanner, Unscrew differential assembly cover bolts and remove the cover. Clean the sealant on cover & banjo housing. Liquid sealant is used to seal cover with banjo beam. Scrap the sealant and clean the cover and banjo surfaces. Using 10 mm socket spanner, Unscrew e-disconnect cover assembly mounting bolts and remove the cover with shifter fork & motor. Using 10 mm socket spanner, Unscrew e-disconnect motor mounting bolts and remove the e-disconnect motor. Hit the shift shaft on suitable block and remove the shift shaft, shaft fork & spring from the disconnect cover. Using MST 0502AUA0002ST - Front Axle Shaft Inboard Oil Seal Puller, remove housing LH Oil seal. Replace the Inboard Oil Seal once removed. Position the Special tool support piece inside the axle housing and using MST 0502AUA0002ST Front Axle Shaft Inboard Oil Seal Puller, remove the RH Oil seal from the housing. Using circlip plier remove the intermediate shaft circlip from housing. Tool should not damage the splines on the axle shaft this affects disconnect operation. Pull out the axle shaft from wheel end side of e-disconnect housing. Remove the shifter shaft thrust washers from e-disconnect housing. Remove the shifter sleeve from edisconnect housing. Using MST 0502AUA0008ST Front Axle Tube Needle Bearing Puller, Needle bearing from e-disconnect housing LH side. Remove LH Side differential shaft from the housing wheel end side. Using 16 mm socket spanner, Remove the Differential bearing caps mounting bolts. Remove the Differential bearing caps. Identification marks are punched on bearing cap; this is to ensure correct bearing cap is installed on correct side. Ensure correct bearing caps used While reassembly. Mount MST 0502AUA0030ST Front Axle Expander on carrier and Spread carrier by rotating nut on expander. Do not spread more than 0.5 mm. Using MST 0502AAA0001ST - Tommy Bars-X, Pry out differential case from carrier. Remove the expander from housing. Mount the MST 0502AUA0023ST \u2014 Front Axle Diff Case Bearing Puller Adapter and Using MST 0502AUA0012ST \u2014 Axle Bearing Puller on side bearing cone and remove the bearing from differential case assembly. Identify shims and side bearings on both sides, they are not to be interchanged during assembly. Similarly remove ring gear other side bearing cone by using MST 0502AUA0023ST \u2014 Front Axle Diff Case Bearing Puller Adapter and MST 0502AUA0012ST \u2014Axle Bearing Puller. Identify shims and side bearings on both sides, they are not to be interchanged during assembly. Using 17 mm socket spanner, Remove the ring gear mounting bolts and remove the ring gear. If require tap ring gear by mallet to remove the ring gear. By Using MST 0502AUA0033ST \u2014 Front Axle Diff Case Pin Remover & Installer and hammer, remove the roll pin retaining the cross shaft. Using suitable punch & hammer, remove the cross pin from case. To remove side gears and pinion mate gears, rotate the side gears, this will allow the pinion mate gears to turn to opening of the case. Remove pinion mate gears and spherical washers behind the gears. Lift out the side gears and thrust washers. Using MST 203 - Wrench Universal Joint Flange Holding tool hold the companion flange and remove the pinion nut and washer using 30 mm socket spanner from the differential housing. Using mallet tap and remove the companion flange along with dust cover. If not able to remove the companion flange tapping by mallet, use suitable 2 Jaw puller for removal. If companion flange shows wear in the area of seal contact, it should be replaced. Using a mallet, tap the pinion assembly and remove the pinion assembly from the differential housing. Make a centre punch and tap at top of the pinion assembly by using a mallet. Hold the pinion with hand to avoid falling. Gear teeth have sharp edges. Handle gears carefully to avoid injury Discard collapsible washer. Remove the Pinion Oil seal By using Screw driver/ Oil Seal Puller. Remove the slinger and outer bearing. Turn Carrier and Using MST 0502AUA0028ST Front Axle Pinion Inner Bearing Cone Remove Adapter and MST 0502AUA0032ST Front Axle Universal Handle, Remove the Inner Pinion bearing cone. Turn Carrier and Using MST 0502AUA0029ST \u2014 Front Axle Pinion outer Bearing Cone Remove Adapter and MST 0502AUA0032ST \u2014 Front Axle Universal Handle, Remove the outer Pinion bearing cone. Using the MST 0502AUA0022ST Front Axle Pinion Inner Bearing Puller Adapter and MST 0502AUA0012ST Axle Bearing Puller, Remove the Pinion Inner Bearing. Take out the pinion shims from the pinion. Using MST 0502AUA0006ST Front Axle Tube Cyl Roller Bearing Puller, Remove the Cylindrical roller bearing from disconnect housing. Inspect all bearings and races for pitting or uneven wear. The inner carrier bearing races should not spin on the carrier journals. The carrier races should fit snugly in the differential housing. Inspect the carrier race bores for grooves from spinning races. The side gear bores inside the carrier should not have any abnormal wear. Inspect all gear teeth for pitting, chips, breaks, and for signs of uneven wear and overheating. Inspect the axles for pitted, grooved or dull and rough bearing surfaces. Inspect gear teeth of side gears and pinion mate gears for wear and cracks. Inspect external teeth of side gears for wear & cracks. Inspect cross pin for excessive wear. Replace if necessary. If replacement of one gear is required, then both side gears, pinion mate gears and washers have to be replaced. Always replace gears as a complete set, do not mix new gears with old gears, as this may cause uneven wear and short gear life. Ring gear and pinion is supplied as a set. They are matched with each other during service. Matching numbers on both pinion and ring gear are etched for verification. Refer illustration shown below for more clarity. If a new gear set is used, verify numbers on pinion and ring for matching before proceeding with assembly. Standard mounting distance from centre line of ring gear to back face of pinion is 103.5 \u00b1 0.1 mm. This dimension is controlled by selecting shims, which are positioned between the inner pinion bearing cone and pinion gear. Best running position of gear set is achieved by proper shim selection. This dimension for front live axle will be different. On the bottom face of pinion, a number is etched. It can be a plus (+) number, a minus (-) number or Zero (0). Required pinion shim selection is achieved with help of this number. If alphabet 'm' appears on pinion face shim, selection has to be done in mm (Metric). If alphabet 'm' does not appear on pinion face, shim selection has to be done in inches (English). Shims with different thicknesses are available for selection. Use tables shown below for selecting correct thickness of shims either for addition or for subtraction from old shim pack. Ring and pinion etched with inch identification. Refer Table A. Ring and pinion etched with metric identification. Refer Table B. Observe the marking on pinion. If \u2018m\u2019 is found etched on the face, refer table B. If not refer table A. Pinion Position shims selection can be done using MST\u2019s Pinion Height Master Block & Pinion Height Setting Gauge, in the absence of removed Ring/Pinion gear or Old shim not available. Ring and pinion etched with inch identification. Refer Table A. Ring and pinion etched with metric identification. Refer Table B. Position the MST 0502AUA0010ST - Front Axle Pinion Height Master Block on the pinion inner bearing setting area. Fix the dial gauge on MST 0502AUA0009ST Front Axle Pinion Height Setting Gauge and set dial gauge to zero reading on surface plate. Place the MST 0502AUA0009ST Front Axle Pinion Height Setting Gauge with Dial gauge on differential housing as shown. Rock the MST 0502AUA0009ST Front Axle Pinion Height Setting Gauge and load the Dial gauge on MST 0502AUA0010ST - Front Axle Pinion Height Master Block and measure the reading on Dial Gauge (X mm). Say X mm for example which is measured by using special tool - 0.79 mm (i.e X = 0.79 mm) Convert mm to thau, i.e (0.79*39) = 31 Thau Then see the Pinion off set i.e (+ 2) Thou (For example) Final shim size = 31 - 2 = 29 Thau Convert to mm = 29*0.0254 = 0.74 mm If Pinion offset is Positive (+), then subtract the pinion offset value. If Pinion offset is Negative (-), then add the pinion offset value. Using MST 0502AUA0026ST Front Axle Pinion Inner Bearing Cone Press Dolly and MST 0502AUA0032ST Front Axle Universal Handle, refit the pinion inner bearing cone into carrier housing. Using MST 0502AUA0027ST - Front Axle Pinion Outer Bearing Cone Press Dolly and MST 0502AUA0032ST - Front Axle Universal Handle, refit pinion outer bearing cone into carrier housing. Place shims selected as per Shim Selection procedure on pinion gear. Using MST 0502AUA0025ST Front Axle Pinion Inner Bearing Press Dolly, Install pinion inner bearing cone. Take care to avoid damaging the pinion teeth while installing the bearing. Place the Pinion outer Bearing cone and slinger into housing. Using MST - 0502AUA0031ST Front Axle Pinion Oil Seal Installer, Install the New pinion seal into housing. Ensure to replace New Oil seal while Install. Apply a light coat of oil to the lip of oil seal. Install a new collapsible spacer into pinion shaft. Collapsible spacer should rest on bearing inner race and pinion shoulder and it can be fitted in any one direction. Assemble the Pinion into differential housing. Install the end yoke, washer and new pinion mounting nut. Hold the end yoke using (MST203 - Companion Flange Holding Tool) and torque tighten the mounting nut. Tighten nut to Initial torque as 217 Nm. Measure the Pinion Rotational Torque (PTTR), It should be within 17 \u2013 34 Kgf\u2013cm (1.7 to 3.3 Nm) If measured Pinion Rotational Torque (PTTR) not within (1.7 to 3.3 Nm), Then tighten nut to incremental torque from 217 Nm onwards to 678 Nm until specified PTTR ( Pinion torque to rotate) is achieved Excessive care must be taken during bearing preload torque adjustment. Do not over tighten, loosen and then retighten nut. Do not exceed specified bearing preload torque Measure and ensure the Final Pinion Rotational Torque (PTTR), It should be within 17 \u2013 34 Kgf\u2013cm (1.7 - 3.3 Nm) PTTR SPEC : 17 \u2013 34 Kgf\u2013 cm (1.7 to 3.3Nm) If preload torque is exceeded, a new collapsible spacer must be installed and torquing sequence as above to be repeated If only oil seal needs to be changed, measure rotating torque of pinion with the help torque measuring tool. In this case use new collapsible spacer and keep same rotational torque of pinion as before. Apply grease to new side gear thrust washers and hubs of side gears. Assemble both side gears. Apply grease to new pinion spherical washers, and pinion mate gears. Assemble pinion mate gears. Assemble both side gears and thrust washers, hold them in place with one hand and then assemble the pinion mate gears with thrust washer to hold the side gears in place An easy way to assemble the side gears and pinion mate gears is to have all parts lubricated before assembly Always replace gears as a complete set. Do not mix new gears with old gears, as this may cause uneven wear and shorter gear life Rotate the side gears until the holes of the spherical washers and pinion mate gears line up with the holes in the case by the help of engaging the splines of axle shaft to side gears. When both the cross bore hole matched and insert the differential shaft Use MST 0502AUA0033ST Front Axle Differential Case Pin Remover and Installer to line holes of the gears up with case Assemble differential shaft and pull out MST. Be sure vertical lock pin hole is lined up with that of the case, and that pinion mate washers are in place and lined up with gear and case. Align the differential shaft hole, insert the lock pin and fix using (0502AUA0033ST - Differential gear lock pin removal tool)and hammer. Always replace with new Lock pin while Installation. When roll pin bottoms out, stake (peen) metal of case over pin in two places, 180 degrees apart. Assemble MST 0502AUA0011ST Front Axle Dummy Bearings on to differential case as shown in the illustration. Assemble the differential case with Dummy Bearings on housing (Without Ring Gear). Mount the magnetic dial indicator with magnetic base, locate its tip on that surface of case. Force differential assembly to the extreme in the direction towards indicator, With force still applied set indicator to 0.00. Force differential assembly to the extreme end in opposite direction. Repeat above steps until the same reading is obtained, Record reading in the format given as 'A'. Remove dummy bearing and keep aside. Assemble ring gear to the differential case using mounting bolts. Tighten the bolts to specified Torque Value in recommended sequence. Torque : 95 - 122 Nm ",
+ "file": null,
+ "display_order": 216
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Notice",
+ "content": "Always use new ring gear bolts. Assemble MST 0502AUA0011ST Front Axle Dummy Bearings on differential case as shown in the illustration. Position differential assembly into housing and Mount the magnetic base dial indicator on housing and locate the tip of indicator on the surface of one of the ring gear screws. Force differential case assembly away from pinion gear. With force still applied set indicator to zero. Force differential case assembly and ring gear to mesh with pinion gear. Rock the ring gear to allow teeth to mesh, Repeat to obtain the reading and continue the procedure until the same reading is obtained. Record reading in the format given as' B'. Remove dial indicator and dummy differential bearings from differential housing. Calculate the Ring Gear Backlash & Differential Bearing Preload shims based on below calculation. Install the selected shim pack in between side bearing and carrier assembly. Using MST 0502AUA0024ST Front Axle Differential Case Bearing Dolly, Install side bearing cone on hub of differential assembly. It is always preferred to replace side bearings once pulled out. But one can confirm free rolling of bearings and reuse it, if they are defect free. Install the selected shim pack in between other side bearing and carrier assembly. Using MST 0502AUA0024ST Front Axle Differential Case Bearing Dolly, Install other side bearing cone on hub of differential assembly. It is always preferred to replace side bearings once pulled out. But one can confirm free rolling of bearings and reuse it, if they are defect free. Install spreader and dial indicator and expand the carrier. Never expand the differential housing over 0.5 mm to avoid distortion. Remove dial indicator from the differential housing. Install differential case assembly into carrier with the help of mallet. Ensure differential case shim is behind the bearing cap. Carelessness while installing differential case assembly may result in injury. Position the bearing caps and install the mounting bolts and torque tighten the bolts to specified torque. Torque : 47 - 68 Nm ",
+ "file": null,
+ "display_order": 250
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "Notice",
+ "content": "Ensure correct fitment of caps by matching letters on caps and carrier on either side. Remove the expander from differential housing. Check ring gear and pinion backlash at three equally spaced points with dial indicator. Backlash tolerance is 0.13 to 0.20 mm and should not vary more than 0.08 mm between the three points checked. Fix the Dial Gauge on Housing, Set the Dial Indicator 0 on Ring gear teeth as shown. Hold the pinion flange at the bottom side. Rotate the ring gear by using ring spanner & measure the backlash. High backlash is corrected by moving ring gear closer to pinion. Low backlash is corrected by moving ring gear away from pinion. These corrections are made by switching shims from one side of differential case to other. If backlash is as per specification, check ring gear and pinion tooth contact pattern. Interpretation of Contact Pattern The TOE of the gear is the portion of the tooth surface at the end towards the centre. The HEEL of the gear tooth is the portion of the tooth surface at the outer end. The TOP LAND of a gear tooth is the surface of the top of the tooth. Every gear has a characteristic pattern. Measure and ensure the Final Total Torque To Rotate (TTTR) at pinion nut, It should be within 28 - 51 Kgf-cm (2.8 - 5 Nm). TTTR SPEC : 28 - 51 Kgf-cm (2.8 - 5 Nm). Using MST 0502AUA0005ST Front Axle Tube Cyl Roller Bearing Dolly, Install the RH housing cylindrical roller bearing through the oil seal bore In the housing. Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, Install the RH side housing Oil seal. Clean the intermediate shaft and insert the shims in intermediate shaft. Push intermediate shaft in same way the direction used during removal. Install the synthetic bush in the bore of axle shaft with the help of light nylon mallet. Press force must not so high which may damage the bush during pressing. Insert the thrust washers in the sequence opposite to removal in the disconnect housing. Insert the axle shaft through wheel end side of the disconnect housing. Install the circlip on the axle shaft with the help of circlip pressing tool. Check end play with dial gauge at the axle shaft end. End play should be 0.025 to 0.1 mm. End play can be adjusted by adding/ deleting shims from the intermediate shaft. After adjusting end play, remove the circlip & axle shaft from the housing. Install the shifter sleeve on the intermediate shift through disconnect housing window while aligning with the splines on it. shift splines and shifter sleeve must be free from foreign particles and burr Insert the axle shaft through wheel end side of the disconnect housing. Install the circlip on the axle shaft with the help of circlip pressing tool. Ensure there should not be excessive play between two shafts this affects the disconnect. Insert the spring and shaft fork through the disconnect cover window while aligning the spring into bore in the cover and sitting in the slit of shift fork. Insert the shaft shift fork in the opposite way of removal ensuring that it passing through shift fork as well as spring. Orientation of the shift fork is important and it should be in same way while was removing. Ensure old spring is discarded and to use spring during installation. Ensure cleanliness of the disconnect housing cover, shift fork shaft , shift fork and spring. Press the shaft shift fork in the bore by hand. Install the new cover gasket while locating in the dowel on the disconnect housing. Ensure to use New Gasket while Installation. Ensure the cleanliness of disconnect housing cover face and cover resting face. Do not bent the wrap the Gasket while installing. Gasket orientation is fixed by dowel on the disconnect housing hence it will fit in one direction only. Bent or warped cover gasket may lead to leak during running. Locate the disconnect cover on the dowel and install the bolts. Tighten the mounting bolts to specified Torque Value. Torque : 17\u00b12 Nm. Ensure to use New bolts while Installation. Apply locktite sealant on the bolts while installing, this avoid the leak through cover. Install the electrical motor on the cover assembly and tighten the screw with specified torque. Torque : 12.5\u00b13.5 Nm. Ensure that the 'O' ring on the electrical motor is not cracked or damaged if so replace the 'O' ring as new one. By using MST 0502AUA0007ST - F Axle Tube Needle Bearing Dolly, Install the LH Side needle bearing In the disconnect housing. By using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, Install the housing LH side Oil seal. Apply the uniform sealant bid along the carrier cover face and avoiding the bolt holes as far as possible. Use Anabond A-676 or 3M sealant on the cover plate. Ensure the cleanliness of the carrier cover face before Installation. Install the carrier cover plate and locate it on the cover plate mounting studs on the carrier. Install cover plate bolts and tighten them to specified Torque Value. Torque : 38 - 45 Nm. Discard the old bolts and Use new bolts for cover plate mounting as the bolts are coming with sealant patch on it and during sealant patch wears off. Reusing cover bolts may leads to leakage from cover bolts sides. Refit the Front Axle Assembly. Refill the front axle oil upto Max level. For additional information refer to Front differential oil draining and filling procedure. Remove E-Disconnect motor. Using 10 mm socket spanner, Unscrew electric disconnect housing mounting bolts. Torque : 17\u00b12 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Carefully remove the E-Disconnect Housing with Fork . Refit in the reverse order of removal. While Installation Apply Locktite sealant on the E-Disconnect Housing bolts to avoid the leak through cover. Check the E-Disconnect motor, connector for any damage, Replace if necessary. Remove E-Disconnect stone guard. For additional information refer to E-Disconnect stone guard \u2013 R &R; section. Disconnect E \u2013 Disconnect electric connector. Using 10 mm socket spanner, unscrew E \u2013 Disconnect motor mounting bolts. Torque : 12.5\u00b13.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the E-Disconnect motor Refit in the reverse order of removal. While Installation ensure to replace the New O Ring for E \u2013 Disconnect motor Check the E-Disconnect motor, connector for any damage, Replace if necessary. Front Axle Oil \u2014 Mahindra 'MAXIMILE ELITE' New Generation Genuine Differential Fluid.Capacity \u2014 1.25 Litres.
Using 10 mm square bit spanner, loosen and remove front axle filler plug. Using 10 mm square bit spanner, loosen and remove front axle drain plug and drain the entire oil. Wait till the entire oil get drained. Place a tray beneath the front axle for collecting the oil while draining. Refit the drain plug and torque tighten to specified value. Clean the drain plug and differential housing with a clean cloth before refitting. Torque : 34 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refill specified quantity of recommended differential oil into differential assembly. Never reuse drained oil. Always use recommended oil only. Never mix different types of oil and use. Clean filler plug area properly using a cloth before filling the oil. Check the oil level and ensure its up to the level. Ensure that the oil level is up to lower most point of the filler plug. Refit the filler plug back and torque tighten to specified value. Clean the filler plug with a clean cloth before refitting. Torque : 34 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Recommend to use only Mahindra 'MAXIMILE Elite' new generation genuine differential fluid. In case of non availability of 'Maximile' brand, other brands meeting API GL5, SAE 80W-90 specification can be used as second preference and oil change period should be reduced as 20,000 km.
2. Visually inspect the front axle for any noticeable signs of mechanical damage.
3. If an obvious cause is found during the inspection, correct the same before proceeding to the next step.
4. If the cause is not found visually during the inspection, refer to the troubleshooting chart.
5. Check for oil level and condition.
",
+ "file": null,
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Mechanical",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "1. Check for any oil leakage in the differential assembly, gasket and axle shaft oil seal.
2. Check for any noise in the bearing, pinion gear, crown wheel and planet gears.
",
+ "file": null,
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "various symptoms, causes and there remedial actions of system",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/17548.pdf",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Noise when the vehicle is coasting",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/17549.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Intermittent Noise",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/17550.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Noise when the vehicle is turning",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/17551.jpg",
+ "display_order": 6
+ }
+ ]
+ },
+ {
+ "procedure_name": "Constant Noise",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/17552.jpg",
+ "display_order": 7
+ }
+ ]
+ },
+ {
+ "procedure_name": "Vibration",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/17553.jpg",
+ "display_order": 8
+ }
+ ]
+ },
+ {
+ "procedure_name": "Oil leakage from Differential carrier leakage",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/17554.jpg",
+ "display_order": 9
+ }
+ ]
+ },
+ {
+ "procedure_name": "Axle case oil leakage",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/17555.jpg",
+ "display_order": 10
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 66,
+ "sys_id": "THAR.AX-0006-en-SM-Manual Transmission",
+ "system_name": "Manual Transmission",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1008,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 76,
+ "sys_id": "THAR.AX-0006-Manual Transmission",
+ "subsys_id": "THAR.AX-0006-Manual Transmission-Clutch Housing And Input Shaft Oil Seal",
+ "systems": "Manual Transmission",
+ "sub_systems": "Clutch Housing And Input Shaft Oil Seal",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A110018.jpg",
+ "myid": 1156,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Clutch Housing And Input Shaft Oil Seal-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110018.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21536.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21537.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "Description",
+ "content": "Tools Required ",
+ "file": null,
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the Transmission fluid. For additional information refer to Transmission fluid Drain & Filling Section. Remove the Clutch Concentric Slave Cylinder. For additional information refer Clutch Concentric Slave Cylinder - R &R; Section. Using a 14 mm socket spanner remove the clutch housing mounting bolts and then gently tap using plastic mallet & remove clutch housing. Using a screw driver/suitable oil seal remover, remove the input shaft oil seal from clutch housing. Check for any external cracks, if found replace. Check the oil seal for deformation, if found replace. Using a 10 mm socket spanner, loosen and remove the battery negative terminal. Remove Rear Propeller Shaft Assembly. For additional information refer to Rear Propeller Shaft R &R; Session. Using a 8 mm socket spanner, loosen and remove the front propeller shaft mounting C clamp bolts from the transfer case. Torque: 65 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110429.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110430.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the cross pin and detach the Shifter cable from the shifter control housing on transmission. Using a 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the Selector cable from the Shifter Control Housing ball pin. Detach the Selector cable & Shifter cable abutments from the cable brackets on transmission by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Using a 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the transfer case cable from the transfer case ball pins. Detach the transfer case cable abutment from the cable bracket on transmission by pressing locking clip and pull up the abutments. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Disconnect the GNS sensor & transfer case switch electrical connection. Disconnect the reverse switch electrical connection. Disconnect the transmission wiring routing clips. Disconnect the clutch bundy tube connection from clutch slave cylinder. Using a 14 mm socket spanner, loosen and remove the starter motor mounting bolts then keep aside the starter motor. Torque: 44 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110008.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the transmission housing mounting bolts. Torque: 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B110003.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Provide a jack to support the transmission. Using a 12 mm socket spanner, loosen and remove the transmission bed mounting bolts from transmission. Torque: 25\u00b15 Nm ",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B110005.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using 14mm, 15mm socket and ring spanners, unscrew transmission cross member mounting bolts, nuts and detach it. Torque: 65 \u00b110.0 Nm ",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B110004.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Lower the jack and remove the transmission along with the transfer case. Install in reverse order of removal. Carry-out clutch bleeding procedure. For additional information refer to clutch fluid Refilling and bleeding procedure. While refit Cables, Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Front housing is used to provide support for mounting transmission shafts with the help of bearings. It is mounted in between clutch housing and Intermediate plate. Remove the Clutch housing assembly. Using a 22 mm ring spanner, loosen and remove the neutral sensor. Remove the rear housing assembly. Using a snap ring removal tool/ flat end screw driver, remove the input shaft snap ring from the front housing. Using a snap ring removal tool/ flat end screw driver, remove the counter shaft snap ring from the front housing. Using open end spanner, detach the front housing from the intermediate plate. Remove the front housing assembly. Apply loctite 5188 on the front housing in intermediate plate side. Install the front housing assembly. Use 3 nos. of 17 mm dummy bolts (Appox. length of 40 mm) to tighten the front housing to ensure proper sealant application. Ensure to fix the dowels before tighten the front housing. Using a snap ring, removal tool/ screw driver install the counter shaft snap ring. Using a snap ring, install the input shaft snap ring. Refit the Clutch housing assembly. Refit the Rear housing assembly. Install the neutral sensor. Torque tighten the nut to specified value. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 38
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-3",
+ "content_type": "Link",
+ "content": "THAR.AX-0006,1008,1158",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Link",
+ "content": "THAR.AX-0006,1008,1156",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Link",
+ "content": "THAR.AX-0006,1008,1158",
+ "file": null,
+ "display_order": 35
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " 1. Check for any external damage, if found replace. ",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 66,
+ "sys_id": "THAR.AX-0006-Manual Transmission",
+ "subsys_id": "THAR.AX-0006-Manual Transmission-Gear Cable Setting Procedure",
+ "systems": "Manual Transmission",
+ "sub_systems": "Gear Cable Setting Procedure",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A110443.jpg",
+ "myid": 1147,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Gear Cable Setting Procedure-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Gear Cable Setting",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110443.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Move the shifter cable quick adjuster outer cover in forward direction and unlock the QA clip in transmission end. Position the shifter control housing in Neutral Position on transmission. Ensure the Selector cable is properly fitted on Shifter Control Housing ball pin on transmission. Ensure the selector cable & shifter cable butments are properly fitted on transmission cable brackets. Remove the gear shifter lever knob with spring and 4WD selection knob. Using trim removal tool, remove the Gear selection rod cover with trim. Ensure the selector cable & shifter cable abutments are properly fitted on shifter lever bracket Inside passenger cabin. Move the selector cable quick adjuster outer cover in forward direction and unlock the QA clip. Insert the Neutral lock Special tool to shifter housing hole and lock the tool C profile to shifter lever as shown for ensuring selector & shifter arm in neutral position. After Inserting the Neutral lock special tool, Shifter lever should not move in any direction. In this Condition press the selector cable QA clip as shown to lock it fully and release the quick adjuster outer cover. Ensure the proper locking by confirming/ hearing the click noise while install. Ensure the shifter cable end is properly fitted on the shifter lever ball pin inside passenger cabin. Ensure Transmission is in Neutral at transmission end. In this condition press the shifter cable QA clip towards arrow mark as shown to lock it fully and release the cable quick adjuster outer cover. Ensure the proper locking by confirming/ hearing the click noise while install. After adjustment remove the special tool from shifter lever. Refit the Gear selection rod cover with trim. Refit the gear shifter level knob with spring and 4WD selection knob. Inspect the shifter lever smooth shifting & gear engagement to all the gear range. Remove the Transfer Case. Using a screw driver, remove the rear end oil seal from the Rear housing. Position the rear end oil seal along with 0703BBA0002ST - Transmission Rear Housing Oil Seal Installer & install the oil seal using a mallet. Remove the Transmission with Transfer case. Pull the clutch bleeder lock and detach the bleeder from CSC. Using a 12 mm socket spanner, loosen and remove the CSC mounting bolts. Torque: 25 \u00b1 3.5 Nm ( Step UP Torque \u2013 5, 15 , 25) ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110016.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110017.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 15 mm socket spanner/ combination spanner, loosen and remove the transfer case mounting nuts then detach the transfer case from the transmission. Torque: 45 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Carry-out clutch bleeding procedure. For additional information refer to clutch fluid Refilling and bleeding procedure. Check the Transmission oil level and topup if needed. For additional information refer to transmission oil level inspection and refilling procedure. Remove the Shifter Control Housing. By Using 5 mm thin Punch & hammer, remove the Select lever guide locking pin and detach the guide. Take out the control housing boot from the shift lever assembly. By using 3 mm Allen key, remove the Plug to access shift lever ball assembly locking pin. By Using 5 mm thin Punch and hammer, remove the shift lever ball assembly locking pin by accessing through plug hole. Remove the Shift lever assembly from the housing and remove the shift lever ball assembly as shown in the Illustration. Remove the other side boot from the shift control housing. By using screw driver, remove the seal from the housing (One Side). By using screw driver, remove the seal from the housing (Other Side). By using M 8 flange headed bolt and 8 mm punch, remove the bush from the housing (One Side). Position the M8 flange headed bolt on bush as shown above & hit the bolt by using punch and mallet. By using M 8 flange headed bolt and 8 mm punch, remove the bush from the housing (Other Side). Position the M8 flange headed bolt on bush as shown above & hit the bolt by using punch and mallet. By using screw driver, remove the select lever circlip. By screw drive, hit the select lever shift pivot and remove the shaft. Detach select lever from the housing. By using 15 mm ring/open end spanner, remove the breather from the housing. By using 15 mm ring/open end spanner,refit the breather on the housing. Position the select lever on housing and insert the select lever shaft on lever. Refit the select lever circlip on select lever by using nose plier. Position the bush on housing (One side) and Install by using M8 flange headed bolt, 8 mm punch & mallet as shown illustration. After Installation, Ensure bush face parallel to housing bore face as shown. Install the Oil seal by gently press by using hand or suitable dolly. Position the bush on housing (Other side) and Install by using M8 flange headed bolt, 8 mm punch & mallet as shown illustration. After Installation, Ensure bush face parallel to housing bore face as shown. Install the Oil seal by gently press by using hand or suitable dolly (Other side). Refit the one side boot on shifter control housing. Insert the shift lever assembly on housing and insert the Shift lever ball assembly to the shift lever assembly (As direction shown). Align the Ball Assembly and shift lever shaft hole and Install the locking pin by using 5 mm punch and hammer. Install the Plug on housing. Insert the other side control housing boot to the shift lever. Insert the lever guide on shift lever. Install the select lever guide locking pin by using 5 mm punch and hammer. Refit the Shifter Control Housing. For additional information refer to Shifter Control Housing - R &R; Section. Remove the Floor Console. Using a MST 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the Selector cable & Shifter cable from the shift lever ball pins. Detach the Selector cable & Shifter cable abutments from the shifter bracket by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Using a 13 mm socket spanner, loosen and remove the gear shifter lever assembly mounting nuts. Remove the gear shifter lever assembly from the vehicle. Position the gear shifter lever assembly on the vehicle. Refit the gear shifter lever assembly mounting nuts and torque tighten the nuts to specified value. Torque: 21\u00b13 NM ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110365.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110368.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Refit the Selector cable & Shifter cable abutments on shift lever bracket. Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Refit the Selector cable & Shifter cable on shift lever. Carry out Gear Cable Setting. New Shifter Lever Assembly supplied with Gear shifter Neutral position tool, ensure to remove the tool from shifter housing after Gear cable setting. Support the transmission using jack. Using a 18 mm socket spanner, loosen and remove the transmission bed mount nuts. Using a 14 mm & 15 mm socket/ring spanner, loosen and remove the cross member mounting bolts & nuts then remove the transmission cross member. Torque: 65\u00b1 10 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110021.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110085.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the transmission bed mounting bolts then remove the transmission bed mount from the vehicle Torque: 25\u00b15 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Detach the Shifter cable abutment from the cable bracket on transmission by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Using a 12 mm socket spanner, loosen and remove the shifter cable bracket mounting bolts and remove the bracket. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110395.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the GNS electrical connection and detach the wiring routing clip. Using a 22 mm open end spanner, loosen & remove the Gear Neutral Sensor. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110382.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "install in reverse order of removal. While Install cable, Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Bead width : 2\u00b10.5mm Bead width : 2\u00b10.5mm Bead width : 2\u00b10.5mm Bead width : 2\u00b10.5mm Remove the Air Cleaner Assembly. Remove the Floor Console. Using a 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the Selector cable & Shifter cable from the shift lever ball pins. Detach the Selector cable & Shifter cable abutments from the shifter bracket by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Remove the cross pin and detach the Shifter cable from the shifter control housing on transmission. Using a 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the Selector cable from the Shifter Control Housing ball pins. Detach the Selector cable & Shifter cable abutments from the cable brackets on transmission by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Using a 10 mm socket spanner, loosen and remove the shifter & selector cable grommet mounting bolts. Detach the shifter and selector cable from routing clips & take out from the vehicle. Routing the shifter and selector cable to the vehicle and position the cables on routing clips. While routing the cable ensure to insert Selector cable in the left side of the Gear shifter lever and shifter cable in the right side. Select & Shift cable should not cross each other. Refit the shifter & selector cable grommet mounting bolts and torque tighten the bolts. Torque: 13\u00b1 2 Nm ",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Caution",
+ "content": "Ensure the cable grommet should get assemble from outside the cabin. Refit the selector cable & shifter cable abutments on transmission cable brackets. Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Attach the Shifter cable on shifter control housing on transmission and refit the cross pin on Shifter control housing. Attach the Selector cable on Shifter Control Housing ball pins by hand. Refit the selector cable & shifter cable abutments on shift lever bracket inside passenger cabin. Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Attach the Selector cable end on Shifter lever ball pin by hand. Refit the shifter cable end on Shifter lever ball pin by hand. Carry out Gear Cable Setting. Refit the Air Cleaner Assembly. Rear housing is used to protect rear parts of transmission components from external environment. It is used to hold the Shifter Control Housing assembly & detent block. Tools Required ",
+ "file": null,
+ "display_order": 6
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the transmission oil. Using a 12 mm socket spanner, remove the gear control housing mounting bolts and then gently detach and remove the gear control housing assembly. Yellow colored bolts are fitted with dowel inside, this bolts should be removed & refit first. Using a T30 torx spanner, remove the torx bolt from the shift block actuator. Using a 22 mm socket spanner, remove the reverse switch. Using a 12 mm socket spanner, remove the idler shaft front mounting bolt & using a 13 mm socket spanner remove the bottom idler shaft bolt. Using a 12 mm socket spanner, loosen and remove the selector bracket mounting bolts. Using a 12 mm socket spanner, loosen and remove the shifter bracket mounting bolts. Using a 14 mm socket spanner, remove the rear housing bolts from the front housing side. Ensure and take more care on not to breakage the front housing sealant while removing rear housing bolts from the front housing side. Using a 14 mm socket spanner/Open end spanner, remove the rear housing mounting bolts. Turn the shift block actuator & release from the spring support. By using screw driver, release the rear housing dowels and using open end spanner detach the rear housing. Release the dowels from the rear housing and ensure not to remove fully from the housing and it leads to touch the dowels on center housing projection as shown. Use the open end spanner on both the side simultaneously. Lift the rear housing assembly along with the shift block actuator. Remove the rear housing assembly and take out shift block actuator from housing. Using a screw driver/suitable oil seal remover, remove the rear end oil seal from the Rear housing. Using a 12 mm socket spanner, remove the H plate mounting bolts & the H plate assembly from the Rear housing. Using hydraulic press, remove both the detents by pressing from outside to inside. Check for any external oil leakage. Rectify if found. Using suitable tool and hydraulic press, fit the detent (press from outside to inside) Position the rear end oil seal along with 0703BBA0002ST - Transmission Rear Housing Oil Seal Installer & install the oil seal using a mallet. Check for the rear end oil seal correct seating. Refit the H plate mounting bolts & torque tighten the bolts to specified value. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110333.jpg",
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110322.jpg",
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Apply loctite 5188 on Intermediate plate and insert the rear housing assembly. Install the shift block actuator while installing the rear housing. Insert the rear housing mounting bolts,torque tighten the bolts specified value. Torque : 30\u00b15 Nm ",
+ "file": null,
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110121.jpg",
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110122.jpg",
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Insert the rear housing mounting bolts,torque tighten the bolts specified value. Torque : 30\u00b15 Nm ",
+ "file": null,
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110116.jpg",
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Refit the reverse light switch, torque tighten the switch to specified value. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 76
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110119.jpg",
+ "display_order": 77
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110120.jpg",
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Insert the front & the bottom idler shaft mounting bolts, torque tighten the bolts to specified value. Torque : Idler Shaft Bolts - 30\u00b15 Nm ",
+ "file": null,
+ "display_order": 80
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110417.jpg",
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Refit the shifter bracket with mounting bolts , torque tighten them to the specified value. Torque: 20.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 83
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110416.jpg",
+ "display_order": 84
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Refit the selector bracket with mounting bolts , torque tighten them to the specified value. Torque: 20.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 86
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110323.jpg",
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110114.jpg",
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Position the shift block actuator, apply Loctite 262 & insert the torx bolt and torque tighten the bolt to specified value. Torque : 10 - 15 Nm ",
+ "file": null,
+ "display_order": 90
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110324.jpg",
+ "display_order": 91
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110325.jpg",
+ "display_order": 92
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Apply 5188 loctite on the rear housing to fit gear control housing. Refit the gear control housing & the mounting bolts. torque tighten the bolts to specified value. Yellow colored bolts are fitted with dowel inside, this bolts should be refit first. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 98
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 69,
+ "sys_id": "THAR.AX-0006-Manual Transmission",
+ "subsys_id": "THAR.AX-0006-Manual Transmission-Shifter Control Housing",
+ "systems": "Manual Transmission",
+ "sub_systems": "Shifter Control Housing",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A110076.jpg",
+ "myid": 1149,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Shifter Control Housing-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110076.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110054.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Shifter Control Housing is for gear selecting and shifting. It is connecting element between gear shift lever and shift rail through Shifter & Selector cables. Remove the Transmission with Transfer case. Using a 12 mm socket spanner, remove the gear control housing mounting bolts and then gently detach and remove the gear control housing assembly. Position the shifter lever in Natural Position on transmission. Yellow colored bolts are fitted with dowel inside, this bolts should be removed & refit first. While Installation, Apply sealant LOCTITE 5188 on the rear housing shifter control housing seating area . Install in reverse order of removal, before installation apply the sealant if required. Top up the transmission oil. Drain the Transmission fluid. For additional information refer to Transmission fluid Drain & Filling Section. Using a 12 mm socket spanner, remove the gear control housing mounting bolts and then gently detach and remove the gear control housing assembly. Yellow colored bolts are fitted with dowel inside, this bolts should be removed & refit first. Using a T30 torx spanner, remove the torx bolt from the shift block actuator. Using a 22 mm socket spanner, remove the reverse switch. Using a 22 mm open end spanner,remove the neutral sensor. Using a 12 mm socket spanner,remove the idler shaft front mounting bolt & using a 13 mm socket spanner, remove the bottom idler shaft bolt. Using a 14 mm socket spanner, remove the rear housing bolts from the front housing side. Using a 14 mm socket spanner/Open end spanner, remove the rear housing mounting bolts. Turn the shift block actuator & release from the spring support. By using screw driver, release the rear housing dowels and using open end spanner, detach the rear housing. Release the dowels from the rear housing and ensure not to remove fully from the housing and it leads to touch the dowels on center housing projection as shown. Use the open end spanner on both the side simultaneously. Lift the rear housing assembly along with the shift block actuator. Remove the rear housing assembly and take out shift block actuator from housing. Using a screw driver/suitable oil seal remover, remove the rear end oil seal from the Rear housing. Using a 12 mm socket spanner remove the H plate mounting bolts & the H plate assembly from the Rear housing. Using hydraulic press, remove both the detents by pressing from outside to inside. Remove the idler gear, shaft & the plastic support assembly. Remove washer, idler gear & needle roller bearing from shaft. Remove main shift rod & the washers on both sides. Ensure Gear in neutral position Using a 14 mm socket spanner remove the counter shaft lock bolt in clock wise direction. The bolt is reverse threaded, hence rotate in clockwise for removing. Using a MST 0703AD2720H116 \u2013 Lock Nut Dolly, loosen the output shaft lock nut. Using a bearing puller (SKF TMMR 120F), remove the counter shaft rear DGBB (Double Grove Ball Bearing). Use Counter shaft dummy bolt for support bearing puller. Using a puller (SKF TMMR 350F), remove the reverse driven gear, washer & CRB (Cylinder Roller Bearing) from output shaft. Remove reverse synchro ring and remove the reverse driven gear needle bearing & remove the bush. Remove reverse synchro stud and reverse fork & rail shift assembly along with reverse synchro sleeve from output shaft. Using a puller (SKF TMMR 350F) remove the reverse synchro hub from output shaft. Using a puller (SKF TMMR 120F), remove the reverse drive gear, thrust washer & 5th drive gear from counter shaft. Remove the 5th drive gear NRB (Needle Roller Bearing) and 6th synchro ring. Using a suitable puller (SKF TMMR 350F) remove the 5th driven gear & bush from output shaft. Remove the 5th & 6th synchro studs and remove the 5th & 6 th synchro sleeve along with fork & rail shift. Using a puller (SKF TMMR 120F) remove 5th drive gear bush, 5th & 6th synchro hub, synchro ring & 6th drive gear from counter shaft. Remove the 6th drive gear NRB. Using 14 mm socket spanner, remove the clutch housing bolts. Gently tap using plastic mallet & remove clutch housing. Using a screw driver/suitable oil seal remover, remove the input shaft oil seal from clutch housing. Using a snap ring removal tool/ flat end screw driver, remove the input shaft snap ring from the front housing. Using a snap ring removal tool/ flat end screw driver, remove the counter shaft snap ring from the front housing. Using open end spanner, detach the front housing from the intermediate plate. Using a roll punch & hammer, remove the pin spring dowel from the 1st & 2nd shifter fork & rail assembly. Using a roll punch & hammer, remove the pin spring dowel from the 3rd & 4th shifter fork & remove fork rail assembly from intermediate plate. By using snap ring removal tool,expand the output shaft snap ring and release the output shaft from intermediate plate. Using a mallet tap and remove the intermediate plate. Remove the counter shaft assembly. Remove the output shaft assembly from the input shaft assembly. Remove the pilot bearing & Synchroring from input shaft. Using a circlip plier, remove the circlip from input shaft. By Using a puller (SKF TMBS 150E ) remove the DGBB from input shaft. Using a circlip plier, remove the circlip from counter shaft front end. By using a puller (SKF TMBS 150E) remove the DGBB from counter shaft front end. By using a puller (SKF TMMR 160F) remove the DGBB, 6th drive gear bush & thrust washer from counter shaft rear end. Using a puller (SKF TMBS 150E) remove the 1st driven gear, 2nd driven gear, 1st & 2nd synchro pack along with output shaft DGBB & 6th driven gear. Engage puller legs in the 2nd driven gear. Remove in the sequence of 6th driven gear, output shaft DGBB, 1st driven gear with bush, 1st driven gear NRB, 1st & 2nd synchro pack, 2nd driven gear. Remove the 2nd driven gear NRB. Using a circlip plier remove the circlip from the output shaft. Remove the 3rd & 4th synchro studs & sleeve. Using puller (SKF TMMR 350F) remove the 3rd & 4th synchro hub, synchro ring & the 3rd driven gear assembly. Remove the 3rd driven gear NRB. Shift Control Components ",
+ "file": null,
+ "display_order": 145
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check contact and sliding surfaces of shifter fork & rails for wear, scratches, projections and other damage. Gear Components ",
+ "file": null,
+ "display_order": 149
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Check shafts for cracks, wear and bend. Check gears for excessive wear, chips and cracks. Synchronizers ",
+ "file": null,
+ "display_order": 152
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Check spline portion of coupling sleeves, synchronizer hubs, and gears for wear, chips, and racks. Check ring for cracks and deformation. Check struts for wear and deformation. Bearings ",
+ "file": null,
+ "display_order": 155
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Make sure all bearings roll freely and are free from noise, cracks, pitting or wear. Remove the gear shifter level knob with spring and 4WD selection knob. Using trim removal tool, remove the Gear selection rod cover with trim. Using a screw driver , loosen and remove the gear selection rod cover mounting screw and detach boot from trim. Install in reverse order of removal. Transmission Oil \u2013 MAHINDRA \u201cMAXIMILE SYNTEC F2\u201d New Generation Genuine Transmission Fluid. Capacity \u2013 2.25 Litres. Using a 8 mm square bit spanner, loosen and remove the filler plug. Using a 8 mm square bit spanner, loosen and remove the drain plug & allow the oil to drain out completely. Place a tray or drain oil collecting bin under the drain plug to collect the oil. Install the drain plug. Torque tighten the drain plug to specified value. Always replace the drain plug washer with a new one. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110343.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Fill recommended oil using an oil filling machine or by clean transparent pipe attached to the mechanical hand pump. Ensure that the oil level is up to lower most point of the filler plug. Refit the filler plug. Torque tighten the filler plug to specified value. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Recommend to use only Mahindra MAXIMILE SYNTEC F2 new generation genuine transmission fluid. In case of genuine oil non-availability, manual transmission oil meeting API GL-4 SAE 80W-90 specification is suggested. This alternate oil or other brand may not provide equivalent performance of recommended genuine oil. Drain Interval should be reduced as 20,000 km. Never mix two different oils. Remove rear front facing Seat Back Rest Assembly. Open the seat cover strip back side of back rest assembly. Press the lock and remove the head rest. Unzip the seat cover LH & RH sides. Press the lock and remove the head rest guide inside seat cover. Detach the seat cover with foam from the frame and remove from back rest frame. Install in the reverse order of removal. Check for any damages. Replace if required. Check for any damages on seat trims. Replace if required. Remove Driver Seat Back Rest Foam with Cover. Using Nose Plier, Remove the copper ring locks and remove cover from foam. Take extreme care to not to damage the foam and seat cover. Install in the reverse order of removal. Check the foam for any damages. Replace if required. Check for seat cover any damages. Replace if required. Remove Driver Seat Back Rest Assembly. Unlock the seat cover lock from the bottom side. Using Nose plier and Screw driver, Remove the seat cover locking rings. Using star screw driver, Unscrew seat side cover mounting screw and remove the cover. Detach the cover with foam. Install in the reverse order of removal. Check the Cushion and Frame Assembly for any damages. Replace if required. Remove the Rear Seat Recliner Cover. For additional information refer to the Rear Seat Recliner Covers - R &R; section. Detach the seat folding cable from the lock and remove the cable. Remove the cable from the bottom cushion routing bracket. Remove the cable from the seat. Install in the reverse order of removal. Check seat folding cable for any damages. Replace if found. Remove Diver Seat Assembly. For additional information refer to Driver Seat Assembly - R &R; Section. Remove seat recliner and height adjustment handle cover. By using star screw driver remove seat height adjustment handle mounting screws & remove the handle. By using star screw driver, remove LH & RH valance cover mounting screws and detach the covers. Detach back cushion cover lock from seat bottom. Using T50 torx socket spanner, Unscrew back rest mounting bolts. Torque: 47.5 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230111.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Detach the back rest from Seat assembly. Press the Lock and remove the head rest from the back rest assembly. Install in the reverse order of removal. Check for any damages. Replace if required. Check for any damages on seat trims. Replace if required. Remove the Rear Front Facing Bottom Cushion. Remove the copper locks from the rear front facing bottom cushion. Detach the both side the cable from the lock. Remove the both routing bracket cable tie from the seats. Remove the bottom cushion from the frame assembly and separate the Bottom Cushion Frame. Install in the reverse order of removal. Install in the reverse order of removal. Check for any damages on seat trims. Remove the Wiper Motor & Link Assembly. By using screw driver partially remove the wiper link from the motor. Using a 10 mm open end spanner loosen and remove the wiper motor link assembly mounting bolt. Torque : 10 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the wiper motor separately. Install in the reverse order of removal. Check the motor for any damage. Replace if found any. Check the linkage for any damage. Replace if found any. Remove Front Grill Assembly. For additional information refer to Front Gril Assembly \u2013 R &R; Section. Using a screw driver, Carefully remove the dust tray from vehicle. Disconnect wiper motor electrical connector. Using a 10 mm open end spanner, loosen and remove the wiper motor mounting bolts. Torque : 10.50 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the wiper motor and link assembly from vehicle. Install in the reverse order of removal. Check the motor for any damage. Replace if found any. Check the linkage for any damage. Replace if found any. Remove the Roof Speaker LH & RH. For additional information refer to Roof Speaker - R &R; section. Remove the Roof Tweeter LH & RH. For additional information refer to Roof Tweeter - R &R; section. Using a trim removal tool pull out center bow trim and disconnect roof lamp electrical connector. Disconnect the sound bar electrical connector. Using 10 mm socket spanner, Unscrew sound bar mounting bolts. Detach the Wiring Harness from routing and remove from the sound bar assembly. Install in the reverse order of removal. Inspect the Wiring Harness for any physical damage. Replace if found. Inspect the connector for any damage. Remove the Driver Sun Visor. For additional information refer to Driver Sun Visor - R &R; Section. Remove the Co-Driver Sun Visor. For additional information refer to Co-Driver Sun Visor - R &R; Section. Using Torx screw driver, Unscrew Centre bow trim mounting screw and detach the bow trim. Torque Value: 5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280011.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the MIC electrical. Remove the MIC from Centre bow trim. Install in the reverse order of removal. Inspect the MIC unit for any damage. Inspect the electrical connectors for any damage. Using trim removal tool remove the infotainment center bezel. Using trim removal tool remove infotainment top side cover. Using star screw driver, Unscrew infotainment mounting screws. Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1015.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect Infotainment electrical connectors. Remove the Infotainment unit. Install in the reverse order of removal. Inspect the infotainment unit for any damage. Inspect the electrical connectors for any damage. Using star screw driver remove front LH wheel arch mounting screw rivets. Using T25 socket spanner remove the antenna mounting screw. Torque Value: 3 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280048.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the antenna electrical connector through wheel arch. Remove the antenna assembly separately. Inspect the antenna assembly and connector for any physical damage. Replace if found. Using star screw driver unscrew the panel assembly floor console RH screvits and detach the panel from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console LH screvits and detach the panel from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew vertical ascent RH mounting screw and detach the vertical ascent RH from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew vertical ascent LH mounting screw and detach the vertical ascent LH from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "partially detach the switch bang assembly and remove electric connector to take out from the vehicle. Carefully pull and remove the Audio Unit port Assembly. Disconnect the Audio Unit port electrical connectors and 12 volt electric connector. Using star screw driver unscrew the ,Audio Unit port mounting screws. Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the USB and DOC station assembly from the trim. Install in the reverse order of removal. Inspect the USB and DOC station assembly unit for any damage. Inspect the electrical connectors for any damage. Remove the Infotainment Assembly. Using star screw driver, Unscrew cluster bezel mounting screw and remove the bezel. Cut the GNSS antenna wire routing tag. Install in the reverse order of removal. Inspect the GPS Antenna for any damage. Inspect the electrical connector for any damage. Using star screw driver unscrew the panel assembly floor console RH screvits and detach the panel from vehicle. Using star screw driver unscrew the panel assembly floor console LH screvits and detach the panel from vehicle. Using star screw driver unscrew vertical ascent RH mounting screw and detach the vertical ascent RH from vehicle. Using star screw driver unscrew vertical ascent LH mounting screw and detach the vertical ascent LH from vehicle. partially detach the switch bang assembly and remove electric connector to take out from the vehicle. Carefully pull and remove the Audio Unit port Assembly. Disconnect the Audio Unit port electrical connectors and 12 volt electric connector. Using a small screw driver pull out the power port and remove the power port. Install in the reverse order of removal. Inspect the 12V power point for any physical damage. Replace if found.
1. Clutch sensor related error is registered in EMS ECU or
2. The gap between magnetic holder and the sensor body is more than 2 mm.
",
+ "file": null,
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the clutch pedal box assembly. For additional information refer to Clutch Pedal box Assembly - R &R; section. Loosen the sensor lock nut with the help of 13 mm open end spanner. Insert a 2 mm spacer in the gap between magnetic holder and sensor body. Using a 12 mm open end spanner, adjust the magnetic holder till it touches the surface of spacer, thus maintain 2 \u00b10.5 mm gap between sensor body and magnetic holder. Tighten the sensor lock nut. For additional information refer to Clutch Pedal box Assembly - R &R section. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "After completing the clutch sensor setting, connect i-SMART and navigate to THAR \u2013 THAR_BS6. Select \u201cEMS\u201d in the ECU List. Click on \u201cLIVE DATA\u201d and select \u201cDriveability\u201d. Release the clutch pedal fully, the value of clutch status should be \u201c64\u201d. Press the clutch pedal to 10%, the value of clutch status should be \u201c65\u201d. Press the clutch pedal fully, the value of clutch status should be \u201c81\u201d. If the clutch status value is not changing according to different clutch pedal position, re-adjust the clutch sensor.
Unless the cause of a clutch problem is extremely obvious, accurate problem diagnosis will require a road test to confirm whether the problem exists or not. During the road test, drive the vehicle at normal operating speeds, shift the gears and observe the clutch action. If chatter, grab, slip or improper release is experienced, check clutch free pedal play, clutch fluid leakages, also do clutch bleeding, if the problem still persists, then remove & inspect the suspected parts. However if problem is noise or hard shift then the problem may not be in clutch only but also with the transmission or the drive-line. If the clutch slip is suspected then drive the vehicle in 1st or 2nd gear at the top speed (corresponding to the gear). Keeping the accelerator fully pressed; slowly apply the brake with your left feet. If the engine stalls then the clutch is not slipping. To find out the actual root cause of the problem, the failed parts needs to be examined. Fluid contamination is the most frequent cause of clutch malfunction. Oil, water on the clutch contact surface will cause faulty operation viz. slip, grab, and judder. During inspection check if any parts in the clutch are coated with oil or water splash from road. Oil contamination indicates a leak at either engine rear oil seal or transmission input shaft. The oil leaks from either of these areas will normally coat the housing interior or clutch cover or flywheel. Heat buildup due to slippage between the clutch plate and the flywheel or the pressure plate can result into the leaked oil literally getting baked. Visually this will result in a glazed residue varying from amber to black. Roads splash contamination will mean that the dirt water is entering the clutch housing either due to loosen bolt or torn rubber boot. The clutch housing has to be aligned with the engine so that the input shaft is aligned with the crankshaft. Absence of this alignment results in clutch noise, incomplete release of the clutch plate. It can normally be judged by uneven wear of the finger and pilot bearing. In severe case it can also damage the spline of the input shaft and clutch hubs well as the clutch splines. The clutch component i.e. the clutch plate, flywheel and the pressure plate have to be aligned with the crankshaft and the transmission input shaft. Misalignment caused by run outs/ warpage will cause clutch to grab judder as well as improper release (also manifesting as hard gearshift). Normally the clutch housing misalignment is a result of: Incorrect seating on the engine/transmission. Missing alignment dowel holes. Loose or missing mounting bolt. Mounting surfaces that are damaged/ not parallel. A noisy gearshift operation especially in 1st and 2nd gear can be due to clutch not getting disengaged completely. To check, turn the engine OFF, shift the gear lever to 1st or 2nd gear and then jack up the rear axle till both the wheels gets lifted enough from the ground. Now press the clutch pedal completely and start the engine, the wheels should not be spinning after that slowly release the pedal till it has moved about 10 mm, the wheel should still not be spinning. If some spinning is noticed then it indicates improper lift of the pressure plate. Do clutch bleeding and, then check for the pressure plate lift. To check the clutch housing misalignment bell housing run out will also need to be checked. Remove the transmission assembly with transfer case. For additional information refer to Transmission Assembly With Transfer Case \u2013 R &R; section. Put the dust cap/cotton cloth in CSC nozzle port during clutch or transmission service. Pull the locking clip outwards using a small flat end screw driver and disconnect concentric slave cylinder upper part of bleeder. using a 12mm socket spanner remove concentric slave cylinder mounting bolts . Torque : 25\u00b13.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100055.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove concentric slave cylinder assembly. Install in the reverse order of removal. Carry-out clutch circuit bleeding. For additional information refer to Clutch Fluid Air Bleeding Procedure. Inspect clutch slave cylinder for any leakages. Check the clutch slave cylinder Axial movement (Up & down) & bearing rotational movement (Right & left) for any abnormality. Inspect clutch slave cylinder boot condition for any damages. Inspect clutch slave cylinder mountings for any damages. Assemble the extension shaft and flat head to the push rod (Push end) of the Push & pull gauge. Switch OFF the Push & Pull gauge and adjust the gauge dial to zero. Now switch ON the gauge. Ensure engine is in running condition at idle speed. The push & pull gauge should be in line with the clutch pedal travel direction. Measurement taken by hitting the pedal to the bottom stopper would be wrong. Do not push the gauge by holding the top end. It would give us a wrong reading due to the extra force applied. Position the push & pull gauge at the centre of the clutch pedal pad with gauge\u2019s flat surface touching the pedal pad surface in parallel. Push the gauge by holding the gauge at the sides (as shown the figure) till the pedal moves down, stop before the pedal hits the bottom stopper. Note the peak values on the push & pull gauge during the clutch pedal travel. Repeat the procedure for another 2 times and record the peak values. The average of the three values would be the pedal effort in Kgf. New clutch assembly 9 -12 Kgf (88-118N). The maximum allowable clutch pedal effort is 17 Kgf (167N) Max. The pilot bearing is mounted in the crankshaft and supports and locates the input shaft of the transmission. Use of a rolling bearing in place of the conventional bush, reduces the rolling resistance. However it should be noted that because of the bearing, it gives less leeway during assembly procedure. Remove the clutch pressure plate & disc . For additional information refer to Clutch Pressure Plate & Disc - R&R; section. using a MST 543 - Extractor flywheel bearing, remove the Flywheel Pilot Bearing. Refit the Flywheel Pilot Bearing by using MST 0312CBH0001ST - Flywheel Pilot Bearing Installer. Refit the clutch pressure plate & disc . For additional information refer to Clutch Pressure Plate & Disc - R&R; section. Inspect the pilot bearing for any damage, crack. Replace if found any. Remove the clutch pressure plate & disc . For additional information refer to Clutch Pressure Plate & Disc - R&R; section. Lock the flywheel using MST 0307ABH0001ST \u2013 Flywheel Locking Tool. Using 19 mm socket spanner, remove flywheel mounting bolts and detach the flywheel. Torque : 50 \u00b1 3 Nm + 45\u00b0\u00b11\u00b0 ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100080.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the flywheel assembly. Install in the reverse order of removal. Always replace flywheel mounting bolts with new one before installation. Tighten the flywheel as per sequence and torque tighten the bolts to specified value. Torque : 50 \u00b1 3 Nm + 45\u00b0\u00b11\u00b0 ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carry-out clutch circuit air bleeding. For additional information refer to Clutch Fluid Air Bleeding Procedure. Check Flywheel face-out and run-out. Check Flywheel Surface Thermal Cracks Condition. Check the flywheel ring gear for worn-out or damage. The clutch cover is a diaphragm type with single-piece construction. In the engaged position (when the clutch pedal is not pressed), the diaphragm spring of the clutch cover assembly holds the clutch pressure plate against the clutch disc, thus clutch disc is held strongly in between flywheel & clutch pressure plate. This enables the engine torque to be transmitted to the input shaft of the gearbox, without any slip / loss Remove the transmission assembly with transfer case. For additional information refer to the transmission assembly with transfer case \u2013 R &R; section. Lock the flywheel using MST 0307ABH0001ST \u2013Flywheel Locking Tool. Using a 12 mm socket spanner, loosen and remove clutch cover assembly mounting bolts. Insert MST 0801BUA0001ST \u2013 Clutch Disc Aligner Tool, before loosening the clutch cover bolts to prevent clutch plate falling down and getting damage. Torque : 25 \u00b1 5Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B100026.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100056.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the clutch cover assembly along with the clutch disc. Detach the clutch disc from clutch cove assembly. Install in the reverse order of removal. While Installation, the projected part of clutch plate should come towards transmission side only, false installation can lead to clutch plate damage. While Installation, Using MST 0801BUA0001ST \u2013 Clutch Disc Aligner Tool, align the clutch cover assembly and clutch disc and fix the clutch cover assembly with the help of mounting bolts. Carry-out clutch circuit air bleeding. Check for abnormal wear in finger, pressure plate. Check pressure plate face-out and run-out. Check thickness of clutch plate, replace if found below MIN value. Clutch pedal return spring helps in returning the clutch pedal as soon as the load on pedal is released. Remove the clutch pedal box assembly. Using a 14 mm socket and ring spanner loosen and remove the Clutch Pedal Pivot Shaft nut and bolt. Remove the pedal pivot bolt and remove the pedal shank from the clutch pedal box. Using a nose plier, pull-down the double torsion Spring downwards and detach from pedal box and then gently pullout spring. Install in the reverse order of removal. Check return spring for proper stiffness. Check the Clutch Pedal Shank & Return Spring for any damage, crack. Replace if found any. 2 post lift /4 post lift.
Clutch/Brake Fluid- Mahindra 'Maximile DOT 4' Genuine Brake fluid.Clutch/Brake FluidCapacity- 1.75 Liters (Including bleeding quantity).Entire bleeding operation should be done with engine ON condition. In case of fluid reservoir or brake fluid replacement, bleeding of brake circuit is required. Always use recommended fluid and do not mix different brand fluids. Always use fresh and clean fluid from a sealed container. Do not reuse the drained fluid. Fluid level in the reservoir must be at MAX level at the start of bleeding and should be checked after bleeding each brake circuit and top up as required. Using a flat end screw driver pull the bleeder lock and pull-out the clutch bundy tube upward from bleeder to drain the clutch fluid. Keep a tray beneath, pull-out the clutch bundy tube and collect the drained fluid in the tray. Press the clutch pedal gently for draining the entire fluid. Collect the fluid drained in a tray. Avoid spilling on floor. Drain the complete brake fluid. Connect the bundy tube back and press locking clip to lock the bundy tube. Ensure the bundy tube connected back and locking clip locked the bundy tube in its position. Fill recommended brake fluid up to MAX mark on brake fluid reservoir. Press and release the clutch pedal gently to full stroke a few times for the fluid to enter completely in the circuit. Remove bleeder plug cap from clutch operating slave cylinder pipe. Attach a vinyl tube to bleeder plug and insert the other end into container. Ensure that the other end of the tube is fully immersed in the bottle having clean clutch /brake fluid. If the bleeding operation is done without connecting a tube and in the open air then the chance of air trapped in the system is high. Ensure that the other end of the tube is fully immersed in the bottle having clean brake fluid. Press and release the clutch pedal 3-4 times slowly to the full stroke and hold the pedal in depressed condition. Using 11 mm open end spanner, rotate the bleeder screw by 90 degree in anticlockwise rotation and allow all the air bubbles to escape into the container. Bleeding plug to be in opened condition during bleeding process only. Remaining time it should be in closed position. Fluid starts flowing through the transparent tube into the container. Tighten the bleeder screw as soon as there is no air bubbles visible in the transparent tube. Repeat this operation until there are no more air bubbles in hydraulic line. Ensure sufficient fluid level in reservoir throughout the bleeding procedure. Remove the transparent tube. Then attach bleeder plug cap. Check fluid level in reservoir, maintain brake fluid at MAX level mark. Close the reservoir cap back and tight properly. Check and ensure proper working of clutch. Ensure to check any leakage in the bundy tube connector & bleeding plug cap, if leak found ensure to fit properly the bundy tube connector & bleeding plug cap. If pedal sponginess is present do the entire bleeding procedure again. Check clutch pedal for sponginess. If found spongy, repeat the entire procedure of bleeding. Check and ensure there is no leakage from pipes and joints. Do not spill brake fluid on the vehicle, it may damage the paint, if the brake fluid does contact the paint, wash it off immediately with water. Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. The fluid reservoir cap should not be opened with dirty hands. Avoid direct water spray on reservoir while washing engine compartment. If Maximile DOT 4 brake fluid is not available and in emergency conditions, use Brake Fluid Meeting SAE J1703 FMVSS NO.116 DOT 4 OR IS 8654 TYPE-2 Specification. Change it at 30,000 km or 2 years whichever is earlier. During the bleeding operation ensure the container and pipe used is of transparent for better visual. At all times during the bleeding process, it has to be ensured that the fluid level in the reservoir does not drop below minimum. The clutch master cylinder push rod is connected to clutch pedal. The clutch master cylinder converts driver's foot effort to hydraulic pressure and transmits the pressure to the slave cylinder through clutch bundy tube. Remove the transmission assembly with transfer case . Detach clutch master cylinder(CMC) fluid inlet hose CMC end. Pull the lock clip upwards and detach clutch high pressure pipe CMC end. Carefully remove the clutch master cylinder. Install in the reverse order of removal. Carry-out clutch circuit bleeding. For additional information refer to Clutch Fluid Air Bleeding Procedure. Inspect the clutch high pressure tube for any damage. Replace if found. Inspect the Clutch Master Cylinder for any damage, crack. Cleck the fluid level in clutch fluid reservoir. Fluid Level Low \u2013 Check the Fluid Leakage in Lines, Bleeder or CSC. Fix the leaks or replace the part/s. Then perform clutch bleeding and check the pedal condition. Fluid Level is Ok \u2013 Go to Step 2. Check the Clutch Pedal to Clutch Master Cylinder Link for damage. Not Ok \u2013 Replace the Clutch master Cylinder and perform Bleeding. OK - Go to Step 3. Check Clutch master cylinder operation for internal leak. Checking procedure \u2013 Disconnect the CMC outlet Hose CMC side, then hold the output with figure. Press the clutch pedal and feel the fluid get compress and experience the pressure., Not Ok \u2013 Replace CMC., CMC output pressure as per specification \u2013 Go to Step 4. Check the Clutch Disc or Pressure plate condition., Clutch Disc & Cover Inspection Procedure. , Clutch pressure plate Spring damage or clutch disc burn \u2013 Replace the Set and check the clutch pedal condition. 2 post lift/ 4 post lift. 2. Turn the ignition OFF. ",
+ "file": null,
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "DTC \u2014 Check Procedure using i-Smart diagnostic tester",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Connect the i-SMART diagnostic tester and turn the ignition ON. Select Dearborn Electronics India Pvt Ltd. \u2014 Garuda and then click START. Select THAR from the list of vehicles displayed as in following window then select the HAR_ BS6. Click on the GENERATE button on the bottom right side of the Express View screen to generate DTC report. This will generate and store a report. Once completed, i-SMART will prompt to open Excel file. If any DTC is active, Refer Diagnostic manual for more information. Connect the miniSMART Bluetooth VCI on DLC and turn the ignition ON. Pair the Bluetooth of android tablet / smartphone with miniSMART VCI. Launch the miniSMART App and select the THAR from the vehicle list. Connect the miniSMART Android and select each \u201cECU\u201d from the list of controllers. From the list, select DTC Fetch. The ECU will be analysed and the registered DTCs will be displayed, then take screen shots of all registered DTCs and their Freeze Frame data by clicking over the DTC / FF icon, for records. If any DTC is active, Refer Diagnostic manual for more information. Repeat the above steps 4 to 7 for other ECU\u2019s present in the vehicle. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect engine WH connector ECU end and detach harness from routing clips. Disconnect AC compressor electrical connector. Using 12 mm socket spanner, Unscrew ignition coil ground connector mounting nut. Disconnect Variable oil pump solenoid electrical connector. Disconnect upstream Lambda sensor electrical connector and connector holder. Disconnect Engine oil pressure sensor electrical connector and routing clip. Disconnect WGTelectrical connector. Disconnect Dump valve electrical connector and routing clip. Disconnect VVT IN (Intake Phaser) electrical connector. Disconnect VVT Out (Outlet Phaser) electrical connector. Disconnect Throttle Valve Actuator & Position Sensor electrical connectors. Disconnect Spark plug (4 nos) electrical connectors. Disconnect Glow Plug inter-connector. Disconnect downstream lambda sensor electrical connector and routing clip. Disconnect Exhaust CAM sensor electrical connector. Disconnect Intake CAM phase sensor electrical connector. Disconnect Crankshaft Sensor electrical connectors. Disconnect Coolant temperature sensor electrical connector. Disconnect FIP electrical connector. Disconnect Common rail electrical connector. Disconnect Injector (4 nos) electrical connector. Disconnect Knock sensor electrical connector & routing clips. Disconnect Alternator connector & routing clip. Using 8 mm socket spanner, Unscrew starter motor solenoid switch electrical connector. Torque : 2.5\u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Disconnect reverse switch electrical connector. Disconnect GNS electrical connector. Disconnect transfercase switch electrical connector. Detach Engine WH on intake manifold side. Using 10 mm socket spanner, Unscrew engine WH carrier mounting bolts. Disconnect engine WH inter connector, Holding clip and routing clip fire wall end. Detach the WH harness from engine assembly. Detach engine wiring harness from engine compartment. Install in the reverse order of removal. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Torque tighten the earth mounting nuts to specified values. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove HVAC Control Panel (Manual). Carefully pull the Telltale Bank from inside. Disconnect the Telltale Bank electrical connectors and 12 volt electric connector and remove the Assy from IP. Using star screw driver remove Telltale bank mounting screws. Torque : 1.5 \u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the telltale bank. Install in the reverse order of removal. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the telltale bank for any external damage, If any replace it. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Instrument Panel Assembly. Using 10 mm socket spanner, Unscrew fuse box mounting bolts. Torque : 4 .0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the RH side door to IP interconnector and holding clip. Disconnect engine compartment to IP RH side inter-connector and holding clips. Disconnect the MBFM electrical connectors. Using 10 mm socket spanner, Unscrew ground cable mounting nuts and detach the connectors. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Disconnect the ignition key barrel electrical connectors. Disconnect the HVAC assembly electrical connectors. Disconnect LH door electrical connector. Disconnect the IP to Roof wiring harness inter-connector. Disconnect LH side IP to engine interconnectors with holding clip. Using 10 mm socket spanner, Unscrew earth cable mounting nuts. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Remove the IP wiring routing clips from CCB. Remove the front LH scuff Plate. For additional information refer to Front LH Scuff Plate \u2013 R &R; Section. Detach the LH B pillar partially. Disconnect the Pre tensioner electrical connectors LH side. Disconnect the LH seat electrical connector and routing clips. Disconnect the Airbag ECU electrical connector. Using a 10 mm socket spanner, Unscrew earth cable mounting nut and disconnect the cable. Disconnect the parking brake switch electrical connector. Remove the Front RH Scuff Plate. For additional information refer to Front RH Scuff Plate \u2013 R &R; section. Detach the RHS B pillar partially. Disconnect the Pre tensioner electrical connectors RH side. Disconnect the floor console inside wiring Harness routing clips. Disconnect the RH seat electrical connector and routing clips. Remove the wiring harness from vehicle. Install in the reverse order of removal. Ensure proper engagement of all the connectors Ensure proper engagement of all the wiring harness mounting clips Ensure proper routing of wiring harness Torque tighten the earth mounting nuts to specified values Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove A Pillar Upper Trim LH. Disconnect speaker electrical pigtail inter-connector. Detach MIC wire from routing. Detach roof wiring harness from routing clips. Disconnect IP to roof WH inter-connector and holding clip with routing clips. Remove IP TOP Cover with PAB Assembly LH. For additional information refer to IP TOP Cover with PAB Assembly LH \u2013 R &R; section. Detach WH routing clip and from vehicle. Install in the reverse order of removal Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Rear RH Tail Lamp Assembly. For additional information refer to Rear RH Tail Lamp Assembly \u2013 R &R; section. Disconnect floor to tail door interconnector and holding clips. Detach the tail door WH grommet. Disconnect BIW pigtail inter-connector and connector holding clip. Remove the tail door Trim. For additional information refer to Tail Door Trim - R &R; Section. Disconnect door latch electrical connector. Remove the Tail Door Wiring Harness from vehicle. Install in the reverse order of removal. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Service Reminder Indicator Reset Procedure ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Service Reminder Indicator - Reset.mp4",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "In the instrument cluster, the service reminder alert will start popping up in the cluster screen at 200 kms before the actual kilometers at which the service is due. This will continue at every ignition cycle. It is necessary to reset the service reminder once the service is rendered to the vehicle. If not reset, the service alert will continue to pop up at every ignition cycle, till it is reset by using recommended procedures. Press the OK button on Driver side switch bank and simultaneously turn the ignition ON. Release the OK button within 5 seconds after ignition on. Check and ensure that the service reminder alert is OFF in the cluster. The above procedure would reset the Service Reminder Alert till the next scheduled maintenance. Service reminder alert is provided with the intent of reminding the customer about a pending service visit hence, perform this SOP only after the vehicle has actually undergone servicing. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect the MBFM electrical connectors. Detach the IP wiring harness holding clip from MBFM bracket. Using 10 mm socket spanner, Unscrew MBFM bracket mounting bolts from BIW and remove MBFM with bracket from the vehicle. Torque : 6.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew MBFM mounting bolts from the bracket and detach the MBFM. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370057.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the MBFM and bracket for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect the EMS ECU GASOLINE-K connector. Disconnect the HFM sensor C 19 connector. Remove the front splash shield. For additional information refer to Spash shield \u2013 R &R; section. Using 10 mm socket spanner remove earth cable mount nut and a routing clip. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove LH Side marker lamp connector with a routing clip. Disconnect LH side turn lamp electrical connector. Disconnect LH DRL connector and detach grow mat to take out connector. Disconnect LH Head lamp and levelling motor(HLLD) electrical connectors. Disconnect Horn electrical Connectors (2Nos) and 3 routing clip. Disconnect Electrical fan electrical connector. Disconnect LH Crash sensor electrical connector. Disconnect fog lamp electrical connector routing clips. Disconnect ambient temperature sensor electrical connector. Using 10 mm socket spanner, Unscrew engine compartment fuse box mounting bolts. Torque : 10\u00b11 Nm ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using 8 mm socket spanner remove fuse box positive cable mounting nut and disconnect from battery fuse connection. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Disconnect engine WH inter connector, Holding clip. Detach WH routing clips from fire wall. Using 10 mm socket spanner unscrew earth cable mounting nut from fire wall and detach cable. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Remove Air Cleaner Assembly. Using 10 mm combination spanner Remove LH fender ground mounting nut and detach it. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Disconnect brake fluid level sensor electrical connector. Disconnect ABS ECU electrical connector. Disconnect HVAC triple pressure switch electrical connector. Disconnect RH Crash sensor electrical connector. Remove the Splash Shield Front RH. For additional information refer to Splash Shield Front RH - R &R; section. Disconnect RH fog lamp electrical connector routing clips. Disconnect RH head lamp electrical connector. Disconnect RH head lamp levelling motor(HLLD) electrical connector. Disconnect RH side marker lamp electrical connector with a routing clip. Disconnect Front RH indicator and DRL connector and detach grow mat to take out connector. Using 10 mm socket spanner unscrew earth cable mounting nut from RH fender and detach cable. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "Description",
+ "content": "Detach WH routing clips from fender. Disconnect engine compartment to IP electrical connectors. Disconnect accelerator pedal electrical connector. Disconnect brake switch electrical connector with a routing clip. Disconnect clutch sensor electrical connector. Detach WH routing clips and take out wiring. Detach WH from inside to outside. Remove the scuttle Grill. Disconnect Wiper motor electrical connector and a routing clip. Disconnect IP to Engine compartment wiring harness inter-connectors. Disconnect engine compartment to chassis WH inter-connector. Disconnect washer tank electrical connector. Detach Engine compartment Wiring Harness from engine compartment. Install in the reverse order of removal. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Torque tighten the earth mounting nuts to specified values. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the e-disconnect stone guard. For additional information refer to edisconnect stone guard - R &R; section. Disconnect the Front RH wheel speed sensor C 361 connector. Detach wiring harness routing clips on front cross member. Disconnect the e-disconnect motor C 231 connector. Disconnect the front LH wheel speed sensor C 360 connector. Detach wiring harness routing clips on chassis. Disconnect engine compartment WH to Chassis WH inter-connector. Detach routing clips on chassis LH side. Disconnect the chassis to FDM C 485 F inter-connector. Disconnect the rear LH wheel speed sensor C 362 connector. Detach routing clips on chassis rear LH side . Disconnect the chassis to bumper C 434 F inter-connector. Disconnect the DEF pigtail C 707 F inter-connector. . Detach rear chassis routing clips. Disconnect the rear RH Wheel Speed Sensor C363 connector. Detach routing clips on chassis rear RH side. Remove the Rear LH Tail Lamp Assembly. For additional information refer to Rear LH Tail Lamp Assembly \u2013 R &R; section. Using 10 mm socket spanner unscrew LH tail lamp earth cable mounting nut and detach it. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Detach routing clip and grow mate. Remove the Rear RH Tail Lamp Assembly. For additional information refer to Rear RH Tail Lamp Assembly \u2013 R &R; section. Using 10 mm socket spanner unscrew RH tail lamp earth cable mounting nut and detach it. Disconnect the tail lamp RH C 153 connector. Disconnect the tail lamp LH C 154 connector. Disconnect the chassis to tail gate-2 C 708 F inter- connector. Disconnect the chassis to tailgate-3 C 709 F inter-connector. Remove the chassis wiring harness from vehicle. Install in the reverse order of removal. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Torque tighten the earth mounting nuts to specified values. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the HVAC Control Panel. Open the glove box and remove the glove box by detaching the lock. Remove the Driver side IP panel assembly. Disconnect the HVAC control panel C 720 connector. Disconnect the intake actuator C 722 connector. Disconnect the blower motor C 721 connector. Disconnect the blower resistor C 723 connector. Disconnect the thermo amplifier C 724 connector. Disconnect the HVAC unit C 117 M connector. Disconnect the blower switch C 720A connector. Using 10 mm socket spanner, loosen and disconnect the HVAC ground G 2 connector. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Remove the wiring harness separately. Install in the reverse order of removal. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Torque tighten the earth mounting nuts to specified values. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the sensor from the routing slot. Take out the sensor and disconnect the electrical connector. Install in the reverse order of removal. Inspect the ambient temperature sensor for any external damage, If any replace it. Using a star screw driver, loosen and remove the front splash shield mounting screw rivets from both the sides of vehicle. Remove the front splash shield both the sides from vehicle. Using a 10 mm socket spanner, loosen and remove the front stone guard front mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen and remove the rear stone guard rear mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the stone guard mounting screw rivets. Remove the stone guard from the vehicle. Disconnect the fog lamp electrical connectors LH & RH sides. Pull and remove the front bumper winch cover clips and remove the panel. Using 10 mm socket spanner, Unscrew front bumper mounting nuts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290004.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew front bumper bottom mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front bumper top side mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front bumper top centre mounting screw rivets.. Remove the front bumper assembly from the vehicle. Install in the reverse order of removal. Inspect the front bumper assembly for any crack or damage. Replace if found. Remove Front Turn Indicator And DRL LH. For additional information refer to Remove Front Turn Indicator And DRL LH - R &R; section. Remove Splash Shield Front LH. For additional information refer to Splash Shield Front Lower LH - R &R; section. Using a screw driver, unscrew the antenna from the fender LH. Torque : 3\u00b11 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the front grill mounting screw rivets. Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm combination spanner, Unscrew show lock mounting nut fender end. Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250139.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew fender top mounting bolts. Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250142.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew fender side mounting bolts. Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew fender bottom mounting bolts. Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew fender mounting bolts door side. Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the fender from vehicle. Refit in the reverse order of removal. Inspect the fender panel for any damage. Replace if found. Remove the Cladding Rear Wheel Arch RH. For additional information refer to Cladding Rear Wheel Arch RH - R &R; section. Remove the Cladding Rear Wheel Arch LH. For additional information refer to Cladding Rear Wheel Arch LH - R &R; section. Using a star screw driver,loosen and remove the rear fender RH/ LH side mounting screws. Using a star screw driver , loosen and remove the rear bumper bottom side mounting screwrivets. Using a star screw driver , loosen and remove the rear bumper side mounting screws. Using 10 mm socket spanner, Unscrew the rear bumper mounting bolts body end. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Flip the bumper and disconnect the electrical main connectors and remove rear bumper. Remove the wiring routing clips from the bumper assembly. Disconnect the rear parking sensor electrical connectors. Disconnect license plate electrical connector. Remove the rear bumper wiring harness. Remove the parking sensors with holder. Remove the license plate lamp from rear bumper assembly. Inspect the rear bumper assembly for any crack or damage. Replace if found. Using a star screw driver, Unscrew hard top quarter glass frame mounting screws from the rear window. Pull - out the glass beading from Quarter Glass. Carefully push from inside to outside and remove the rear window from the vehicle. Install in the reverse order of removal. While Installation always replace with New frame mounting screws Inspect the hard top quarter glass for any damage/crack etc. Replace if found any Inspect the hard top quarter glass mounting fasteners for any damage. Replace the fasteners if required Remove the hard top assembly. Inspect the Hard-Top windshield upper frame Seal and replace if needed when the seal loses its softness or if found any damages.
Follow the below steps for replacement of Hard-Top windshield upper frame Seal
Remove the X-mas tree clips by trim remover from over the roof rail outer frame. Then pull the seal by manually, due to this seal has fixed with two-way pasting tape. Clean the surface by digresses cloth. Peel the sticker label sheet from the new Seal, then paste on the roof rail outer frame followed by press the X-mas tree clips. The Seal must be replaced along with X-mas tree clips, when the seal loses its softness or if found any damages, don't reused the X-mas tree clips. This seal is for preventing the water leakage and wind noise only. Seal coming with Two-way pasting tape. Install in the reverse order of removal. Remove the B pillar lower trim. For additional information refer to B pillar lower trim \u2013 R &R; section Remove the centre roof bow trim. Open the top cover and Using a 14 mm socket spanner, loosen and remove the seat belt upper mounting bolt. 38 \u00b16 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210071.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the upper trim from vehicle. Install in the reverse order of removal. Inspect the B-pillar upper trim for any damage/crack/cut etc. Replace if found any. Inspect the B-pillar upper trim fasteners for any damage. Replace the fasteners if found any damage.. Remove Side window RH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Unzip the tail gate window, detach the tail gate bar locking from rear RH & LH belt rails remove the tailgate window. Unhook the \u2018C\u2019 pillar cover from rear RH & LH belt rails and fold the cover at top of the soft top. Using a T30 socket spanner, loosen and remove the belt rear rail Mounting bolts and remove the belt rail from the vehicle. Follow the same procedure for LH side. Using a T30 socket spanner, loosen and remove the belt center rail Mounting bolts and remove the belt rail from the vehicle Follow the same procedure for LH side. Using T30 socket spanner, loosen and remove the belt vertical rail mounting bolts and remove the belt rail from the vehicle. Follow the same procedure for LH side. Remove the belt corner rail from the vehicle. Follow the same procedure for LH side. Using T30 socket spanner, loosen and remove the belt door rail mounting bolts and remove the belt rail from the vehicle. Follow the same procedure for LH side. Install in the reverse order of removal. Inspect the Seal/rail for any damage/crack/cut etc. Replace if found any. Remove the Hardtop Assembly. Remove the Seal from the vehicle. Inspect the Front Lateral trim for any damage/crack/cut etc. Replace if found any. Inspect the Front Lateral trim mounting legs for crack/bend etc. Using a trim removal tool pull out center bow trim and disconnect roof lamp electrical connector Remove the centre bow trim from the vehicle. Remove the roof lamp from bow trim. Install in the reverse order of removal. Inspect the trim for any damage/crack/cut etc. Replace it if found. Remove the B Pillar Upper Trim. Using a 10 mm socket spanner unscrew Grab handle mounting bolts. 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner unscrew front lateral trim mounting bolt. 2 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the Front lateral trim. Install in the reverse order of removal. Inspect the Front Lateral trim for any damage/crack/cut etc. Replace if found any. Inspect the Front Lateral trim mounting legs for crack/bend etc. Remove driver sun visor. For additional information refer Driver Sun Visor \u2013 R &R.; Remove co-driver sun visor. For additional information refer Driver Sun Visor \u2013 R &R.; Using a T40 Torx Socket spanner unscrew centre bow trim mounting screws. 5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a trim removal tool carefully detach the trim and remove electrical connector. Detach the MIC carefully from the trim.. install in the reverse order of removal. Inspect the trim for any damage/crack/cut etc. Replace it if found . Remove Front Roof Bow Trim. Remove Front Lateral Trim. For additional information refer to Front Lateral Trim \u2013 R &R; section. Using a 10 mm socket spanner unscrew A pillar trim mounting bolt. Torque : 2 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the A pillar upper trim from vehicle. Install in the reverse order of removal. Inspect the A-pillar upper trim for any damage/crack/cut etc. Replace if found any. Inspect the A-pillar upper trim mounting legs for crack/bend etc. When the engine is stopped and the ignition switched off, the battery feeds accessories which are directly connected to battery, such as alarms, clock, radio code and certain computers that operate continuously. Dark currents are considered normal if they do not exceed a few tens of milli amperes. If the value is more than that, one or more permanent electrical component is drawing too much current. They can be isolated by withdrawing the fuses one by one until the faulty circuit is identified. A multi-meter is the best tool for these measurements. A current clamp cannot accurately measure currents of less than 1 A. The measurement must be taken at the battery itself. Before carrying out leakage current test, Turn all accessories OFF. Switch OFF the ignition and remove the key. Close all doors and windows. Wait for minimum 3 Minutes and then do the checking procedure. In multi-meter, current selection should be in milliampere. Set the current measuring range of the ammeter to 10 A. Disconnect the negative terminal from the battery. Connect the positive terminal of multimeter (Red probe) with the negative terminal removed from the battery and connect the negative terminal of multimeter (black probe) with negative pole of the battery. Read the value in multi-meter. If the current measured is more than permissible value (For MT Variants \u2013 7 mA (Max) & for AT Variants \u2013 12 mA (Max)) ,check for any: Loose connection in ground points. Check for any active loads ( like roof lamp,etc;). Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the cable. Using 10 mm socket spanner, loosen and remove the engine feed cover mounting bolts. Using 14 mm socket spanner, rotate the auto tensioner in anti-clockwise direction and detach the accessory belt. Disconnect the alternator electrical connector. Remove alternator positive cable cover. Using 12 mm socket spanner, loosen and remove the alternator positive cable nut. Using 12 mm socket and ring spanner, Remove the alternator top mounting bolt and nut. Using 12 mm socket spanner, loosen and remove the alternator bottom mounting bolt and nut. Carefully remove the alternator from engine compartment. Install in reverse order of removal.
2. Check free play of alternator pulley.
3. Check alternator drive belt for any damage. If found replace with a new one.
",
+ "file": null,
+ "display_order": 30
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 40,
+ "sys_id": "THAR.AX-0006-Charging System",
+ "subsys_id": "THAR.AX-0006-Charging System-Specific Gravity Test",
+ "systems": "Charging System",
+ "sub_systems": "Specific Gravity Test",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B080001.jpg",
+ "myid": 1121,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Specific Gravity Test-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Hydrometer is a float-type device used to determine the State-of-Charge by measuring the specific gravity of the electrolyte in each cell. It is an accurate way of determining a battery's state of charge and weak or dead cells. Wear suitable eye protectors (goggles). With the help of a flat end screw driver, remove the vent caps or covers from the battery. Squeeze the hydrometer bulb and insert the pickup tube into the cell close to the battery positive terminal. Slowly release the bulb to draw in only enough electrolyte to cause the float to rise. Do not remove the tube from the battery Read the specific gravity indicated on the float. Be sure the float is drifting free, and does not contact with sides of the barrel. Read the hydrometer at eye level. Disregard the slight curvature of liquid on the float. The specific gravity for fully charged battery is as follows: 1. AMARON -1.270 \u00b1 0.010 at 27\u00b0C
",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Specific gravity readings. By measuring the specific gravity of the electrolyte, you can identify whether the battery is fully charged, requires charging, or must be replaced. Specific gravity varies with the temperature. If the electrolyte temperature is substantially above 27\u00b0 C add seven points (0.007) to the observed specific gravity reading for every 10\u00b0 C by which the actual temperature is above 27\u00b0 C. Deduct seven points per 10\u00b0 C where the observed reading is below 27\u00b0 C to obtain the temperature corrected reading at 27\u00b0 C. Inspect battery electrolyte specific gravity whenever required. level ground.
2. Open the bonnet and lock it in open position using bonnet stay rod.
",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Battery Health - Checkup.mp4",
+ "display_order": 2
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25352.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080001.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Testing",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "When you start a new test, the last test results in memory are overwritten. Remember to record or print the results if you need to retain them. Connect the MDX - 650P battery tester to battery terminals connecting probes on the battery posts respectively. Press the Enter button and confirm the BATTERY LOCATION by selecting the \u201cIN VEHICLE\u201d in the tester using navigation button Up or Down . Press the Enter button and confirm the POST TYPE by selecting the \u201cTOP POST\u201d in the tester using navigation button Up or Down . Press the Enter button and confirm the APPLICATION by selecting the \u201cAUTOMOTIVE\u201d in the tester using navigation button Up or Down . Press the Enter button and confirm the BATTERY TYPE by selecting the \u201cREGULAR FLOODED\u201d in the tester using navigation button Up or Down . Press the Enter button and confirm the BATTERY STANDARD by selecting the \u201cJIS\u201d in the tester using navigation button Up or Down . Press the Enter button and get the recommended JIS Number value by pressing button Up or Down . Press the Enter button and perform the TESTING. Once the TESTING done, the initial battery result will be display. Press the PRINT button to get the hard copy print out. Disconnect the battery tester probes from battery terminals. Follow the below table for Battery Testing test results condition and remedial action Check the electrolyte level. Add distilled water to all the cells which require water. Ensure the electrolyte level between MIN and MAX marks. Refit the vent plugs properly. Topping up should be done with distilled water only. Never use normal water or mineral water to top battery electrolyte. Vent holes should be clear Clean the terminals. Tighten terminals to specified torques. Check battery electrolyte level whenever required. Specific Gravity v/s With% Charge v/s With OCV Do battery electrolyte level inspection when required.
2. Visually inspect the charging system for any noticeable signs of mechanical or electrical damage.
3. If any obvious cause is found, correct the same before proceeding to the next step.
",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/17517.jpg",
+ "display_order": 4
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 37,
+ "sys_id": "THAR.AX-0006-Charging System",
+ "subsys_id": "THAR.AX-0006-Charging System-Open Circuit Voltage Test",
+ "systems": "Charging System",
+ "sub_systems": "Open Circuit Voltage Test",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1118,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Open Circuit Voltage Test-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Open Circuit Voltage Test Turn ON the head lamp high beam for 30 seconds to remove any surface charge. Digital voltmeter checks the battery\u2019s open circuit voltage. Analogue meters do not show accurate readings and should be avoided. Turn OFF the head lamp, disconnect the battery and connect the digital voltmeter across the battery terminals. Note the readings in the voltmeter. A fully charged battery will have an open-circuit voltage based on below table value. Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. Using 10 mm socket spanner, loosen battery positive cable mounting nut and disconnect the cable. Using 13 mm socket spanner, loosen and remove the battery holding clamp mounting nuts. Remove the battery from the vehicle. Install in reverse order of removal.
2. Check for any cracked or broken cables/connections, and replace the cables if necessary.
3. Check for corrosion on terminals and dirt/acid on the battery case top. Clean the terminals and the battery case top with mixture of water and baking soda. A battery wire brush tool can also be used to clear heavy corrosion on the terminals. Prevent further corrosion by applying petroleum jelly to the outside of the terminals.
",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 222,
+ "sys_id": "THAR.AX-0006-en-SM-Restraint System",
+ "system_name": "Restraint System",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1019,
+ "active_status": true,
+ "Assets": [
+ {
+ "systemdisplayorder": 9,
+ "system_asset": "/files/Safety.mp4",
+ "active_status": true
+ }
+ ],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 224,
+ "sys_id": "THAR.AX-0006-Restraint System",
+ "subsys_id": "THAR.AX-0006-Restraint System-Driver Airbag Module",
+ "systems": "Restraint System",
+ "sub_systems": "Driver Airbag Module",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A210041.jpg",
+ "myid": 1337,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Driver Airbag Module-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The driver airbag module is located in the steering wheel and its function is controlled by the airbag ECU. A bag within the module inflates to protect the driver in the event of a collision severe enough to deploy the system.
The driver airbag module connects to the steering column wiring harness via a rotary coupler called as clock spring. Within the driver airbag module there is a squib which, when given the correct current by the airbag ECU, inflates the airbag by initiating a chemical reaction. In deployment, the airbag inflates within a fraction of a second and then deflate at a controlled rate as the driver body regions; typically head and chest interact with airbag. Vents in the airbag control its deflation.
",
+ "file": "",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": "Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Steering Column Shrouds. Turn the steering wheel to 90\u00b0 counter clockwise direction from the steering wheel straight position and using a screw driver press the RHS DAB lock then release the lock. DAB locks are made up of plastic, ensure to press the locks softly by screwdriver. Turn the steering wheel to 90\u00b0 clockwise direction from the steering wheel straight position and using a screw driver press the LHS DAB lock then release the lock. DAB locks are made up of plastic, ensure to press the locks softly by screwdriver. Gently pull-out the DAB module from the steering wheel. Using a small flat end screw driver release the lock of the DAB electrical connector, then disconnect the DAB and horn electrical connectors. While refit ensure wires are routed out of the snapping zones to avoid damage. Remove the DAB module separately. Install in the reverse order of removal. Inspect the DAB module for any physical damage. Replace if found any Inspect the DAB connector for any damage.
Within the passenger airbag module is a squib which, when given the correct current by the airbag ECU, inflates the airbag by initiating a chemical reaction. In deployment, the airbag inflates within a fraction of a second and then deflates at a controlled rate as the passenger body regions; typically head and chest interact with airbag. Vents in the airbag control its deflation.
",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210035.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210045.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/32012.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/32013.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080024.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Glove Box Assembly. Remove the IP grab handle cover. Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts. Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220023.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting screws. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220024.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle. Partially detach the door edge beading and using a trim removal tool, remove the IP LH side cover. By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt. Torque : 8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220076.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220066.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector. Take out the IP LH side top cover with Passenger air bag from the IP. Using a 10 mm ring spanner, loosen and remove the air bag mounting bolt from IP top cover. Torque :4.5\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210046.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Expand the PAB module holder both sides using screw driver and detach the PAB separately from IP top cover. Install in the reverse order of removal. Inspect the PAB module for any damage. Replace if found any. Inspect the PAB module connector for any damage. Inspect the PAB module trim for any damage. The Airbag ECU is installed on the floor panel under the floor console. It deploys the proper Airbag according to the signals from the impact sensors. This ECU communicates with other ECU\u2019s through CAN directly. Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Front console assembly. For additional information refer to Front Console Assembly R&R; section. Using star screw driver remove the Airbag ECU Cover screw from airbag ECU. Disconnect the SRS/ Airbag ECU electrical connectors. Using a 10 mm socket spanner, loosen the SRS/ Airbag ECU mounting nuts on the floor panel. Torque :8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210052.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the SRS/ Airbag ECU from the body. Install in the reverse order of removal. Inspect the airbag ECU for any damage, replace if found any. Inspect the airbag ECU connectors for any damage. The Airbag unit monitors the internal/external devices of the Airbag system including battery voltage, limits certain functions of the Airbag, and turns on the Airbag warning lamp on the instrument cluster according to the conditions. Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front splash shield lower mounting screws. Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts. Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield. Disconnect the front Crash sensor electrical connector. Using a 10 mm socket spanner, loosen and remove the front Crash sensor mounting bolt from the vehicle. Torque :8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210057.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the front crash sensor from the vehicle. Install in the reverse order of removal. Inspect the front crash sensor for any damage. Replace if found. Using vehicle key open the fuel filler door. Rotate fuel filler lid cap anti-clock wise direction and remove the cap. Using 10 mm socket spanner unscrew fuel filler neck mounting bolts. Torque : 5 \u00b1 1.0 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner loosen hose clamp and remove fuel filler hose pipe end and detach the hose. Torque : 6 \u00b1 1.0 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect fuel vent and fuel vapour line quick couplers. Disconnect fuel filler hose routing clip and remove the hose from vehicle. Refit in the reverse order of removal. Inspect fuel filler pipe assembly for any physical damage, replace if found any. Inspect fuel filler pipe assembly for any leakage. Rectify if found any. Fuel Delivery Module delivers the fuel to the low pressure line and to measure the fuel level in the tank. Fuel delivery module consists ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040092.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "
Disconnect the FDM electrical connector. Remove fuel tank protection cover screw nuts and detach cover from tank. Press the lock and disconnect the fuel supply line and return line pipe from the fuel delivery module and remove the hoses from the fuel tank. Using shaft and mallet carefully hammer on the FDM lock in counter clock wise direction and release it. Carefully remove FDM unit from fuel tank. Install in the reverse order of removal. Always replace the O ring with a new one once FDM removed. Ensure the FDM top flange extension should be matched with the arrow mark on the fuel tank shell as shown in the above illustration Using a suitable metal shaft and hammer, tap the FDM lock ring to get properly lock. Inspect fuel delivery module for any damage. Inspect the float assembly operation and for any damage. Fuel System Low Pressure Circuit Test Gauge ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040231.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Fuel System Low Pressure Circuit Test Gauge tool kit is used to diagnose Fuel System Low pressure circuit related concerns only. Without removing FDM Assembly or Fuel Tank assembly from vehicle, we can able to check the Fuel Delivery Module supply pressure. Any blockages/ choke or air entrapment in Fuel line low pressure circuit can be diagnosed by using this Kit. Above steps are for removal of Residual pressure in Gasoline vehicles. Detach the fuel line quick coupler from the fuel supply pipe inter connection end. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Detach the fuel line quick coupler from the FIP. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Engage the Female adapter of gauge with the fuel supply pipe interconnection (Filter to FIP) Qwik fix connector. Connect the male Qwik fix connector of gauge with the FIP inlet. Turn the Ignition ON, FDM starts operating. Note down the maximum pressure reading. Allowable pressure Range of New Thar Gasoline vehicles : 5.2 to 5.4 bar. Turn the Ignition OFF and remove the Fuel Gauge. Connect the fuel line to FIP Inlet pipe and fuel supply pipe interconnection. The fuel tank is a reservoir for the fuel and incorporates the Fuel delivery module inside Disconnect fuel vent hose quick coupler from gasoline tank. Using hose clamp plier release fuel filler hose spring band clamp and disconnect the hose fuel tank endr. Disconnect fuel vapour hose quick coupler from gasoline tank fuel filter side. Disconnect the fuel vapour quick couplers in the tank supply end. Disconnect the fuel tank supply pipe quick coupler. Disconnect the fuel tank return hose quick coupler. Disconnect fuel tank electrical connector. Provide Jack to support the fuel tank. Using 13 mm socket spanner unscrew fuel tank mounting bolts. Torque : 55 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the tank Assembly from vehicle. Install in the reverse order of removal. Check for fuel leakage in the fuel tank. Check for any external damage, if found please replace. Disconnect fuel rail pressure sensor electrical connector. Before working on the high pressure side fuel components (Fuel Injection Pump, High Pressure Pipe, Fuel Rail & Injectors) turn the engine off, disconnect fuel supply hose quick coupler at FIP end and wait for Ten minutes. The fuel system is a non \u2013 return fuel system and fuel pressure within the system is very high. Failure to follow above instruction will result in personal injury Eye protection and a mask must be worn at all times while working near any fuel related components. Failure to follow this instruction will result in personal injury Using 24 mm deep socket spanner, Loosen and remove fuel rail pressure sensor. Torque : 25 \u00b1 3.0 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040026.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal. Fuel Rail sensor should be remove & refit only 5 times, ensure to replace New Assembly beyond 5 times Inspect the rail sensor for any damage. Replace if found. Inspect the rail sensor for any damage. Replace if found. Disconnect FDM electrical connector routing clip and detach WH. Detach the fuel tank vapour pipe from routing and tank end. Drain the fuel from the tank. Remove fuel tank bracket mounting push clips and detach the bracket. Refill the fuel in the tank. Install in the reverse order of removal. Check for fuel leakage in the fuel tank Check for any external damage, if found please replace. Check for free movement of float assembly without any restriction. Fuel System Low Pressure Circuit Test Gauge ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040231.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Fuel System Low Pressure Circuit Test Gauge tool kit is used to diagnose Fuel System Low pressure circuit related concerns only. Without removing FDM Assembly or Fuel Tank assembly from vehicle, we can able to check the Fuel Delivery Module supply pressure. Any blockages/ choke or air entrapment in Fuel line low pressure circuit can be diagnosed by using this Kit. Remove the Fuel Delivery Module Assembly. Press the clip and unlock the sensor from the mount, move the level sensor in upward direction with moderate strength & remove the sensor assembly from the FDM. Detach the wiring from the level sensor housing. By Using suitable pin take out the wiring pins from sensor. Pressing the both sided snap-on tabs of the cable connector through the opening of the housing and cover carefully and simultaneously pull out the wire connectors from float unit. Prior to the Installation, both the wiring connector snap-on tabs have to be bent back to the right position as shown below (By using Knife or suitable tool). Plug the wiring connectors pins on the New sensor housing at appropriate place with moderate force. Ensure to Plug the wiring connectors pins on the New sensor housing at appropriate slots based on wiring colours as shown The firm snap-on of the wire connectors is to be examined by a moderate pulling examination. Attach the wiring from the level sensor housing. Lock the sensor on the mount & refit the sensor assembly on the FDM. Refit the Fuel Delivery Module Assembly. Check for free movement of float assembly without any restriction. Inspect the float assembly for proper working condition. Check for any damage in float assembly, If any damage found replace it. This high pressure fuel line connects High pressure pump with fuel rail and supplies compressed high pressure fluid to fuel rail. Using 17 mm open end spanner loosen the HP pipe mounting from FIP and common rail ends. Torque : 22.5 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040061.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before working on the high pressure side fuel components (Fuel Injection Pump, High Pressure Pipe, Fuel Rail & Injectors) turn the engine off, disconnect fuel supply hose quick coupler at FIP end and wait for Ten minutes The fuel system is a non \u2013 return fuel system and fuel pressure within the system is very high. Failure to follow above instruction will result in personal injury Eye protection and a mask must be worn at all times while working near any fuel related components. Failure to follow this instruction will result in personal injury Remove the HP pipe from vehicle. Refit in the reverse order of removal. Inspect the high pressure fuel pipe for any damage. Replace if found any. Inspect the high pressure fuel pipe for leakage, rectify if found. Remove High Pressure Pipe (Pump to Rail). Before working on the high pressure side fuel components (Fuel Injection Pump, High Pressure Pipe, Fuel Rail & Injectors) turn the engine off, disconnect fuel supply hose quick coupler at FIP end and wait for Ten minutes. The fuel system is a non \u2013 return fuel system and fuel pressure within the system is very high. Failure to follow above instruction will result in personal injury. Eye protection and a mask must be worn at all times while working near any fuel related components. Failure to follow this instruction will result in personal injury. Using 10 mm socket spanner unscrew oil dipstick guide mounting bolt, nut and keep aside dipstick guide. Torque : 11 \u00b11.0 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect fuel rail electrical connector. Disconnect injector electrical connectors. Using 12 mm socket spanner loosen and remove the fuel rail mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully remove the Fuel Rail Assembly with injectors. Injectors Combustion Seals should be replaced with new ones when ever removing & refitting the Fuel Rail Assembly from the cylinder head. Remove the Combustion Seal by using plastic lever or plastic pliers or Nose plier. The Combustion Seal can be stretched until it breaks or can be removed off the component. When removing Combustion Seal, no metallic fixtures (pliers, fork, scissors, cutter, trimmer) are allowed to be used, which may damage injector sealing surface. Only plastic fixtures can be used Take care not to damage the surface of the injector Inspect the sealing surface and replace the complete injector in case there is a defect on sealing surface (such as a tool mark) properly Clean the Combustion Seal groove & injector tip by bathing it in an appropriate cleaning fluid, before assembling the Combustion Seal. Position the injector in vertical position (O-ring in the upper side) in the cleaning bath for 10 to 15 min, not above the middle of the Valve Body Cleaning fluid must not content acids and/or substances not recommended to get in contact with steel or PA and avoid oil, lubricant, grease Can use P3-Galvaclean20 (Henkel) cleaning fluid with a concentration of 20 to 80 g/l diluted in demineralized water pre heated at 50\u00b0C Cleaning fluid must not get in the connector and/or inside the injector and non metallic parts of the injector Does not use brush, emery paper or ultrasonic device on clean the injector Inspect the sealing surface and replace the complete injector in case there is a defect on sealing surface (such as a tool mark) The surfaces of the new Combustion Seal must be clean and free of grease. The geometry of the groove must not be damaged or modified. Place the Combustion Seal installation special tool on the injector tip. Insert and push the sealing ring by using pushing tool over the sealing ring tool until it snaps into the groove. The seal must be completely free of grease and oil Remove the Combustion Seal installation special tool from injector tip. Insert the injector to the sizing special tool and turn 180\u2070 so that the seal fits well in the groove. Remove Injector from the sizing tool by turning it in the reverse direction. Check that the Combustion Seal has not been damaged during assembly to the injector and ensure seal must fit properly in the relative groove. Inspect the Fuel rail for any damage. Replace if found. Check injectors, Injector clips for any external damage, If found replace. Inspect the Injectors connectors for any damage. Replace if found. Refit in the reverse order of removal. After Installation, Running the engine at idle for few minutes and Check for fuel leakage in fuel rail and injector assembly. If found rectify the same. Carry out Injector routine procedure - using i-SMART. For additional information refer to the diagnostic manual. During assembly in Fuel Rail, no hammers or impact tools should be used which could directly bear on or affect the High Pressure Fuel Injector Fuel Rail Assembly should be remove & refit only 5 times, ensure to replace New Assembly beyond 5 times The Purge valve is a solenoid valve in a plastic housing which is controlled by the EMS ECU. The Purge valve controls the hydrocarbon vapours flow into Intake manifold in accordance with the engine\u2019s operating status. Disconnect the vapour hose quick coupler purge valve end. Using hose clamp plier release vapour hose spring band clamp and disconnect the hose. Disconnect purge valve electrical connector. Detach purge valve from holding bracket on the intake manifold. Refit in the reverse order of removal. Inspect the hose for any physical damage, replace if found any. Inspect the hose for any leakage. Rectify if found any. The high pressure pump (Direct Type) receives drive from intake cam shaft. The rotation of camshaft lifts and releases the roller tappet up and down according to the cam profile. The upward motion of Roller tappet compresses the plunger of pump which pressurizes the fuel and thus high pressure fuel gets feed to fuel rail through the delivery port on the top Once the roller tappet comes down, plunger comes back to its normal position. This cycle is continued to provide high pressure fuel to fuel Rail Using 17 mm open end spanner loosen the HP pipe mounting from FIP and common rail ends Torque : 22.5 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040061.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before working on the high pressure side fuel components (Fuel Injection Pump, High Pressure Pipe, Fuel Rail & Injectors) turn the engine off, disconnect fuel supply hose quick coupler at FIP end and wait for Ten minutes. The fuel system is a non \u2013 return fuel system and fuel pressure within the system is very high. Failure to follow above instruction will result in personal injury Eye protection and a mask must be worn at all times while working near any fuel related components. Failure to follow this instruction will result in personal injury Remove the HP pipe from vehicle Press the lock and disconnect the fuel inlet pipe pump end All are quick fix connectors, press gently and remove it carefully; avoid seal damages Disconnect FIP electrical connector Disconnect FIP electrical connector Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect FIP electrical connector Replace the FIP O Ring with a new one when installing Remove roller tappet from the high pressure pump housing Refit in the reverse order of removal While Installation, Ensure that the projection in the roller tappet should be matched with slot in the cylinder head for correct orientation Inspect the FIP for any physical damage, replace if found any Inspect the Roller Tappet for any physical damage, replace if found any It is an electromechanical device, which is used to inject the fuel to the cylinder head. The quantity of fuel injected in the combustion chamber is controlled by an electronic control module. Remove the Fuel Rail Assembly. Before working on the high pressure side fuel components (Fuel Injection Pump, High Pressure Pipe, Fuel Rail & Injectors) turn the engine off, disconnect fuel supply hose quick coupler at FIP end and wait for Ten minutes. The fuel system is a non \u2013 return fuel system and fuel pressure within the system is very high. Failure to follow above instruction will result in personal injury. Eye protection and a mask must be worn at all times while working near any fuel related components. Failure to follow this instruction will result in personal injury. Pull & Remove the injector locking clips from the dedicated groove on the Injectors and detach the fuel injectors from the fuel rail. Injector Clip, O-ring & Backup ring should be replaced with new ones when ever removing & refitting the Fuel Injector from the Rail Assembly Injectors Combustion Seals should be replaced with new ones when ever removing & refitting the Fuel Rail Assembly from the cylinder head If Injector/Injectors struck with Cylinder Head and not able to remove from head, Injector can be removed by using Injector removal tool and follow the below steps Insert the Injector removal tool twisting shaft and lateral sliding it onto injector and making sure the extraction socket of twisting shaft below the extraction bump on injector. Assemble the torsion pin with twisting shaft, twist it clockwise and counter clockwise. Ensure not to apply a more torque (Not greater than 5 Nm) Extract the injector from the cylinder head pulling it out with the tool. if not able to remove injector from cylinder head, extract the torsion pin and insert the shot mass on to twisting shaft. Then insert torsion pin. Hit the torsion pin with the shot mass to extract the injector from the cylinder head. Extract the injector together with spring clip after injector separate from the cylinder head. An excessive impulsive application of the pull-out load by an extraction tool might damage the injector in an irreversible way which may not be apparent visually. In this case it is strongly recommended to replace the injector Remove the O-ring by using hand or plastic lever or plastic pliers. The O-ring can be stretched until it breaks or can be removed off the component. Remove the Backup ring by using hand or plastic pliers. When removing O-ring, Backup ring, no metallic fixtures (pliers, fork, scissors, cutter, trimmer) are allowed to be used, which may damage injector sealing surface. Only plastic fixtures can be used Take care not to damage the surface of the injector Inspect the sealing surface and replace the complete injector in case there is a defect on sealing surface (such as a tool mark) Install the New Backup ring by gently rolling it over the O-ring Adapter upper collar and position it into the proper position inside the groove. Check that the Backup ring fit properly in the relative groove Install the New O-ring by gently rolling it over the O-ring adapter upper collar and position it into the proper position inside the groove. The O-ring must be always at the fuel side, the back up ring must be below the O-ring respect to the fuel side Inspect the Fuel rail for any damage. Replace if found. Check injectors, Injector clips for any external damage, If found replace. Inspect the Injectors connectors for any damage. Replace if found. Insert the injector locking clips in the dedicated groove on the Injectors and attach the fuel injectors on the fuel rail. Position the injector in front of the injector cup in such a way that the rib of the spring clip is aligned with the Ushape feature on the external of the injector cup Insert the injector into the fuel rail cup up to the complete engagement of the clip rib over the U-shape feature Inspect accurately the sealing surfaces of the fuel rail prior to reassemble the injectors. In case of defect (such as a tool mark) replace the fuel rail Refit the Fuel Rail Assembly. For additional information refer to Fuel Rail Assembly - R &R; section. After Installation, Running the engine at idle for few minutes and Check for fuelleakage in fuel rail and injector assembly. If found rectify the same. Carry out Injector routine procedure - using i-SMART. For additional information refer to the diagnostic manual. During assembly in Fuel Rail, no hammers or impact tools should be used which could directly bear on or affect the High Pressure Fuel Injector Fuel Rail Assembly, Injector should be remove & refit only 5 times, ensure to replace New Assembly beyond 5 times Canister (charcoal filter) traps the hydrocarbon vapours from the tank and supply this hydrocarbon vapours to intake manifold by Purge valve for rich air fuel mixture. Disconnect vapour line quick couplers canister end. Using 13 mm socket spanner unscrew canister mounting bolts. Torque : 10 \u00b1 2.0 Nm Detach fuel supply hose from canister and take out canister. Refit in the reverse order of removal. Inspect Canister for any physical damage, replace if found any. Inspect Canister for any leakage. Rectify if found any. Remove the wheel. For additional information refer to Wheel \u2013 R &R; Section. Remove the tyre from the rim. For additional information refer to Tyre - R &R; Section. Using a T10 Socket Spanner, loosen and remove the TPMS sensor mounting screw and detach the sensor. The TPMS and Valve cannot be replaced separately.These can be replaceable as assembly. The valve must be positioned just left of the start position to avoid sensor damage. Do not touch the sensor with the tyre tool. Starting to mount the tyre from the valve location is a wrong fitment. The fixing tool/ stem may hit the sensor and damage it. Start from the opposite direction. By using suitable TPMS removal/Installer tool, remove the valve from the rim. Install in the reverse order of removal. Ensure that the TPMS Sensor is not damaged while removing the tyre. Check the tyre inner surface for cuts and punctures. TPMS Manual Learning is the process by which the identities of 5 sensors installed inside the tyres are learnt & programmed in to the memory of receiver module. It should be mandatory to performe on any of the following conditions or operations done. Any of the old TPMS sensors are damaged & sensors are replaced. Any of the tyre among 5 tyres are replaced. if any of the tyres or set of tyres are shuffled or swapped in position. If tyres rotation operation is performed. If observed that the alert indications in TPMS screen are not correlating with respect to their actual position in vehicle. Once the manual learning is initiated the sensors inside the tires needs to triggered by leaking the air from each tire one at a time and should be completed within 90 secs post to each event for learning all 5 tires. Do not perform Manual learning process at the same time on two vehicles with in the radius of 20 meters. It is mandatory that manual learning of tyres should follow the sequence of \u2018front left tyre position, front right tyre, rear right tyre, rear left tyre and spare tyre\u2019. It is required to ensure the tires are having pressure > 32 psi & < 36 psi before initiating the manual learning process. It is mandatory that manual learning of tyres should follow the sequence of \u2018front left tyre position, front right tyre, rear right tyre, rear left tyre and spare tyre\u2019. It is required to ensure the tires are having pressure > 32 psi & < 36 psi before initiating the manual learning process. Post to manual learning all tire should be filled with recommended tyre pressure value. At any point of time during the learning process if learning takes more than 90 secs of time for each tire position then the system shall exit the learning mode and show the Learning not successful screen. At a time, only one tyre can be swapped with the spare wheel and then follow the learning procedure. Position the vehicle on a flat surface. Press the Scroll Up arrow button on Driver side switch bank and simultaneously turn the ignition ON. Wait for cluster\u2019s tachometer & speedometer self-check rotation and then release the arrow button. Identifying weather the learning is initiated. Infotainment will show popped out screen TPMS Learning screen. TPMS telltale in cluster shall keep blinking. Three vehicle siren chirps will be heard. If failed to enter in to manual learning mode. Try initiating the manual learning once again. Check if reverse gear is engaged, if engaged disengage it. Check MBFM, Infotainment & Cluster software versions. Check if variant coding is done in all three. Check if Scroll Up arrow button on Driver side switch bank button is working fine. TPMS learning procedure must be done in the below sequence: 1. Front left tyre 2. Front right tyre 3. Rear right tyre 4. Rear left tyre 5. Spare tyre Start leaking the air from front left tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If front left tyre is learned 1 siren chirp sound is heard and FL tyre shows learned in infotainment system. Start leaking the air from front right tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If front right tyre is learned 1 siren chirp sound is heard and FR tyre shows learned in infotainment system. Start leaking the air from rear right tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If rear right tyre is learned 1 siren chirp sound is heard and RR tyre shows learned in infotainment system. Start leaking the air from rear left tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If Rear left tyre is learned 1 siren chirp sound is heard and RL tyre shows learned in infotainment system. Start leaking the air from the spare wheel tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If spare tyre is also learned then 1 siren chirp sound is heard and ALL tyres show learned at respective tyre positions and \u2018All tyres Learned successfully\u2019 in the center of the screen. At any point of time during the learning process, if learning takes more than 90 seconds of time for each tyre position then the system shall exit the learning mode and show the \u201cLearning not successful\u201d screen. After tyre rotation or TPMS sensor replacement, TPMS must be learnt,otherwise the system will show TPMS malfunction indicator. TPMS learning need to be carried out whenever : 1. Tyre rotation happens. 2. 2 or more wheels are swapped. 3. TPMS sensor is replaced. 4. MBFM is replaced. The TPMS should not be used as a tyre pressure gauge while adjusting vehicle tyre pressure. No two vehicles should be done with manual learning process at a time in same location with in radius of 20 meters. Post to manual learning all tire should be filled with recommended tyre pressure value Remove the gear shifter level knob and 4WD selection knob by rotating them in anticlock wise direction. Using trim removal tool, remove the gear selection rod cover with trim. For AT Variants top trim removal follow (Steps 3 - 8) : , Remove the 4WD selection knob by rotating it in anti-clock wise direction. Pull and fold the gear shifter boot from gear shifter bezel . Partially detach the bezel from the console. Excessive pull may leads to damage of the electrical connector. Disconnect the AT gaiter electrical connector from the bezel. Carefully remove the bezel trim from the TGS lever. Handle bezel assembly carefully to prevent it from damage or scratches. Using trim removal tool, carefully remove the floor console top trim with transfer case shifter boot. Detach the transfer case cable abutment from the shifter bracket by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Using 13 mm socket spanner unscrew transfer case shifter lever assembly mounting nuts. Take out the shifter and tilt the lever assembly gear shifter lever side to remove the TC shifter cable 'R' clip. Detach the TC shifter cable from shifter assembly. Remove the transfer case shifter from the vehicle. Inspect the transfer case shifter for any damage. Replace if found any. Position the transfer case cable on shift lever bracket. Install the shifter cable locking R clip. Position the transfer case shifter lever assembly. Position the transfer case shifter lever at 2H position. Ensure that the transfer case link should be in 2H position on transfer case (Extreme Rear end position from front of the vehicle). Refit the transfer case cable abutments on shift lever bracket. Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Refit the shifter lever assembly mounting nuts. Tighten the mounting nuts to specified torque value. Torque value :22.51\u00b14 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from '2H' to other range. If Shifting not smooth Carry-out Transfer Cable setting. For AT Variants top trim Installation follow (Steps 8 \u2013 12) : , Refit the floor console top trim with transfer case shifter boot. Connect the AT gaiter electrical connector with the bezel. Refit the bezel trim with shifter bezel. Handle bezel assembly carefully toprevent it from damage or scratches Unfold the gear shifter boot and refit the boot with gear shifter bezel. Refit the 4WD selection knob by rotating it in clock wise direction. Refit the Manual transmission gear selection rod cover with trim. Refit gear shifter level knob and 4WD selection knob by rotating them in clock wise direction. Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from 'N' to other range. Inspect that engine can be started with shift lever only 'N' or 'P', but not in other range (For AT variants). Inspect that indicating lamp can be turned on correctly in PRND positions (For AT variants). Using MST 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the transfer case shifter cable from the transfer case ball pins. Detach the transfer case cable abutment from the cable bracket on transmission by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Using 10 mm socket spanner unscrew shifter cable grommet mounting bolts on fire wall. Remove the gear shifter level knob and 4WD selection knob by rotating them in anticlock wise direction. Using trim removal tool, remove the gear selection rod cover with trim For AT Variants top trim removal follow (Steps 6 \u2013 11) : Remove the 4WD selection knob by rotating it in anti-clock wise direction. Pull and fold the gear shifter boot from gear shifter bezel. Partially detach the bezel from the console. Excessive pull may leads to damage of the electrical connector. Disconnect the AT gaiter electrical connector from the bezel. Carefully remove the bezel trim from the TGS lever. Handle bezel assembly carefully to prevent it from damage or scratches. Using trim removal tool, carefully remove the floor console top trim with transfer case shifter boot. Remove the floor console side trim mounting screw rivet and remove the trim both sides. Detach the transfer case cable abutment from the shifter bracket by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Detach the transfer case cable from the cable bracket routing clamp. Using nose plier, remove cable cross pin from the transfer case shifter and detach shifter cable. Keep the Transfercase shifter in 4L position while remove R Clip. Detach the cable from lever and take out from vehicle. Keep the Transfercase shifter in 2H position while remove the cable. Inspect the transfer case for any damage. Replace if found any. Position and route the cable inside the vehicle. Move shifter to 2H position and attach the cable with the shifter lever. Keep the Transfercase shifter in 2H position while refit the cable. Refit shifter cable R clip with the transfer case shifter cable. Keep the Transfercase shifter in 4L position while refit R Clip. Attach the transfer case cable abutment with the shifter bracket by pressing locking clip. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Attach the transfer case cable with the cable bracket routing clamp. Refit the floor console side trim and install the mounting screw rivet. Refit the gear selection rod cover with trim. Refit gear shifter level knob and 4WD selection knob by rotating them in clock wise direction. For AT Variants top trim Installation follow (Steps 9 \u2013 13) : , Refit the floor console top trim with transfer case shifter boot. Connect the AT gaiter electrical connector with the bezel. Refit the bezel trim with shifter bezel. Handle bezel assembly carefully to prevent it from damage or scratches. Unfold the gear shifter boot and refit the boot with gear shifter bezel. Refit the 4WD selection knob by rotating it in clock wise direction. Refit shifter cable grommet and install the mounting bolts on fire wall. Ensure the cable grommet should get assemble from outside of the cabin. Torque Value : 10 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Position the transfer case lever at 2H position on transfer case (Extreme Rear end position from front of the vehicle). Refit the transfer case cable abutments on transmission cable brackets. Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. For adjust cable length, move the cable quick adjuster outer cover in forward direction and unlock the QA clip. Adjust the cable length to fix the cable on link ball pin. After adjusting the length, position the quick adjuster body on link ball pin. Once quick adjuster body snap on ball pin, press the QA clip towards arrow mark shown to lock it fully and release the cable quick adjuster outer cover. Ensure the proper locking by confirming/ hearing the click noise while install. Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from '2H' to other range. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Rear Propeller Shaft Assembly. For additional information refer to Rear Propeller Shaft R &R; Session. Using a 8 mm socket spanner, loosen and remove the front propeller shaft mounting C clamp bolts from the transfer case. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the transfer case electrical connector. Using a 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool , detach the transfer case cable from the transfer case ball pins. Pressing locking clip and detach the transfer case cable abutment from the cable bracket on transmission and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Provide a jack to support the transmission. Using a 12 mm socket spanner, loosen and remove the transmission bed mounting bolts. Torque: 70\u00b15 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 14 mm, 15 mm socket and ring spanners, unscrew transmission cross member mounting bolts, nuts and detach it. Torque: 65 \u00b110.0 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using a 15 mm socket spanner, loosen and remove the transfer case mounting nuts Torque: 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner unscrew transfercase front facing mounting bolts Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner unscrew transfercase rear facing bottom mounting bolt. Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using 12 mm ring spanner unscrew transfercase rear facing top mounting bolt. Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Remove the transfer case from the vehicle. Install in reverse order of removal While Installation of transfer case cable abutments on transmission cable brackets, Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. After Installation of Transfer Case Assembly on vehicle, Carry-out below cable setting Procedure. , Ensure that the transfer case link should be in 2H position on transfer case (Extreme Rear end position from front of the vehicle). For adjust cable length, move the cable quick adjuster outer cover in forward direction and unlock the QA clip. Adjust the cable length to fix the cable on link ball pin. After adjusting the length position the quick adjuster body on link ball pin. Once quick adjuster body snap on ball pin, press the QA clip towards arrow mark shown to lock it fully and release the cable quick adjuster outer cover. Ensure the proper locking by confirming/ hearing the click noise while install. Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from '2H' to other range. Check transfer case oil level & top up if required. Inspect the transfer case for any damage. Replace if found any Drain the Transfer case fluid. For additional information refer to Transfer case fluid Drain & Filling Section. Remove the Transfer case from the vehicle. Position the transfer case on the suitable Wooden/ Nylon blocks. Ensure the oil is drained prior to disassembly of the transfer case. Using a Special tool MST 203 Companion Flange Holding Tool, hold the transfer rear flange. Using a 30 mm socket spanner, loosen and remove rear flange center nut. Torque Value : 340 - 370 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120130.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a magnetic stick, take out flange washer and remove seal from transfer case rear flange. Ensure the use New washer & Seal while installation. Using a mallet, remove the transfer case rear flange. Use suitable 2 Jaw puller to remove the flange, In case of flange not able to remove by mallet. Using a 10 mm square bit spanner, remove the transfer case draining & filling oil plugs from the cover. Using a 15 mm socket spanner remove the assembly cover mounting bolts and remove the mounting bolts & identification tag. Separate the front assembly cover and the rear case assembly. To avoid damage of the metal surface, apply limited force to the bosses on the cover and the transfer case while breaking the sealant bond. Using a flat end screw driver, remove transfer case Rear output shaft oil seal from the cover. Remove the Spacer from the cover. Separate the return spring from the front assembly cover by pulling them outwards. Using flat screw driver& circlip plier, remove the ball bearing snap ring. Rotate the cover and by using MST 0707BBA0003ST - Universal Mandtral remove the ball bearing from the cover. By using suitable Internal puller, pull out the needle bearing from the cover. Care must be taken not to damage the metal surface while removing the needle bearing. Position the transfer case casing and remove the shift collar hub from the output shaft. Remove the 2W-4W lock up assembly and lock up fork together from output shaft and separate lock up fork from the 2W-4W lock up assembly. To dismantle 2W-4W lockup assembly, remove snap ring, lock up hub return spring from lock up collar. Using a circlip plier & flat screw driver, remove the snap ring from the output shaft and remove the spacer. Remove the drive chain with sprocket and drive sprocket from the output shaft. Separate the drive chain, driven sprocket and drive sprocket. Remove the magnet from the slot in the case. Remove the coupler from the case. Remove the output shaft and the gear rotor (Gearotor) pump from the case. Rotate and align the guide pin of the shaft to the slot on the pump body and Separate the gear rotor pump and strainer assembly from the output shaft. By using nose plier, remove the hose clip and remove the hose from pump and remove the strainer. Remove the rail shaft assembly from the case. Remove the reduction hub and the reduction fork from the case. Separate the reduction hub and the reduction fork. Remove the two shift fork facings from the shift fork assembly (if required). Using a Special tool MST 203 Companion Flange Holding Tool, hold the transfer case output shaft yoke. Using a 30 mm socket spanner, loosen and remove rear output shaft yoke center nut. Torque Value : 340 - 370 Nm ",
+ "file": null,
+ "display_order": 93
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120141.jpg",
+ "display_order": 94
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "Description",
+ "content": "Using a magnetic stick & flat screw drive , take out flange washer and remove seal from transfer case output shaft yoke. Ensure the use New washer & Seal while installation. Using a mallet, remove the transfer case rear flange. Use suitable 2 Jaw puller to remove the flange, In case of flange not able to remove by mallet. Remove the lower output shaft from the casing. Using a 15 mm socket spanner, remove the adapter assembly, input shaft and carrier assembly bolts. Take out the adapter assembly with input shaft and carrier assembly. Using an outer circlip plier, Expanding the long ends snap ring unlock the bearing lock circlip and remove the input shaft and carrier assembly. Remove snap ring and oil seal from adapter assembly. Remove the input shaft bearing retaining ring. Remove the input shaft bearing retaining ring. Remove the ASM Carrier from the input shaft. Remove the sun gear snap ring from ASM Carrier. Remove the thrust plate & sun gear from ASM Carrier. By using suitable Internal puller, remove the copper bush from the input shaft. By using suitable Internal puller, remove the needle bearing from the input shaft. By using 17 mm Open end spanner, remove the Breather (For MT variants located at Adapter plate & for AT variants at Adapter case assembly). By using 13 mm socket spanner, remove the hexagonal nut of the shift shaft. By using T25 torx spanner, remove the transfer case and shift cam torx screws. By using flat end screw driver & mallet, remove the clip ring and pull out shift shaft & lever. Remove shift lever from shift shaft. By using flat end screw driver, remove the \u2018o\u2019 ring from shift shaft. Remove 4L assist spring and roller, shifter cam. Remove plunger and spring from the transfer case. By using 24 mm ring spanner, remove 4WD indicator switch from the transfer case (If required). By using flat end screw driver, remove the oil seal from the assembly case. By using flat end screw driver, remove the retaining ring from the assembly case. By using MST 0707BBA0003ST \u2014 Universal Mandtral remove the ball bearing from the case. By using cutting plier, remove the dowel pin from transfer case. Do not remove the ring gear shown in the below figure from the case. Before cleaning, check the magnet for the presence of metal particles which indicate internal chipping of the transfer case. Using a cleaning solvent, clean the old oil and dirt deposits. Before cleaning, check the magnet for the presence of metal particles which indicate internal chipping of the transfer case. After cleaning dry the parts with low pressure (20 psi maximum) compressed air. Lubricate the ball bearings and needle bearing with ATF oil. Protect lubricated bearings from dust. Always replace the hose coupling, O-ring , oil seal and flange/Yoke Nut with new parts. Visually check all the parts for damage. Referring to normal gear tooth face, specifically inspect the uneven wear and chips of gear tooth. Replace or repair if necessary Insert dowel pins to the ring gear casing Dropping of heavy/large objects will damage the part and cause personal injury. Press the ball bearing to the front casing by using MST\u2019s (0707AUA0005ST - Trasfer case Case Covers Ball Bearing Pressing tool) & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Check the ball bearing for functionality prior to installation. Using a snap ring removal tool/screw driver install the retainer ring to the front casing. Install the new output oil seal into the case by using 0707BBA0001ST-Transfer Case Output Shafts Oil Seal Installer & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Check the oil seal prior to installation. In case of any external damages are observed, then replace the oil seal. Install new \u2018O\u2019 ring on the shift shaft and lubricate it. Refit the shift shaft in to the shift lever. Position spring and plunger in the hole of the transfer case. Partially Insert star splined end of the shift shaft into the transfer case. Position shift cam into transfer case with flat end of cam approximately parallel with front face of case (as shown in the picture). Install clip ring in groove near inside end of shift shaft. Install 4L assist spring in groove of shift cam and slot of transfer case. Refit the transfer case and shift cam torx screws by using screwdriver. Make sure that shift shaft is fully engaged so that second screw end enters groove in shaft. Refit the hex nut of the shift shaft, Torque tighten mounting nut to specified value. Install 4WD indicator switch to transfer case. Press the needle bearing into the input shaft by using MST 0707AUA0003ST - T Case Input Shaft Sleeve Pressing tool & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Press the new sleeve bearing into the input shaft by using MST 0707AUA0004ST - T Case Input Shaft NRB Pressing tool & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Refit the input shaft to the carrier assembly by matching the splines. Install the thrust plate, thrust washer onto the input shaft. Position and press the bearing onto the input shaft by using a MST 0707AUA0002ST - T Case Input Shaft Ball Brg Pressing tool. Install the retaining on the input shaft assembly by using circlip plier. Invert from adapter assembly. Install snap ring by making sure that snap ring is correctly install in the groove. Using a circlip plier expand the snap ring and insert the carrier assembly with input shaft to the adapter case. (Ensure that planet carrier assembly on the work bench is such that the retaining rings\u2019 mounting groove faces upward. Press spiral the pin into the front adapter. Using a suitable MST, refit an oil seal from the carrier assembly body by using a MST 0707BAJ0001ST \u2014 Transfer Case Input Shaft Oil Seal Installer - MT (or) 0707BAJ0001ST \u2014 Transfer Case Input Shaft Oil Seal Installer - AT & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Apply a 1.6 mm bead of sealant on the mounting face for the transfer case. Refit the adapter input shaft and carrier assembly to the case, and using a 16 mm socket spanner, tighten the mounting nuts to specified torque. Refit the breather nipple. Position the output shaft in the transfer case. Position the output shaft in transfer case, and install the end yoke assembly, seal, washer and the lock nut. Using a suitable MST yoke holder, socket spanner and torque wrench, tighten the front flange mounting lock nut to specified torque. Install the two forks facing on the reduction shift fork assembly. Install the reduction hub in to the fork. Refit the reduction hub and reduction shift fork into the planet carrier. Slide roller of fork in to the cam groove. Insert shift rail in reduction fork bore, to match with case bore. Align rotor slot of the pump and slot of the pump body in line. Align the slide the pump assembly on output shaft over pump pin. Align the guide pin of the shaft to the slot on the pump body and slide the pump assembly onto the output shaft over pump pin. Assemble the strainer and hose to the gear rotor pump. Install the output shaft and gear rotor pump assembly into the reduction hub housing by matching the splines. Couple strainer with case and insert the magnet into the transfer case slot. Refit the magnet into body. Position the drive sprocket to the rear output shaft end and driven sprocket to the front output shaft end. Install the drive chain onto the sprockets. Holding each sprocket with drive chain tight and parallel with transfer case, install the drive chain assembly to the output shaft. Holding each sprocket with the drive chain tight and parallel with the transfer case, install the drive chain assembly to the output shaft. Rotate the driven sprocket slightly to engage splines on the front output shaft. Install the spacer to the front output shaft. Install the snap ring into the groove of the front output shaft. Install the lockup hub and return spring to the lockup collar and insert the snap ring. Install new facings to the fork. Engage the lockup fork in the groove in 2WD-4WD lockup assembly and slide this group down over output shaft and rail shaft. Check the ball bearing prior to installation. In case of any external damages are observed, then replace the ball bearing. Install shift collar engaging splines on output shaft and in 2WD-4WD lockup assembly. Position the cover with the open end facing up on the table. Position the end of the needle bearing with the identification mark and up the press into the cover by using a suitable MST 0707AUA0006ST\u2014 T Case Rear Cover NRB Pressing tool & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Press the ball bearing into cover by using MST 0707AUA0005ST \u2014 T Case Covers Ball Brg Pressing tool & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Install snap ring over the ball bearing into cover by using screw driver or circlip plier. Install the return spring over rail shaft in the transfer case. Position the cover with the open end facing down on the table. Install the spacer over output shaft spline in the cover assembly. Press the new oil seal into the cover assembly by using MST 0707BBA0001ST \u2014 Transfer Case Output Shafts Oil Seal Installer & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Apply 1.6 mm bead of Loctite RTV598 to the transfer case mounting surface. Installation of cover, align the transfer case with cover. Do not use excessive force. Align the cover holes with the transfer case dowel pins. Align the cover bearing with output shaft. Align the cover blind hole with rail shaft and make sure that return spring is not cocked. Refit the front and rear housing cover mounting bolts along with identification tag and torque tighten the bolt to specified value. Install the two oil plugs to the cover, torque tighten the nut to specified value. Install the flange and washer and lock nut to the output shaft. Do not fully tighten the bolts at this stage. Holding the flange by flange holder torque tighten the nut to specified value. Refit the Transfer case on the vehicle. Refill the Transfer case fluid. For additional information refer to Transfer case fluid Drain & Filling Section. Position the transfer case shifter lever at 2H position. Ensure cable cross pin is properly fitted on transfer case shifter. Ensure the transfer case cable abutment is properly fitted on shifter bracket. Ensure the transfer case cable abutment is properly fitted on transmission cable bracket. Using a 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the transfer case cable from the transfer case ball pins. Ensure that the transfer case link should be in 2H position on transfer case (Extreme Rear end position from front of the vehicle). For adjust cable length, move the cable quick adjuster outer cover in forward direction and unlock the QA clip. Adjust the cable length to fix the cable on link ball pin. After adjusting the length, position the quick adjuster body on link ball pin. Once quick adjuster body snap on ball pin, press the QA clip towards arrow mark shown to lock it fully and release the cable quick adjuster outer cover. Ensure the proper locking by confirming/ hearing the click noise while install. Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from '2H' to other range. Transfer case Oil \u2013 MAHINDRA 'MAXIMILE POWER STEERING FLUID' Genuine Power Steering Fluid.Capacity \u2013 1.2 Litres.Using a 10 mm square bit spanner, remove the oil filling plug from the transfer case. Place a tray beneath the drain plug for collecting the oil while draining. Using a 10 mm square bit spanner, loosen and remove the drain plug. Collect the drained oil in a suitable container. Refit the drain plug. Torque tighten the drain plug to specified value. 34\u00b16 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Fill recommended transfer case fluid with the help of a mechanical pump through filler plug. Ensure that the oil level by insert the 8 mm allen key and check the oil level mark. Refit the filler plug and torque tighten the filler plug to specified torque value. 34\u00b16 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Recommend to use only MAHINDRA 'MAXIMILE POWER STEERING FLUID' Genuine Power Steering Fluid. In case of non-availability of Genuine fluid, SHELL MAKE 'SPIRAX S3 ATF MD3' can be used. In emergency conditions, fluid meeting DEXRON III specification can be used and oil change interval should be at every 40000 km. It is a structure of a pipe, which carries air into the combustion chamber in an engine The primary function of the intake manifold is to evenly distribute the air to each intake port in the cylinder head. Even distribution is important to optimize the efficiency and performance of the engine Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable. Disconnect the purge valve vapor hose quick coupler and disconnect the hose intake manifold end. Pull out the purge valve from holding bracket and hose routing to partially detach purge valve vapor hose. Using hose clamp plier, Release breather hose clamp, routing clip and detach hose intake manifold end. Disconnect MAP sensor electrical connector. Using T25 Torx socket spanner, Unscrew boost pressure & temperature sensor mounting bolt and remove it. Torque : 4 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew engine oil dipstick guide routing bracket mounting bolt. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew intake manifold support bracket mounting bolt manifold end. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 16 mm ring spanner, Loosen and remove NVH cover mounting stud on intake manifold. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew intake manifold mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Carefully remove the intake manifold from engine compartment. Replace the gaskets to the intake manifold whenever removed from the engine. Install in the reverse order of removal. Check the intake manifold for the external damage. If any damage found replace it.
The intercooler is fitted with separate Electric fan for further better cooling.
",
+ "file": "",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4B020210.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A020001.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/30337.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/30338.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable.",
+ "file": "",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4B080003.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the NVH cover.",
+ "file": "",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4B010045.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner, Loosen intercooler inlet and outlet hose clips and detach hoses intercooler end.",
+ "file": "",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4B020278.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.5 \u00b1 0.6 Nm ",
+ "file": "",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4B020279.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect boost pressure & temperature sensor electrical connector.",
+ "file": "",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4B020280.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, remove boost pressure & temperature sensor mounting bolt and detach it. ",
+ "file": "",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4B020281.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5 \u00b1 0.5 Nm ",
+ "file": "",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect intercooler electric fan electric connector.",
+ "file": "",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4B020285.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew degassing tank mounting bolts to partially detach the tank.",
+ "file": "",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4B020282.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.5\u00b10.5Nm ",
+ "file": "",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew intercooler fan mounting nuts.",
+ "file": "",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4B020286.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the Intercooler fan from intercooler assembly.",
+ "file": "",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4B020287.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Notice",
+ "content": "While installing the fan, Ensure to align the arrow mark on Top side as shown below.",
+ "file": "",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4B020288.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4B020043.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew Intercooler mounting bolts.",
+ "file": "",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4B020286.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": "",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew Intercooler mounting bolts.",
+ "file": "",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4B020284.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Torque Value",
+ "content": "Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": "",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4B020227.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": "",
+ "display_order": 38
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for the intercooler for external damage. If found replace it Inspect intercooler hoses for any damage. Replace if found any Inspect intercooler rubber Isolators for any damage. Replace if found any Inspect the Intercooler Fan Assembly for any external damage, Replace the fan assembly if required. ",
+ "file": "",
+ "display_order": 39
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 345,
+ "sys_id": "THAR.AX-0006-Air Intake",
+ "subsys_id": "THAR.AX-0006-Air Intake-Boost Pressure Sensor",
+ "systems": "Air Intake",
+ "sub_systems": "Boost Pressure Sensor",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B020216.jpg",
+ "myid": 1008,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Boost Pressure Sensor-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The boost pressure & temperature sensor is used to monitor the intake air pressure & temperature at the intercooler outlet. The sensor is an NTC type sensor. EMS ECU uses signal from this sensor for Air-intake system control & flow rate modelling. Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable. Disconnect the boost pressure & temperature sensor electrical connector. Using 10 mm Socket Spanner, Unscrew boost pressure & temperature sensor mounting bolt. Torque : 2.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the boost pressure & temperature sensor. Install in the reverse order of removal. Check for any external cracks or damage, replace if found any. Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable. Disconnect HFM sensor electrical connector and routing clip. Using a 10 mm socket spanner, Unscrew HFM sensor mounting bolts and detach sensor from air clear assembly. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020252.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew air cleaner assembly mounting bolts from BIW. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully take out the air cleaner assembly and air intake dirty duct. Using 5 mm Allen key, loosen and remove the dirty side duct mounting bolts from the air cleaner assembly then separate the air cleaner assembly. Install in the reverse order of removal. Check the air cleaner housing for the external damage. If any damage found replace it. The air cleaner element is Non woven +Pleated Media type (Dry Type). Filtration happens in two stages. Coarser particles are filtered in first stage by foam media and fine particles are filtered by Paper media in second stage. The dust and other fine particles which are sucked inside along with air gets trapped in the air cleaner while passing through the filter element. Don\u2019t tap or hit the filter element. The air filter element should be inspected and replaced from time to time, when driving under the following conditions: Unpaved road. Dusty air-polluted road. Long-term driving in rainy weather. Using 5 mm allen key, Unscrew air cleaner dirty duct mounting screws and lift the top housing. Gently take out the air cleaner element from the housing. Clean the inner side of the air cleaner housing using a lint free cloth. Refit the air filter element gently inside the air cleaner housing. During Installation ensure to keep foam side of the filter element in the bottom side Ensure dust should not fall inside the clean hose area while fitting. Always use recommended genuine air filter element. Do not tap or hit the new filter element. Position the air cleaner assembly top cover and refit the mounting screws. Torque : 10 Nm ",
+ "file": null,
+ "display_order": 25
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 340,
+ "sys_id": "THAR.AX-0006-Air Intake",
+ "subsys_id": "THAR.AX-0006-Air Intake-HFM Sensor Cleaning",
+ "systems": "Air Intake",
+ "sub_systems": "HFM Sensor Cleaning",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B020018.jpg",
+ "myid": 1502,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-HFM\u00a0Sensor\u00a0Cleaning-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The HFM sensor is used to find out the mass flow rate of air entering into fuel injection internal combustion engine The air mass information is necessary for the ECU to balance and deliver the correct fuel quantity to the engine. Possible Customer Complaints/ Symptoms ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Root Cause ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Wrong indication of the air flow to the ECU from the HFM sensor. This is due to the deposition of oil & dust particles on sensor element Logic ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Under normal driving conditions, if required boost pressure is not generated by the turbocharger, the smoke limitation map limits the fueling to avoid smoke due to lack of air If oil/ other soot particles are deposited on the HFM sensor element, the HFM sensor will not read the actual airflow and may report a lesser value to the ECU, thereby limiting the fuelling.This brings down the vehicle performance below acceptable limits. In such cases, the HFM sensor performance can be restored by cleaning the sensor with Petrol thoroughly as per the procedure given below Take Petrol in a container such that HFM sensor unit can be immersed completely. Ensure that the electrical connector is not immersed in the petrol bath Allow the HFM sensor unit to immerse in Petrol for about 5-10 min. Petrol once used should not be re-used for cleaning the HFM sensor. Remove the sensor assembly from the Petrol bath and remove the Petrol completely from the sensor. Allow the sensor to get dry Blow pressurized air jet (Pressure between 3 to 5 bars) from a distance of 10 to 15 cm from one end of the sensor so as to remove any Petrol content present in the mesh. Intake manifold pressure & temperature sensor is mounted located at the plenum of the intake manifold. This sensor continuously monitors the variation in intake air pressure & temperature. EMS ECU uses this information for fuel correction & turbocharger pressure control Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable. Remove the engine top encapsulation cover Disconnect pressure & temperature sensor electrical connector. Using T25 Torex socket spanner, loosen and remove the pressure & temperature sensor mounting bolt. Torque : 4 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully remove the sensor from intake manifold. Install in the reverse order of removal. Check for any external cracks, replace if found any. Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable. Disconnect the throttle valve electrical connector. Using 7 mm socket spanner, loosen intercooler outlet hose clip and detach the hose throttle end. Torque : 6.5 \u00b1 0.6Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew throttle valve mounting bolts. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully remove throttle body from intake manifold. Install in the reverse order of removal. Check for any external cracks, replace if found any. The HFM sensor is used to find out the mass flow rate of air entering into fuel injection internal combustion engine. The air mass information is necessary for the ECU to balance and deliver the correct fuel quantity to the engine. Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable. Disconnect the HFM sensor electrical connector. Using a 7 mm socket spanner, loosen the hose clip and detach hose from HFM sensor. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew the HFM sensor mounting bolts. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew the HFM sensor mounting bolts. Install in the reverse order of removal. Check for any external cracks, replace if found any. Check for the obstruction of the air flow, if found please replace. The air cleaner element is Non woven +Pleated Media type (Dry Type). Filtration happens in two stages. Coarser particles are filtered in first stage by foam media and fine particles are filtered by Paper media in second stage. The dust and other fine particles which are sucked inside along with air gets trapped in the air cleaner while passing through the filter element. Don\u2019t tap or hit the filter element. The air filter element should be inspected and replaced from time to time, when driving under the following conditions: Unpaved road. Dusty air-polluted road. Long-term driving in rainy weather. Using a 5 mm allen key, Unscrew air cleaner top housing mounting allen screws and lift the top housing. Gently take out the air cleaner element from the housing. Clean the inner side of the air cleaner housing using a lint free cloth. Blow the compressed air from the top clean side of filter element. Blow the compress air from the top clean side of filter element (From Paper side) Do not blow the air from bottom dirty side (Foam side) While cleaning, ensure the air pressure should be less than 2 bar. Clean the inner side of the air cleaner housing using a lint free cloth. Gently insert the air cleaner element inside the air cleaner housing. During Installation ensure to keep foam side of the filter element in the bottom side Ensure dust should not fall inside the clean hose area while fitting. Always use recommended genuine air filter element. Do not tap or hit the new filter element. Refit the air cleaner top housing and install the mounting allen screws. Torque : 10 Nm ",
+ "file": null,
+ "display_order": 28
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 123,
+ "sys_id": "THAR.AX-0006-en-SM-Wheel & Tyre",
+ "system_name": "Wheel & Tyre",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1014,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 130,
+ "sys_id": "THAR.AX-0006-Wheel & Tyre",
+ "subsys_id": "THAR.AX-0006-Wheel & Tyre-Front Wheel",
+ "systems": "Wheel & Tyre",
+ "sub_systems": "Front Wheel",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.05,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A160002.jpg",
+ "myid": 1511,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Front Wheel-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160002.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/56070.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/56071.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 21 mm Wheel spanner/ deep socket spanner, loosen and remove the wheel mounting bolts. Torque :140\u00b110 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the mounting bolts and then remove the wheel. Install in the reverse order of removal. Check for any external damage in the tyre or the rim, if found replace. Check for any foreign material on tyre or rim, remove if found. Remove the spare wheel from the vehicle. Torque :50\u00b17.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the spare wheel carrier from the vehicle. Install in the reverse order of removal. Check for any external damage in the spare wheel carrier , if found replace. Using 21 mm socket spanner, loosen and remove the wheel nuts on the spare wheel carrier. Torque :70\u00b110 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the spare wheel from the vehicle. Install in the reverse order of removal. Check for any external damage in the tyre or the rim, if found replace. Check for any foreign material on tyre or rim, remove if found. Tyres on the front and rear side of vehicles operate at different loads and perform different steering, handling, and braking functions. For these reasons, they wear at unequal rates and develop irregular wear patterns. Rotation will increase tread life. help to maintain mud, snow, and wet traction levels, and contribute to a smooth quiet ride Follow the recommended tyre rotation frequency for your type of driving more frequent rotation is permissible f desired. The reasons for any rapid or unusual wear should be corrected prior to rotation being performed It is recommended to rotate the tyres as per Maintenance Schedule. TPMS Learning needs to be carried out for vehicle models equipped with TPMS (Tyre Pressure Monitoring System), procedure as below. Press the Scroll Up arrow button on Driver side switch bank and simultaneously turn the ignition ON. Wait for cluster\u2019s tachometer & speedometer self-check rotation and then release the arrow button. Infotainment will show popped out screen TPMS Learning screen. TPMS telltale in cluster shall keep blinking. Three vehicle siren chirps will be heard. Try initiating the manual learning once again. Check if reverse gear is engaged, if engaged disengage it. Check MBFM, Infotainment & Cluster software versions. Check if variant coding is done in all three. Check if Scroll Up arrow button on Driver side switch bank button is working fine. TPMS learning procedure must be done in the below sequence: 1. Front left tyre 2. Front right tyre 3. Rear right tyre 4. Rear left tyre 5. Spare tyre Start leaking the air from front left tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If front left tyre is learned 1 siren chirp sound is heard and FL tyre shows learned in infotainment system. Start leaking the air from front right tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If front right tyre is learned 1 siren chirp sound is heard and FR tyre shows learned in infotainment system. Start leaking the air from rear right tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If rear right tyre is learned 1 siren chirp sound is heard and RR tyre shows learned in infotainment system. Start leaking the air from rear left tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If Rear left tyre is learned 1 siren chirp sound is heard and RL tyre shows learned in infotainment system. Start leaking the air from the spare wheel tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If spare tyre is also learned then 1 siren chirp sound is heard and ALL tyres show learned at respective tyre positions and \u2018All tyres Learned successfully\u2019 in the center of the screen. At any point of time during the learning process, if learning takes more than 90 seconds of time for each tyre position then the system shall exit the learning mode and show the \u201cLearning not successful\u201d screen. After tyre rotation or TPMS sensor replacement, TPMS must be learnt, otherwise the system will show TPMS malfunction indicator. TPMS learning need to be carried out henever : 1. Tyre rotation happens. 2. 2 or more wheels are swapped. 3. TPMS sensor is replaced. 4. MBFM is replaced. The TPMS should not be used as a pressure gauge while adjusting vehicle tyre pressure. No two vehicles should be done with manual learning process at a time in same location with in radius of 20 meters. Post to manual learning all tire should be filled with recommended tyre pressure value. Remove the front wheel. For additional information refer to front WHEEL - R &R; Section. Using chisel Remove the drive shaft mounting nut caulking. Using 36 mm socket spanner, loosen and remove Drive shaft mounting nut by Applying brake. Torque : 240 \u2013 260 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the caliper stem mounting bolts then hang the caliper. Torque : 31 \u2013 38 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Pull the Brake Pad outwards upto pad contact with clip as shown in the illustration. Twist the pad in anti clock wise direction, lift the pad upwards and remove the pad. Using 19 mm socket spanner, loosen and remove the caliper bracket mounting bolts then remove the caliper bracket. Torque : 90 \u2013 100 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using star screw driver, remove the brake disc mounting screw and detach the disc from the front wheel hub. Remove the disc separately. Using 19 mm socket spanner, loosen and remove Hub mounting bolts and remove the hub with carrier plate. Torque : 87 - 90 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150030.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Before assembly clean the mating faces of the front wheel hub and brake disc. Check for any external damage in the wheel hub, if found replace. Check for any wheel hub bearing condition, if found replace. Using 21 mm Wheel spanner/ deep socket spanner, loosen and remove the wheel mounting bolts. Torque :140\u00b110 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the mounting bolts and then remove the wheel. Install in the reverse order of removal. Check for any external damage in the tyre or the rim, if found replace. Check for any foreign material on tyre or rim, remove if found. Proper Tyre inflation pressure is essential to the safe and satisfactory operation of your vehicle. Three primary areas are affected by improper Tyre pressure: Safety Economy Ride Comfort and Vehicle Stability Proper Tyre inflation contributes to a comfortable and safe ride. Over inflating produces a jarring and uncomfortable ride. Both under inflation and over inflation affect the stability of the vehicle and can produce a feeling of sluggish response or over responsiveness in the steering. Unequal Tyre pressures can cause erratic and unpredictable steering response or may cause the vehicle to drift left or right. Improper inflation pressures can cause uneven wear patterns to develop across the Tyre tread. These abnormal wear patterns will reduce tread life resulting in a need for earlier Tyre replacement. Under inflation also increases Tyre rolling resistance and results in higher fuel consumption. TYRE PRESSURE LABEL ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160038.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Tyre Label is located on the driver side inner B-pillar. This label tells you important information about tyre size designed for your vehicle, and the tyre inflation pressures for the front & rear tyres. Never overload the vehicle. Overloading can cause tyre failure, affect vehicle handling, and increase your stopping distance, resulting in an accident and/ or personal injury. Improper inflated tyres can adversely affect vehicle handling or can fail unexpectedly, resulting in an accident and or personal injury. If weight is not equally distributed around the wheel, unbalance centrifugal force by the wheel rotation produces vibration. As the centrifugal force is produced proportional to the square of the rotating speed, the wheel weight should be balanced even at high speed. There are two types of the tire and wheel balancing: static and dynamic. Abnormal vibration may also occur due to unbalanced rigidity or size of tyres. Static Balance ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A180032.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "When the free rotation of the wheel is allowed, the heavier part is stopped on the bottom if the wheel weight is unbalanced and this is called Static Unbalance . Also, the state at which tyre's stop position is not same is called Static Balance when the wheel is rotated again. If the part A is heavier as shown in the figure, add the balance weight corresponding to unbalanced weight from B to A to maintain the static balance. If the static balance is not maintained, tramping, up and down vibration of the wheels, occurs. Dynamic Balance ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A180033.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "The static unbalance of the wheel creates the vibration in the vertical direction, but the dynamic unbalance creates the vibration in the lateral direction. As shown in the figure (A) , if two parts, (2) and (3), are heavier when the wheels are under the static balance condition, dynamic unbalance is created, resulting in shimmy, left and right vibration of the wheels, and the torque Fxa is applied in the axial direction. To correct the dynamic unbalance, add the balance weight of a same weight for two points of the circumference of the rim, M1 and M2, as shown in the figure (B) , and apply the torque in the opposite direction to the torque Fxa to offset in order to ensure smooth rotation of the wheel. The wheel should always be balanced and aligned in order to provide: 1. Enhanced tyre life. 2. Driving safety and steering control. 3. Better performance of the vehicle. 4. Unbalanced tyre may lead to premature tyre wear and driver fatigue due to vibration.Tyres should always be balanced when they are mounted on wheels for the first time. 5. When they are remounted after repair. 6. When there are signs of shimmy or vibrations. For balancing a wheel, follow the manufacturer\u2019s (of balancing machine) manual for balancing instructions, recommendations and any other additional information. Remove the Instrumental Panel Assembly. Using a star driver, loosen and remove the IP driver side switch bank mounting screws. Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270121.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Detach the IP driver side switch bank from the Instrumental Panel Assembly. Install in the reverse order of removal. Inspect the IP driver side switch bank condition, if required replace. By using Trim Removal tool, remove the bezel rest from front door RH. Disconnect the electrical connector from the bezel. Using flat screw driver detach the switch from the bezel. Install in the reverse order of removal. Check the mounting clips condition to avoid rattling and falling down. Check the switch condition. If required replace. Remove the IP center switch bank assembly. Using a star driver, loosen and remove the center switch mounting screws. Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270005.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the center switch from IP center switch bank assembly. Install in the reverse order of removal. Check the mounting clips condition to avoid rattling and falling down. Check the switch condition. If required replace. Remove front grill assembly. Pull the lock disconnect head lamp electrical connectors. Using 10 mm socket spanner, loosen and remove the head lamp mounting bolts. Torque : 6 \u00b11Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270022.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the head lamp assembly separately. Install in the reverse order of removal. Inspect the head lamp for any damage, crack and glass fading. Inspect the bulbs. Remove tail lamp cover from tail lamp. Using 10 mm socket spanner unscrew tail lamp mounting bolts. Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270044.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect tail lamp electrical connector. Remove and turn the backup lamp bulb socket in the direction of the arrow. Remove the reverse lamp bulb from holder. Install in the reverse order of removal. Check the bulb condition to avoid rattling and falling down. Check the bulb condition. If required replace. Using a star screw driver, Unscrew front splash shield lower mounting screws (Front side screws). Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nut. Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the front side of shield to access front turn indicator and DRL. Disconnect the front turn indicator and DRL electrical connectors. Using a 10 mm socket spanner loosen and remove the front turn indicator and DRL mounting bolts. Torque : 4\u00b11 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270112.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully remove front turn indicator and DRL. Refit in the reverse order of removal. Inspect the front turn indicator and DRL for any damage, replace if required. Using a star screw driver, Unscrew front splash shield lower mounting screws. Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts. Torque : 6.5 \u00b10.7 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield. Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270047.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Rotate the bulb holder in anti clock wise direction and remove the holder with bulb. Remove the bulb from the holder. Install in the reverse order of removal. Check the bulb condition to avoid rattling and falling down. Check the bulb condition. If required replace. Using a star screw driver, Unscrew front splash shield lower mounting screws. Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts. Torque : 6.5 \u00b10.7Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield. Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270037.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the electrical connector. Using hand, Push the side marker lamp assembly from the cladding and remove. Remove the Side Marker Lamp from vehicle. Install in the reverse order of removal. Inspect the side marker lamp assembly for any physical damage/crack etc. Inspect the glass for fading. Inspect the condition of bulbs. Inspect the connectors for proper fitment. Remove tail lamp cover from tail lamp. Using 10 mm socket spanner unscrew tail lamp mounting bolts. Torque :4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270044.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect tail lamp electrical connector. Remove the bulb from holder by turning the bulb in counter clock wise direction. Gently pull out the bulb from holder. Install in the reverse order of removal. Check the bulb condition to avoid rattling and falling down. Check the bulb condition. If required replace. Using a star screw driver, Unscrew front splash shield lower mounting screws. Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts. Torque : 6.5 \u00b1 0.7 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield. Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270058.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect parking lamp electrical connector. Rotate and remove the bulb holder from vehicle. Remove bulb from holder by turning the bulb in counter clock wise direction. Detach the bulb from holder. Install in the reverse order of removal. Check the bulb condition to avoid rattling and falling down. Check the bulb condition. If required replace.
2. Check and ensure all four tyre pressures as per specification.
3. Head lamp levelling switch position is on zero (0). Vehicle needs to be parked 10 meters or 3 meters away from the aiming board. (L = 10 meters / 3 meters which is the distance from starting point of front tyre to the aiming board as shown in illustration below).
4. Select the aiming board according to the value of \u201cL\u201d. Head lamp Alignment by Visual Method.
",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12540.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270085.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Refer below illustration for \u201cL= 10 Meters\u201d. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270086.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refer illustration for \u201cL= 3 Meters\u201d. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270091.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Refer the illustration for the head lamp adjustment arrangement ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270087.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270088.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Refer the illustration for the head lamp aiming board dimensions of Head Lamps ",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ },
+ {
+ "procedure_name": "Low Beam Setting Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270089.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270090.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Refer below illustration for the head lamp aiming board dimensions of Head Lamps ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Low beam & high beam aiming settings are common. Hence if adjust low beam, high beam will also get aligned with low beam. Using 5 mm socket spanner, rotate the adjusting screw on motor to vary the Low beam cut-off pattern in vertical direction. Clockwise rotation \u2013 Downwards. Anti-clockwise rotation \u2013 Upwards. Using star screw driver, rotate the RH side lamp adjusting screw to vary the low beam cut-off pattern in horizontal direction. Clockwise rotation \u2013 Left Side Anti-clockwise rotation \u2013 Right Side. RH & LH Head lamps are common for New THAR vehicle. Using star screw driver, rotate the LH side lamp adjusting screw to vary the low beam cut-off pattern in horizontal direction. Clockwise rotation \u2013 Right side. Anti-clockwise rotation \u2013 Left side. Check the function of system, by operating the switch from '0' to '3' and observe the cutoff pattern movement in downward direction accordingly. At zero position of switch, the cut- off should come at \u201ch\u201d heights 833 mm (For L= 10,000 mm) & 924 mm (For L=3,000 mm) on screen. Low beam & high beam aiming settings are common. Hence if adjust low beam, high beam will also get aligned with low beam. RIGHT TURN INDICATOR ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "For inspection, push the lighting control stalk clockwise (to stop position B) to indicate a right turn. The instrument cluster arrow lamp pointing towards the right flashes along with the right side turn signal lamps with chime indicating your intention of turning towards right After you have completed your right turn, the stalk will automatically return to the neutral position. Both the right turn lamp and the right turn signal lamp switch OFF. LEFT TURN INDICATOR ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "For inspection, push the lighting control stalk anti-clockwise (to stop position A) to indicate a left turn. The instrument cluster arrow lamp pointing towards the left flashes along with the left side turn signal lamps with chime indicating your intention of turning towards left. LAMPS OFF ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "For inspection, rotate the outer rotary switch on the lighting control stalk aligning the \u2018Arrow\u2019 on the switch to \u2018O\u2019 on the stalk to switch OFF all lamps. LANE CHANGING ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "For inspection of signal a lane change, move the light control stalk clockwise or anti-clockwise to the limit point of free movement of the lever and release. The turn signals will flash three times and stop. PARKING LAMPS ON ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "For inspection, rotate the outer rotary switch on the lighting control stalk aligning the \u2018arrow\u2019 on the switch to the \u20181st d\u00e9tente\u2019 position on the stalk to switch ON the parking lamps. HEAD LAMP ON ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "For inspection, rotate the outer rotary switch on the lighting control stalk aligning the \u2018Arrowt\u2019 on the switch to the \u20182nd d\u00e9tente\u2019 position on the stalk to switch ON the head lamps. HEAD LAMP HIGH BEAM/LOW BEAM ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "For inspection, with the head lamp ON, push the lighting control stalk down (away) from steering wheel to switch ON the head lamp high beam. The head lamp high beam tell-tale lamp in the instrument cluster illuminates indicating high beam option selected. With the head lamp high beam ON, pull the lighting control stalk up towards the steering wheel to switch ON the head lamp low beam. HEAD LAMP FLASH ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "For inspection, pull the lighting control stalk (from the head lamp low beam position) towards the steering wheel to instantaneously flash the head lamp high beam. The head lamp flash works even when the head lamp is OFF. FOG LAMPS OFF ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "For inspection, align the inner rotary switch on the lighting control stalk to the fog lamp off \u2018dot\u2019 on the inner fixed stalk as shown to switch OFF the fog lamps. FRONT FOG LAMPS ON ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "To inspect the front fog lamps, switch ON the ignition and the parking lamps. Turn the inner rotary switch on the lighting control stalk to align to the fog lamp symbol on the inner fixed stalk as shown. The front fog lamp indicator in the instrument cluster indicates the operation status. HAZARD WARNING LAMP ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "For inspection, press the hazard switch ON, All the turn signal lamps flash. To turn OFF, press the switch again. CENTER ROOF LAMP ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "The Roof lamp switch has three operation modes to choose from;
WIPER CONTROL STALK ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "1. Wiper Off For inspection, move the wipe stalk in neutral position (B). Wiper remains OFF.
2. Flick-Wipe (Mist) For inspection, push the wipe control stalk to position A for a flick-wipe, hold to operate the wipe continuously (simultaneously lift the wiper stalk towards the steering wheel to operate the wash). The stalk automatically comes back to position B when released.
3. Intermittent (INT) Mode For inspection, push down the stalk down to position C. In the INT mode, the wiper operates on preset intervals.
4. Low Speed Wiping For inspection, push the wipe control stalk up to the position D to operate the wiper at a fixed low speed.
5. High Speed Wiping For inspection, push the wiper control stalk up to position E to operate the wiper at a fixed high speed.
",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A320002.jpg",
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "FRONT WIPE/WASH ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "For inspection, pull/lift the wiper control stalk towards the steering wheel from any position to activate the front wipe/wash function. Washer fluid is sprayed on the front windshield and the wipers wipe the windshield 3 times after the washer spray is stopped and wipe once after 4 sec. Hold the stalk in position for continuous spray of washer fluid. HORN ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "For inspection, press the pad on the steering wheel to sound the horn. The horn functions even when the ignition has been switched OFF. STOP LAMP/HIGH MOUNTED STOP LAMP ",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "For inspection, Press the brake pedal and the Stop Lamp /high mounted stop lamp will illuminate. REVERSE LAMP ",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "For inspection, Engage the reverse gear and the reverse lamp will illuminate. Remove the switch bank driver side. Remove the aiming switch lock by using flat screw driver. Insert the screw driver one side to release lock & release other side. Detach the IP driver side switch bank from the vehicle. Install in the reverse order of removal. Inspect the aiming switch condition, if required replace. Using star screw driver unscrew the panel assembly floor console RH screvits and detach the panel from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290031.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console LH screvits and detach the panel from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290034.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew vertical ascent RH mounting screw and detach the vertical ascent RH from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290033.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew vertical ascent LH mounting screw and detach the vertical ascent LH from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290035.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290036.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/IP center.PNG",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "partially detach the switch bank assembly and remove electric connector to take out from the vehicle. Install in the reverse order of removal. Inspect the center switch for any physical damage. Replace if found. Using a star screw driver, Unscrew front splash shield lower mounting screws. Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts. Torque :6.5\u00b10.7 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield. Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270033.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect front indicator electrical connector. Rotate and remove the bulb holder from vehicle. Remove bulb from holder by turning the bulb in counter clock wise direction. Install in the reverse order of removal. Check the bulb holder condition to avoid rattling and falling down. Check the bulb condition. If required replace. Pull and remove the tail lamp cover from vehicle. Using 10 mm socket spanner, loosen and remove tail lamp mounting bolts and partially detach it. Torque : 4 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270044.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect tail lamp electrical connector. Remove tail lamp from vehicle. Install in the reverse order of removal. Inspect the tail lamp/ rear lamp assembly for any physical damage/crack etc. Inspect the glass for fading. Inspect the condition of bulbs. Inspect the connectors for proper fitment. Remove the Convertible Soft top Canopy. Remove the support centre Rexine rivets other side. Remove the Support Side Rexines rivets RH & LH. Using star screw driver, loosen and remove the Bow 1 Injection Mould mounting screws (locate 1 screw at bottom side of centre rexine support). Using star screw driver, loosen and remove the Latch mounting screws. Remove the Bow 1 Injection mould from front side bow and remove the Convertible Soft top Frame Complete assembly. Refit in the reverse order of removal. Inspect the Convertible Soft top Frame Complete assembly for any crack or damage. Replace if any. Remove Side window RH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Remove Side window LH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Unzip the tail gate window, detach the tail gate bar locking from rear RH & LH belt rails remove the tailgate window. Unhook the \u2018C\u2019 pillar cover from rear RH & LH belt rails and fold the cover at top of the soft top. Slide the Sun visors and Remove the Footman's loops from front header. While unlock the Footman loop hook from the front header metal bracket, ensure to press & move the softtop assembly slightly in forward direction and release the hook from the bracket. Slide back the convertible top from front header to rear and roll up properly. Properly Roll up the convertible soft top assembly in the rear side as shown in fig . Unlock two Quick release knuckle RH & LH from main pivot brackets . Lift the convertible soft top assembly upwards (both sides) , silding towards rear and take out assembly from the vehicle. Lift the convertible soft top assembly upwards (both sides), sliding towards front and position on the vehicle as shown. Align the convertible soft top assembly both sides & Lock the two Quick release knuckle to RH & LH main pivot brackets . Properly open rolled convertible soft top assembly from the rear side. Slide convertible top from rear end to front header and position on front header properly. Lock the Footman's loops to the front header and slide the Sun visors. Lock the Footman loop hook on the front header metal bracket & press the loop handle While locking ensure top plastic support project on top of the header metal bracket for proper locking as shown. Unfold and Hook the \u2018C\u2019 pillar cover to rear RH & LH belt rails . Attach the tail gate bar locking to rear RH & LH belt rails and zip tailgate window. Position and hook LH side window to the vertical and horizontal belt rail. Zip the window and refit the LH Side window Velcro . Position and hook RH side window to the vertical and horizontal belt rail. Zip the window and refit the RH Side window Velcro . Check the Convertible Soft Top Assembly for any damage, replace if required. Remove Front Roof caps using trim remover and Using a T30 socket spanner, loosen and remove the roof front top mounting bolts. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250214.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250215.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250216.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250217.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Rear Roof caps using trim remover and Using a T30 socket spanner, loosen and remove the roof rear top mounting bolts. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240016.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240018.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a trim remover pull out center bow trim and disconnect roof lamp electrical connector. Ensure to use trim remover while removing centre roof bow trim, and avoid the press clip damage. Replace the press clip for proper fixing, if it is damaged. Remove the centre bow trim from the vehicle. Using a T30 socket spanner, loosen and remove the roof top mounting bolts inside bow trim. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250102.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250103.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "By Using T30 Torx Socket Spanner remove the RH & LH roof side upper frame mounting bolts. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250104.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250104.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "By Using T30 Torx Socket Spanner remove the RH & LH roof side lower frame mounting bolts Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250206.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250207.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "By Using T30 Torx Socket Spanner remove the RH & LH rear lower bracket mounting bolts. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250208.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250209.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a T30 socket spanner, loosen and remove the roof top mounting bolts from roll cage. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250108.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Disconnect the HMSL electrical connector. Insert and split the panel with trim remover, in between Hard-Top and frame mounting plate. Lift and Carefully remove the hard top assembly from the vehicle with sufficient manpower and keep it in Trolly bench or flat working bay. Use the recommended safety equipment\u2019s; Safety goggles, Cotton gloves, Safety shoes etc. while lifting the Hard-Top. Prepare the Hard-Top assembly for installation
Remove the dust & strain marks by Steel wire brush. (as shown in illustration) Clean with degreaser cloth for silicon sealant application.
",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Notice",
+ "content": "Don't use ordinary solvent for HardTop cleaning. (it may result some undefined problems in Hard-Top). The Seal must be replaced along with X-mas tree clips, when the seal loses its softness or if found any damages, don't reused the X-mas tree clips. This seal is for preventing the water leakage and wind noise only. Seal coming with Two-way pasting tape. Silicon sealant must be applied for water leakage and wind noise prevention. Refit in the reverse order of removal. While Installation hand tighten all the Hard top mounting bolts first for proper positioning and finally torque tighten all the bolts. Don\u2019t over tighten the screws to avoid the thread slipping and other damages. While Installation properly position the Hard top dowels in the body for proper positioning & fitment. Inspect the hard top assembly for any damage. Replace if found. Remove the Spare Wheel Carrier. Remove the air extractor from the vehicle. Refit in the reverse order of removal. Inspect the air extractor for any crack or damage. Replace if any. Tools Required: ",
+ "file": null,
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250184.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 12 mm socket and 13 mm combination spanner, Unscrew front bracket mounting bolt and nut. Using 12 mm socket and 13 mm combination spanner, Unscrew front centre bracket mounting bolt and nut. Using 13 mm socket combination spanner, Unscrew rear bracket mounting bolt. Remove the front foot step assembly from vehicle. Front extreme portion of foot step is not to stand, Since front portion is aesthetic part to merge the design theme with cladding. Refit in the reverse order of removal. Check for any damages or crack in foot step assembly. Replace if found. Tools Required ",
+ "file": null,
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250007.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Pull out cover cap from the wiper arm. Using a 13mm socket spanner, loosen and remove the Wiper arm mounting nuts. Torque : 15 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250009.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the wiper arms from vehicle. Using a star screw driver, loosen and remove the Scuttle Grill mounting screws . Torque : 1.9\u00b10.5Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250010.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the Scuttle Grill mounting Scrivets . Remove the Scuttle Grill from the vehicle. Refit in the reverse order of removal. Inspect the Scuttle grill for any damage. Replace if found. Inspect the mounting push buttons, replace if required. Using a star screw driver, loosen and remove the front splash shield mounting screw rivets from both the sides of vehicle. Remove the front splash shield both the sides from vehicle . Using a 10 mm socket spanner, loosen and remove the front stone guard front mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250064.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen and remove the rear stone guard rear mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250033.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the stone guard mounting screw rivets. Remove the stone guard from the vehicle. Disconnect the fog lamp electrical connectors LH & RH sides. Pull and remove the front bumper top panel trim clips and remove the panel. Using a 10 mm socket spanner, Unscrew front bumper mounting nuts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290005.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "using a 13 mm socket spanner, Unscrew front bumper bottom mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290006.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew front bumper top side mounting bolts. Using a star screw driver, Unscrew front bumper top centre mounting screw rivets. Remove the front bumper assembly from the vehicle. Using a 13 mm socket spanner, Unscrew front bumper center bracket mounting bolts and remove the front bumper center mounting bracket. Torque : 10.0\u00b11 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250060.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the front grill mounting screw rivets. Using a star screw driver, loosen and remove the bottom side front grill mounting screw rivets. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250061.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the front grill mounting bolts. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250062.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250063.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Remove the front grill assembly from the vehicle. Using star screw driver, Remove centre grill mounting screws and locking clips from front facia. Remove the centre grill from front facia. Refit in the reverse order of removal. Inspect the front bumper assembly for any crack or damage, Replace if found any. Check the front grill assembly for any external cracks, replace if found any. Remove the Soft top canopy. Using a 10 mm socket spanner, loosen and remove the rear side cover LH mounting bolts. Using a 10 mm socket spanner, loosen and remove the rear side cover RH mounting bolts. Carefully remove the rear side covers LH and RH sides. Using a 10 mm socket spanner, loosen and remove the rear side member RH mounting bolts. Carefully remove the rear side member RH from vehicle. Using a 10 mm socket spanner, loosen and remove the rear side member LH mounting bolts. Carefully remove the rear side member LH from vehicle. Using a 10 mm socket spanner, loosen and remove the rear centre panel assembly mounting bolts. Using a T40 torx socket spanner, loosen and remove the rear structure frame mounting torx bolts. Remove the rear structure frame from vehicle. Refit in the reverse order of removal. Check the rear structure frame for any external cracks and damages, replace if found any. Remove the convertible soft top assembly. Using a star screw driver, loosen and remove Canopy mounting screws from the front side bow assembly RH and LH. Remove the lock from the RH and LH Front side bow assembly. Using star screw driver, loosen and remove Canopy mounting screws from Front side bow assembly inner side. Remove the Canopy from the front side bow assembly. Detach or unlock the spring from the Bow 2 Pivot assembly & remove Canopy from Bow 2 Pivot assembly . Using star screw driver, loosen and remove the canopy mounting screws from bow 2 pivot assembly and detach canopy. Using star screw driver, loosen and remove the canopy mounting screws from bow 3 assembly and detach canopy. Remove the Center Support Rexine Rivets. Remove the Canopy from the Frame. Remove the Cable with Spring from the Canopy (RH &LH;). Refit in the reverse order of removal. While Installation, Insert the cable from bracket side to Spring side (Insert spring inside from top) Inspect the convertible soft top canopy for any crack or damage. Replace if any. Remove the front door inner trim. For additional information refer to the Front Door Inner Trim - R &R; section. Using 10 mm socket spanner, loosen and remove the mounting nuts from the ORVM. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250275.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250276.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the ORVM from the vehicle completely. Refit in the reverse order of removal. Inspect the ORVM for any crack or damage. Replace if any. Tools Required ",
+ "file": null,
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove front lateral trim. Remove Roof Speaker trim assembly. Open the top cover and Using a 14 mm socket spanner, loosen and remove the seat belt upper mounting bolt. Torque :38 \u00b16 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210081.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the seat belt lower mounting bolt. Torque :38 \u00b16 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250023.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the hand support belt. Remove the floor mate partially from the vehicle. Using a 13mm socket spanner, loosen and remove the roller gage bar rear mounting bolt. Torque : 25 \u00b1 4Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250026.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 13mm socket spanner, loosen and remove the roller gage bar front mounting bolt. Torque : 25 \u00b1 4Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250027.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 13mm socket spanner, Unscrew roller gage bar side mounting bolts. Torque : 25 \u00b1 4Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250028.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the roller gage bar from vehicle. Remove the roller bar cover and separate roller gage bar. Refit in the reverse order of removal. Check for any damages or crack in roller gage bar assembly. Replace if found. Using a 10 mm socket spanner, loosen and remove the rear mounting tube pipe structure mounting bolts. Remove the welcro from the rear tubes . Remove the side cover from window bracket LH and RH sides. Using a 10 mm socket spanner, loosen and remove the front mounting tube pipe structure mounting bolts. Remove the welcro from the front tubes . Using a star screw, loosen and remove the canopy front LH and RH screw rivets. Using a 10mm socket spanner, Unscrew canopy front end mounting bolts. Remove the Canopy from the vehicle. Refit in the reverse order of removal. Check the canopy assembly for any external cracks, replace if found any. Remove the HVAC Mode Actuator. Using star screw driver, Unscrew plate mode main link mounting screws and remove the link. Remove the lever sub assembly and lever foot from the plate mode main link. Install in the reverse order of removal. Inspect the plate mode main link for any damage. Replace if found. Recover the AC gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. Remove the Air Cleaner Assembly. Remove the Steering Lower Intermediate Shaft. Using 12 mm open end spanner, Remove suction and discharge hose mounting nut from compressor. Torque Value: 14.0+1.0 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200093.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the AC/water pump belt. For additional information refer to AC/Water Pump Belt - R &R.; Disconnect the AC compressor electrical connector. Using 12 mm socket spanner, Remove the compressor mounting nuts from the crank case. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200095.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the compressor from the vehicle. Install in the reverse order of removal. Refit the Steering Lower Intermediate Shaft. Refit the Air Cleaner Assembly. Remove the AC/water pump belt. For additional information refer to AC/Water Pump Belt - R &R.; Recharge the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. During installation, fix the new O-ring into both liquid tube and discharge hose mounting joints without any damage. Damage to the O-ring may cause A/C refrigerant leakage which leads to A/c failure. Inspect the compressor for any physical damage. Replace if found. Inspect the clutch pulley for any damage. Replace if found. Inspect the drive belt and Pulley for any physical damage. Replace if found. Using screw driver, remove the floor console RH panel assembly scrivet and detach the panel from the vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220004.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220005.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the floor console LH panel assembly scrivet and detach the panel from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220006.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220007.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the RH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1547.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1549.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the LH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220010.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1548.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Partially detach bezel HAVC control panel assembly and disconnect electrical connectors. Disconnect Heater, Mode selection control cables from the HVAC control panel. Disconnect the cable routing clips and take out the bezel Assembly with HVAC control panel. By using star screw driver, remove the HVAC control panel mounting screws and remove the panel from the bezel assembly. Torque : 1.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200160.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200161.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the HVAC Control Panel Assembly for any damage. Replace if found. Do not release the refrigerant into the atmosphere. Use approved recovery/ recycling equipment to capture the refrigerant whenever the air conditioning System is discharged. Always wear eye and hand protection (goggles and gloves) when working with any Refrigerant or air conditioning system. Close the high pressure and low pressure refrigerant lines with dust caps to avoid air entry and/or contamination. Recover AC gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. Remove Front Grill Assembly. Using 12 mm Combination Spanner, Unscrew the AC pipe compressor side mounting nut. Torque : 14.0+1.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200070.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew radiator LH seal mounting bolt and remove the seal. Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200071.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Remove HVAC pipe condenser side mounting nut. Torque : 6.0+1.0 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both pipe ends mounting joints without any damage. Damage to the Oring may cause A/C refrigerant leakage which leads to A/c failure. Remove the HVAC pipe assembly from the vehicle. Install in the reverse order of removal. Recharge the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. Inspect the AC pipe for any damage. Replace if found. Disconnect the HVAC blower motor electrical connector. Using star screw driver, loosen and remove the blower motor mounting screw. Remove the blower motor from the HVAC unit assembly. Install in the reverse order of removal. Rotate the blower motor and check for any noise due to bearing wear. Check the blower motor fan blade for damage. Replace the blower motor if necessary. Whenever over voltage/under voltage situation will occur over ignition Line. These voltages will get sense by MCU and based on these sense voltages panel functionality will disabled or in case of under/over Voltage system will not detect any switch command. It is a kind of Security over connector Pins except Power supplies Pins. If any shorting occur on connector pin either short to battery or short to ground there should be no damage to control panel or circuitry. Over Current/Short to Ground: Face Indicator on off with Frequency 1000 mSec Interval. Short to Battery/ Actuator Stuck: Face Indicator on off with Frequency 500 mSec Interval. Over Current/Short to Ground: Air Intake Indicator on off with Frequency 1000 mSec Interval. Short to Battery/ Actuator Stuck: Air Intake Indicator on off with Frequency 500 mSec Interval. Over Current/Short to Ground: Defrost Indicator on off with Frequency 1000 mSec Interval. Short to Battery/ Actuator Stuck: Defrost Indicator on off with Frequency 500 mSec Interval. AC Indicator Blink with 500 mSec Frequency. The purpose of the condenser is to dissipate the heat accumulated during gas evaporation and compression. Once it is cooled, the gas becomes a liquid and remains under high pressure. To improve thermal exchange, the fluid is exposed to air flow produced by the engine cooling fans and vehicle movement.This step allows for fluid expansion. Its location is in front of the radiator. From compressor high pressure high temperature refrigerant is introduced into the top of the condenser as the gas moves through the condenser it gets cooled. As the refrigerant cools, it condenses and exits the bottom of the condenser as a high pressure low temperature liquid. Do not release the refrigerant into the atmosphere. Use approved recovery/ recycling equipment to capture the refrigerant whenever the air conditioning System is discharged. Always wear eye and hand protection (goggles and gloves) when working with any Refrigerant or air conditioning system. Close the high pressure and low pressure refrigerant lines with dust caps to avoid air entry and/or contamination. Recover the A/C gas. For additional information refer to AC gas recovery procedure. Remove the Radiator LH & RH seal. For additional information refer to the Radiator LH & RH Seal R&R; section. Using 10 mm socket spanner, Unscrew condenser mounting bolts from radiator end. Torque : 5 \u00b11 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200075.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Remove the radiator bottom seal mounting bolts and detach it. Torque : 7\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200196.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200074.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the ambient temperature sensor from the routing clip. Carefully remove the condenser from vehicle. Install in the reverse order of removal. Refit the Radiator LH & RH seal. For additional information refer to the Radiator LH & RH Seal R&R; section. Recharge the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. Inspect the condenser for any physical damage, leakages etc. Replace if found any. Inspect for any foreign materials on condenser. Clean if found. Check and ensure free flow of condenser. Using screw driver, remove the floor console RH panel assembly scrivet and detach the panel from the vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220004.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220005.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the floor console LH panel assembly scrivet and detach the panel from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220006.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220007.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the RH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1541.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1542.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the LH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220010.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1543.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Partially detach HAVC control panel bezel and remove the mode cable from HVAC control panel end and routing clip. Remove the driver side IP panel assembly. Disconnect the mode cable from HVAC unit end. Remove the cable from the vehicle. Install in the reverse order of removal. Inspect the HVAC mode cable for any damage, Replace if required. Inspect the Mode Cable locks for any damage, Replace if required. performed AC PERFORMANCE TEST - Check the grill temperature (Engine Idle condition): Close Door test (Grill temperature individually from 4 vents). Open Door test (Grill temperature individually from 4 vents). Grill Temperature closer to Ambient Temperature \u2013 Go to Step 2. Connect the diagnostic Tool and DTC registered in EMS ECU. Yes \u2013 fix the error, clear the DTC and check the AC Performance. NO \u2013 GO to Step 3. Using Diagnostic tool actuate the compressor Clutch. No \u2013 Clutch Not actuating \u2013 Check the clutch condition, circuit and rectify or replace. Yes \u2013 Clutch Actuating as per input Go to Step 4. Check the compressor Drive Belt Condition and tightness. Yes \u2013 Matching the Specification \u2013 Go to Step 5. No \u2013 Replace the Drive Belt. Check The compressor condition. Yes - Compressor Overheating and Noisy \u2013 Replace the Compressor. Compressor in good condition \u2013 Go to Step 6. Check the System Refrigerant Quantity by using reconnector Equipment. Yes \u2013 The Refrigerant quantity is less (Gas Leakage) \u2013 Perform pressure test and Vacuum test by maintaining the pressure. Fix the leakage if any and charge the Refrigerant to recommended quantity and top up 50 ml compressor Oil. Then Go to Step 7. Check the grill temperature (Engine Idle condition). Close Door test (Grill temperature individually from 4 vents). Open Door test (Grill temperature individually from 4 vents) match the Recommended temperature \u2013 Go to Step 8. Perform test Drive and check the Temperature and any reproduce of the insufficient cooling. NO \u2013 Hand back the vehicle to customer Yes \u2013 Replace the HVAC System. Remove the Glove Box Assembly. Disconnect the electrical connector from the temperature actuator. Using star screw driver, Unscrew temperature actuator mounting screws. Remove the temperature actuator. Install in the reverse order of removal. Inspect the actuator for mechanical damage. Check and clean the connector pins for sulphation and deposits. Remove the Evaporator Assembly. For additional information refer to Evaporator Assembly \u2013 R &R; Section. Carefully remove the heater core assembly. Install in the reverse order of removal. Refit the Evaporator Assembly. For additional information refer to Evaporator Assembly \u2013 R &R; Section. Recharge the AC Gas. For additional information refer to AC Gas Recharging Procedure. Inspect the heater core assembly for any damage. Replace if found. Inspect the evaporator coil for free flow. If found any obstruction Repair/Clean or replace. Remove the IP lower panel from the vehicle. Disconnect the mode actuator electrical connector. Using star screw driver, Unscrew mode actuator mounting screws. Remove the mode actuator. Install in the reverse order of removal. Inspect the actuator for mechanical damage. Check and clean the connector pins for sulphation and deposits. Disconnect the blower motor and actuator electrical connectors and its routing clips. Using 10 mm socket spanner, Unscrew the blower case assembly mounting bolts. Using screw driver, Heater coil holding bracket mounting screws. Using a star screw driver, Unscrew expansion valve cover mounting screw. Disconnect the HVAC resistor electrical connector. Using a star screw driver, Unscrew the resistor mounting screw and remove the resistor. Using star screw driver, Unscrew evaporator cover mounting screws. Detach thermistor from evaporator and remove the evaporator with cover. Remove the evaporator from the cover and separate the evaporator. Detach the thermistor trim from HVAC assembly and Disconnect the thermistor electrical connector and holding clip. Remove the thermistor from the HVAC unit assembly. Install in the reverse order of removal. Refit the HVAC Unit Assembly. Recharge the AC Gas. For additional information refer to AC Gas Recharging Procedure. Inspect the evaporator coil for any damage. Replace if found. Inspect the blower and evaporator unit for any damage. Inspect the evaporator coil for free flow. If found any obstruction repair/clean or replace. Inspect the evaporator coil for any foreign particles. Clean if found. Inspect the thermistor for any physical damage. If found replace. Inspect the thermistor for proper functioning. Before going to performance test, ensure following points are taken care \u2013
2. AC gas \u2013 Use only R134a A/C gas and only from recommended suppliers.
3. Ensure correct amount of A/C gas is filled in the system.
4. Ensure cleanliness of the condenser surface at regular interval.
5. Ensure proper function of condenser fan.
6. For A/C System testing use only approved Tools & Equipment.
",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "This A/C performance test is only to check mechanical performance of the HVAC system and not the flow or circulation related complaints Park the vehicle on level work bay. Open the left front door. Open the glow box and detach the stopper by pressing it. Disengage the glow box from the assembly. Press and remove the HVAC particulate filter cover from HVAC unit. Remove the HVAC particulate filter. Install the HVAC particulate filter on HVAC unit. Install the HVAC particulate filter cover. Engage the glow box stopper and refit the glow box in its position. While installing the filter take sufficient care to prevent bent, damage etc. Close the co-driver door. Use only genuine filter element. Never clean and reuse the HVAC particle filter element. Using screw driver, remove the floor console RH panel assembly scrivet and detach the panel from the vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220004.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220005.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the floor console LH panel assembly scrivet and detach the panel from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220006.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220007.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the RH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1538.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1539.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the LH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220010.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1540.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Partially detach HAVC control panel bezel and remove the heater cable from HVAC control panel end and routing clip. Open the glove box and remove the glove box by removing the glove box lock. Disconnect the heater cable from the HVAC unit end. Remove the cable from the vehicle. Install in the reverse order of removal. Inspect the HVAC heater cable for any damage, Replace if required. Inspect the heater Cable locks for any damage, Replace if required. Remove the driver side IP panel assembly. Remove mode selector cable from HVAC assembly. Using star screw driver, Unscrew plate mode main link mounting screws and remove the link. Remove the lever sub assembly and lever foot from the plate mode main link. Install in the reverse order of removal. Inspect the plate mode main link for any damage. Replace if found. Position the vehicle on 2 post lift/ 4 post lift. Check the HVAC drain pipe locking grommet fitment condition on BIW. Ensure that pipe is straight downwards. Do not pull the water drain pipe excessively. Remove the Cross Car Beam (CCB) Assembly. Recover the AC gas. For additional information refer to AC gas recovery procedure. Using 10 mm open end spanner, Remove the HVAC Pipe mounting nut from expansion valve end. Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both liquid tube and discharge hose mounting joints without any damage.Damage to the O-ring may cause A/C refrigerant leakage which leads to A/c failure. Detach heater inlet and outlet hose quick couplers. Do not open the degassing tank cap when the coolant is hot. Failure to follow this instruction will lead to personal injury. Before removing the heater core hoses, open the degassing tank cap for releasing the coolant pressure. Coolant will leak, while removing the heater core hoses, as a result drain the coolant into a container. Using 10 mm Socket Spanner, Unscrew the HVAC unit assembly mounting bolt and nuts. Torque : 7 \u00b11 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 7 \u00b11 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 7 \u00b11 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200098.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200099.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200100.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200101.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm Socket Spanner, Remove the HVAC earth cable mounting nut. Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200104.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the HVAC unit assembly from vehicle. Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200102.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200103.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Refit the Cross Car Beam. Recharge the Refrigerant. For additional information refer to AC gas recovery procedure. Start the engine, check the coolant level. Refill if required. Check the coolant leak when engine is started. Check the A/C system cooling and operation. Inspect the HVAC assembly for any physical damages. Repair if found. Inspect the kinematics for proper functioning. Inspect the actuators / cables for proper operation. Inspect the filter element and clean/replace if required. Disconnect air fresh and recirculation actuator electrical connector. Using star screw driver, Unscrew the actuator mounting screws. Remove the air fresh and recycling actuator. Install in the reverse order of removal. Inspect the actuator for mechanical damage. Check and clean the connector pins for sulphation and deposits. Do not release the refrigerant into the atmosphere. Use approved recovery/ recycling equipment to capture the refrigerant whenever the air conditioning System is discharged. Always wear eye and hand protection (goggles and gloves) when working with any Refrigerant or air conditioning system. Close the high pressure and low pressure refrigerant lines with dust caps to avoid air entry and/or contamination. Recover the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. Remove the Front Grill Assembly. For additional information refer to Front Grill Assembly \u2013 R &R; section. Remove the Air Cleaner Assembly. Using 10 mm open end spanner, Liquid pipe mounting nut from expansion valve end. Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200061.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Remove Liquid pipe routing bracket mounting nut from the vehicle. Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200062.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen and remove the suction hose routing bracket mounting nut. Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200063.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200129.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect the pressure switch electrical connector. Using 10 mm socket spanner, Unscrew radiator LH seal mounting bolt and detach it. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1536.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew Liquid pipe mounting nut from condenser end. Torque : 6.0+1.0 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both end of liquid tube mounting joints without any damage. Damage to the O-ring may cause A/C refrigerant leakage which leads to A/c failure. Remove the liquid pipe from the vehicle. Install in the reverse order of removal. Refit the Air Cleaner Assembly. Refit the Front Grill Assembly. Recharge the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. Inspect the suction hose assembly for any physical damage, leakages etc. Replace if found any. Inspect for any foreign materials on condenser. Clean if found. Check and ensure free flow of condenser. Remove the HVAC control panel. Remove the Glove Box Assembly. Remove the driver side IP panel assembly. Remove the wiring harness routing clips from the HVAC assembly. Disconnect the fresh air actuator, mode actuator, blower motor, blower resistor, evaporator temperature sensor and blower switch Connectors. Carefully remove the HVAC wiring harness from the IP assembly. Install in the reverse order of removal. Inspect the electrical connectors for mechanical damage. Replace if found. Check and clean the connector pins for sulphation and deposits. Remove the IP Centre Switch Bank Assembly. For additional information refer to IP Centre Switch Bank Assembly \u2013 R &R; section. Using a star screw driver, Unscrew HVAC control unit mounting screws. Torque : 1.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220033.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the HVAC Control panel. Install in the reverse order of removal. Inspect the HVAC Control Panel Assembly for any damage. Replace if found. By using screw driver remove the TVD screw. Torque : 14 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 14 mm ring and socket spanners unscrew rear propeller shaft mounting bolts and nuts from transfer case end. Torque : 55 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the TVD assembly from vehicle and hang the Rear propeller shaft aside. Using a nose plier, pull-down the double torsion Spring downwards and detach from pedal box and then gently pullout spring. Inspect the Torsional Vibration Damper (TVD) for any damage, if found replace the TVD assembly. Inspect the propeller shaft for any bend, crack, twisting and stone penetration, if found replace the propeller shaft assembly. Check the propeller shaft for any flyweights missing. Replace the propeller shaft if found. Clean the propeller shaft if any foreign materials like dirt found. If the propellers shaft unbalance is suspected then it can be verified by the following procedure, removing & rendering the propeller shaft by 180\u00b0 may eliminate some vibrations. Clean all the foreign material from propeller shaft and the universal joint. Ensure that the propeller shaft is not worn, are properly installed and are correctly aligned with the propeller shaft. Check the companion flange mounting bolts. Raise the vehicle and remove rear wheels & tyres. Install the wheel nuts to lock the brake drum. Mark & number the shaft 6 inches from pinion end at four positions 90\u00b0 apart. Run and accelerate the engine until vibration occurs. Note the intensity & the speed at which the vibration occurs. Install a screw clamp at position \u201c1\u201d. Start the engine and recheck for vibrations. If there is little vibration or no change in vibrations then move the clamp to the other 3 positions. If there is no difference in vibration at the other position then the vibration is not due to the propeller shaft imbalance. If the vibration decreases, install a second clamp and repeat the test. If the clamps cause an additional imbalance, separate the clamp (\u00bc inch above & below the mark). Repeat the vibration test. Increase the distance between the clamps until the vibration is at the lowest level. At this position bend the slack end of the clamp so that it does not loosen. Install the wheel & tyres. Lower the vehicle. If the amount of the vibration remains unacceptable then repeat the exercise at the gearbox end. After completing above procedure, if vibration is reduced, which indicates there is some imbalance in the propeller shaft. Replace the propeller shaft. Tyres that are out of round or wheels that are out of balance causes a low frequency vibration. Brake drums that are unbalanced cause a harsh low frequency vibration. Drive line vibrations can also result from loose or damaged engine mountings. Propeller shaft vibrations will keep on increasing as the vehicle speed increase. The propeller shaft does not cause a vibration that is present only in a narrow speed range. Remove the propeller shaft from vehicle. Remove dirt, rust, paint & undercoating from the propeller shaft surface. Keep the propeller shaft on surface plate along with \u2018V\u2019 block at both ends. The dial indicator must be installed perpendicular to the shaft surface. Measure the run out at the center and at the ends by rotating propeller shaft assembly by hand \u2013 away from the weld. Replace the propeller shaft if the run out is beyond the specified limit. Position the vehicle on 2 post lift/ 4 post lift. Inspect the inboard and outboard joint RH side drive shaft boots, clamps for cut, nick, loose, bend, crush or abrasion. Replace if necessary. Rotate Steering wheel from one end to other for better visualization of boots. Inspect the RH side drive shaft condition for cracks or damage. Replace if necessary. Inspect the inboard and outboard joint LH side drive shaft boots, clamps for cut, nick, loose, bend, crush or abrasion. Replace if necessary. Rotate Steering wheel from one end to other for better visualization of boots. Inspect the LH side drive shaft condition for cracks or damage. Replace if necessary. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Remove the Steering Column Shrouds. Remove the steering wheel. Disconnect the clock spring electrical connectors. Dis-engage the clock spring mountings (3 points) and lift out the clock spring assembly from the steering column. Using a flat end screw driver remove the steering angle sensor from the clock spring. Install in the reverse order of removal. If the contact coil is not aligned correctly,the steering wheel may not be able to rotate properly during turning. This kind of restricted turning ability may cause the vehicle to crash or damage the contact coil and prevent the air bags from deploying in a crash event. Carry-out the clock spring setting procedure. Failure to do clock spring setting may result in clock spring damage. Free Play Value \u00b1 5\u00b0
If the free play is out of the specified value, check the free play in steering column shaft connection and steering linkage. Replace or repair if necessary. The rack and pinion design is a simple design. However it is still susceptible to various problems in particular to leaks. If the bellows are ripped or are unable to keep the contaminant\u2019s away then it can cause damage to oil seal and subsequent leaks. One complaint, which can be present, is that the steering may be stiff and jerky when the unit is cold and as the vehicle is driven and it warms up the power assist gradually comes back. This normally indicates that grooves have worn into the bore of the pinion aluminum housing by control valve seals which may have hardened due to ageing. Wear in the centre housing causes the fluid to leak around the rack piston. Causing either steering wander or lack of straight- ahead stability. Another cause of steering wander and erratic control often accompanied by clumping, thunking noise is the deterioration of rack mounting bushings. Fluid leaks can be hard to locate. Sometimes you will see a low level in the pump reservoir but no evidence of escaping fluid. Squeeze the bellows and you will probably find that they are full of fluid. To confirm if that side of the rack is the root cause, then remove the both the bellows, clean the rack housing and then operate the system to observe the seepage directly. A rusty input shaft U joint or deteriorated flexible textile coupling could imitate rack problems
2. Check the accessory drive belt for any damage.
3. Check the Tie-rod ends for bend or damage.
4. Check the steering inner ball joints for any bend or external damage.
5. Check ball joint rubber boots for signs of cracking or deterioration.
6. Check inner and outer ball joints for excessive wear.
7. Inspect all the steering bushes for signs of wear and deterioration.
8. Check the steering oil level in the reservoir. If the level is below \u201cMIN\u201d mark, top up steering fluid.
9. Check the steering gear assembly for any external damage or steering fluid leakage.
10. Check the power steering pressure lines for fluid leakage and deterioration.
11. Check the power steering pump and the reservoir for fluid leakage.
12. Check the steering gear rubber bellows for cuts, cracks, deterioration and oil traces. If the cause is not visually evident, verify the symptom and refer to the Troubleshooting Chart.
",
+ "file": null,
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Trouble shooting chart",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/14513.pdf",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Component Inspection and Remedy Action",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/14514.pdf",
+ "display_order": 4
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 192,
+ "sys_id": "THAR.AX-0006-Steering",
+ "subsys_id": "THAR.AX-0006-Steering-Power Steering Pressure Hose (Pump Gear)",
+ "systems": "Steering",
+ "sub_systems": "Power Steering Pressure Hose (Pump Gear)",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A190113.jpg",
+ "myid": 1305,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Power Steering Pressure Hose (Pump Gear)-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190113.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/3302.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/3303.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the front RH wheel. For additional information refer into Front Wheel - R &R; Section. By using Star Screw driver, remove the scrivets and remove the front RH wheel arch apron. Using a 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially detach the degassing tank. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050128.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner, loosen and detach the pressure hose flare nut from the power steering pump. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190083.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner, loosen and detach the pressure hose flare nut from the power steering gear. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Position a tray below the rack to collect the fluid Using a 12 mm socket spanner, loosen and remove the routing bracket mounting bolt. Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190048.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the supply hose from the vehicle. Install in the reverse order of removal. Fill the fluid and carry-out air bleeding procedure. For additional information refer to Power steering fluid filling procedure. Inspect for any external damage or bent, if found replace. Power Steering Oil - MAHINDRA MAXIMILE POWER STEERING FLUID GENUINE POWER STEERING FLUID. Capacity \u2013 0.85 Litres. In case of non-availability of Genuine fluid, SHELL MAKE SPIRAX S3 ATF MD3 can be used. NO OTHER BRANDS RECOMMENDED. Rotate in anti-clockwise and remove the power steering fluid reservoir cap. Using star screw driver, remove the front stone guard screvits. Using a 10 mm & 13 mm socket spanner, loosen the front & rear mounting bolts and remove the front stone guard. Using a 10 mm socket spanner remove the steering fluid line bracket mounting bolt. Torque: 10\u00b1 2 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190048.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner,loosen the nut and disconnect pump to rack pressure hose. Torque: 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Position a tray below the rack to collect the fluid. Drain the complete fluid in a neat container or bottle. Refit the pump to rack pressure hose.Torque tighten the nut to specified value. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190104.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refit the fluid line mounting clamp with the help of mounting bolt. Torque tighten the bolt to specified value. Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190048.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Fill the recommended fluid to MAX mark on reservoir. Carry-out Power steering circuit air bleeding procedure. Refit the front stone guard screvits & mounting bolts, torque tighten the bolts to specified value. Torque: 4.0 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011105.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011106.jpg",
+ "display_order": 33
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 194,
+ "sys_id": "THAR.AX-0006-Steering",
+ "subsys_id": "THAR.AX-0006-Steering-Front Steering Knuckle",
+ "systems": "Steering",
+ "sub_systems": "Front Steering Knuckle",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A190001.jpg",
+ "myid": 1307,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Front Steering Knuckle-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190001.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/50002.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/50001.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Front wheel. For additional information refer to Front Wheel \u2013 R &R; Section. Remove the respective side Front Wheel Hub. For additional information refer to Front Wheel Hub \u2013 R &R; Section. Using a 10 mm socket spanner , loosen and remove the wheel speed sensor mounting bolt & routing bracket mounting bolt. Torque : 8 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190008.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a cutting plier and 17 mm socket spanner, remove the tie rod end cotter pin and tie rod end nut and detach from knuckle. Torque : 45\u00b19Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190009.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a cutting plier and 24 mm socket spanner, remove the lower ball joint cotter pin and Lower ball joint nut and detach from knuckle. Torque : 130 \u2013 150 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190010.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 22 mm socket spanner, loosen and remove the knuckle Lower Half mounting bolts. Torque :140 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190011.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a cutting plier and 24 mm socket spanner, remove the upper ball joint cotter pin and ball joint nut and detach from knuckle. Torque : 90 \u2014 110 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190012.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the knuckle from the vehicle. After installation of knuckle assembly, Carry out the wheel alignment. Install in the reverse order of removal. Torque tightening should be done without load and with the tyres on level ground. Always use new split pin. Inspect for any external damage or bent, if found replace. The steering pump is a constant flow, vane type incorporating a flow control valve (with an integrated relief valve) and it is belt driven by engine. Drain the power steering fluid. For additional information refer to Power steering fluid draining section. Using a 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially detach the degassing tank. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050128.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the engine feed system cover. For additional information refer into the Engine Feed System Cover \u2013R &R; Section. Using 14 mm rings spanner rotate the auto tensioner in counter clockwise Partially detach the power steering belt. Using a 17 mm open end spanner,loosen and detach the pressure hose flare nut from the power steering pump. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190083.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a hose clip plier, unclip the return hose to reservoir hose clamp from pump. Using a 12 mm socket spanner, loosen and remove the power steering pump mounting bolts. While loosening the bolt hold the nut using 12 mm ring spanner. Torque :25\u00b1 3 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190084.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the power steering pump from the vehicle. Install in the reverse order of removal. While tightening the bolt hold the nut using 12 mm ring spanner. Carry-out power steering fluid filling and bleeding procedure. Inspect the pump for any physical damage. Replace the pump if found. Inspect the pump for any fluid leakages. Inspect the pulley for any damage. Remove the E-Disconnect Motor. For additional information refer into E-Disconnect Motor \u2013 R &R; Section. Remove the engine feed system cover. For additional information refer to Engine feed System Cover - R &R; section. Remove the Front wheels (Both RH & LH). For additional information refer into Front Wheel - R &R; Section. The wheels should be in straight ahead position before disconnecting the steering rack assembly from the vehicle. Using a 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially detach the degassing tank. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050128.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a cutting plier remove the cotter pin from the LH & RH tie rod . Using the 17 mm socket spanner, loosen and remove the LH & RH tie rod end ball joint nuts from the knuckle assembly. Torque : 45 \u00b1 9 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190009.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft mounting nut from the rack and pinion assembly and detach the intermediate shaft. Torque : 22\u00b14Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190044.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner, loosen and remove the flare nuts and detach the steering rack and pinion supply and return lines. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": "Plug the steering rack assembly inlet and outlet hose oil passage with dust cap to avoid any foreign particles entry. Drain the power steering fluid. Using a 12 mm socket spanner, loosen and remove the supply line routing bracket mounting bolt. Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190048.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a 19 mm socket spanner, loosen and remove the steering rack and pinion assembly mounting bolts. Torque : 85 \u00b1 13 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Notice",
+ "content": "Use open end torque wrench for tightening RH side mountingbolt. Detach the front differential breather hose routing tag. Remove the steering rack and pinion assembly from the vehicle. Install in the reverse order of removal. Always use a new cotter pin. Ensure I shaft connector is assembled as per given marking. At straight ahead condition bolt head should face top side for easy torquing. Fill the power steering fluid and do the air bleeding procedure. For additional information refer to Power Steering Fluid Filling Procedure section. Carry out the wheel alignment. Check the steering rack assembly for cracks, damages or leakages. Replace the steering rack assembly if required. Check the steering inner ball joint for any damage. Replace the steering rack assembly if required. Check the steering rack dust boot for any wear or deterioration. Replace if necessary. The combination switch is mounted on the steering column and houses the switches for head lamps, fog lamps and wipers. It comprises a central switch assembly and 2 stalks for controlling the lamps and wipers. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Disconnect the electrical connector from combination switch. Using a star screw driver, loosen and remove the mounting screw to remove combination switch. Gently remove the combination switch from the vehicle. Install in the reverse order of removal. Tighten the combination switch mounting screw as per specification over tighten will lead to damage of the switch.
2. Inspect the combination switch connectors for any damage or loose connection.
",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 188,
+ "sys_id": "THAR.AX-0006-Steering",
+ "subsys_id": "THAR.AX-0006-Steering-Steering Grommet",
+ "systems": "Steering",
+ "sub_systems": "Steering Grommet",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A190110.jpg",
+ "myid": 1301,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Steering Grommet-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190110.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22339.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22340.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Remove the steering wheel. Disconnect the ignition key barrel electrical connector. Disconnect the combination switch & clock spring electrical connectors. Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft bottom mounting bolts and detach the intermediate shaft bottom from the steering column. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190042.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering column mounting nuts then remove the steering column from the vehicle. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190039.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the grommet mounting bolts then remove the grommet from vehicle . Torque : 22 \u00b1 2 Nm Torque :22\u00b12 Nm Install in the reverse order of removal. Ensure to fit the Grommet Projection should face driver side. Ensure Shaft to Grommet clearance is 5 mm in top side. Ensure to install Upper & Lower I shaft connector according to the marking. Remove the Front RH wheel. For additional information refer into Front Wheel - R &R; Section. By using Star Screw driver, remove the scrivets and remove the front RH wheel arch apron. Using a 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially detach the degassing tank. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050128.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the front differential breather hose routing clip. Using a 12 mm socket spanner loosen and remove the steering return line routing bracket mounting bolts. Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190090.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a hose clamp plier, unclip the hose clamp from power steering side. Using a 17 mm open end spanner, loosen the flare nut and detach the return line from the rack and pinion side. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190075.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the steering return line hose gear end from the vehicle. Install in the reverse order of removal. Fill the fluid and carry-out air bleeding procedure. For additional information refer to Power steering fluid filling procedure. Inspect for any external damage or bent, if found replace.
2. Turn the steering wheel to the its both ends and measure the maximum steering angle.
",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Caution",
+ "content": "If the steering angle is out of the specified value, check and adjust the toe. Position the vehicle on a 2 post/ 4 post lift. Do not operate the steering system without power steering fluid. Failure to follow this precaution will lead to the damage of the steering system components. Whenever air enters the power steering hydraulic system, the system must be bleed to ensure free of air. Filling and bleeding the power steering system helps to ensure trouble-free operation as well as prevents the damage of the power steering system components. Inspect the fluid pressure hoses and clips for proper fitment. Rotate in anti-clockwise and remove the power steering fluid reservoir cap. Fill the power steering fluid reservoir to the \u201cMAX\u201d mark. During the bleeding procedure, ensure that the power steering fluid in the power steering fluid reservoir does not fall below the \u201cMIN\u201d mark, as air could enter into the system. Slowly turn the steering wheel to left lock position and hold for about 10 seconds. From left lock position turn the steering wheel slowly to Right lock position. Continue steps 6\u20137 till there is no air bubbles visible in the power steering fluid reservoir and smooth operation of power steering is attained. If the air bleeding is not properly performed, the life span of the power steering pump may be shortened. Top up the fluid to MAX mark on reservoir. The steering wheel is the part of the steering system that is rotated by the driver; the rest of the steering system responds to driver inputs. The steering wheel houses the driver airbag and audio controls. It is connected to the collapsible steering column. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Remove the driver air bag. Using a 17 mm socket spanner, loosen and remove the steering wheel mounting nut. Torque : 47\u00b17Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190022.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect clock spring electrical connector. Remove the steering wheel from the vehicle. Do not use excessive force to the steering wheel for removal. This may cause steering wheel bend. Gently tap if needed. While installing steering wheel ensure the splines are aligned properly and the steering wheel slides easily on the column shaft. Install in the reverse order of removal. Ensure the front wheels are in straight ahead position. Improper or incorrect Removal and Installationof the Restraint components will cause unintentional activation of the system which may lead to personal injury. The service operations should be followed in the correct sequence. Failure to do so may cause the SRS to unexpectedly deploy during service leading to a serious accident. The steering column is bolted to the bulk head. It is a tiltable and collapsible column. The steering column shaft is mounted on two needle bearings internally at the ends suspended by rubber mountings in the steering column assembly. An intermediate shaft connects the steering column to the steering gear. For reasons of safety, the steering column assembly incorporates a collapsible steel cage and an intermediate shaft with a deformation zone designed to crumple progressively in the event of a headon collision. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Remove the combination switch. Disconnect the ignition key barrel electrical connector. Using a Small chisel or punch hit and unscrew the mounting screw of ignition switch barrel with support of hammer. Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft bottom mounting bolts and detach the intermediate shaft bottom from the steering column. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190042.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering column mounting bolts and nuts then remove the steering column from the vehicle. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190039.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the mounting bolt and remove top intermediate shaft from column. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190108.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190040.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Ensure to Assemble Upper & Lower I shaft connector according to the marking. Remove the engine feed system cover. For information refer to Engine Feed System Cover - R &R; section. Remove the front RH wheel. For additional information refer into Front Wheel RH - R &R; Section. By using Star Screw driver, remove the scrivets and remove the front RH wheel arch apron. Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft bolt from the rack and pinion. Torque : 22\u00b14Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "While attempting to remove the intermediate shaft, lock the steering wheel at center position. Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft lower mounting bolt. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190042.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft Center bracket mounting bolts. Torque : 20\u00b12.0Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190043.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the Steering intermediate shaft from the vehicle. Install in the reverse order of removal. Ensure to install Upper & Lower I shaft connector according to the marking. DO NOT HAMMER while disassembly / assembly. Ensure I shaft connector is assembled as per given marking. At straight ahead condition bolt head should face top side for easy torquing. Position the vehicle on 2 post lift/ 4 post lift. Steering Rack Linkage & Boots Inspection Procedure ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the steering rack assembly RH side boots, clamps for cut, nick or abrasion,replace if necessary Check the steering rack assembly LH side boots, clamps for cut, nick or abrasion, replace if necessary. Check the steering rack assembly RH side linkage condition (Without removing boots) for play, damage, replace if necessary. Rotate Steering wheel from one end to other for better visualization of boots. Check the steering rack assembly LH side linkage condition (Without removing boots) for play, damage, replace if necessary Rotate Steering wheel from one end to other for better visualization of boots. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Remove the steering wheel. Disconnect the ignition key barrel electrical connector. Disconnect the combination switch & clock spring electrical connectors. Using a 12 mm socket spanner, loosen the steering intermediate shaft top bolt and remove bottom mounting bolts and detach the intermediate shaft bottom from the steering column. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190042.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering column mounting nuts then remove the steering column from the vehicle. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190039.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the top intermediate shaft mounting bolts then remove the top intermediate shaft from the steering column. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190108.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190109.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Ensure to install Upper & Lower I shaft connector according to the marking. Power Steering Oil - MAHINDRA MAXIMILE POWER STEERING FLUID GENUINE POWER STEERING FLUID. Capacity \u2013 0.85 Litres. Fluid reservoir outlet and return hose connection to reservoir. Check Power Steering fluid level , if found less than MIN mark, top up to MAX mark. Always maintain fluid level at MAX mark on reservoir. Power steering pump inlet and outlet connection. Power steering gear fluid inlet and outlet connection. Power steering rack feed tube connections. In case of non-availability of Genuine fluid, SHELL MAKE SPIRAX S3 ATF MD3 can be used. NO OTHER BRANDS RECOMMENDED. Disconnect the RPAS sensor electrical connectors. Unlock the RPAS sensors from the cover. Detach the sensors from vehicle. Check sensor, wiring, connector for any damage. Check for mud on sensor, clean gently if found. Remove the thermostat valve from the thermostat housing. Thermostat and thermometer bulb should be suspended in water. If they touch bottom or the sides then temperature in which thermostat / thermometer operate will not be correct and wrong diagnosis will take place. Insert the thermostat valve in to a container filled with water. Heat the container and measure the temperature of water by Using digital thermometer. Keep track of water temperature and respective valve opening/ travel. Thermostat should start opening at 88 \u00b1 2 \u00b0 C (0.1 mm travel). Once temperature reaches 96 \u00b1 2\u00b0 C valve should be fully open , at this moment, valve travel will be approximately 8 mm. In case thermostat valve behavior does not confirm to above specifications, it should be replaced. Disconnect the electrical connectors from resistor. Using screw driver, loosen the resistor mounting screw and remove the resistor. Install the reverse order of removal. Check the resistor for any damages, if found then replace it . Drain the engine coolant. For additional information refer to coolant draining procedure. Remove the Pipe Inlet Oil Turbocharger. Using 10 mm socket spanner, Unscrew turbo coolant supply pipe mounting banjo bolt turbo end. Using 10 mm socket spanner, Unscrew turbo coolant supply pipe banjo bolt OCFM end. Remove the turbo coolant outlet pipe. Install in the reverse order of removal. Carry-out coolant filling and de-aeration process. For additional information refer into coolant draining and refilling procedure. Inspect the coolant inlet pipe for any damage, Replace if found. 1. Remove the drive belt.
2. Rotate the water pump pulley and check for free rotation.
3. Replace the water pump, if necessary.
",
+ "file": null,
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 383,
+ "sys_id": "THAR.AX-0006-Cooling System",
+ "subsys_id": "THAR.AX-0006-Cooling System-Coolant Inlet Pipe To OCFM",
+ "systems": "Cooling System",
+ "sub_systems": "Coolant Inlet Pipe To OCFM",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B060178.jpg",
+ "myid": 1068,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Coolant Inlet Pipe To OCFM-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Component Location Index",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060178.jpg",
+ "display_order": 1
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+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25325.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25326.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the engine coolant. For additional information refer into coolant draining and refilling procedure. Remove the CATCON Assembly. For additional information refer to CATCON Assembly - R &R; section. Using 7 mm socket spanner, Loosen hose clip and detach water outlet hose pipe end. Torque : 6.5 \u00b1 0.6 Nm Using 10 mm socket spanner, Unscrew water inlet pipe mounting bolts and remove pipe. Install in the reverse order of removal. Carry-out coolant filling and de-aeration process. For additional information refer to Coolant filling and de-aeration section. Check coolant inlet pipe for any damage or cracks. If found replace the outlet pipe with a new one. Check coolant inlet pipe mounting for proper tightness and damages, replace the outlet pipe if required. Remove the Intercooler Fan. Using 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially remove the degassing tank (Without disconnecting the hoses). Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060135.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect fan resistor electrical connector. Using 10 mm socket spanner, Unscrew fan mounting bolts. Torque : 6.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060137.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060139.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect the shroud holder clips from radiator and fan then remove the clips (Top & Bottom). Using 7 mm socket spanner, Loosen intercooler inlet hose clip and detach the hose intercooler end. Torque : 6.5 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050130.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Detach the fan assembly from radiator bottom seating and remove the radiator fan assembly. While Installing ensure the fan bottom seating are properly seated on radiator. Install the reverse order of removal. Check electric fan blades for any damages. 2 post lift/ 4 post lift. Coolant \u2014 Mahindra 'MAXIMILE ULTRA COOL' Genuine Long Life Coolant (READY TO USE COOLANT. NO NEED TO MIX WATER). Capacity \u2014 ~5.0 Litres.
Coolant Level And Leak Inspection Procedure Inspect the degassing tank pressure cap for any damage or coolant leakage. Rectify the leakage if found. Check the coolant level in the degassing tank, it should be between MAX and MIN marks. Check the coolant level when the engine is cold. If found below MIN mark then top it up with 'MAHINDRA 'MAXIMILE ULTRA COOL' (ready to use coolant. no need to mix water). Inspect the degassing tank to radiator vent hose & engine vent hose for any coolant leakages, also check the mounting spring band clamp for any damage. If found any damage or leak, rectify. Inspect the engine to T connection vent hose for any coolant leakages, also check the mounting spring band clamp for any damage. If found any damage or leak,rectify. Inspect the degassing tank outlet hose assembly at every joints such as degassing tank end, T-connector connections, Turbo outlet pipe & hoses, OCFM side for any coolant leakage, also check the mounting spring band clamp for any damage. If found any damage or leak, rectify. Inspect the radiator inlet hose at radiator and engine block for coolant leakage, rectify the leakage if found. Also inspect the mounting spring band clamp for any damage,replace the mounting spring band clamp if found damaged or loose. Inspect the radiator outlet hose at Radiator & Thermostat, thermostat housing for any coolant leakage, rectify if found any leakage. Also inspect the mounting clamp for any damage, replace if found damaged or loose. Inspect the heater inlet & outlet hoses (Both sides) for any coolant leakage, also check the mounting spring band clamp for any damage. If found any damage or leak, rectify. Inspect the Turbo Inlet & outlet pipes at Turbo & OCFM for any damage. If found any damage or leak, rectify. Never remove the degassing tank cap when the engine is hot. Brand Specific. Don't use other Coolants / Water for top up. In case of emergency, Coolant meeting JIS K2234 Specification should be used (30% Concentration Diluted with Distilled water) and coolant change period has to be reduced as 30,000 KM. Never mix MAHINDRA MAXIMILE ULTRA COOL with water. The degassing tank or coolant reservoir tank is made of plastic it can be visually identified like the washer tank. Function of the degassing tank is to remove air bubbles or vapour from the cooling system and to store the coolant as a reservoir. Proper filling of the coolant inside the cooling system is must in order to pressurize the system. The coolant level should be between the MAX and MIN marks on the reservoir tank after the cooling system has been cooled down. The degassing tank cap rating is 1.4 \u00b1 0.15 bar and vacuum 0.04 to 0.1 bar. Drain the engine coolant. For additional information refer into coolant draining and refilling procedure . Using hose clamp plier, release the radiator vent hose spring band clamp and disconnect the hose. Never work with cooling system when the engine is hot. failing to this may cause personal injury. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060011.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release the degassing tank outlet hose spring band clamp and detach hose degassing tank end. Using 10 mm socket spanner, Unscrew degassing tank mounting bolts. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050129.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully remove the degassing tank. Install in the reverse order of removal. Carry-out coolant filling and de-aeration process. For additional information refer to Coolant filling and de-aeration section.
2. Inspect the hoses for any damages, cracks or kinks, if found replace the hose assembly.
3. inspect the coolant hoses clamps for proper fitment, if found loose then replace the clips.
",
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+ "procedure_link": "THAR.AX-0006-Coolant - Replace-en",
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+ "steps": [
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Coolant - Replace.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25272.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060001.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "Description",
+ "content": " Coolant \u2014 Mahindra 'MAXIMILE ULTRA COOL' Genuine Long Life Coolant (READY TO USE COOLANT. NO NEED TO MIX WATER).Top up Capacity \u2014 ~5.0 Litres.
Engine Coolant Draining Procedure Switch OFF the Ignition and allow Engine to cool down. Never remove the degassing cap when the engine is hot. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/coolant - replacefce0e1.PNG",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Open the degassing tank cap.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011105.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver, remove the front stone guard screvits. Using a 10 mm & 13 mm socket spanner, loosen the front & rear mounting bolts and remove the front stone guard. Remove the radiator drain plug and allow the entire coolant to get drained. Place a tray beneath the drain plug to collect coolant drained. Engine Coolant Filling & De-aeration Procedure Start filling the recommended coolant in degassing tank. While filling, open the drain Plug & wait for the coolant to drop & close drain Plug. Check coolant level in degassing tank, add coolant to MAX level and close the degassing cap. Check all the hoses and clips for leakage and correct fitment. Start the engine and run at 3000 rpm for about 10 minutes. (For Thermostat Opening). Maintain Coolant level at MAX level always and ensure coolant never goes below MIN level. Switch OFF the Ignition and allow the engine to cool down, Check coolant level in degassing tank and add coolant to MAX level. Refit the front stone guard screvits & mounting bolts, torque tighten the bolts to specified value. Torque: 4.0 \u00b1 0.5 Nm Torque: 4.0 \u00b1 0.5 Nm Inspect the coolant circuit for any leakages. For additional information refer to Coolant level & leak inspection section. Never remove the degassing cap when the engine is hot. Never mix MAHINDRA MAXIMILE ULTRA COOL genuine coolant with water. Brand Specific. Don't use other Coolants / Water for top up. In case of emergency, Coolant meeting JIS K2234 Specification should be used (30% Concentration Diluted with Distilled water) and coolant change period has to be reduced as 30,000 KM. Do not overfill the system; allow free space in the degassing tank for expansion of the fluid. Remove the Coolant Inlet Pipe. Carefully remove thermostat from OCFM. Install in the reverse order of removal. Always replace the O ring with New one while removing the thermostat. Carry-out coolant filling and de-aeration process. For additional information refer into coolant draining and refilling procedure. Check thermostat valve opening and closing temperatures, if found deviation from specified value, replace the thermostat. Check travel of thermostat valve, if found deviation from specified value, replace the thermostat. Drain the engine coolant. For additional information refer to coolant draining procedure. Remove the CATCON Assembly . For additional information refer to CATCON Assembly - R &R; Section. Using hose clamp plier, Release heater outlet hose clamp and detach hose. Using 10 mm socket spanner, Unscrew pipe routing bracket mounting bolt engine block end. Using 12 mm socket spanner, Unscrew pipe routing bracket mounting bolt cylinder head end. Torque : Torque : 25 \u00b1 3 Nm Using 10 mm combination spanner, Unscrew heater pipe mounting bolt OCFM end and remove pipe. Torque : Torque : 11 \u00b1 1 Nm Remove the turbo coolant outlet pipe. Install in the reverse order of removal. Carry-out coolant filling and de-aeration process. For additional information refer into coolant draining and refilling procedure. Inspect the coolant outlet pipe for any damage, Replace if found. Remove the front grill assembly. For additional information refer into Front Grill Assembly \u2013R &R; Section. Using 10 mm socket spanner, Unscrew the LH and RH radiator seal mounting bolts. Torque : 4.5 \u00b10.5Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060132.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver, loosen and remove the LH and RH radiator seal mounting screw rivets. Torque : 4.5 \u00b10.5Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060133.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060134.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the both LH and RH radiator seal from the vehicle. Install the reverse order of removal. Drain the engine coolant. For additional information refer into coolant draining and refilling procedure. Remove the Intercooler assembly. Using hose clamp plier, Release radiator vent hose clip and disconnect hose radiator end. Using hose clamp plier, Release degassing tank Outlet and remove degassing tank. Using 10 mm socket spanner, Unscrew degassing tank mounting brackets mounting bolts LH & RH. Disconnect radiator fan electrical connector. Using 10 mm socket spanner, loosen and remove fan mounting bolts and remove fan from engine compartment. Torque : 6.5\u00b1 1.5 Nm Disconnect the shroud holder clips from radiator and fan then remove the clips (Top & Bottom). Detach the fan assembly from radiator bottom seating and remove the radiator fan assembly. While Installing ensure the fan bottom seating are properly seated on radiator. Using Hose clamp plier, release radiator inlet and outlet hose spring band clamps and disconnect the hoses radiator end. Using hose plier, release vent hose spring band clamp and disconnect hose radiator end. Using 13 mm socket spanner, Unscrew radiator mounting bolts. Torque : 12.5 \u00b1 1.5 Nm Using 10 mm socket spanner, Unscrew radiator LH & RH seal mounting bolts Using 10 mm socket spanner, Unscrew condenser mounting bolts and partially detach the condenser from the radiator. Remove the radiator from the vehicle. Install in the reverse order of removal. Carry-out coolant filling and de-aeration process. For additional information refer to Coolant filling and de-aeration section.
2. Check the radiator for coolant leakage, replace if found any.
3. Check the radiator for dust accumulation, clean with compressed air if dust accumulation is noticed.
4. Check the radiator drain plug for any leakage.
",
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+ "display_order": 49
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+ ]
+ }
+ ]
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+ "procedure_link": "THAR.AX-0006-Troubleshoot - Cooling System-en",
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+ "procedure_name": "Troubleshoot",
+ "steps": [
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+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4728.pdf",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 319,
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+ "systems": "Chassis System",
+ "sub_systems": "Chassis Dimensions \u2013 Side View",
+ "symptom": 0,
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+ "procedure_link": "THAR.AX-0006-Chassis Dimensions \u2013 Side View-en",
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+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31373.pdf",
+ "display_order": 1
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+ }
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+ "systems": "Chassis System",
+ "sub_systems": "Chassis Dimensions \u2013 Top View",
+ "symptom": 0,
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+ "estimated_time": 0.0,
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+ "cover_image": "/files/W4A360002.jpg",
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+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A360002.jpg",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 321,
+ "sys_id": "THAR.AX-0006-Chassis System",
+ "subsys_id": "THAR.AX-0006-Chassis System-Under Body Nuts & Bolts For Tightness Inspect",
+ "systems": "Chassis System",
+ "sub_systems": "Under Body Nuts & Bolts For Tightness Inspect",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.5,
+ "rts": null,
+ "mat": "J10-MAT-0630",
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+ "file": "/files/W4A170174.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Preliminary Activities/Conditions",
+ "content_type": "Description",
+ "content": "Position the Vehicle on 4 post lift. Inspect and ensure the following nuts/bolts are with proper torque as recommended: Front shock absorber assembly on chassis (LH/RH). Torque value: 40 \u00b1 5Nm Torque Wrench Type - Open end Torque Wrench Front shock absorber mounting bolt on LCA (LH/RH). Torque value: 120 \u00b1 12 Nm Front stabilizer bar mounting bracket bolts. Torque value: 50 \u00b1 5 Nm Front stabilizer bar link mounting bolts on LCA (LH/RH). Torque value: 90 \u00b110 Nm Front upper control arm pivot mounting bolts on chassis (LH/RH). Torque value: 97\u00b1 10 Nm Front Lower arm mounting bolts on chassis (LH/RH). Torque value: 250 \u00b1 20 Nm Ensure to do the torquing in the nut side and holding the bolt while torquing. Knuckle bottom mounting bolts LHS & RHS. Torque value: 140 \u00b1 10 Nm Torque Wrench Type - Open end Torque Wrench Rear stabilizer bar mounting on Rear Axle (RH/LH). Torque value : 70 \u00b1 7 Nm Rear stabilizer bar link rod mounting on chassis (LH/RH). Torque value : 90 \u00b110 Nm Torque Wrench Type - Open end Torque Wrench Rear lower link mounting on chassis and axle (LH&RH;). Torque value: 230 \u00b1 20 Nm Torque Wrench Type - Open end Torque Wrench for LH chassis side While torquing axle side, hold the nut by open end spanner & do the torquing in the bolt side. Rear upper link mounting on chassis and axle (LH&RH;). Torque value: 230 \u00b1 20 Nm Torque Wrench Type - Open end Torque Wrench for LH chassis & axle side Rear shock absorber bottom mounting on Rear axle (LH&RH;). Torque value : 110\u00b111 Nm Torque Wrench Type - Open end Torque Wrench Rear shock absorber top mounting on chassis (LH&RH;). Torque value : 65\u00b110Nm Pan hard rod mountings on axle & chassis. Torque value: 230 \u00b1 20 Nm Position the vehicle on a 2 post / 4 post lift. Check the insulators of the exhaust front pipe , intermediate pipe with muffler and tail pipe with muffler, replace if found elongated or damaged. Check the joint between exhaust tail pipe with intermediate pipe, if found leakage then replace the gasket and torque tighten the nuts to specified value. Check the joint between exhaust intermediate pipe with front pipe for any leakage, if found leakage then replace the gasket and torque tighten the nuts to specified value. Check the joint between exhaust front pipe with Catalytic Converter for any leakage, if found leakage then replace the gasket and torque tighten the nuts to specified value.
\u2022 Check all the exhaust joints for leakage and correct fittings. If leakage is found, check the exhaust pipe gasket. Replace if required.
",
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+ "display_order": 15
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+ ]
+ }
+ ]
+ },
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+ "sys_id": "THAR.AX-0006-Exhaust & Emission Control",
+ "subsys_id": "THAR.AX-0006-Exhaust & Emission Control-Troubleshoot - Exhaust & Emission Control",
+ "systems": "Exhaust & Emission Control",
+ "sub_systems": "Troubleshoot - Exhaust & Emission Control",
+ "symptom": 1,
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+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Troubleshoot - Exhaust & Emission Control-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Symptom Possible Causes",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/17500.pdf",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Component Inspection and Action Table",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/17501.pdf",
+ "display_order": 2
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 357,
+ "sys_id": "THAR.AX-0006-Exhaust & Emission Control",
+ "subsys_id": "THAR.AX-0006-Exhaust & Emission Control-Pipe Oil Inlet Turbocharger",
+ "systems": "Exhaust & Emission Control",
+ "sub_systems": "Pipe Oil Inlet Turbocharger",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B030158.jpg",
+ "myid": 1034,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Pipe Oil Inlet Turbocharger-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030158.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4783.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30495.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove turbo bottom heat shield. For additional information refer to turbo bottom heat shield - R &R; section. Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury. Using 10 mm socket spanner, Unscrew turbo oil supply pipe mounting banjo bolt turbo end. Torque : 18 \u00b1 2Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew turbo oil supply pipe banjo bolt OCFM end. Torque : 18 \u00b1 2Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the turbo oil inlet pipe. Install in the reverse order of removal. Check Engine Oil level & Top-up the engine oil. For additional information refer to engine oil refilling procedure. Check oil inlet tube for any external damage, replace if found any. The Lambda Sensor or Heated Oxygen Sensor which is bolted into the top of the catalytic converter is called as upstream lambda sensor. The Lambda Sensor measures the residual oxygen level in the exhaust gases. A lambda value of 1 indicates engine is running at stoichiometric air fuel ratio. A minimum temperature of 300\u00b0 C is required for proper functioning of the Lambda sensor. The integrated heater ensures that the sensor functions even at extremely low exhaust gas temperatures. The Lambda Sensor is used to correct the fuel injection quantity to maintain stoichiometric air fuel ratio for combustion. Second lambda sensor is bolted to the bottom of catalytic converter. The downstream lambda Sensor is used for diagnosis of catalytic converter and to ensure good catalytic converter efficiency. The voltage output of the sensors depends upon the oxygen content in the exhaust gas. Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury Disconnect the Lambda sensor electrical connector. Using 22 mm open end spanner loosen the sensor and remove sensor from CATCON. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030142.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Check for any external damage on sensor , replace if found any. Remove the Catalytic Converter Assembly Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury. Using 12 mm socket spanner remove turbo support bracket mounting bolts. Using 7 mm socket spanner loosen clean hose clip and detach it from turbo end. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner loosen Intercooler inlet hose clip and detach it from turbo end. Torque : 6.5\u00b10.6Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect turbo dump valve electrical connector. Using 10 mm socket spanner, remove turbo oil inlet pipe banjo bolt. Torque : 18 \u00b1 2Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner remove turbo coolant inlet, outlet pipe banjo bolts. Torque : 18 \u00b1 2Nm ",
+ "file": "",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner remove turbo oil drain pipe mounting bolts. Torque : 11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner remove turbo mounting nuts. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Notice",
+ "content": "Always use new metal gasket once removed. check for any leakages While installing, Molykote to be applied on both sides of stud on exhaust manifold- turbocharger. Torquing to be done immediately after application of molykote sealant. Nuts to be re torque after initial tightening in the same sequence. Disconnect turbo electrical interconnector. Remove Turbocharger Assembly from vehicle. Disconnect turbo pigtail electrical connector and remove pigtail. Install in the reverse order of removal. Check Engine Oil level & Top-up the engine oil. For additional information refer to engine oil refilling procedure. Inspect the Compressor/Turbine wheel for damage. Inspect the Compressor/Turbine wheel for rubbing. Inspect the Rotor for free rotation. Inspect the rotor play by pressing the shaft outward & rotate, It should be rotate freely. Remove turbo bottom heat shield. For additional information refer to turbo bottom heat shield - R &R; section. Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury. Using 10 mm socket spanner, Unscrew turbo oil drain pipe mounting bolts cylinder head end. Torque : 11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew turbo oil drain pipe mounting bolts turbo end. Torque : 11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the turbo oil drain pipe. Install in the reverse order of removal. Check Engine Oil level & Top-up the engine oil. For additional information refer to engine oil refilling procedure. Check oil return tube for any external damage, replace if found any. The Closed coupled catalytic converter is mounted between the turbo charger and the exhaust front pipe assembly. The three way catalytic converter allows the three pollutants (CO, HC, NOx) to be converted simultaneously in a single chamber. It converts harmful carbon monoxide and hydrocarbons into water vapor & carbon dioxide and reduces NOx into nitrogen & carbon dioxide. In three way catalytic converter, Substrate is coated over with oxidation catalysts Platinum & Palladium and reduction catalyst Rhodium.High amount of substrate is loaded in the top portion & less amount in the bottom portion. Using 12 mm combination spanner remove turbo top heat shield mounting bolts and detach shield. Disconnect Upstream and Downstream lambda sensor electrical connectors Using 22 mm open end spanner remove Upstream and Downstream lambda Sensors Using 13 mm socket spanner unscrew exhaust front pipe mounting bolts CATCON end Carefully remove the fan assembly Using 13 mm socket spanner remove CATCON mounting nuts from turbocharger Using 12 mm socket spanner, Unscrew Upstream O2 sensor electrical connector holding bracket mounting bolt and remove the bracket Using 12 mm socket spanner, Unscrew Upstream O2 sensor electrical connector holding bracket mounting bolt and remove the bracket Using 12 mm socket spanner remove CATCON bracket mounting bolts and remove the brackets Refit the CATCON mounting brackets on CATCON and hand tighten the bolts. Ensure to only hand tighten the bracket bolts in this stage for proper position of Cat con on vehicle and after that torque tighten. Place and position the CATCON inside the engine compartment. Always replace the metal gasket once removed. Install the CATCON mounting nuts on turbocharger. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "Ensure to apply Molykote on stud tapping threads while Installation. Torquing to be done immediately after application of molykote sealant. Tighten the CATCON bracket mounting bolts on cylinder block side to the specific torque value. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030125.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Tighten the CATCON bracket mounting bolts on CATCON to the specific torque value. Torque : 25\u00b13 Nm ",
+ "file": "/files/W4B030020.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit exhaust front pipe and install the mounting bolts CATCON end and torque tighten. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refit the Upstream and Downstream lambda sensors on the CATCON and torque tighten. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030135.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Reconnect Upstream and Downstream lambda sensor electrical connectors. Refit turbo top heat shield and torque tighten the mounting bolts. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 58
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external cracks on catalytic converter assembly, replace if found any. Check for the obstruction of the air flow, replace if found any. The Lambda Sensor or Heated Oxygen Sensor which is bolted into the top of the catalytic converter is called as upstream lambda sensor. The Lambda Sensor measures the residual oxygen level in the exhaust gases. A lambda value of 1 indicates engine is running at stoichiometric air fuel ratio. A minimum temperature of 300\u00b0 C is required for proper functioning of the Lambda sensor. The integrated heater ensures that the sensor functions even at extremely low exhaust gas temperatures. The Lambda Sensor is used to correct the fuel injection quantity to maintain stoichiometric air fuel ratio for combustion. Second lambda sensor is bolted to the bottom of catalytic converter. The downstream lambda Sensor is used for diagnosis of catalytic converter and to ensure good catalytic converter efficiency. The voltage output of the sensors depends upon the oxygen content in the exhaust gas. Disconnect the downstream Lambda sensor electrical connector. Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury. Using 22 mm open end spanner loosen the sensor and remove sensor from CATCON. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030138.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Check for any external damage on sensor , replace if found any. Ignition Coil gives high voltage current to the spark plug and is basically a step up transformer. Ignition timing is decided by the EMS ECU. Using a 10 mm socket spanner, loosen and remove the battery negative terminal. Before starting of the procedure, always switch off the ignition. Do not smoke or carry lighted tobacco/open flame while working near any fuel related components. The fuel may ignite and cause personal injury. Always follow fuel handling precautions to avoid personal injury. Remove the engine top encapsulation cover. Disconnect the ignition coil electrical connectors. Using a 10 mm socket spanner, loosen and remove Ignition coil mounting bolts and remove the Ignition coils. Check for any external damage in ignition coil, if found replace. Refit the Ignition coil mounting bolts and torque tighten to specified value. Torque Value: 10 - 12 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1043.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Connect Ignition coil electrical connectors. Refit the engine encapsulation cover.. Connect the battery negative cable mounting nut. It is a device for delivering electric current from the ignition system to the combustion chamber in the spark-ignition engine to ignite the charge by an electric spark. The timing of the spark ensure that the combustion pressure within limits and also the emissions. The spark plug has a metal threaded shell, electrically isolated from the central electrode by a porcelain insulator. The central electrode, is connected by a heavily insulated wire to the output terminal of an ignition coil. The spark plug's metal shell is screwed into the engine's cylinder head and thus electrically grounded. The central electrode protrudes through the porcelain insulator into the combustion chamber, forming spark gap between the inner end of the central electrode and the inner end of the threaded shell and designated the side, earth, or ground electrode. Do not smoke or carry lighted tobacco/open flame while working near any fuel related components. The fuel may ignite and cause personal injury. Always follow fuel handling precautions to avoid personal injury. Special care should be taken for the heating portion of the spark plug while removal or installation and storing. Do not remove the spark plug when the engine is in hot condition. Failure to follow this will cause personal injury. Before starting of the procedure, always switch off the ignition. Using a 10 mm socket spanner, loosen and remove the battery negative terminal. Remove the engine top encapsulation cover. Disconnect the ignition coil electrical connectors. Using a 10 mm socket spanner, loosen and remove Ignition coil mounting bolts and remove the Ignition coils. Using a MST 0308CBG0001ST - Spark Plug Installer Tool , loosen and remove spark plugs from cylinder head. Refit the new spark plugs and torque tighten them to the specified value. Torque Value: 20 - 25 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W152.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Tighten the spark plug to specified torque value. Over tightening may damage the spark plug. Spark plug gap is a gap between the centre and side electrodes of a spark plug. Before installing new spark plug, ensure that the specified gap is maintained between the electrodes. For Thar, Spark Plug gap should be maintained as 0.7 - 0.8 mm and Incorrect spark plug gaps can cause the following problems Rough, irregular engine Idle. Engine hesitation or stumbles while acceleration. Engine to miss or run erratically especially during idle. Poor engine performance. Engine knocking or pinging. Refit the Ignition coil mounting bolts and torque tighten to specified value. Torque Value: 10 - 12 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W154.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Connect Ignition coil electrical connectors. Refit the engine encapsulation cover. Connect the battery negative cable mounting nut. ground level/ 2 post lift/ 4 post lift and turn engine OFF. 2. Open the bonnet and lock it in open position using bonnet stay rod. ",
+ "file": null,
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010013.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 27 mm 12 point doublehexagonal socket spanner, Loosen the engine oil filter bowl. To access Oil filter cap mounting slightly move the Intercooler hose (without removing) and Carefully remove the damaging the hose. Remove the engine oil filter with bowl from engine assembly. Ensure gasket isn\u2019t in casting housing and element assembly should come along with filter cap. Carefully rotate the oil filter element in clockwise direction, pull upward and remove the filter element. Remove the filter element carefully, with no damage to the plastic snaps. Pay attention not to damage the oil bypass valve while removing the oil filter element. Smear a layer of fresh oil on new oil filter O-ring and Position the O-ring on filter cap. Replace the O-ring with new one when replacing the oil filter element. Ensure no damage to O-ring during assembly, with no sharp edges damaging O-ring or element. Ensure to fix the oil bypass valve in proper position on oil filter cap. Place the oil filter in the bowl projection, push the filter inside and rotate the filter in anti-clockwise direction to lock it. Install the fuel filter element carefully, with no damage to snaps Position the oil filter cap with filter on the oil cooler surface. Tighten the oil filter cap in clockwise direction and torque tighten cap to the specified value. Torque :25 - 30 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Don\u2019t apply improper torque which leads to damage in threads. Check the engine oil level. Start the engine and check for Oil leakage/ seepage at: Oil pan & crankcase joint. Oil pan drain plug. Oil filter joint. Recommend to use only the Mahindra genuine oil filter for better engine protection and lubricant life. Make sure for all the subassembly and components going into engine assembly should be clean and away from foreign material. Remove the Engine case cover. For additional information refer to Engine Case Cover - R &R; Section. Remove MST 0307ABH0001ST - Flywheel Locking Tool - Eagle mounting bolts and detach it. Refit engine front lifting hook and torque tighten the mounting bolts to the specified value. Using 18 mm socket spanner, unscrew engine mounting bracket nut (Both LH & RH) from engine bed. Torque : 110 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010618.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Provide engine support beam to support engine. Lift the engine with care, don\u2019t over lift since chances of damaging parts are more. Ensure none of the components are effected or damaged during lifting. Using a 14 mm combination spanner & socket spanner, unscrew LH Side engine mounting bracket mounting bolts and remove the bracket from engine compartment. Using a 6 mm square socket spanner, loosen and remove TDC locking pin plug. Torque : 20\u00b12 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010622.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Position damper pulley and install damper pulley mounting bolt on crankshaft. Insert the TDC locking pin (MST 0312ABH0001ST \u2013 Crankshaft Locking Tool - TDC Pin ) and lock the crankshaft. Ensure the crankshaft locking tool is seated properly into the slot on crankshaft and ensure the TDC locking pin insert upto Red mark in the pin as shown. Check and ensure the 1st cylinder piston position to TDC. Ensure that correct TDC locking tool is used. TDC locking hole is near crankcase left side below intake manifold (Near Engine LH Mounting bracket). If not able to position the MST in proper position into crankshaft, Slightly rotate damper pulley and align the crankshaft to insert MST:- 0312ABH0001ST Crankshaft Locking Tool - TDC Pin on crankshaft. Using 24 mm socket spanner, loosen and remove damper pulley mounting bolt and detach damper pulley. Check Crankshaft Sprocket woodruff key slot in 12\u2019o Clock Position, Intake and Exhaust camshaft cam phaser locking pin in 12\u2019o clock position. Align the MST \u2013 0310ABG0001ST Camshaft locking tool on the front side of engine in the camshaft slot as shown and fix the camshaft locking tool on cylinder head using appropriate bolts. Ensure that correct Camshaft locking tool is used. Ensure the Cam locking tool is seated properly on Cam shaft. If the tool is not properly seat on the cam shaft slot then the engine is not in proper timing and follow the below steps for Engine timing adjustment. Using 10 mm socket spanner, Unscrew chain tensioner mounting bolts and remove the tensioner. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010607.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using 8 mm Allen socket spanner, Unscrew chain tensioner LH fixed guide mounting bolt and remove the guide. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010606.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using 8 mm Allen socket spanner, Unscrew chain tensioner RH guide mounting bolts and remove the guide. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010608.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew chain tensioner top guide mounting bolt and remove the guide. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010609.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Remove the timing chain from sprocket. Align the MST \u2013 0310ABG0001ST Camshaft locking tool on the front side of engine in the camshaft slot as shown and fix the camshaft locking tool on cylinder head using appropriate bolts. If not able to position the MST in proper position into camshaft, Slightly rotate Intake/Exhuast cam shaft and align the tool. Ensure Crankshaft Sprocket woodruff key slot in 12\u2019o Clock Position, Intake and Exhaust camshaft cam phaser locking pin should be in 12\u2019o clock position. Ensure the Cam locking tool is seated properly on Cam shaft. Position and Refit the timing chain. Ensure Timing mark provided on the crankshaft sprocket match with highlighted chain link (Blue Link) on timing chain. 1st link (Blue Link) of timing chain started on timing mark provided on the crankshaft sprocket. Ensure Timing mark provided on the cam phaser (Intake and Exhaust) match with highlighted chain link (Blue Link) on timing chain. 29th link (Blue Link) of timing chain on timing mark provided on the Intake cam phaser sprocket (Anti-clock wise direction from Crank shaft first chain link). 40th link (Blue Link) of timing chain on timing mark provided on the Exhaust cam phaser sprocket (Anti-clock wise direction from Crank shaft first chain link). Refit the timing chain fixed guide and install the Allen bolts. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010607.jpg",
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": "Refit the chain tensioner guide and install the mounting Allen bolt. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010612.jpg",
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Compress the chain tensioner and lock it using lock pin. Refit the chain tensioner. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010608.jpg",
+ "display_order": 76
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Refit the timing chain top guide and install the mounting bolts. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010612.jpg",
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Remove the chain tensioner locking pin. Remove the CAM shafts locking MST. Remove the TDC Pin from crankshaft. Apply the Loctite 574 on TDC lock plug and tighten the plug on engine block to specified torque. Torque : 20\u00b12 Nm ",
+ "file": null,
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010975.jpg",
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "Description",
+ "content": "Refit engine mounting LH bracket, torque tighten the mounting bolts to the specified value. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 90
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010618.jpg",
+ "display_order": 91
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "Description",
+ "content": "Remove engine support beam. Install engine bed mounting nuts Both RH & LH, torque tighten the mounting nut to the specified value. Torque : 110 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010617.jpg",
+ "display_order": 97
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner , loosen and remove engine front lifting hook from head. Torque : 35\u00b13 Nm ",
+ "file": null,
+ "display_order": 99
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010971.jpg",
+ "display_order": 100
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "Description",
+ "content": "Refit Flywheel locking tool (MST\u20130307ABH0001ST) with suitable mounting bolts on crankcase. Refit the Engine Front cover. For additional information refer to Engine Front cover - R &R; Section. Drain the engine coolant. For additional information refer to coolant drain procedure. Remove the Air Cleaner Assembly. For additional information refer to OCFM-Degassing Tank Outlet Pipe - R &R.; Remove Steering Lower Intermediate Shaft. For additional information refer to Steering Lower Intermediate Shaft - R &R; section. Using the MST 0306GAM0006ST - Stretch Fit Belt Removal Tool Remove the AC compressor Drive belt. Disconnect the AC compressor electrical connector. Using 12 mm socket spanner, Unscrew AC compressor mounting bolts and keep aside the compressor. Torque : 23 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010140.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew degassing tank coolant outlet pipe OCFM end. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010139.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010138.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using T45 socket spanner, Unscrew Oil cooler mounting bolts. Remove the oil cooler from the engine. Replace New O ring while refitting. Ensure to clean the Engine oil spillages. Install in reverse order of removal. Refill the engine oil and check for the oil leakage. Refill the engine coolant and carry-out de-aeration procedure. Check the oil cooler assembly for any external damage, Replace if required. Remove the crankshaft pulley. For additional information refer into Flywheel \u2014 R &R; Section. Using a suitable tool remove the front end oil seal. Remove the seal from the engine. Install in reverse order of removal. The crankshaft oil seals are one time use, should never be reused.
1. Position the front oil seal on the Front Cover.
2. Place the front oil seal installer (MST\u20130311DBH0001ST) over the oil seal and tighten the torsional vibration damper pulley bolt.
3. Tighten the torsional vibration damper pulley bolt till the front oil seal is pushed to the Front Cover.
",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Notice",
+ "content": "Apply thin layer of oil on the new oil seal lip. Visually inspect the oil seal for proper seating. Check & Top-up the engine oil. Check and clean the oil seal seating area thoroughly for any damage. Hydro lock or hydrostatic lock is an abnormal condition in internal combustion engine. This occurs when a volume of liquid (Coolant/water or fuel) greater than the volume of the cylinder at its minimum (end of the piston stroke) enters the cylinder. Since liquids are nearly incompressible the piston cannot complete its travel; either the engine stop rotating or a mechanical failure occurs. When an engine is suspected to be hydrostatically locked, regardless of what caused the problem, the following steps should be used. DO NOT use starter motor to rotate the engine, severe damage may occur. Squirt approximately one teaspoon of oil into the cylinders, rotate engine to lubricate the cylinder walls to prevent damage on restart. Drain engine oil and remove oil filter. Install a new oil filter. Fill engine with specified amount of approved oil. Connect negative battery cable. Install all Injectors. Start engine and check for any leaks. The Oil Sump is the reservoir for the oil and also cover for the crank case. Oil sump is bolted to the ladder frame. The oil sump structural type to have better NVH. A liquid sealant is used to provide an leak proof joint. Drain the engine oil. For additional information refer to engine oil draining procedure section. Remove electric disconnect stone guard. For additional information refer to Electric Disconnect Stone Guard \u2013 R &R; Section. Remove Water Pump/ AC compressor belt. For additional information refer to Water Pump/ AC compressor belt - R &R; section. Using 14 mm socket spanner, Unscrew water pump idler mounting bolt and remove dealer. Torque : 45 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010623.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the transmission bottom mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010527.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Provide jack to support the front axle assembly. Using 15 mm socket spanner, unscrew front axle mounting bolts and partially detach the axle. Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010918.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Partially down the front axle assembly . Using a 12 mm socket spanner, loosen and remove the AC compressor bottom mounting bolts. Torque : 23 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010529.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using a 14 mm ring and 15 mm socket spanner, Unscrew the front cross member mounting bolts and nuts. Torque : 65 \u00b110 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010916.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Detach the front cross member from the vehicle. Remove Stabilizer bar with link. For additional information refer to Stabilizer bar with link - R &R; section. Using a 8 mm socket spanner, loosen and remove the oil sump bottom mounting bolts. Torque : 11 \u00b1 1.0 Nm ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010531.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the oil sump bottom mounting bolts. Torque : 22.5 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010532.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1518.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Detach engine oil sump from the vehicle . Torque : 22.5 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010653.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010119.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11586.jpg",
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Clean the sump and sump seating area on crankcase . Gently apply sealant for engine oil sump. Apply sealant 5188 as per recommendation and position the sump on crankcase. Please refer Sealant pattern session for sealant apply pattern. Torque tighten the bolts as per sequence below while Installation. Refill the engine oil and check for oil leakage. Check the oil sump for any cracks, damage etc, replace if found any. Remove Timing Chain. For additional information refer to Timing Chain - R &R; section. Align the MST \u2013 0310ABG0001ST Camshaft locking tool on the front side of engine in the camshaft slot as shown and fix the camshaft locking tool on cylinder head using appropriate bolts. Using 22 mm socket spanner, Loosen and remove Inlet CAM phaser mounting bolt. Torque : 30 \u00b1 2 Nm + 34\u00b0\u00b1 3\u00b0 ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11655.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. While Installation, Check Exhaust Cam phaser mounting bolt tightening torque first and then torque tightened the Intake Cam phaser mounting bolt. Inspect the CAM Phaser for any physical damage. If found replace. This is a Variable type oil pump uses to supply variable oil pressure to the system. It is chain driven and integral oil strainer. The oil pump circulates the engine oil to lubricate the components such as bearings, piston and valve. The lower chain drives oil pump to lubricate the engine. This oil pump are integrated with the strainer. The oil strainer is the first stage in the filtration of the lubricant. It filters the coarse particles present in the oil before it enters the oil pump. Remove the Engine Oil Sump. For additional information refer to Engine Oil Sump \u2013 R &R; section. Using 10 mm socket spanner, Unscrew oil strainer bracket mounting bolt. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010473.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010474.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew Oil strainer mounting bolts and remove strainer. Always replace a new metal gasket once it removed. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010521.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 8 mm Allen socket spanner, Loosen and remove oil pump chain tensioner shoulder bolt. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010522.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010523.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the tensioner and detach the chain from oil pump. Using 12 mm socket spanner, Unscrew oil pump mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010525.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1519.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Carefully remove engine oil pump. Install in reverse order of removal. Make sure that the retaining key on the rear side of the oil pump is fitted correctly to the retaining key hole on the surface of the cylinder block bed plate. While Installation, Partial attach the Oil Pump tensioner first and insert the tensioner spring lock on position. Then torque tighten the shoulder bolt. Refill the engine oil and check for oil leakage. Inspect the oil pump for any damage. Replace if found. Inspect the oil pump and strainer for any blockage, clean if found. Remove Vacuum pump. For additional information refer to vacuum pump - R &R; section. Remove the FIP. For additional information refer to FIP - R &R; section. Remove the timing chain. For additional information refer to Timing Chain - R &R; section. Using the MST \u2013 0310ABG0001ST Camshaft locking tool lock the cam shafts. Using 22 mm socket spanner, Loosen and remove exhaust CAM phaser mounting bolt. Torque : 30 \u00b1 2 Nm + 34\u00b0\u00b1 3\u00b0 ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010539.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 22 mm socket spanner, Loosen and remove Inlet CAM phaser mounting bolt Torque : 30 \u00b1 2 Nm + 34\u00b0\u00b1 3\u00b0 ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010537.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010540.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 8 mm socket spanner, Unscrew CAM shafts cap mounting bolts. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010541.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010543.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the camshaft from the cylinder head. Install in reverse order of removal. While Installation, Apply a thin layer of engine oil to the mounting parts of the Cam shafts & on Cam shafts. Sealant (Loctite 5188 - 2mm thickness) to be applied on rear (Vacuum Pump) bearing cap as per below pattern. Extra sealant to be wiped off after assembly of rear bearing cap. Exhaust Cam phaser mounting bolt should be torque tightened first and then torque tightened the Intake Cam phaser mounting bolt. Check the inlet camshaft and the exhaust camshaft for any damage and replace it if necessary. Inspect the camshaft bearing journals for scoring or excessive wear. Inspect the camshaft lobes for scoring or excessive wear. Inspect the threaded bolt holes in the front of the camshaft for damaged threads or debris. Remove the flywheel. For additional information refer into Flywheel - R &R; Section. Using a screw driver, remove the crankshaft rear end oil seal. Install the rear end oil seal by using MST 0302ABH0001ST - Engine Rear End Oil Seal Installer on the crankshaft. Always use new oil seal while installation. Install in reverse order of removal. Check & Top-up the engine oil. Check and clean the oil seal seating area thoroughly for any damage. Drain the engine coolant. For additional information refer into engine coolant draining procedure. After installation of water pump, carry out refilling of the coolant. For additional information refer into coolant refilling procedure. Remove the water pump pulley. For additional information refer into Water Pump Pulley \u2013 R &R; Section. Detach the wiring routing clip from the water pump. Using a 13 mm socket spanner, Unscrew water pump mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010633.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully remove the water pump from the engine. Remove the O ring from the water pump. Install in reverse order of removal. Always replace the O ring new one once removal of water pump. Refill the engine coolant and carry-out de-aeration procedure. Check for coolant seepage on the engine. Rectify if any traces found. Inspect the water pump for any damage or leakage or noise. Replace if found. Inspect the impeller for any damage, Replace if found. Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable. Improper tie-up of the lifting rope/chain will cause damage to the vehicle and the persons involved. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010045.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the engine top encapsulation cover. Drain the Engine Coolant. For additional information refer to Engine Coolant Draining procedure. Recover AC gas. For additional information refer to AC gas recovery procedure. Using 17 mm open end spanner, Loosen power steering pump outlet pipe mounting nut and Drain power steering fluid. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove Clean Side Hose Assembly. For additional information refer to Clean Side Hose Assembly - R &R; Using 13 mm socket spanner, loosen starter motor positive cable mounting nut and detach cable from starter motor end. Torque : 12\u00b12 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B090002.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 8 mm socket spanner, Unscrew starter motor solenoid switch electrical connector. Torque : 2.5\u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B090005.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the starter motor mounting bolts and remove starter motor from vehicle. Torque : 44 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1506.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner unscrew exhaust front pipe mounting bolts CATCON end. Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove Radiator Air Guides. For additional information refer to Radiator Air Guides - R &R; section. Remove Transmission with Transfer Case. Using a hose clamp plier, Release coolant vent hose clamps radiator end,engine end and detach the hose both the ends and from routing clips. Using hose clamp plier, Release degassing tank coolant outlet hose clamp and detach hose OCFM end. Using hose clamp plier, Release turbo coolant outlet hose clamp and detach hose turbo end. Using 10 mm socket spanner, Unscrew degassing tank mounting bolts and detach tank with hoses. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010069.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew front top cross member mounting bolts. Torque : 25 \u00b1 4.0 Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010213.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Detach front top cross member and disconnect bonnet latch cable from routing and from lock. Using 10 mm socket spanner, unscrew degassing tank mounting bracket LHS & RHS mounting bolts. Torque : 10 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1509.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020285.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Disconnect boost pressure sensor, and intercooler fan electrical connectors. Using 7 mm socket spanner, Loosen turbo outlet hose clip and detach hose turbo end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010215.jpg",
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner, Loosen intercooler outlet hose clip and detach hose throttle valve end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010073.jpg",
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew intercooler mounting bolts and remove intercooler with hoses and fan. Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010216.jpg",
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner, Loosen radiator outlet hose clip and detach hose OCFM end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010218.jpg",
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release radiator inlet hose clamp and detach hose cylinder block end. Disconnect heater inlet and outlet hose quick coupler heater end. Press and disconnect the quick coupler carefully to avoid seal damages. Disconnect fuel inlet pipe quick coupler FIP end and detach hose. Press and disconnect the quick coupler carefully to avoid seal damages. Disconnect purge valve vapour hose quick coupler purge valve end and detach hose. Disconnect purge valve electrical connector. Disconnect purge valve electrical connector. Disconnect vapour hose quick coupler and routing clip intake manifold end and detach hose. Press and disconnect the quick coupler carefully to avoid seal damages. Detach purge valve from mounting bracket and remove purge valve with vapour hose assembly. Using hose clamp plier, Release vacuum hose clamp and detach hose vacuum pump end. Open the alternator positive cable cover. Using 12 mm socket spanner, Unscrew alternator positive cable mounting nut and detach cable alternator end. Torque : 15 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 92
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1510.jpg",
+ "display_order": 93
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010130.jpg",
+ "display_order": 94
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "Description",
+ "content": "Disconnect engine WH inter connector, Holding clip and routing clip fire wall end. Disconnect engine WH connector ECU end and detach harness from routing clips. Using hose clamp plier, Release power steering oil inlet hose clamp and detach hose pump end. Using 12 mm socket spanner, Unscrew AC compressor suction and discharge hose mounting nuts. Torque : 14.0+1.0 Nm ",
+ "file": null,
+ "display_order": 103
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010081.jpg",
+ "display_order": 104
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "Description",
+ "content": "Support the engine using engine removal support floor crane. Improper tie-up of the lifting rope chain will cause damage to the vehicle and the persons involved. Using 18 mm socket spanner, unscrew engine bed mounting nuts LHS & RHS. Carefully remove the engine from compartment. Improper tie-up of the lifting rope chain will cause damage to the vehicle and the persons involved. Using hose clamp plier, Release heater inlet and outlet hose clamps and detach the hoses. Using 10 mm socket spanner, Unscrew engine WH carrier mounting bolts. Using 12 mm socket spanner, Unscrew ignition coil ground connector mounting nut. Disconnect AC compressor electrical connector Disconnect Variable oil pump solenoid electrical connector. Disconnect upstream Lambda sensor electrical connector and connector holder. Disconnect Engine oil pressure sensor electrical connector and routing clip. Disconnect WGTelectrical connector. Disconnect Dump valve electrical connector and routing clip. Disconnect VVT inlet and exhaust cam phase solenoid connector & routing clip. Disconnect throttle valve electrical connector. Disconnect MAP sensor electrical connector. Disconnect Spark plug (4 nos) electrical connectors. Disconnect Exhaust CAM sensor electrical connector. Disconnect downstream lambda sensor electrical connector and routing clip. Disconnect Inlet CAM phase sensor electrical connector. Disconnect Coolant temperature sensor electrical connector. Disconnect FIP electrical connector. Disconnect Common rail electrical connector. Disconnect Injector (4 nos) electrical connector. Disconnect Knock sensor electrical connector & routing clips(2Nos). Disconnect Alternator connector & routing clip. Detach the WH harness from engine assembly. Using 13 mm socket spanner, Unscrew CATCON mounting bolts and remove CATCON from Turbo end. Using 12 mm socket spanner, Unscrew CATCON brackets mounting bolts and remove CATCON from engine. Using 12 mm socket spanner loosen and remove clutch cover assembly mounting bolts and remove it. Torque : 25 \u00b1 5.0 Nm (Step Torque : 5,15,25) ",
+ "file": null,
+ "display_order": 174
+ },
+ {
+ "step_name": "Step-67",
+ "content_type": "Notice",
+ "content": "Install the MST : 0307ABH0001ST \u2013 Flywheel locking tool and lock the flywheel rotation. Insert MST \u2013 0801BUA0001ST \u2013 Master clutch plate assembly, before loosening the clutch cover bolts to prevent clutch plate falling down and getting damage. While Installation, the projected part of clutch disc should come towards transmission side only, fails may result in clutch disc damage. Using 10 mm socket spanner, Unscrew engine feed cover mounting bolts and remove feed cover. Install in the reverse order of removal. Recharge the AC refrigerant system. For additional information refer to Recharge the AC refrigerant system - R&R; section. Refill Engine coolant. For additional information refer to coolant refilling Procedure. Check & Top-up the engine oil. Check for coolant seepage and any oil seepage on the engine and transmission. Rectify if any traces found. Check & Clear DTC if found any. For additional information refer to diagnostic manual. Check the accessory drive belt for any cracks, damage etc, replace if found any Check SMF face-out and run-out. Check SMF Surface thermal cracks condition. Check the flywheel ring gear for worn-out or damage, Refer SMF Inspection procedures for more details. Engine Oil \u2013 \u2013MAHINDRA 'MAXIMILE ULTRA' Gen-NXT Technology Genuine Engine Fluid. Capacity \u2013 6.0 Liters.
2. Open the bonnet and lock it in open position using bonnet stay rod.
3. Wait for about 10 minutes for oil in circulation to drain down.
",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010002.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Pull out the dip stick gauge and wipe it clean with a cloth/paper. Insert the dip stick gauge into the dip stick guide fully till the end. Pull out the dip stick slowly and check for the oil level mark between Maximum and Minimum level - if found below minimum level, top up with recommended oil. Insert the dip stick back and fix properly. Start the engine and check for oil leakage/ seepage at: Oil sump & crankcase joint. Oil sump drain plug. Oil filter joint. Always use MAHINDRA 'MAXIMILE ULTRA'Gen-NXT Technology GENUINE ENGINE Fluid. This is specially developed for your engine\u2019s efficiency. In extreme cases of emergency and non-availability of above oil, we suggest to use 'Maximile Feo' engine oil, take the vehicle to nearest Mahindra Authorised Service centre and replace the oil with 'MAXIMILE ULTRA'. No other brand / grade oil recommended. The cylinder head gasket failure can be easy to determine. A large stream of white smoke blowing from the exhaust and an overheating engine are sure signs. However, more suitable cylinder head gasket failure signs may be more difficult to diagnose. The engine may experience mysterious coolant loss, or only lose coolant when the engine is driven under heavy load. You may even experience a rough running engine when you first start the vehicle. An initial inspection of cooling system components and a comprehensive test drive may be necessary to confirm the customer's complaint of coolant loss or overheating. Check for the presence of white steam/smoke coming from the exhaust. Steam coming out of the exhaust may smell slightly sweet as the steam gently dissipates into the surrounding air. Another sign that the head gasket may be leaking is the presence of oil in the cooling system. Check for oil residue in the coolant reservoir. It is important to confirm actual engine running temperature and accuracy of the temperature gauge. This can be verified by using a non-contact infrared heat detection gun. It is a non intrusive method used by most repair shops to verify temperature gauge accuracy and actual engine running temperature. Pressurizing the cooling system (to eliminate coolant leaks as being the source of coolant loss), checking for proper operation of the cooling fan, and checking radiator efficiency are important before jumping to the conclusion that the head gasket is defective. Cylinder to Cylinder Leakage Test ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the cylinder compression pressure as already explained. Leakage between cylinders will be result in drop of compression pressure by nearly 50 to 70% in the affected cylinders. Cylinder to Water jacket Leakage Test ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the degassing pressure cap. Warm up the engine and allow it to warm up until the engine thermostat opens. If large combustion pressure leak exist, bubbles will be visible in coolant. If bubbles are not visible, install a pressure tester and pressurize the cooling circuit. If a cylinder is leaking combustion pressure into the water jackets then the tester\u2019s needle will pulsate with every combustion stroke of the cylinder. ground level/ 2 post lift/ 4 post lift and turn engine OFF.
2. Open the bonnet and lock it in open position using bonnet stay rod.
",
+ "file": null,
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W375.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the engine feed cover mounting bolts. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W376.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the engine feed cover from engine compartment. Using a 24 mm socket spanner, rotate the crank pulley 360\u2070 till belt completes one full rotation to check belt condition and confirm following belt appearances if any. Random Cracking Across the Ribs ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Small yet visible cracks along the length of a rib or ribs. Causes: ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Continuous exposure to high temperatures and the stress of bending around the pulleys leads to cracking. Cracks begin at the rib top and grow to the cord line. As a rule, if cracks appear 1 or 2 cm apart, 80% of the life is gone and the belt should be replaced. Chunk-Out ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Pieces or chunks of rubber material have come off the belt. When chunk-out has occurred, a belt can fail at any moment. Belt should be replaced immediately. Causes: ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Chunk-out can happen when several cracks in one area move parallel to the cord line. Heat, age and stress are the primary contributors. Pilling ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Belt material wears off from the ribs and builds up in the belts grooves. Causes: ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "There are a number of causes, including misalignment, new belt on worn pulleys, lack of tension or a combination of these factors. Gravel Penetration ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Small pinholes are visible on the backside of the belt. Bumps may be visible and fabric around the holes can be frayed. Causes: ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Granular gravel or pebble gravel is wedged between the belt groove(s) and pulley ridge(s). Damaged Outermost Ribs ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Sidewalls of the belt may appear glazed or the edge-cord may become frayed and ribs removed. A noticeable noise may result. Causes: ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Pulley misalignment is a common cause of premature belt failure. Misalignment forces the belt to twist while running, causing premature wear. Oil Contamination ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "The belt surface is flaky, sticky or swollen. Causes: ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Oil and grease are a rubber compound\u2019s worst enemies, weakening the compound\u2019s bonds and making the belt soft and spongy. Eventually, such a belt will slip, create heat and fail. Abrasion ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "The backside of the belt appears very shiny or glazed. In advance stages, the fabric or even the cord becomes exposed and gets damaged. Causes: ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "When in motion, the belt makes contact with the foreign objects in its path such as a flange or bolt. This may be caused by improper belt tension or by belt flutter (vibrations) on longer span lengths between two pulleys. Rib Separation ",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "The belt rib shears off or begins to separate from the belt base. Causes: ",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "The belt is not correctly positioned. One of the belt ribs is placed outside the pulley groove, causing a belt rib to run without a supporting or aligning pulley groove. Uneven Rib Wear ",
+ "file": null,
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Wear that is more severe on one rib than on the others or one rib that exhibits a different wear pattern than the others. A thumping or grinding noise may also be heard. Causes: ",
+ "file": null,
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "A foreign object \u2014 such as a pebble \u2014 in the pulley will cause uneven wear and cut into the belt and break the tensile cords. Broken Belt ",
+ "file": null,
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "A large foreign object between the belt and pulley can cut into the belt and break the tensile cords. Tensile break may occur but go unnoticed when the belt is forced or pried on during installation. Other possible causes may be severe shock loads or a blocked pulley and/or accessory. Belt Noise ",
+ "file": null,
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "Inspection: ",
+ "file": null,
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Run the engine and inspect for Chirping, squealing. tapping, ticking or grinding noise coming from the belt. It is recommended to remove & check the drive belts thoroughly if any abnormality noticed. Check belt tension as per procedure mentioned below: ",
+ "file": null,
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Turn ON belt tension gauge. Select reading mode in hertz (Hz) and hold the probe approximately 5mm distance in front of the belt. Do not touch the probe to the belt, this can damage the probe. Belt tension needs to be checked at the green points shown in illustration. Between Crank pulley & water pump pulley. Between water pump pulley & AC Compressor Pulley. Tap on the belt near the probe. Note the reading, if the reading is within 195 \u2013 228 Hz, belt tension is OK. If the reading is not within the above limit, check & replace the belt if required.
2. Open the bonnet and lock it in open position using bonnet stay rod.
",
+ "file": null,
+ "display_order": 86
+ }
+ ]
+ },
+ {
+ "procedure_name": "Accessory Drive Belt Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W383.jpg",
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen and remove the engine feed cover mounting bolts. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 89
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W384.jpg",
+ "display_order": 90
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the engine feed cover from engine compartment. Using a 24 mm socket spanner, rotate the crank pulley 360\u2070 till belt completes one full rotation to check belt condition and confirm following belt appearances if any. Random Cracking Across the Ribs ",
+ "file": null,
+ "display_order": 95
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Small yet visible cracks along the length of a rib or ribs. Causes: ",
+ "file": null,
+ "display_order": 98
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Continuous exposure to high temperatures and the stress of bending around the pulleys leads to cracking. Cracks begin at the rib top and grow to the cord line. As a rule, if cracks appear 1 or 2 cm apart, 80% of the life is gone and the belt should be replaced. Chunk-Out ",
+ "file": null,
+ "display_order": 101
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 102
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Pieces or chunks of rubber material have come off the belt. When chunk-out has occurred, a belt can fail at any moment. Belt should be replaced immediately. Causes: ",
+ "file": null,
+ "display_order": 104
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Chunk-out can happen when several cracks in one area move parallel to the cord line. Heat, age and stress are the primary contributors. Pilling ",
+ "file": null,
+ "display_order": 107
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 108
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Belt material wears off from the ribs and builds up in the belts grooves. Causes: ",
+ "file": null,
+ "display_order": 110
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "There are a number of causes, including misalignment, new belt on worn pulleys, lack of tension or a combination of these factors. Gravel Penetration ",
+ "file": null,
+ "display_order": 113
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 114
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Small pinholes are visible on the backside of the belt. Bumps may be visible and fabric around the holes can be frayed. Causes: ",
+ "file": null,
+ "display_order": 116
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Granular gravel or pebble gravel is wedged between the belt groove(s) and pulley ridge(s). Damaged Outermost Ribs ",
+ "file": null,
+ "display_order": 119
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 120
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Sidewalls of the belt may appear glazed or the edge-cord may become frayed and ribs removed. A noticeable noise may result. Causes: ",
+ "file": null,
+ "display_order": 122
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Pulley misalignment is a common cause of premature belt failure. Misalignment forces the belt to twist while running, causing premature wear. Oil Contamination ",
+ "file": null,
+ "display_order": 125
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 126
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "The belt surface is flaky, sticky or swollen. Causes: ",
+ "file": null,
+ "display_order": 128
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Oil and grease are a rubber compound\u2019s worst enemies, weakening the compound\u2019s bonds and making the belt soft and spongy. Eventually, such a belt will slip, create heat and fail. Abrasion ",
+ "file": null,
+ "display_order": 131
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 132
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "The backside of the belt appears very shiny or glazed. In advance stages, the fabric or even the cord becomes exposed and gets damaged. Causes: ",
+ "file": null,
+ "display_order": 134
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "When in motion, the belt makes contact with the foreign objects in its path such as a flange or bolt. This may be caused by improper belt tension or by belt flutter (vibrations) on longer span lengths between two pulleys. Rib Separation ",
+ "file": null,
+ "display_order": 137
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 138
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "The belt rib shears off or begins to separate from the belt base. Causes: ",
+ "file": null,
+ "display_order": 140
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "The belt is not correctly positioned. One of the belt ribs is placed outside the pulley groove, causing a belt rib to run without a supporting or aligning pulley groove. Uneven Rib Wear ",
+ "file": null,
+ "display_order": 143
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 144
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Wear that is more severe on one rib than on the others or one rib that exhibits a different wear pattern than the others. A thumping or grinding noise may also be heard. Causes: ",
+ "file": null,
+ "display_order": 146
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "A foreign object \u2014 such as a pebble \u2014 in the pulley will cause uneven wear and cut into the belt and break the tensile cords. Broken Belt ",
+ "file": null,
+ "display_order": 149
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 150
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 151
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 152
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "A large foreign object between the belt and pulley can cut into the belt and break the tensile cords. Tensile break may occur but go unnoticed when the belt is forced or pried on during installation. Other possible causes may be severe shock loads or a blocked pulley and/or accessory. Belt Noise ",
+ "file": null,
+ "display_order": 155
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "Inspection: ",
+ "file": null,
+ "display_order": 156
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Run the engine and inspect for Chirping, squealing. tapping, ticking or grinding noise coming from the belt. It is recommended to remove & check the drive belts thoroughly if any abnormality noticed. Inspect the auto-tensioner carefully for symptoms such as cracked arms, excessive vibration during idle speeds, looseness, noise (clatter or rattling) and sticking or seized operation. These all can be signs that roller needs replacement. Rust bleed and cracks ",
+ "file": null,
+ "display_order": 163
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 164
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Rust bleeding between arm and base or dripping from the tensioner. Also, check the tensioner for cracks or damage to arm, housing and bracket. Causes: ",
+ "file": null,
+ "display_order": 166
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Rust bleeding or dripping is a sign of internal component wear. Most common crack damage occurs at tensioner \u201cStops\u201d and mounting bolts. Solution: ",
+ "file": null,
+ "display_order": 168
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Replace the auto-tensioner. Pulley bearing wear ",
+ "file": null,
+ "display_order": 171
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 172
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "If any abnormality noticed, remove the belt and manually rotate the pulley. If you notice, resistance or roughness, the problem is likely to be pulley bearing wear. Causes: ",
+ "file": null,
+ "display_order": 174
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Defective bearing and/or pulley. Solution: ",
+ "file": null,
+ "display_order": 176
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Replace the complete tensioner. Do not attempt to replace a worn pulley in a used tensioner assembly but always replace the entire tensioner assembly, as part failure will inevitably follow quickly. TENSIONER ASSEMBLY MISALIGNMENT ",
+ "file": null,
+ "display_order": 180
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 181
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Abnormal belt tracking on tensioner pulley. Causes: ",
+ "file": null,
+ "display_order": 183
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Bent or misaligned mounting bracket,improper tensioner installation or corrosion/ contamination between tensioner base and mounting surface. A small amount of contamination results in a large amount of at tensioner pulley. Tensioner Noise ",
+ "file": null,
+ "display_order": 185
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 186
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Squeaks and rattles coming from the tensioner. Causes: ",
+ "file": null,
+ "display_order": 188
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Failure of bearings or pivot are will cause excessive noise. Solution: ",
+ "file": null,
+ "display_order": 190
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Replace the tensioner assembly. The crankshaft speed sensor is an hall effect type sensor. It measures the speed of the trigger wheel mounted on the crankshaft. During engine cranking and running, the EMS ECU receives the output signal from crankshaft speed sensor. Remove Air Cleaner Assembly. For additional information refer to Air Cleaner Assembly - R &R; section. Remove Steering Lower Intermediate Shaft. For additional information refer to Steering Lower Intermediate Shaft - R &R; section. Place the MST 0306GAM0006ST \u2013 Drive Belts Removal Tool on damper pulley side as shown in the image. Using a 24 mm socket spanner, rotate the damper pulley to clockwise direction then remove the water pump drive belt and MST 0306GBH0001ST \u2014 Drive Belts Removal Tool separately. Disconnect AC compressor electrical connector. Using 12 mm socket spanner, Unscrew AC compressor mounting bolts and keep aside the compressor. Torque : 23 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010240.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect engine speed sensor electrical connector detach it from holding clip. Using 10 mm socket spanner unscrew engine speed sensor mounting bolt and remove sensor. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Notice",
+ "content": "Take sufficient care not to damage the sensor while removing. Ensure proper torque value is applied to sensor mounting bolt. Else chances of sensor malfunction is high. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Inspect the sensor and connector for any physical damage. Replace if found. EMS (Engine Management System) ECU is an electronic control unit which is used to ensure optimal engine performance. It does this by analyzing values or signals from various sensors and other ECU\u2019s and adjusting the actuators accordingly. EMS ECU is mounted on front left side apron in the engine compartment. ECU electrical connector should be disconnected before carrying out any welding activities in the vehicle. Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010243.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Open the lock and gently pull-out and disconnect EMS ECU electrical connector. Using 10 mm socket spanner remove EMS ECU mounting bolts. Torque : 6 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. For New EMS ECU replacement carry out Necessary Procedures by using iSMART. For additional information refer Diagnosis Manual. ECU electrical connector should be disconnected before carrying out any welding activities in the vehicle. Check for any external damage, if found replace. Engine Oil \u2013 MAHINDRA 'MAXIMILE ULTRA' Gen-NXT Technology Genuine Engine Fluid. Capacity \u2013 6.0 Liters.
2. Position the vehicle on ground level/ 2 post lift/ 4 post lift and turn engine OFF.
3. Open the bonnet and lock it in open position using bonnet stay rod.
",
+ "file": null,
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Draining",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1501.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the engine top encapsulation cover. Remove the engine oil filler cap. Using 22 mm ring/ socket spanner, Unscrew engine oil drain plug located under the oil sump. Allow the entire oil to get drained. Place a tray under the drain plug to collect the oil. Refit the drain plug with a new copper washer and tighten the drain plug to specific torque. Torque : 25\u201330 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Always replace the copper washer with a new one. Fill fresh recommended oil to specified quantity. Refit the engine oil filler cap. Refit the engine encapsulation cover. Pull out the dip stick gauge and wipe it clean with a cloth/paper. Insert the dip stick gauge into the dip stick guide fully till the end. Pull out the dip stick slowly and check for the oil level mark between Maximum and Minimum level - if found below minimum level, top up with recommended oil. Insert the dip stick back and fix properly. Start the engine and check for oil leakage/ seepage at: Oil sump & crankcase joint. Oil sump drain plug. Oil filter joint. Always use MAHINDRA 'MAXIMILE ULTRA'Gen-NXT Technology GENUINE ENGINE Fluid. This is specially developed for your engine\u2019s efficiency. In extreme cases of emergency and non-availability of above oil, we suggest to use 'Maximile Feo' engine oil, take the vehicle to nearest Mahindra Authorised Service centre and replace the oil with 'MAXIMILE ULTRA'. No other brand / grade oil recommended. The knock sensor converts mechanical oscillations of the cylinder block into electrical impulses which can then be processed by the EMS ECU. The Knock sensor consists of piezo-ceramic crystals that generate a voltage when subjected to a mechanical load. Disconnect the knock sensor electrical connector. Using 12 mm socket spanner, Unscrew Knock sensor mounting bolt and remove sensor. Torque : 20 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the knock sensor for any physical damage. If found replace. Oil Pressure sensor operates the low oil pressure indicator in the cluster. This serves as a warning indicator to the driver, indicating a decrease in the oil pressure which might harm the engine if driver continues running the engine. The Oil Pressure Sensor is A Piezo \u2013 Resistive type sensor. It Sends oil pressure values to EMS ECU. Disconnect the oil pressure sensor electrical connector. Using 24 mm socket spanner, Loosen and remove the oil pressure sensor from OCFM. Torque : 20 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Check engine oil level, Top up engine oil and check for oil leakage. Check oil pressure sensor for any cracks, damage etc, replace if found any. Drain the coolant. For additional information refer to coolant drain procedure. Remove CATCON Assembly. For additional information refer to CATCON Assembly - R &R; section. Remove Engine Feed Cover. For additional information refer to Engine Feed Cover - R &R; section. Remove Air Cleaner Assembly. For additional information refer to Air Cleaner Assembly - R &R; section. Using the MST 0306GAM0006ST - Stretch Fit Belt Removal Tool Remove the Water Pump Drive belt. Using 7 mm socket spanner, Loosen radiator outlet hose clip and detach hose water inlet pipe end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010506.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew degassing tank coolant filling pipe mounting bolt OCFM end. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010507.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew heater outlet pipe routing bracket mounting bolt engine block end. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010508.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew heater outlet pipe routing bracket mounting bolt cylinder head end. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010509.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 10 mm combination spanner, Unscrew heater outlet pipe mounting bolt and partially remove pipe. Torque :11\u00b11 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010592.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Disconnect AC compressor electrical connector. Disconnect oil pressure sensor electrical connector. Disconnect crank speed sensor electrical connector. Disconnect engine variable oil pump solenoid electrical connector. Using 12 mm socket spanner, Unscrew engine wiring routing bracket mounting bolt. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010515.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew Turbo wiring routing bracket mounting bolt. Torque : 10\u00b11 Nm ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1515.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew turbo coolant inlet and oil inlet mounting banjo bolts OCFM end. Torque : 18\u00b12 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010517.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release oil separator hose clamp clean hose end. Using 7 mm socket spanner, Loosen clean hose clip and detach hose turbo end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010519.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew OCFM rear mounting bolts. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010520.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew OCFM mounting bolt and strut. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Caution",
+ "content": "Replace New rubber gasket while refitting. Remove OCFM from engine compartment. Using a 10 mm socket spanner, Unscrew water pump pulley mounting bolts and remove pulley from water pump. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Notice",
+ "content": "Using a suitable tool hold the pulley then remove the water pump pulley. Using a 13 mm socket spanner, Unscrew water pump mounting bolts and remove the water pump from the OCFM. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Refill the engine oil and check for the oil leakage. Refill the engine coolant and carry-out de-aeration procedure. Check the OCFM for any external cracks, replace if found any. This vehicle is equipped with one autotensioner to maintain the accessory drive belt tension for Alternator and Power steering pump drive belt. It is mandatory to maintain belt tension through out the belt life in-order to have maximum efficiency and life. A tensioner is a device that applies a force to create or maintain recommended belt tension. ground level/ 2 post lift/ 4 post lift and turn engine OFF. 2. Open the bonnet and lock it in open position using bonnet stay rod. ",
+ "file": null,
+ "display_order": 6
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W128.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen and remove the engine feed cover mounting bolts. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W129.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the engine feed cover from engine compartment. Place the MST 0306GAM0006ST Stretch Fit Belt Removal Tool on dampe pulley side as shown in the image. Using a 24 mm socket spanner, rotate the damper pulley to clockwise direction then remove the water pump drive belt and MST separately. Place the MST 0306GBH0001ST - Stretch Fit Belt Installation Tool on damper pulley as shown in the image. Using a 24 mm socket spanner, rotate the damper pulley in anticlockwise direction. By rotating pulley, belt started getting into pulley groove and once belt installed properly on pulley, then remove the MST and spanner. Ensure proper engagement of belt teeth in all the pulley grooves after Installation. Check the Belt tension. Refer Belt Tension Checking Procedure session below. Refit the engine fead cover on engine compartment, torque tighten the bolts to specified value. Torque : 11\u00b1 1Nm ",
+ "file": null,
+ "display_order": 27
+ }
+ ]
+ },
+ {
+ "procedure_name": "Checking Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W137.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W138.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Check belt tension as per procedure mentioned below: ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Run the engine for few minutes. Turn ON belt tension gauge. Select reading mode in hertz (Hz) and hold the probe approximately 5mm distance in front of the belt. Do not touch the probe to the belt, this can damage the probe. Belt tension needs to be checked at the green points shown in illustration. Between Crank pulley & water pump pulley. Between water pump pulley & AC Compressor Pulley. Tap on the belt near the probe. Note the reading, if the reading is within 195 \u2013 228 Hz , belt tension is OK. ground level/ 2 post lift/ 4 post lift and turn engine OFF. 2. Open the bonnet and lock it in open position using bonnet stay rod. ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11386.jpg",
+ "display_order": 36
+ }
+ ]
+ },
+ {
+ "procedure_name": "Accessory Drive Belt & Auto-tensioner Removal Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove AC Compressor /Water Pump Stretch Fit Belt. Using a 14 mm ring spanner, turn the hexagon knob in the belt tensioner counterclockwise direction to release the tension. Using 14 mm socket spanner, remove the alternator/power steering auto tensioner mounting bolt and remove the tensioner. Refit the new auto-tensioner assembly . Torque tighten the mounting bolt to specified value. Torque : 45 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W144.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1551.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 14 mm ring spanner, swing the auto-tensioner in counter-clockwise direction and install the belt. Refit AC Compressor /Water Pump Stretch Fit Belt. Remove Timing Chain. For additional information refer to Timing Chain - R &R; section. Align the MST \u2013 0310ABG0001ST Camshaft locking tool on the front side of engine in the camshaft slot as shown and fix the camshaft locking tool on cylinder head using appropriate bolts. Using 22 mm socket spanner, Loosen and remove Inlet CAM phaser mounting bolt Torque : 30 \u00b1 2 Nm + 34\u00b0\u00b1 3\u00b0 ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11648.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. While Installation, Check Exhaust Cam phaser mounting bolt tightening torque first and then torque tightened the Intake Cam phaser mounting bolt. Inspect the CAM Phaser for any physical damage. If found replace. The cylinder compression test is performed to determine the compression pressure of individual cylinders. The test is performed in two stages. 1. Dry Test. 2. Wet Test. The results of the cylinder compression test can be utilized to diagnose several engine malfunctions. Before carrying out the compression test ensures that the battery is in good working condition. Otherwise the indicated pressures may not be valid for diagnostic purpose. Check engine oil level and add oil if necessary. Drive the vehicle until engine reaches normal operating temperature. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Remove all the spark plug. Fit the appropriate adaptor in one cylinder at a time and connect it with the compression gauge. Disconnect the cam phase sensors electrical connector. Note down the max value the gauge indicates. Repeat the procedure for all the other cylinders. Refer to the specification for the value. The variation between the cylinders should not be more than \u00b1 0.5 Bar. Spray 10 to 20 ml of engine oil inside the bore through the spark plug port with the help of an oil can. Fit the appropriate adaptor in one cylinder at a time and connect it with the compression gauge. Disconnect the cam phase sensors electrical connector. Note down the maximum value displaying in the gauge. Repeat the procedure for all the other cylinders. Refer to the specification for the value. Compare both the dry and the wet values with the specifications. The wet test values should always be higher than the dry test values. If the reading does not change during wet test this can hint towards compression leakage from cylinder head or through the valves. If the wet and dry test values vary considerably between cylinders then the piston rings can be suspected. A gasoline engine cylinder head performs several functions. They provide the top seal for the cylinders bore and the air fuel mixture in this location. They provide structure holding the Valves, ignition coil, camshaft, spark plugs and other components. The cylinder head is construct with cross flow cooling system. It has inclined ignition coil bore and integral intake and exhaust VVT. Remove the Spark Plug. For additional information refer to the Spark Plug - R &R; section. Drain the engine coolant. For additional information refer to coolant draining procedure. Remove the HLA assembly. For additional information refer to the HLA Assemblies \u2013 R &R; section. Using 7 mm socket spanner, Loosen Inter cooler outlet hose clip and detach intercooler end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010556.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew dipstick guide mounting bolt. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010558.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew intake manifold mounting bolts and remove Intake manifold With Throttle Valve & Inter cooler outlet hose. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1517.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect fuel rail electrical connector. Disconnect injector electrical connector. Using 12 mm socket spanner, Unscrew fuel rail mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040123.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove fuel rail with Injectors. Injectors Combustion Seals should be replaced with new ones when ever removing & refitting the Fuel Rail Assembly from the cylinder head. For more information refer to Fuel Rail Assembly \u2013 R &R; section in Fuel System. If Injector/Injectors struck with Cylinder Head and not able to remove from head, Injector can be removed by using Injector removal tool. For more information refer to Injector \u2013 R &R; section in Fuel System. Remove the Turbocharger. For additional information refer to the Turbocharger - R &R; section. Using hose clip plier release coolant vent hose clip and detach hose engine head end. Using 10 mm socket spanner, Unscrew heater inlet pipe routing bracket mounting bolt cylinder head end. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010555.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew heater inlet pipe mounting bolt cylinder head end and detach pipe. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010562.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew heater outlet pipe routing bracket mounting bolt cylinder head end. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010563.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Disconnect coolant temperature sensor electrical connector. Using 19 mm deep socket spanner, unscrew Coolant temperature sensor. Torque : 20 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010565.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Remove alternator top mounting bolt. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010566.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Loosen alternator top mounting bolt/nut and rotate alternator. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010567.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Remove CAM shafts front lower bearing cap. Using 15 mm socket spanner, Loosen and remove cylinder head mounting bolts. Torque : 60 \u00b1 6 Nm + (2x95\u00b0) \u00b1 5\u00b0 ",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010569.jpg",
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010570.jpg",
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010572.jpg",
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Remove the cylinder head from engine. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010158.jpg",
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010825.jpg",
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010829.jpg",
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11566.jpg",
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Always replace the cylinder head gasket with a new one when installing. Remove the foreign materials and the gasket residual on the top surface of the cylinder block and cylinder head before installing the cylinder head gasket. Apply fresh engine oil on the head gasket while Installation. Head gasket with the mark of \u201cTC\u201dand gasket part number must be directed towards the cylinder head. When installing the mounting bolts : from the center to the outside diagonally. Do not reuse the mounting bolts for the cylinder head, Always replace the mounting bolts New ones while installing head assembly. Tighten the cylinder head mounting bolts to the specified torque and specified sequence. Refill the engine coolant. For additional information refer to Coolant refilling and Deaeration procedure. Check for coolant seepage and any oil seepage on the engine. Rectify if any traces found. Clean the cylinder head assemblies thoroughly, replace it if any cracks or damages are found. Check the Cylinder Head for external damages. Check the cylinder head height and if not meeting the specified value, replace the cylinder head assembly. Check the Cylinder Head bottom face for distortion. Using 10 mm Allen key, loosen and remove rear axle filler plug. Using 10 mm Allen key, remove rear axle drain plug and drain the entire oil. Wait till the entire oil get drained. Place a tray beneath the rear axle for collecting the oil while draining. Using 13 mm and 16 mm ring and open end spanners unscrew rear propeller shaft mounting bolts and nuts rear axle end. Torque : 65 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "By using Special tool MST 203\u2013Companion Flange Holding Tool, hold the companion flange and Using 32 mm deep socket spanner loosen and remove the companion flange mounting nut. Remove the companion flange using mallet. If companion flange shows wear in the area of seal contact, it should be replaced. Remove the pinion oil seal by using screw driver. Ensure not to damage the oil seal mating surface while remove the Oil seal. Using MST 0502AUA0004ST Rear Axle Pinion Oil Seal Installer, Place and Press New oil seal uniformly on banjo gear carrier housing. Apply a light coat of oil to the lip of oil seal before installation. Install the dust cap, companion flange on the banjo housing and Install the new mounting nut with washer. Always use new flange mounting nut once it removed. Hold the companion flange Using MST203 Companion Flange Holding Tool and torque tighten the companion flange mounting nut. Tighten nut to incremental torque from 270 Nm onwards to 330 Nm until specified PTTR ( Pinion torque to rotate) is achieved. Measure the Pinion Rotational Torque (PTTR), It should be within 2.5 - 3.5 Nm. Attach the propeller shaft to the rear axle with mounting nuts, torque tighten it to the specified value. Torque : 65 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit the drain plug and torque tighten to specified value. Clean the drain plug and differential housing with a clean cloth before refitting. Torque : 47 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refill specified quantity of recommended differential oil into differential assembly. Never reuse drained oil. Always use recommended oil only. Never mix different types of oil and use. Clean filler plug area properly using acloth before filling the oil. Check the oil level and ensure its up to the level. Ensure that the oil level is up to lower most point of the filler plug. Refit the filler plug back and torque tighten to mounting plug specified value. Clean the filler plug with a clean cloth before refitting. Torque : 29 \u00b1 5Nm ",
+ "file": null,
+ "display_order": 55
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 122,
+ "sys_id": "THAR.AX-0006-Rear Axle",
+ "subsys_id": "THAR.AX-0006-Rear Axle-Troubleshoot - Rear Axle",
+ "systems": "Rear Axle",
+ "sub_systems": "Troubleshoot - Rear Axle",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1464,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Troubleshoot - Rear Axle-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Trouble Shooting",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Certain rear axle and driveline trouble symptoms are also common to the engine, transmission, tyres and other parts of the vehicle. For this reason be sure that the cause of the trouble is in the rear axle before adjusting, repairing or replacing any of the axle parts. Basic characteristics in a rear axle are more difficult to diagnose and repair than mechanical failures. Slight axle noise heard only at certain speed or under particular conditions must be considered normal. Axle noise tend to peak or be more pronounced at particular speeds and the noise is in no way a sign of the trouble in the vehicle. Where noise is present in objectionable form (Loud and/ or at all speeds) the first effort should be to isolate the noise. Isolation of noise in any one unit requires care and experience and an attempt to eliminate a slight noise may baffle even the most experienced mechanic/ technician. Before diagnosing the whine as axle gear noise, ensure that the whine:
Occurs in direct transmission ratio (4th gear). Changes with throttle/ accelerator variations (drive and coast) (i.e. driving in neutral with the clutch released and engine running). Always occur at the same road speed and not engine speed. Occurs over a limited vehicle speed. (This can vary over a wide band should the axle be in extremely bad condition.).
",
+ "file": null,
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Bearing Noise",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Bearing noise is inclined to be less throttle sensitive than gear noise and frequently occurs over a wide speed range. Bad cases of faulty bearings can, in fact be detected from walking speed, building up in pitch as speed increases and is not directly affected by changing from drive to coast (i. e., driving in neutral with the clutch released and engine running) and vice versa.
2. A high spot sometimes occur on either the ring gear or the drive pinion; this shows up as a ticking or light knocking noise over a restricted range of throttle position. The frequency of the noise will indicate whether the high spot is on the pinion (drive shaft frequency) or on the ring gear. The severity of the noise indicates the size of the defect. A light \u201ctick\u201d is seldom detrimental and usually occurs in new axle and will normally disappears once the axle has been run in.
3. Louder noise usually indicates a more serious defect and a knock occurring in an axle which was previously free from this type of noise must always be investigated.
",
+ "file": null,
+ "display_order": 6
+ }
+ ]
+ },
+ {
+ "procedure_name": "Trouble Shoot",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/14501.pdf",
+ "display_order": 7
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 118,
+ "sys_id": "THAR.AX-0006-Rear Axle",
+ "subsys_id": "THAR.AX-0006-Rear Axle-Rear Axle Inboard Oil Seal",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Axle Inboard Oil Seal",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A140054.jpg",
+ "myid": 1236,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Rear Axle Inboard Oil Seal-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140054.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31116.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31117.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the rear axle shaft. For additional information refer to Rear Axle Shaft RH - R &R; section. Using 0502CAA0012ST \u2014Puller Oil Seal Pinion /Flange Inbord-X ,remove the inboard oil seal. Refit in the reverse order of removal. Use a MST (0502BUA0001ST \u2014 Rear Axle Shaft Inboard Oil Seal Installer, during Installation. Check differential oil level, top up the oil if required. Carry out Parking Brake Adjustment. For additional information refer to Parking Brake Adjustment Section. Remove the rear axle shaft RH. For additional information refer to Rear Axle Shaft RH - R &R; section. Using circlip plier, remove the toner wheel circlip. By using hydraulic press, remove toner wheel along with Rear bearing carrier assembly. Take sufficient care not to damage the toner ring while removing. Remove the bearing from Rear bearing carrier. Replace the toner ring and bearing assembly once removed. Using a suitable tool, Remove the oil seal from Rear bearing carrier. Replace the outboard oil seal once removed. Refit in the reverse order of removal. Check differential oil level, top up the oil if required. Carry out Parking Brake Adjustment. For additional information refer to Parking Brake Adjustment Section. Remove rear brake drum LH and RH. For additional information refer to Rear brake drum LH and RH \u2013 R &R; section. Detach the hand brake cable from brake shoe. Remove the hand brake cable lock clip and detach the hand brake cable from back plate. Using 11 mm open end spanner, Loosen brake bundy tube flare nut wheel cylinder end. Torque : 16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 17 mm socket spanner, loosen and remove axle shaft mounting nuts. Torque : 35 \u2013 50 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using MST (0505AAA0001ST puller rear axle shaft banjo) remove rear axle shaft, dust shield with brake liner assembly from vehicle. To avoid the back plate falling down, using a plastic tag tie it with any other fixed member before the shaft is pulled out. Clean sealant on the axle housing flange, Back Plate and apply new sealant on the housing. Apply Locktite Sealant 5060 during Installation and Ensure that sealer bead is on the inside of screw holes as shown above. Bead must be 3 to 6mm high and 3 to 6mm wide. Refit in the reverse order of removal. Check differential oil level, top up the oil if required. Carry out Parking Brake Adjustment. For additional information refer to Parking Brake Adjustment Section.
2. Inspect the toner ring for any damage.
3. Inspect the rear wheel bearing for any damage.
4. Inspect the back plate for any damage.
",
+ "file": null,
+ "display_order": 25
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 112,
+ "sys_id": "THAR.AX-0006-Rear Axle",
+ "subsys_id": "THAR.AX-0006-Rear Axle-Rear Axle Oil - Replace",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Axle Oil - Replace",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.18,
+ "rts": null,
+ "mat": "J10-MAT-0340",
+ "cover_image": "/files/W4A140025.jpg",
+ "myid": 1230,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 23,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 46,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 111,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 151,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 193,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 234,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 276,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 292,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 359,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 396,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 443,
+ "kilometers_applicable": 0
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Rear Axle Oil - Replace-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Rear Axle Oil - Replace.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Rear Axle Oil \u2013Mahindra 'MAXIMILE ELITE' New Generation Genuine Differential Fluid. Capacity\u20132.0 Litres. using 10 mm allen key, loosen and remove rear axle filler plug. Using 10 mm allen key, remove rear axle drain plug and drain the entire oil. Wait till the entire oil get drained. Place a tray beneath the rear axle for collecting the oil while draining. Refit the drain plug and torque tighten to specified value. Clean the drain plug and differential housing with a clean cloth before refitting. Torque:47\u00b17Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refill specified quantity of recommended differential oil into differential assembly. Never reuse drained oil. Always use recommended oil only. Never mix different types of oil and use. Clean filler plug area properly using a cloth before filling the oil. Check the oil level and ensure its up to the level. Ensure that the oil level is up to lower most point of the filler plug. Refit the filler plug back and torque tighten to mounting plug specified value. Clean the filler plug with a clean cloth before refitting. Torque:29\u00b15Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Recommend to use only Mahindra 'MAXIMILE Elite' new generation genuine differential fluid. In case of non availability of 'Maximile' brand, other brands meeting API GL5, SAE 80W-90 specification can be used as second preference and oil change period should be reduced as 20,000 km. Drain the Rear axle oil. For additional information refer to Rear axle oil draining procedure. Remove the Rear Axle Carrier Assembly. Mount the Rear Axle carrier assembly on a suitable stand. Liquid sealant is used to seal carrier section with banjo beam. Clean the sealant on the carrier facing. Using a 17 mm socket spanner, loosen and remove the bearing cap mounting bolts and then remove the bearing caps. Using a Mallet, tap and detach the bearing caps. Identification marks are punched on bearing cap; this is to ensure correct bearing cap is installed on correct side. Ensure correct bearing caps used While reassembly. Pry out differential case from carrier with help of (MST 0502AAA0001ST - Tommy Bars) as shown in the illustration. Remove the shims from both the sides of differential case. Backlash shims are not to be interchanged during assembly. If Backlash shims are damaged, replace with new shims during assembly. There is no identification provided on the shim, Needs to be measured by micro meter. Remove the bearing caps from both the ends. Mount the (MST 0502AUA0013ST - R Axle Diff Case Bearing Puller Adapter) and (MST 0502AUA0012ST - Axle Bearing Puller) on side bearing cone as steps shown below. Remove the side bearing cone by tightening the screw rod using 24 mm ring spanner and remove the bearing cone from the differential case. Hold the top plate using 36 mm open end spanner while tightening. It is always preferred to replace side bearings, but one can confirm free rolling of bearings and reuse if they are defect free. Similarly remove ring gear other side bearing cone as steps shown below. Using 14 mm socket spanner remove the ring gear mounting bolts. Ring gear mounting bolts are opposite threaded. Loosen in clock wise direction. Tap ring gear with a mallet to free it from case If required and remove. Follow Steps 15 to 18 to remove Side Gears & Pinion Mate Gears for Open Differential. Using MST 0502AUA0033ST - Front Axle Diff Case Pin Remover &Installer; and hammer remove the differential gear locking pin. Using hammer and punch, Remove the differential shaft from differential case as shown in illustration. To remove side gears and pinion mate gears, rotate the side gears, this will allow the pinion mate gears to turn to opening of the case. Remove the pinion and side gears. Check the differential gear condition, any damage replaces it. Inspect cross pin for excessive wear, replace it if necessary. Always replace differential pinion gears and side gear both along with washer as a complete set. Do not mix new gears with old gears, as this may cause uneven wear and short gear life. Position the carrier assembly on the suitable stand to facing the companion flange side. Hold the companion flange using (MST 203\u2013 Companion Flange Holding Tool) and Using 32 mm deep socket spanner loosen and remove the companion flange mounting nut. Using mallet tap and remove the companion flange, washer and dust cup. If companion flange shows wear in the area of seal contact, it should be replaced. Using a mallet, tap the pinion assembly and remove the pinion assembly from the differential housing. Fit a nut of pinion before tapping to avoid thread damage. Hold the pinion with hand to avoid falling. Gear teeth have sharp edges. Handle gears carefully to avoid injury. Remove the collapsible Washer. Discard collapsible spacer. New one is required to be used during assembly Assemble (MST 0502AUA0014ST - R Axle Pinion Inner Bearing Puller Adapter) and (MST 0502AUA0012ST - Axle Bearing Puller) as shown in the illustration. Tighten the screw rod using 24 mm ring spanner to remove the pinion inner bearing. Hold the top plate using 36 mm open end spanner while tightening. Remove the pinion head bearing & remove the shims from the pinion. Collect shims and keep them together. Replace shims if found damaged. Remove the pinion oil seal by using screw driver. Ensure not to damage the oil seal mating surface while remove the Oil seal. Gently pull-out and remove the pinion outer bearing. Using suitable punch and hammer remove the outer bearing cap. Using suitable punch and hammer remove the inner bearing cap. Ring gear and pinion is supplied as a set. They are matched with each other during manufacture. Matching numbers on both pinion and ring gear are etched for verification. Refer Fig. A or Fig. B for more details. If a new gear set is used, verify numbers on pinion and ring for matching before proceeding with assembly. Standard mounting distance from center line of ring gear to back face of pinion is 109.525 mm . This dimension is controlled by selecting shims, which are positioned between the inner pinion bearing and pinion shoulder. Best running position of gear set is achieved by proper shim selection. On the bottom face of pinion, a number is etched. It can be a plus (+) number, a minus (-) number or Zero (0). Required pinion shim selection is achieved with help of this number. Pinion offset always in thou (1 thou = 0.0254 mm). Fig. A shows ring and pinion etched with inch identification. Fig. B shows ring and pinion etched with metric identification. If no offset on pinion face then assume it zero. Shims with different thicknesses are available for selection. Use tables below as a guide for selecting correct thickness of shims either for addition or for subtraction from old shim pack. TABLE \u2014 Pinion Shim Selection (Formula = Old Pinion offset \u2014 New Pinion offset) If Old Shim Not Available then below mentioned gauge method is recommended for Pinion Shim Selection. Position the rear axle housing on a suitable stand. Position the (MST 0502AUA0016ST - Rear Axle Pinion Height Master Block) over the inner bearing cup seating area as shown. Position the (MST 0502AUA0015ST - Rear Axle Pinion Height Setting Gauge) on the differential housing as shown. Using feeler gauge measure the distance between the MST\u2019s as shown and the value assumed as \u2018A\u2019 . For example consider the value obtained as 1.51 mm. Convert the obtained value in \u201cmm\u201d into \u201cThou\u201d (1.51x39 = 59 Thou). Now see the etched value on pinion, the value assumed as \u2018B\u2019 (For example consider the offset value as +4) Now to get the final shim size, the formula is Shim thickness (In Thou) = A \u2013 (+B or \u2013 B). i.e, (59 \u2013 4 = 55 Thau) Convert the Thou value to mm ( 55 x 0.0254 = 1.40 mm) , which is the final shim thickness required. Select shim pack based on Pinion Shim Selection Procedure to position the pinion at correct mounting distance as per value etched on pinion stem for best running position. Mount the pinion positioning shim pack on pinion. Position the pinion inner bearing on pinion & press the bearing by using (MST 0502AUA0017ST - R Axle Pinion Inner Brg Press Dolly). Insert a new collapsible spacer. Collapsible spacer should rest in between pinion inner and outer bearing and it can be fitted in any direction. Always use new collapsible spacer, never use old one. Install the Inner bearing cup by using (MST 0502AUA0018ST - Pinion Inner bearing cup installer) and (MST 0707BBA0003ST - Universal mandrel) on banjo gear carrier housing. Install the Outer bearing cup by using (MST 0502AUA0019ST - Pinion outer bearing cup installer) and (MST 0707BBA0003ST - Universal mandrel) on banjo gear carrier housing. Install the pinion on the axle banjo housing and provide a support for pinion in the bottom. Using (MST 0502AUA0017ST - R Axle Pinion Inner Brg Press Dolly) and hammer press the pinion outer bearing. Place oil slinger on pinion outer bearing cone. Place and Press oil seal on banjo gear carrier housing using (MST 0502AUA0004ST - Rear Axle Pinion Oil Seal Installer). Apply a light coat of oil to the lip of oil seal. Install the dust cap into the companion flange. Install the companion flange on the banjo housing. Install the companion flange mounting nut. Hold the companion flange using (MST203 - Companion Flange Holding Tool) and torque tighten the companion flange mounting nut. Tighten nut to Initial torque as 270 Nm. Measure the Pinion Rotational Torque (PTTR), It should be within 2.5 - 3.5 Nm. If measured Pinion Rotational Torque (PTTR) not within 2.5 - 3.5 Nm, Then tighten nut to incremental torque from 270 Nm onwards to 330 Nm until specified PTTR ( Pinion torque to rotate) is achieved. Excessive care must be taken during bearing preload torque adjustment. Do not over tighten, loosen and then retighten nut. Do not exceed specified bearing preload torque . Measure and ensure the Final Pinion Rotational Torque (PTTR), It should be within 2.5 - 3.5 Nm. (PTTR SPEC : 2.5 to 3.5 Nm) If preload torque is exceeded, a new collapsible spacer must be installed and torquing sequence as above to be repeated. Follow Steps 17 to 20 to Install Side Gears & Pinion Mate Gears for Open Differential. Assemble both side gears and thrust washers, hold them in place with one hand and then assemble the pinion mate gears with thrust washer to hold the side gears in place. An easy way to assemble the side gears and pinion mate gears is to have all parts lubricated before assembly. Rotate the side gears until the holes of the spherical washers and pinion mate gears line up with the holes in the case by the help of engaging the splines of axle shaft to side gears. When both the cross bore hole matched and insert the differential shaft. Use a drift to line holes of the gears up with case. Assemble differential shaft and pull out drift. Be sure vertical lock pin hole is lined up with that of the case, and that pinion mate washers are in place and lined up with gear and case. Align the differential shaft hole, insert the lock pin and fix using (0502AUA0033ST - Differential gear lock pin removal tool) and hammer. Assemble ring gear to the differential case using mounting bolts. Tighten the bolts to specified torque value in recommended sequence. Always use new ring gear bolts. Ring gear mounting bolts have LH threads. While Installation torque in anti-clocking direction. Assemble (MST 0502AUA0020ST - Rear Axle Dummy Bearing) on to differential case. Place differential case assembly into housing. Push the differential case assembly towards the pinion side and insert the shims pack on the LH side (Back to ring gear) and Insert the shims pack on the RH side (Teeth side). Remove the shims (6 Thou) from LH Side and add to RH Side for backlash tolerance. Install dial gauge and locate tip of indicator on the surface of one of the ring gear teeth and measure the backlash at three equally spaced points (Each 120 degree rotation space), confirm the Backlash tolerance is (0.15 to 0.25 mm). Fix the Dial Gauge on Housing, Set the Dial Indicator 0 on Ring gear teeth as shown. Hold the pinion flange at the bottom side. Rotate the ring gear by using ring spanner & measure the backlash. Backlash variation at three points should not more than 30% . These corrections are made by switching shims from one side of differential case to other. High backlash is corrected by moving ring gear closer to pinion (Move Shims from RH to LH). Low backlash is corrected by moving ring gear away from pinion (Move Shims from LH to RH). Remove dial gauge and take out diff case & remove the dummy differential bearings. Press bearing on Differential case assembly by using (MST 0502AUA0021ST - R Axle Diff Case Brgs Pressing tool). Repeat the same procedure for installation of bearing on other side. Install the Differential bearing caps on both the sides. Install differential case assembly into carrier with the help of mallet. Carelessness while installing differential case assembly may result in injury. Install the shims on both the sides of differential case. Backlash shims are not to be interchanged during assembly. If Backlash shims are damaged, replace with new shims during assembly. Assemble bearing caps using mounting bolts. Ensure correct fitment of caps by matching letters on caps and carrier on either side. Tight the bearing cap bolts to specified value. Install dial gauge and locate tip of indicator on the surface of one of the ring gear teeth and measure the ring gear and pinion backlash at three equally spaced points (Each 120 degree rotation space), confirm the Backlash tolerance is (0.15 to 0.25 mm). Fix the Dial Gauge on Housing, Set the Dial Indicator 0 on Ring gear teeth as shown. Hold the pinion flange at the bottom side. Rotate the ring gear by using ring spanner & measure the backlash. Backlash variation at three points should not more than 30% . These corrections are made by switching shims from one side of differential case to other. High backlash is corrected by moving ring gear closer to pinion (Move Shims from RH to LH). Low backlash is corrected by moving ring gear away from pinion (Move Shims from LH to RH). If backlash is as per specification, check ring gear and pinion tooth contact pattern. If backlash is as per specification, check ring gear and pinion tooth contact pattern as below. The TOE of the gear is the portion of the tooth surface at the end towards the center. The HEEL of the gear tooth is the portion of the tooth surface at the outer-end. The TOP LAND of a gear tooth is the surface of the top of the tooth. Every gear has a characteristic pattern. Flat face of the carrier assembly and flat surface of the banjo beam must be free of any oil film or foreign material. Apply Locktite RTV Sealant 5060 to flat surface of banjo beam. Ensure that sealer bead is on the inside of bolt holes. Bead must be 3 to 6 mm high and 3 to 6 mm wide. Refit the Differential Carrier Assembly. For additional information refer to Differential carrier assembly R &R; section. Fill the differential fluid. For additional information refer to Differential fluid filling procedure. Drain the rear axle oil. For additional information refer to rear axle oil draining procedure. Remove the Rear Axle Shaft Assembly LH . For additional information refer to Rear Axle shaft Assembly LH \u2013 R &R; section. Remove the Rear Axle Shaft Assembly RH . For additional information refer to Rear Axle shaft Assembly RH \u2013 R &R; section. Using 14 mm socket spanner, Unscrew rear propeller shaft mounting bolts and detach propeller rear end and properly hang the shaft. Torque : 65 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew gear carrier to banjo housing mounting bolts. Using 17 mm socket spanner, Unscrew rear stabilizer bar bracket mounting bolts and detach the bracket partially. Torque tightening should be done without load and with the tyres on level ground. Ensure to add washer only for bottom mounting of stabilizer bar. Torque : 70 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 5 mm allen key, hold the rear stabilizer bar link bottom mounting then using a 18 ring spanner, loosen and remove the top mounting nut from stabilizer bar. Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140038.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Remove the rear axle gear carrier from vehicle. Clean the sealant on the gear carrier. Refit in the reverse order of removal. Apply Locktite Sealant 5060 during Installation and Ensure that sealer bead is on the inside of screw holes and pattern as shown below. Bead must be 3 to 6 mm high and 3 to 6 mm wide. Refill the rear axle oil. For additional information refer to Rear Axle Oil Refilling procedure.
2. Check the axle case for yield, deformation or cracks, replace if necessary.
",
+ "file": null,
+ "display_order": 31
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 116,
+ "sys_id": "THAR.AX-0006-Rear Axle",
+ "subsys_id": "THAR.AX-0006-Rear Axle-Rear Toner Wheel",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Toner Wheel",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A140048.jpg",
+ "myid": 1234,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Rear Toner Wheel-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140048.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31098.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31099.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the rear axle shaft assembly. Using circlip plier, remove the toner wheel circlip. By using hydraulic press, remove toner wheel along with Rear bearing carrier assembly & dust shield. Take sufficient care not to damage the toner ring while removing. Replace the toner ring and bearing once removed. Refit in the reverse order of removal. Check differential oil level, top up the oil if required. Carry out Parking Brake Adjustment. For additional information refer to Parking Brake Adjustment Section.
2. Inspect the Rear bearing carrier assembly for any damage, Replace if necessary.
",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 113,
+ "sys_id": "THAR.AX-0006-Rear Axle",
+ "subsys_id": "THAR.AX-0006-Rear Axle-Rear Axle Assembly",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Axle Assembly",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A140025.jpg",
+ "myid": 1231,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Rear Axle Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140025.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31051.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31052.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove rear brake drum LH and RH. Remove the hand brake cable lock clips from both the sides (LH & RH) and detach the hand brake cables from back plate. Remove the hand brake holding spring on the axle from LH & RH side. Remove the bundy tube rear hose to LH wheel. For additional information refer to Bundy Tube Rear Hose to LH Wheel - R &R; section. Remove the bundy tube rear hose to RH wheel. For additional information refer to Bundy Tube Rear Hose To RH Wheel - R &R; section. Remove the flexible hose LH & RH side locking from the axle. Using a 10mm socket spanner, Unscrew wheel speed sensor mounting bolts and detach the sensors. Torque:9\u00b11Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140015.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Provide a jack to support the rear axle assembly. Remove the rear propeller shaft. For additional information refer to Rear Propeller Shaft-R &R; section. Remove the stabilizer bar rear. For additional information refer to Stabilizer Bar Rear-R &Rsection.; Using a 24 mm socket spanner, loosen and remove the upper link mounting bolt/nut. Torque : 230 \u00b1 20 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170029.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 21mm ring spanner. Torque tightening should be done without load and with the tyres on level ground. Using a 24 mm socket spanner, loosen and remove the lower arm mounting bolt/nut. While loosening the nut, hold the bolt using 21mm ring spanner. Torque tightening should be done without load and with the tyres on level ground. Torque:230\u00b120Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using a 17 mm socket spanners, loosen and remove the both rear shock absorbers bottom side mounting bolts and nuts. Torque value: 110\u00b111Nm , Torque Wrench Type - Open end Torque Wrench ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. While loosening the nut, hold the bolt using 15mm ring spanner Remove the rear coil spring and pad securely from vehicle. Pay attention while Installation . Locking lug to be matched with hole on Rear Coil spring dome bracket of Chassis. Yellow coloured PU sleeve should be on chassis side while assembling the coil spring ashown in illustration. Carefully remove the rear axle assembly from vehicle. Refit in the reverse order of removal. Check differential oil level,top up the oil if required. All Suspension Torque tightening should be done without load and with the tyres on level ground.
2. Check the axle case for yield, deformation or cracks, replace if necessary.
3. Inspect rear axle for any oil leakage, seepage.
",
+ "file": null,
+ "display_order": 57
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 43,
+ "sys_id": "THAR.AX-0006-en-SM-Starting System",
+ "system_name": "Starting System",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1006,
+ "active_status": true,
+ "Assets": [
+ {
+ "systemdisplayorder": 5,
+ "system_asset": "/files/Security.mp4",
+ "active_status": true
+ }
+ ],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 45,
+ "sys_id": "THAR.AX-0006-Starting System",
+ "subsys_id": "THAR.AX-0006-Starting System-Ignition Switch",
+ "systems": "Starting System",
+ "sub_systems": "Ignition Switch",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A090001.jpg",
+ "myid": 1126,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Ignition Switch-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090001.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11801.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11802.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm combination spanner,loosen battery negative cable mounting nut and disconnect cable. 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the steering column shrouds. Disconnect the ignition switch electrical connection. Using a Small sizzle and hammer, hit and remove the key barrel screws. Use new screw while installing key barrel. Remove the Ignition key with ICU from the vehicle. Using a star screw driver, loosen and remove the ICU mounting screws then remove the ICU from the key barrel. Insert the key and turn the key into AC position. Cut the micro switch routing tag and detach the connector holding clip from the ICU. Install in reverse order of removal. Always use new mounting bolts while installing the Ignition Switch Assembly clamping unit. Inspect ignition key for crack or damage. Replace if found any. Inspect ICU for crack or damage. Replace if found any. This test can only be performed with starter motor removed from vehicle. Remove Starter Motor from vehicle. Disconnect wire from solenoid field coil terminal. Check for continuity between solenoid terminal and solenoid field coil terminal with a continuity tester. There should be continuity. If OK, go to Step 4. If not OK, replace faulty starter motor. Check for continuity between solenoid terminal and solenoid case. There should be continuity. If not OK, replace faulty starter motor. Remove the relay from fuse box. Once supply is given sound can be noticed which indicated control circuit is perfect.
If sound is not noticed, replace the relay.
",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using multi-meter, check continuity between pin number 30 & 87. (Power given to pin number 86 and earth given to pin number 85). If continuity is there, which indicates that the power circuit is perfect.
If Continuity is not there then replace the relay.
",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090048.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using multi-meter, check for continuity between pin numbers 30 and 87 (No power given to pin number 86 and no earth given to pin number 85). If continuity is there which indicates power circuit is NOT OK (Short internally).Replace the relay.
If continuity is not there, Relay is OK.
",
+ "file": null,
+ "display_order": 5
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 50,
+ "sys_id": "THAR.AX-0006-Starting System",
+ "subsys_id": "THAR.AX-0006-Starting System-Starting System Technical Spec",
+ "systems": "Starting System",
+ "sub_systems": "Starting System Technical Spec",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1131,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Starting System Technical Spec-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": "Starter Motor Specification ",
+ "file": "/files/11820.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Heading",
+ "content": "Starter Motor Specification ",
+ "file": null,
+ "display_order": 2
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 47,
+ "sys_id": "THAR.AX-0006-Starting System",
+ "subsys_id": "THAR.AX-0006-Starting System-Cranking Voltage Test",
+ "systems": "Starting System",
+ "sub_systems": "Cranking Voltage Test",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1128,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Cranking Voltage Test-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Cranking Voltage Test",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "The cranking voltage test measures the voltage available for ignition while the starting motor cranks the engine. Turn off the ignition, connect a voltmeter across the battery and crank the engine. Note the voltage reading. If the starting motor cranks normally and the voltmeter reads 9 volts or higher, cranking voltage is normal. Slow cranking with the voltage above 9 volts indicates high resistance in the motor circuit or starting motor Low cranking speed and low voltage may indicate a discharger battery. If the battery is charger, look for trouble in the starter motor or engine The following operation will require a voltmeter accurate to 1/10 (0.10) volt. The battery should be fully-charged. Engage the parking brake. Position the gearshift selector lever in the neutral position and lock the clutch pedal in the fully depressed position. Verify that all lamps and accessories are turned off. In-order to avoid the engine from starting, remove the starter relay. Connect the positive lead of the voltmeter to the battery negative terminal post and then connect the negative lead of the voltmeter to the battery negative cableterminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery negative cable terminal clamp and the battery negative terminal post. Connect the positive lead of the voltmeter to the battery positive terminal post. Connect the negative lead of the voltmeter to the battery positive cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery positive cable terminal clamp and the battery positive terminal post. Connect the voltmeter to measure between the battery positive cable terminal clamp and the starter solenoid terminal stud.Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt. Clean and tighten the battery positive cable eyelet terminal connection at the starter solenoid terminal stud. Repeat the test. If the reading is still above 0.2 volt,replace the faulty battery positive cable. Connect the voltmeter to measure between the battery negative cable terminal clamp and ground on the transmission. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery negative cable eyelet terminal connection to the engine block. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery negative cable. The starting motor is a device that converts electric energy into mechanical energy to generate rotational power, and transfers the energy required for starting the engine initially with this power.
The starter motor is composed of three parts, which are:
The solenoid, which moves the starter pinion by means of a fork and at the same time closes the power circuit to feed the electric motor. The direct current electric motor, which cranks the engine. The fork and pinion assembly, which makes the connection between the starter motor and the ring gear on the flywheel.
",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090047.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Component Location Index",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B090003.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25391.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25392.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm combination spanner, loosen battery negative cable mounting nut and disconnect cable. Using a 13 mm socket spanner, loosen and remove the battery positive cable mounting nut on starter motor end. Using a 8 mm socket spanner, loosen and remove the starter motor solenoid switch mounting nut on starter motor end. Torque : 2.5\u00b1 0.25 Nm Using a 14 mm socket spanner, loosen and remove the starter motor mounting bolts and remove starter motor from vehicle. Install in the reverse order of removal.
2. Check the starter motor external crack or damage. Replace if found any.
3. Check the starter motor internal gear crack or damage. Replace if found any.
",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 227,
+ "sys_id": "THAR.AX-0006-en-SM-Instrument Panel",
+ "system_name": "Instrument Panel",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1020,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 232,
+ "sys_id": "THAR.AX-0006-Instrument Panel",
+ "subsys_id": "THAR.AX-0006-Instrument Panel-IP Top Cover Assembly LH",
+ "systems": "Instrument Panel",
+ "sub_systems": "IP Top Cover Assembly LH",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A220020.jpg",
+ "myid": 1345,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-IP Top Cover Assembly LH-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220020.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12271.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12272.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Glove Box Assembly. Remove the IP grab handle cover. Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts. Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting screws. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle. Partially detach the door edge beading and using a trim removal tool, remove the IP LH side cover. By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt. Torque : 8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector. Take out the IP LH side top cover with Passenger air bag from the IP. Using a 10 mm ring spanner, loosen and remove the air bag mounting bolt from IP top cover. Torque :4.5\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Expand the PAB module holder both sides using screw driver and detach the PAB separately from IP top cover. Using a star screw driver, Unscrew LH side AC vent mounting screws. Carefully release the vent locking clips from the cover and detach the vent. Check for any external damages or damaged locking clips, Replace if necessary. Inspect the PAB module for any damage. Replace if found any. Inspect the PAB module connector for any damage. Inspect the PAB module trim for any damage. Remove the Combination Switch. For additional information refer to Combination Switch \u2013 R &R; Section. Remove the A Pillar Upper Trim LHS & RHS. Remove the Glove Box Assembly.> Using a trim removal tool, Remove the cluster bezel. Partially detach the door edge beading and using a trim Removal tool, Remove the IP side trim RH side. Using star screw driver, Unscrew Driver side top cover mounting screw and remove the cover. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220073.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew the cluster mounting screws. Torque : 2 \u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Partially Detach Cluster and disconnect the electrical connector. Remove the Instrument Cluster. Remove the Floor Console Assembly. Using trim removal tool, Remove IP side vertical trim LHS And RHS. partially detach the switch bang assembly and remove electric connector to take out from the vehicle. Detach the USB Docking station bezel and disconnect the electrical connectors. Disconnect Driver switch bank electrical connector. Remove the IP grab handle cover. Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts. Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting bolts. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle. Partially detach the door edge beading and using a trim removal tool , remove the IP side trim LH side. By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt. Torque : 8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector. Remove IP Speaker Grill from LH and RH Sides. Disconnect speaker electrical connectors from both the sides. Using a trim removal tool Detach the infotainment trims. Using a star screw driver, Unscrew the infotainment mounting screws. Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220085.jpg",
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Partially detach infotainment and disconnect the electrical connectors. Remove the infotainment from Instrument panel. Using 10 mm socket spanner, Unscrew instrument panel mounting bolts. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 77
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1004.jpg",
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1005.jpg",
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1006.jpg",
+ "display_order": 80
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1007.jpg",
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1008.jpg",
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290094.jpg",
+ "display_order": 83
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290095.jpg",
+ "display_order": 84
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "Description",
+ "content": "Carefully remove the instrument panel from vehicle. Install in the reverse order of removal. check for any external damages or damaged locking clips, Replace if necessary. Using trim removal tool remove the cluster bezel. Using a trim removal tool, remove the IP panel assembly driver side. Partially detach the door edge beading and using a trim removal tool, remove the IP RH side cover. Using star screw driver, Unscrew driver side IP cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the driver side IP cover. Using star screw driver, Unscrew AC vent mounting screws. Remove the RH side AC vent. Carefully release the vent locking clips from the cover and detach the vent. Install in the reverse order of removal. check for any external damages or damaged locking clips, Replace if necessary. Remove the Instrument Panel Assembly. Using a star screw driver, Unscrew the Instrument Panel AC & defroster Duct mounting screws and remove the ducts. Using a star screw driver, Unscrew IP driver switch bank mounting screws. Torque : 1.5 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the Driver Switch bank from Instrument Panel. Using a star screw driver, Unscrew IP centre air vent mounting screws. Remove the Centre Air Vents from Instrument Panel. Install in the reverse order of removal. check for any external damages or damaged locking clips, Replace if necessary. Using trim removal tool remove the cluster bezel. Using a trim removal tool, remove the IP panel assembly driver side. Partially detach the door edge beading and using a trim removal tool, remove the IP RH side cover. Using star screw driver, Unscrew driver side IP cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the driver side IP cover. Using star screw driver, Unscrew AC vent mounting screws. Remove the IP AC Vent RH. Carefully release the vent locking clips from the cover and detach the vent. ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220127.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. check for any external damages or damaged locking clips, Replace if necessary. Tools Required ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12152.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console RH screvits and detach the panel from vehicle Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220005.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console LH screvits and detach the panel from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220007.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Loosen and Remove Gear Knob and Transfer case shifter knobs Remove the gear shifter cover with trim Remove the rummier mat from the cup holder Remove the 4WD selection knob by rotating it in anti-clock wise direction. Pull and fold the gear shifter boot from gear shifter bezel. Partially detach the bezel from the console. Excessive pull may leads to damage of the electrical connector Disconnect the AT gaiter electrical connector from the bezel. Carefully remove the bezel trim from the TGS lever. Handle bezel assembly carefully to prevent it from damage or scratches. Using trim removal tool, carefully remove the floor console top trim with transfer case shifter boot Using 10 mm socket spanner, Unscrew floor console LH and RH side mounting bolts Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220048.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew floor console LH and RH side mounting screws Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220049.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Remove the bottle holder rubber mat Using 10 mm socket spanner, Unscrew floor console mounting bolts Using 10 mm socket spanner, Unscrew floor console LH and RH side mounting bolts Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220052.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Lift the floor console and disconnect the floor console electrical connector Remove the floor console from vehicle. Remove the power window switch assembly from floor console. Install in the reverse order of removal. Check floor console assembly for any damage, replace if found any. Remove the Instrument Panel Assembly. Using 10 mm socket spanner, Unscrew fuse box mounting bolts. Torque : 5.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect ignition key barrel electrical connector. Detach the bonnet cable from the lever. Using a 12 mm socket spanner, loosen the steering intermediate shaft top bolt and remove bottom mounting bolts and detach the intermediate shaft bottom from the steering column. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew steering column mounting bolts and nuts. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220108.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "using mm socket spanner, loosen and remove the Ip RH & LH speaker from Cross Car Beam. Torque : 3 \u00b1 1Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220109.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Disconnect the IP wiring routing clips and HVAC unit electrical connector. Remove the Scuttle Grill. Using 12 mm socket spanner, Unscrew CCB front facing mounting bolts. Using 13 mm socket spanner, Unscrew CCB bottom mounting bolts. Torque : 22\u00b13 Nm ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220115.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew CCB LHS & RHS mounting bolts/nuts. Torque : 22\u00b13 Nm ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220112.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew CCB LHS & RHS side bottom mounting bolts. Torque : 22\u00b13 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220118.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew CCB to HVAC unit mounting screws. Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Remove the Cross Car Beam from vehicle. Install in the reverse order of removal. check for any external damages, cracks or bends on the cross car beam, Replace if necessary. Tools Required ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12182.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200131.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Unlock glove box lock and remove the glove box assembly from IP Using star screw driver, remove the handle mounting screws Remove the glove box handle from the glove box assembly Install in the reverse order of removal. Check the glove box for damage, replace if necessary Using a 10 mm socket spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Glove Box Assembly. Remove the IP grab handle cover. Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts. Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting screws. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle. Partially detach the door edge beading and using a trim removal tool, remove the IP LH side cover. By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt. Torque : 8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector. Take out the IP LH side top cover with Passenger air bag from the IP. Using a star screw driver, Unscrew LH side AC vent mounting screws. Remove the IP AC Vent LH. Carefully release the vent locking clips from the cover and detach the vent. Check for any external damages or damaged locking clips, Replace if necessary. The tachometer indicates the real-time engine speed in thousands of RPM(revolutions per minute). Each division is 500 RPM. Operating the engine at very high RPM may lead to excessive engine wear and low fuel economy. Maintain steady engine speed below 2500 RPM and do not accelerate or decelerate abruptly. Do not over-accelerate the engine during idling, this can cause severe engine damage and would be treated as abuse of the engine which is not covered by warranty The speedometer indicates the real time road surface speed of the vehicle in kilometers per hour. The vehicle speedometer is affected by size of the tyres used. If the size of the tyres are changed from those fitted at the factory, the speedometer might not display the correct road surface speed and distance travelled Using trim removal tool, remove the cluster bezel mounting clips and remove the cluster bezel. Using trim removal tool, remove the IP side trim. Using star screw driver, Unscrew IP cover mounting screw and detach the IP cover using trim removal too. Using star screw driver, Unscrew instrument cluster mounting screw. Torque : 2 \u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect cluster electrical connector and remove instrument cluster. Refit in the reverse order of removal Check for any damage or crack, replace if found. Disconnect the TMC electrical connector then detach from the routing clips. Using 13 mm open end spanner, loosen and remove the TMC to EHCU Primary & Secondary bundy tubes from TMC side flare nuts. Torque :16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using hose clip plier, release brake fluid reservoir tank to clutch TMC hose clip then detach the hose. Using 12 mm combination spanner, Unscrew TMC mounting nuts and remove the TMC assembly from the brake booster. Torque : 16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130187.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Check and top up the brake fluid, If required. Carry-out the brake bleeding procedure. For additional information refer to Brake bleeding procedure. Check for master cylinder external damage, if found replace. Remove the front brake pad assembly. For information refer to front brake pad assembly \u2013 R &R; section. Using 14 mm socket spanner, loosen and remove the brake hose banjo bolt then detach the brake hose. Torque :24 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Replace the banjo bolt washers with new ones always while installation, else brake fluid leakage may happen. Using 19 mm socket spanner, loosen and remove the caliper assembly mounting bolts. Torque : 95 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the caliper assembly from the vehicle. Install in the reverse order of removal. Check and top up the brake fluid, If required. Carry-out the brake bleeding procedure. For additional information refer to Brake bleeding procedure. Inspect the caliper for any physical damage. Replace if found any. Using 13 mm open end spanners, loosen and remove the TMC to primary and secondary bundy tubes flare nuts on EHCU side. Torque :16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 11 and 13 mm open end spanners,loosen and remove the EHCU to FL,FR,RL, RR output bundy tubes flare nuts on EHCU side. Torque : 16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Carefully detach the bundy pipe without any bend. if the bundy tube bends, Constant pressure will not be maintained. Disconnect the EHCU electrical connector. Using 12 mm socket spanner, Unscrew air cleaner housing mounting bolts to partially detach and keep aside. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanners, Unscrew EHCU mounting bolts and remove the EHCU assembly with EHCU mounting bracket. Torque : 23 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner , Unscrew EHCU mounting nuts from the bracket. Torque : 8 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130196.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "After removing the bundy tubes from EHCU, seal each port of ECHU with dummy plugs to avoid dust entry Do not give any impact to hydraulic unit and take at most care not to allow dust to enter the hydraulic unit. Do not place hydraulic unit on its side or upside down. Handling it in inappropriate way will affect its original performance. Take sufficient care while installation and ensure correct bundy is connected to the specified inlet port.Use colour code for identification. Install in the reverse order of removal. Check and top up the brake fluid, If required. Carry-out the brake bleeding procedure. For additional information refer to Brake bleeding procedure. Check the EHCU for any external damage, if found replace. Using trim removal tool, remove the IP panel trim driver side. Using Nose plier, remove the R-clip and the clevis pin from the pedal shank. Using 12 mm socket spanner, loosen and remove the pedal box top mounting bolt. Torque :25 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the pedal box mounting nuts then remove the brake pedal box assembly. Torque :25\u00b15.0 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4D180003.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the brake pedal assembly for any physical damage. Replace if found any. Disconnect battery negative connector. Disconnect the wheel speed senor electrical connector. Detach the wheel speed sensor cable from the routing clips. Using 10 mm socket spanner, loosen and remove the wheel speed sensor mounting bolt then remove the sensor. Torque :9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130035.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the sensor for any physical damage. Replace if found any. Inspect the sensor for foreign particles segregation. Clean if found. Inspect the sensor connector for any damage. Remove the Floor Console. Using 10 mm open end spanner, loosen and remove the parking brake adjusting nut. Detach the parking brake cable from parking brake lever. Disconnect the parking brake switch electrical connector. Using 12 mm socket spanner, Unscrew parking brake lever assembly mounting nuts. Torque :25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the parking brake switch from parking brake lever assembly. Install in the reverse order of removal. Carry-out parking brake adjustment. For additional information refer to Parking brake adjustment section. Inspect the park brake lever for any physical damage. Replace if found any. Remove the front caliper assembly. Blow dry compressed air into the caliper gradually through the inlet port connected to banjo bolt, to gradually move the piston out of the caliper. Remove the piston from the caliper housing. Remove the dust cover from the caliper housing. Remove the rubber seal from the groove in the caliper housing. Piston Outer surface should be free from nicks, score or rust and should feel smooth to touch. Do not use emery paper on piston surface, Replace if found any. Caliper Housing bores should be free from score, pitting, and corrosion, Replace if found any. Carefully refit the rubber seal. Clean all the internal parts thoroughly with fresh brake fluid or alcohol. Do not use mineral oil like kerosene, petrol, diesel etc. If the piston does not move smoothly, remove it and examine the sealing ring for correct seating in its groove. Fit the other end of the piston boot on to the caliper housing. Refit the front caliper assembly. For additional information refer to Caliper assembly \u2013 R &R; section. Press the lock and disconnect the electrical connector from the brake switch. Place the brake pedal in release position. Turn the brake switch in anti-clock wise direction to get the brake switch free from adjuster lock. Insert the brake switch (A) in adjuster (B) till the switch plunger get completely pressed against brake pedal (at this point switch body will rest on brake pedal). Ensure no play between adjuster and the mounting bracket . Replace the adjuster if play is observed. While replacing new Switch with adjuster - Adjuster is to be snapped on mounting bracket. Ensure no play between the adjuster and mounting. Rotate the brake switch in clock wise direction till the switch gets locked. After locking the switch, the gap between the switch body and brake pedal will set to 1 \u00b10.15mm. Connect the brake switch electrical connector. Disconnect the brake switch electrical connector. Rotate the brake switch in anti-clockwise direction and remove the brake switch. Install in the reverse order of removal. Carry out brake switch adjustment setting. Inspect the brake switch for any damage. Replace if required. Inspect the connector for any damage. Check proper fitment of connector. 2 post lift/ 4 post lift and turn engine OFF.
2. Open the bonnet and lock it in open position using bonnet stay rod.
",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Clutch/Brake Fluid - Mahindra Maximile DOT 4 Genuine Brake fluid. Capacity - 1.75 Liters (Including bleeding quantity). Entire bleeding operation should be done with engine ON condition. In case of fluid reservoir or brake fluid replacement, bleeding of brake circuit is required. Always use recommended fluid and do not mix different brand fluids. Always use fresh and clean fluid from a sealed container. Do not pump the brake pedal at any time while bleeding (i. e. when the bleeding screw is opened). Air in the system will be further compressed into small bubbles and distributed throughout the hydraulic system and will result in additional bleeding operations. Do not reuse the drained fluid. Fluid level in the reservoir must be at MAX level at the start of bleeding and should be checked after bleeding each brake circuit and top up as required. Open brake fluid reservoir cap. Pull-out the bleeding nipple dust cap from both front & Rear (RH and LH) bleeding nipple. Connect a transparent tube into rear LH side bleeding nipple and using a 9 mm ring spanner, loosen the brake fluid nipple then allow the brake fluid to drain. Press the brake pedal gently to drain the fluid completely. Collect the brake fluid in the container and tighten the brake fluid nipple then detach the hose from bleeder nipple. Connect a transparent tube into rear RH side bleeding nipple and using a 9 mm ring spanner, loosen the brake fluid nipple then allow the brake fluid to drain. Press the brake pedal gently to drain the fluid completely. Collect the brake fluid in the container and tighten the brake fluid nipple then detach the hose from bleeder nipple. Connect a transparent tube into front LH side bleeding nipple and using a 8 mm ring spanner, loosen the brake fluid nipple then allow the brake fluid to drain out completely. Press the brake pedal gently to drain the fluid completely. Collect the brake fluid in the container and tighten the brake fluid nipple then detach the hose from bleeder nipple. Connect a transparent tube into front RH side bleeding nipple and using a 8 mm ring spanner, loosen the brake fluid nipple then allow the brake fluid to drain. Press the brake pedal gently to drain the fluid completely. Collect the brake fluid in the container and tighten the brake fluid nipple then detach the hose from bleeder nipple. Hand tighten all the bleeding nipples. Fill recommended brake fluid up to \u201cMAX\u201d mark on the brake fluid reservoir. Press and release brake pedal gently several times, so that brake fluid will get circulated throughout the circuit.
During the bleeding process, it has to be ensured that the fluid level in the reservoir does not drop below minimum. Refer the below illustration for the bleeding sequence. Connect a transparent tube into Rear LH side bleeding nipple and insert the other end of tube in a transparent container. Ensure other end of tube is submerged in liquid, else chances for air entry is high. Always use transparent tube for better visibility of air bubbles. Press and release the brake pedal 3 - 4 times gently to the full stroke and hold the pedal in depressed condition. Ensure proper quantity of brake fluid in the reservoir throughout the bleeding procedure. Using a 9 mm ring spanner, loosen the brake fluid nipple and allow the brake fluid to drain. Air bubbles will escape from brake circuit to container through transparent pipe and the bubbles will be clearly visible. Tighten the bleeder screw as soon as there is no air bubbles visible in the transparent tube. Continue procedure steps 2 - 4 till there is no air bubbles visible in the transparent tube. Remove the transparent tube and firmly tighten the brake fluid nipple. Follow steps from 1\u2013 6 for Rear RH side brake. Refit the bleeding nipple dust cap on both REAR RH and LH bleeding nipples. Connect a transparent tube into Front LH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Ensure other end of tube is submerged in liquid, else chances for air entry is high. Always use transparent tube for better visibility of air bubbles. Press and release the brake pedal 3 - 4 times gently to the full stroke and hold the pedal in depressed condition. Ensure proper quantity of brake fluid in the reservoir throughout the bleeding procedure. Using a 8 mm ring spanner, loosen the brake fluid nipple and allow the brake fluid to drain. Air bubbles will escape from brake circuit to container through transparent pipe and the bubbles will be clearly visible. Tighten the bleeder screw as soon as there is no air bubbles visible in the transparent tube. Continue procedure Steps 10 \u2013 12 till there is no air bubbles visible in the transparent tube. Remove the transparent tube and firmly tighten the brake fluid nipple. Follow steps from 9 \u2013 14 for Front RH side brake. Refit the bleeding nipple dust cap on both Front RH and LH brake bleeding nipples. Maintain recommended brake fluid up to MAX mark on the brake fluid reservoir. Refit the brake fluid reservoir cap. During the tool-bleeding process, ensure that the fluid level in the reservoir does not drop below minimum. Connect i-SMART diagnostic tester and turn the ignition \u201cON\u201d . Launch i-SMART Select ABS ECU and Navigate to Write Data. Routine screen will appear. Click on \u201cROUTINE SELECTION\u201d drop down list and select \u201cREPAIR BLEEDING\u201d. Click on \u201cSTART ROUTINE\u201d to initiate the tool bleeding. Ensure the fluid level in brake fluid reservoir is at \u201cMAX\u201d mark. Connect a transparent tube into rear LH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Loosen and open the rear LH bleeding screw and then press \u201cOK\u201d button. Click on \u201cYES\u201d button to proceed for \u201cBleeding phase I\u201d. The following pop up window appears once the \u201cBleeding phase I\u201d ends. Close the rear LH bleeding nipple once the above mentioned pop up window appears. Ensure other end of tube is submerged in liquid, else chances for air entry is high. After pressing \u201cYES\u201d button, Press and hold the brake pedal for 3 seconds and then release for 0.5 seconds. Continue above procedure till \u201cBleeding phase I \u201d ends Connect a transparent tube into front LH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Loosen and open the front LH bleeding screw and then press \u201cOK\u201d button. Click on \u201cYES\u201d button to proceed for \u201cBleeding phase II\u201d. The following pop up window appears once the \u201cBleeding phase II\u201d ends. Ensure other end of tube is submerged in liquid, else chances for air entry is high. After pressing \u201cYES\u201d button, Press and hold the brake pedal for 3 seconds and then release for 0.5 seconds. Continue above procedure till \u201cBleeding phase II \u201d ends. Close the front LH bleeding nipple once the above mentioned pop up window appears. Connect a transparent tube into front RH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Loosen and open the Front RH bleeding screw and then press \u201cOK\u201d button. Ensure other end of tube is submerged in liquid, else chances for air entry is high. Click on \u201cYES\u201d button to proceed for \u201cBleeding phase III\u201d. The following pop up window appears once the \u201cBleeding phase III\u201d ends. After pressing \u201cYES\u201d button, Press and hold the brake pedal for 3 seconds and then release for 0.5 seconds. Continue above procedure till \u201cBleeding phase III\u201d ends. In bleeding phase III, pump motor switches ON and OFF in a pre defined intervals. While pump motor is ON, brake pedal pulsations can be felt along with the motor operating sound. Connect a transparent tube into Rear RH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Loosen and open the Rear RH bleeding screw and then press \u201cOK\u201d button. Ensure other end of tube is submerged in liquid, else chances for air entry is high. Click on \u201cYES\u201d button to proceed for \u201cBleeding phase IV\u201d. The following pop up window appears once the \u201cBleeding phase IV\u201d ends. Press \u201cOK\u201d button to complete brake bleeding through i-SMART. After pressing \u201cYES\u201d button, Press and hold the brake pedal for 3 seconds and then release for 0.5 seconds. Continue above procedure till \u201cBleeding phase IV\u201d ends. In bleeding phase IV, pump motor switches ON and OFF in a pre defined intervals. While pump motor is ON, brake pedal pulsations can be felt along with the motor operating sound. Once again carry-out mechanical bleeding. For additional information refer to Manual bleeding section. Check brake/clutch pedal for sponginess. If found spongy, repeat the entire procedure of bleeding. Check and ensure there is no leakage from pipes and joints. Do not spill brake fluid on the vehicle, it may damage the paint, if the brake fluid does contact the paint, wash it off immediately with water. Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. The fluid reservoir cap/ container should not be opened with dirty hands. Avoid direct water spray on reservoir while washing engine compartment. If Maximile DOT 4 Brake fluid is not used and in emergency conditions, use brake Fluid Meeting SAE J1703 FMVSS NO.116 DOT 4 OR IS 8654 TYPE-2 Specification and change it at 30,000 kms or 2 years whichever is earlier. During the bleeding operation ensure the container and pipe used is of transparent for better visual. Brake and Clutch Fluid - Mahindra Maximile DOT 4 Genuine Brake fluid.Brake and Clutch Fluid - 1.75 Liters (Including bleeding quantity).
2. Check the reservoir for leakage and check the level of fluid, if found less top up till MAX mark.
3. Always maintain fluid level at MAX mark on reservoir.
",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130134.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Check for Brake Fluid leakages",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for brake fluid leakage at master cylinder primary & secondary tubes. Check for brake fluid leakage at EHCU primary, secondary and outlets tubes. Check for brake fluid leakage or seepage at front bundy tube I to front bundy tube II connections (Both LH & RH side). Check for brake fluid leakage or seepage at front bundy tube to flexible hose (Both LH & RH side). Check for brake fluid leakage at front caliper inlet & bleeding nipple (Both LH & RH side). Check for brake fluid leakage or seepage from rear RH & LH bundy tube joints shown in illustration. Check for brake fluid leakage or seepage from rear LH bundy tube II & tube III joints shown in illustration. Check for brake fluid leakage at rear RH/LH flexible hoses. Check for brake fluid leakage at rear wheel cylinder inlet & bleeding nipple (Both LH & RH side). Using trim removal tool, remove the IP panel trim driver side. Using Nose plier, remove the R-clip and the clevis pin from the pedal shank. Using 12 mm socket spanner, loosen and remove the pedal box top mounting bolt. Torque :25 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the pedal box mounting nuts then remove the brake pedal box assembly. Torque :25\u00b15.0 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130330.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the brake pedal assembly for any physical damage. Replace if found any. Using a 21 mm wheel spanner, remove wheel mounting nuts and then remove the front wheel. For vehicles with Alloy wheels,measuring can be done without removing the wheels. Insert the Brake pad gauge between caliper housing and edge of brake pad backing plate and contact Tip of tool housing (A) on rotor machined surface as shown. Brake pad gauge should be in perpendicular to rotor surface while measuring. Push the Rear barrel (E) of tool inward and rotate the barrel to rotate Probe tip (B) of the tool as shown. Release the barrel (E) outward upto the probe tip (B) in contact with surface of brake pad back plate as shown. Rotate Knurled ring (D) of rear measuring barrel in same direction to view quick reference color pattern (C) and find actual brake pad thickness (In mm). Refer Brake Pad Thickness Vs Quick reference colors table mentioned below. Wear Limits
11.35 mm. 10.35 mm. Follow the Step 2 to 7 for measuring thickness of Inboard Brake Pad. 30 mm. 28 mm. Refit the front wheel back with the help of mounting nuts and torque tighten it to specified torque value. Follow the above procedure for front other side wheel brake pad and disc inspection. Remove the primary bundy tube. For additional information refer Primary Bundy Tube \u2013 R &R; section. Remove the secondary bundy tube. For additional information refer Secondary Bundy Tuber \u2013 R &R; section. Using hose clip plier detach the vacuum hose clip and remove hose from the brake booster. Disconnect the brake booster electrical connector and detach from the routing clips. Using hose clip plier, release the brake fluid reservoir tank to clutch TMC hose hose clip then detach the hose. Using cutting plier, remove the R-clip then remove the clevis pin. Using 12 mm socket spanner, Unscrew brake booster mounting nuts and remove the brake booster with TMC. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130024.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Carry out brake switch adjustment setting. Check and top up the brake fluid, If required. Carry-out the brake bleeding procedure. For additional information refer to Brake bleeding procedure. Check for the booster diaphragm if found check & replace the assembly. Disconnect battery negative terminal. Disconnect the wheel speed senor electrical connector. Detach the wheel speed sensor cable from the routing clips. Using 10 mm socket spanner, loosen and remove the wheel speed sensor mounting bolt then remove the sensor. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130227.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the sensor for any physical damage. Replace if found any. Inspect the sensor for foreign particles segregation. Clean if found. Inspect the sensor connector for any damage. Using a 21 mm wheel spanner, Loosen and remove the rear LH wheel. Using a star screw driver, Loosen and remove drum mounting screw. Clean the brakes by blowing compressed air. Check the wheel cylinder for oil leakage. (It is recommended to check the oil seepage from wheel cylinder by lifting the dust boots.) Check the brake lining for wear/cracks. Measure the brake lining thickness by using Vernier caliper. The minimum usable thickness of the rear brake liner is 4.6 mm. Replace when thickness falls Minimum thickness of lining below 1 mm. The brake shoe must be replaced before the rib starts touching the drum. Measure the wear of the brake lining at the maximum worn out place. Place the drum in its position and install the mounting screw. Refit the LH wheel and torque tighten the nuts to specified value. Whenever the brake shoes are replaced, replace both RH & LH assemblies as a set to prevent car from pulling to one side when braking. If there is significant difference in the thickness of the liner on the left and right sides, check parking brake operation/ wheel cylinders piston for free movement. Apply and release the parking brake 5 times to condition the cables for normal use and Put the parking brake lever into the released position. Check both the rear wheels for free rotation. Position the parking brake lever at 5th notch position. Check both the rear wheels for free rotation, if the wheels are rotate then tighten the adjusting nut 14 mm till the rear wheels can no longer be rotated using hands. Apply and release the parking brake 5 times. Set the parking brake lever into the released position. The rear wheels must be able to turn freely. If not, loosen the adjusting nut gradually until the wheel can turn freely. Using 21 mm wheel spanner, Loosen and remove the rear LH wheel. Using star screw driver, Loosen and remove drum mounting screw. Using flat screw driver, slide the parking brake retaining lever and Using plier, remove the parking brake cable. Disconnect the parking brake cable connection from the liner assembly. Using plier, remove the liner spring holder. Gently expand and remove the liner assembly carefully. Remove the auto-adjuster and adjuster lever. Using flat end screw driver detach the top shoe return spring and the bottom shoe return spring and remove the liners. Align the shoes and fit bottom return spring. Refit the auto-adjuster and auto-adjuster lever. Refit the top shoe return spring. Refit the liner kit assembly. Refit the liner spring holder. Using plier slide the parking brake retainer lever & fix the parking cable. Refit the brake drum with the help of mounting screw. Refit the LH wheel and torque tighten the nuts to specified value. Whenever the brake shoes are replaced, replace both RH & LH assemblies as a set to prevent car from pulling to one side when braking. If there is significant difference in the thickness of the liner on the left and right sides, check parking brake operation/ wheel cylinders piston for free movement. Brake pads convert the kinetic energy of the car to thermal energy by friction. Two brake pads are contained in the brake caliper with their friction surfaces facing the brake disc which are pressed together against the rotating disc to slow/stop the vehicle. Using 21 mm wheel spanner remove mounting nuts and remove the front RH wheel. Remove front caliper lower mounting bolt using 12 mm socket spanner. Lift the caliper upwards as shown in the illustration. Pull the Brake Pad outwards upto pad contact with clip as shown in the illustration. Twist the pad in anti clock wise direction, lift the pad upwards and remove the pad. Follow Step 4 & 5 for remove another pad. While inserting the pads between the carrier and disc care should be taken that the friction material should be towards the disc. Rotate the disc and make sure it is free to rotate. If it is not free to rotate, inspect and rectify. Before inserting the pads ensure that caliper is returned fully to its position. (Push the caliper inside if necessary.) Never polish pad lining with sandpaper. If lining is polished with sandpaper, hard particles of sandpaper will be deposited in lining and may damage disc. When pad lining requires correction, replace it with a new one. While fitting the guide pin ensure that the straight portion of the pin matches with the ear of the calliper body. The Pads in the Pad kit should be replace on the respective caliper i.e. assemble RH marked pads on RH Caliper and LH marked pads on LH Caliper. If the pads are to be reused make sure they are assembled back in the same position as they were when removed i.e., inboard pad on to the piston side and outboard pad to the wheel side. This is possible only when at the time of removal these pads are marked for their positions and kept aside. Never lubricate the pad seating areas as it may lead to jamming. After assembly of pads, apply brake pedal 5 - 6 times in static condition in order to make the pads align properly. It is recommended to apply light braking during the road test and avoid heavy and continuous braking during the initial 200 kms of run or until the new pads are performing satisfactorily. Never lubricate the pad seating areas as this may lead to jamming. Always ensure that the anti rattle pad clips (small low abutment clip \u2013 sLAC) are replaced whenever the pads are replaced. Always ensure the grease (Wolfracote) between clip & carrier whenever the sLAC clips are removed/replaced. Ensure that the sLAC clips are placed properly and fitted in correct direction in the caliper bracket as shown in the illustration. Ensure that the sLAC clips are replaced/swapped diagonally as shown in the illustration. Ensure that no damage or no deformation of retraction loop in the sLAC clips before fitment. Don\u2019t overload or pull the retraction loop during pad assembling. Don\u2019t use deformed clips & don\u2019t damage the clips during pad insertion. Ensure the proper fitment of all the small low abutment clip (sLAC) . Replace sLAC clips with a new one if found any damage or crack. Refit the brake pad by pushing the pad inside the clips in angled approach as shown in the illustration. Rotate the pad in clockwise direction to vertical position and push the pad inside to caliper. Ensure pad touching the clip retraction. Move the caliper downwards and bring back to its original position. For easy movement, pull the caliper outwards a bit and move it down. Chances for piston seal damage is high, so take adequate precaution while moving the caliper downwards. If the pads are changed with a new one, push both the pistons inside before moving the caliper downwards. Refit the caliper bottom mounting bolt and torque tighten to specified torque value. Ensure the sliding pins are greased well, whenever removed or replaced. Torque : 31 \u2013 38 Nm ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit the front RH wheel back with the help of mounting nuts and torque tighten it to specified torque value. Torque : 140\u00b110 Nm ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Follow the same procedure for front LH brake pad and caliper inspection. If any one pad is worn out (inboard /outboard) then replace both the pads. If pads on one wheel only are worn, even then replace the other wheels also. Remove Brake Shoes. For additional information refer to brake shoe \u2013 R&R; section. Remove the hand brake cable lock clip and detach the hand brake cable from back plate. Using 11 mm open end spanner, Loosen brake bundy tube flare nut wheel cylinder end. Torque : 16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew Wheel cylinder mounting bolts and remove the cylinder. Using 17 mm socket spanner, loosen and remove axle shaft mounting nuts. Torque : 90 \u2013 100 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using MST (0505AAA0001ST puller rear axle shaft banjo) remove rear axle shaft, dust shield with brake liner assembly from vehicle. To avoid the back plate falling down,using a plastic tag tie it with any other fixed member before the shaft is pulled out. Clean sealant on the axle housing flange, Back Plate and apply new sealant on the housing. Apply Locktite Sealant 5060 during Installation and Ensure that sealer bead is on the inside of screw holes as shown above. Bead must be 3 to 6 mm high and 3 to 6 mm wide. Remove Back plate from vehicle. Install in the reverse order of removal. Check and top up the brake fluid, If required. Carry-out the brake bleeding procedure. For additional information refer to Brake bleeding procedure. Check the brake back plate any external damage & also check the brake back plate usable thickness, if required replace. Remove the front wheel assembly. For additional information refer to Front wheel R&R; section. Remove the Front stabilizer bar assembly. For additional information refer to Front Stabilizer Bar \u2013 R&R; section. Using 24 mm socket spanner, loosen and remove the front lower control arm mounting nuts on chassis. While loosening the nut, hold the bolt using 24 mm ring spanner. Torque tightening should be done without load and with the tyres on level ground. Torque value: 250 \u00b1 20 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 19 mm socket spanner, loosen and remove strut fork mounting bolt. Torque : 120 \u00b1 12 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Ensure to insert the washer before Install the bolt. Using a cutting plier, remove the cotter pin from the ball joint. Never reuse the split pin, always replace with a new one. Using a 24 mm socket spanner, loosen and remove lower arm ball joint mounting nut. Torque : 130 \u2013 150 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Using a 22 mm socket spanner, loosen and remove knuckle bracket mounting bolts, remove the knuckle lower half. Torque value: 140 \u00b1 10 Nm Torque Wrench Type - Open end Torque Wrench ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Using a hammer, tap strut fork and release it from lower arm. Remove the lower control arm mounting bolts from the vehicle frame. Torque value: 250 \u00b1 20 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the lower control arm from the vehicle. Install in reverse order of removal. Pay attention while Installation. Torque tightening should be done without load and with the tyres on level ground. LH and RH identification sticker available on part for orientation. Camber and caster bolt marking position required at center. Camber and caster bolt should be fitted in the direction of Arrow shown in illustration.
2. Inspect the lower control arm ball joint and bushes for any damage.
",
+ "file": null,
+ "display_order": 40
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 147,
+ "sys_id": "THAR.AX-0006-Suspension",
+ "subsys_id": "THAR.AX-0006-Suspension-Panhard Rod Bushes Overhaul",
+ "systems": "Suspension",
+ "sub_systems": "Panhard Rod Bushes Overhaul",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170248.jpg",
+ "myid": 1262,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Panhard Rod Bushes Overhaul-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/VST-0075_Rear Suspension Panhard Rod Bushes Removal & Installation.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-0006,1015,1254",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Place the Pan hard on suitable base block. Place the suitable dolly on the Pan hard bush One end. Using a hydraulic press or hammer remove the Pan hard bush one end. Place the Pan hard other end on base block and place the dolly on Pan hard bush. Using a hydraulic press or hammer remove the Pan hard bush other end. Place the Pan hard one end on base block and place the bush installer (MST:0401BAA0043ST) .on the bush. Using a hydraulic press or hammer,Install the Pan hard bush One end. Panhard bush should be fitted in center of panhard and ensure to maintain equal distance on both side of panhard as shown. Place the Pan hard other end on base block and place the bush installer (MST:0401BAA0043ST) .on the bush. Using a hydraulic press or hammer,Install the Pan hard bush other end. Remove the Front Upper Control Arm. Place the base block (MST: 0401BAA0033ST) and place the collar support (MST: 0401BAA0037ST) . on the base block. Place the upper arm one end on the base block. Place the upper arm bush remover (MST: 0401BAA0040ST) on the bottom bush. Place the Pin cage (MST: 0401BAA0041ST) & the support cage (MST: 0401BAA0013ST) as shown. Using a hydraulic press remove the upper arm one side (bottom) bush. Place the upper arm other end on the base block (MST: 0401BAA0033ST) and collar support (MST: 0401BAA0037ST) . Place the upper arm bush remover (MST: 0401BAA0040ST) on the bush. Place the upper arm dummy bush (MST: 0401BAA0042ST) on the upper side bush seating hole. Place the upper arm pin cage (MST: 0401BAA0041ST) & the support cage (MST: 0401BAA0013ST) as shown. Using a hydraulic press remove the other side bush. Place the Upper arm on the base block (MST: 0401BAA0033ST) & collar support (MST: 0401BAA0037ST) and place the bush over the upper arm. Place the bush installer (MST: 0401BAA0043ST) on the bush. Using a hydraulic press, Install the upper arm one side bush. Place the Upper arm other side on the base block (MST: 0401BAA0033ST) & collar support (MST: 0401BAA0037ST) and place the bush over the upper arm. Place the bush installer (MST:0401BAA0043ST) .on the bush. Using a hydraulic press, Install the upper arm bush. Refit the Front Upper Control Arm. Rear Upper Link is used to compensates the longitudinal load to the vehicle. Using a 24 mm socket spanner, loosen the mounting bolt and nut in the chassis end then remove nut from the link. Torque : 230 \u00b1 20 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 21 mm ring spanner. Torque tightening should be done without load and with the tyres on level ground. Torque Wrench Type - Open end Torque Wrench for LH chassis & axle ends Using a 24 mm socket spanner, loosen and remove the link mounting nut from the axle end. Torque : 230 \u00b1 20 Nm Torque Wrench Type - Open end Torque Wrench for LH chassis & axle ends While loosening the nut, hold the bolt using 21 mm ring spanner Torque tightening should be done without load and with the tyres on level ground. Using a appropriate jack support slightly lift the rear axle. Using a 17 mm socket spanners, loosen and remove the both rear shock absorbers bottom side mounting bolts and nuts. Torque value : 110\u00b111 Nm Torque Wrench Type - Open end Torque Wrench ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. While loosening the nut, hold the bolt using 15 mm ring spanner. Remove the respective side coil spring. Jack up the rear axle slightly. Remove the rear upper link chassis end mounting bolt then remove the front and rear upper link from the vehicle. Pay attention while Installation. Bolt should be fitted in the direction of Arrow shown in illustration.
2. Inspect the upper link bushes for any damage, crack or material deterioration. Replace the bushes if found any.
",
+ "file": null,
+ "display_order": 28
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 148,
+ "sys_id": "THAR.AX-0006-Suspension",
+ "subsys_id": "THAR.AX-0006-Suspension-Rear Lower Link Bushes Overhaul",
+ "systems": "Suspension",
+ "sub_systems": "Rear Lower Link Bushes Overhaul",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170276.jpg",
+ "myid": 1263,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Rear Lower Link Bushes Overhaul-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/VST-0074_Rear Suspension Rear lower Link Bushes Removal & Installation.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Rear Lower Link. Place the base block (MST:0401BAA0033ST) & place the Rear Lower and Upper Link Coller (MST : 0401BDD0001ST) . Place the Lower link one end on the base block. Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) on the lower link one end bush. Using a hydraulic press, remove the lower link one end bush. Place the Lower link other end on the base block. Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) on the lower link other end bush. Using a hydraulic press, remove the lower link other end bush. Place the Lower link one end on then base block and place the bush over the lower link. Place the Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press While Installation ensure to maintain Bush Void at 45\u00b0 angle as shown. Ensure to Install the Bush with Void end should be fitted in Chassis end on vehicle. Place the Lower link other end on the base block and place the bush over the lower link. Place the Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press. Refit the Rear Lower Link. Remove the front wheel assembly. For additional information refer to Front wheel R&R; section. Using a 13 mm socket spanner , loosen and remove the brake hose routing bracket mounting nut. Using a 19 mm socket spanner , loosen and remove the strut fork mounting bolt at lower arm end and detach it. Torque : 120 \u00b1 12 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Using hammer, tap strut fork gradually and release strut fork from lower arm. Using a 17 mm ring spanner, loosen and remove the strut top mounting nuts from chassis. Torque value: 40 \u00b1 5Nm Torque Wrench Type - Open end Torque Wrench Detach Wheel speed sensor routing clips from upper control arm. Using 14 mm socket spanner and 18 mm open end spanner, unscrew upper arm bolt and nut and detach partially. Torque value: 97\u00b1 10 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170137.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Remove front strut assembly from front suspension. LH and RH identification sticker available on part for orientation. Using a 17 mm socket spanner and 19 mm open end spanner, loosen the fork mounting bolt and nut and remove fork from strut assembly. Install in reverse order of removal.
2. Check for oil leakage from the shock absorber.
",
+ "file": null,
+ "display_order": 32
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 149,
+ "sys_id": "THAR.AX-0006-Suspension",
+ "subsys_id": "THAR.AX-0006-Suspension-Rear Upper Link Bushes Overhaul",
+ "systems": "Suspension",
+ "sub_systems": "Rear Upper Link Bushes Overhaul",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170276.jpg",
+ "myid": 1264,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Rear Upper Link Bushes Overhaul-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/VST-0073_Rear Suspension Rear upper Link Bushes Removal & Installation.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Rear Upper Link. For additional information refer to Rear Upper Link \u2013 R &R; section. Place the base block (MST:0401BAA0033ST) & place the Rear Lower and Upper Link Coller (MST : 0401BDD0001ST) . Place the upper link one end on the base block. Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) over the upper link one end bush and Using a hydraulic press, remove the bush. Place the upper link other end on the base block. Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) on the upper link other end bush and Using a hydraulic press, remove the bush. Place the upper link one end on then base block and place the bush over the upper link. Place the Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press. While Installation ensure to maintain Bush Void at 45\u00b0 angle as shown. Ensure to Install the Bush with Void end should be fitted in Chassis end on vehicle. Place the upper link other end on the base block and place the bush over the upper link. Place the bush & Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press. Refit the Rear Upper Link. Using a appropriate jack support and slightly lift the rear axle. Using a 24 mm deep socket spanner, loosen and remove the pan hard rod mounting nut and bolt from chassis side. Torque : 230\u00b1 20 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt with the help of 21 mm deep socket. Torque tightening should be done without load and with the tyres on level ground. Using a 21 mm socket spanner, loosen and remove the pan hard rod mounting bolt from axle side. Torque : 230\u00b1 20 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Remove pan hard rod separately. Yellow color all round marking added on Pan hard rod to identify chassis end. Install in reverse order of removal. After installation of pan hard rod remove the jack support. Pay attention while Installation. Bolt should be fitted in the direction of Arrow shown in illustration. While Installation, ensure to refit the Anti Rotation Bracket in the axle end bold side.
2. Check upper control arm front and rear bush condition (both LH & RH) for wear & tear, cracks & shift. Replace if necessary.
3. Check the ball joint boots for damage, cracks, replace if necessary.
4. Check shock absorber bushes, shock absorber dust boot, stabilizer bar bushes, stabilizer bar link boots, bump stop for wear & tear, cracks and shift, replace if necessary.
",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170083.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Rear Suspension Bushes",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "1. Check the lower link, pan hard rod, Upper link, stabilizer bar and stabilizer bar links bushes for any damage/crack or deterioration. Replace the bushes if found any.
2. Check shock absorber bushes, dust boot & bump stop for wear, crack and shift.
",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170082.jpg",
+ "display_order": 6
+ }
+ ]
+ },
+ {
+ "procedure_name": "Lower Control Arm",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect front suspension lower control arm for any bend, damage or crack. Inspect front suspension upper control arm for any bend, damage or crack. Inspect front suspension stabilizer bar for any bend, twisting, damage or crack. Inspect rear suspension lower link for any bend, damage or crack. Inspect rear suspension upper link for any bend, twisting, damage or crack. Inspect rear suspension panhard rod for any bend, twisting, damage or crack. Inspect front & rear suspension stabilizer bar link for any bend, twisting, damage or crack. While tightening the link & torquing ensure that wheels are resting on the ground/ 4 post lift. If it is not done, the ride quality will get adversely affected. Remove the Front Lower Control Arm. Place the base block (MST:0401BAA0033ST) & place the Front Lower Arm Big End Bush Collar (MST : 0401BBB0001ST) on the base block. Place the Lower arm big bush end over the fixture. Place the LCA big bush remover (MST: 0401BAA0038ST) and Front Lower Arm Bushs Support tool (MST: 0401BBB0002ST) on the big end bush. Place the Pin cage (MST:0401BAA0019ST) & the support cage (MST:0401BAA0013ST) as shown. Using a hydraulic press, remove the lower arm big end bush. Place the LCA small bush end on the base block (MST: 0401BAA0033ST) and LCA small bush collar support (MST : 0401BAA0036ST) . Place the Lower arm small bush end over the fixture. Place the LCA small bush remover (MST: 0401BAA0039ST) & Front Lower Arm Bushs Support tool (MST : 0401BBB0002ST) over the lower arm bush. Place the dummy bush (MST: 0401BAA0016ST) on the big end bush seating hole. Place the Pin cage (MST: 0401BAA0019ST) & support cage (MST: 0401BAA0013ST) as shown. Using a hydraulic press, remove the LCA small bush. Place the lower arm on the base block (MST: 0401BAA0033ST). Place the bigger end bush on the lower arm & place the bush installer (MST: 0401BAA0044ST)on the bush. Lower arm big end bush has Void profile and While Installation ensure to maintain Bush Void at appropriate angle as shown. Using a hydraulic press, Install the lower arm big end bush. Place the lower arm small end on the base block (MST: 0401BAA0033ST) Place the lower arm small end bush & the installer (MST: 0401BAA0045ST). Using a hydraulic press, Install the lower arm small end bush. Refit the Front Lower Control Arm. Support the rear axle using the appropriate hydraulic jack. Using a 17 mm socket spanners, loosen and remove the both rear shock absorbers bottom side mounting bolts and nuts. Torque value : 110\u00b111 Nm Torque Wrench Type - Open end Torque Wrench Torque tightening should be done without load and with the tyres on level ground. While loosening the nut, hold the bolt using 15 mm ring spanner Remove the rear coil spring and pad securely from vehicle. Install in reverse order of removal. Pay attention while Installation. Locking lug to be matched with hole on Rear Coil spring dome bracket of Chassis. Yellow coloured PU sleeve should be on chassis side while assembling the coil spring ashown in illustration.
2. Inspect the coil spring pad for any damage. Replace if found.
",
+ "file": null,
+ "display_order": 21
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 152,
+ "sys_id": "THAR.AX-0006-Suspension",
+ "subsys_id": "THAR.AX-0006-Suspension-Troubleshoot - Suspension",
+ "systems": "Suspension",
+ "sub_systems": "Troubleshoot - Suspension",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.15,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1466,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Troubleshoot - Suspension-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Symptom possible causes remedy",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/14506.pdf",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Components Inspection and action table",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/14507.pdf",
+ "display_order": 2
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 144,
+ "sys_id": "THAR.AX-0006-Suspension",
+ "subsys_id": "THAR.AX-0006-Suspension-Assembly Front Strut Overhaul",
+ "systems": "Suspension",
+ "sub_systems": "Assembly Front Strut Overhaul",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170158.jpg",
+ "myid": 1259,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Assembly Front Strut Overhaul-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Disassembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Front strut assembly. Using a spring compressor compress the strut coil spring. Ensure that the spring compressor is tightened with the spring, else expansion of the spring cause severe injury Using a 6 mm open end spanner hold the shock absorber & using a 16 mm ring spanner remove the mounting nut. Remove the shock absorber washer & bush. Remove the bracket coil spring guide assembly. Remove the coil spring seat. Remove the compressed coil spring. Remove the shock absorber bush. Remove the bump stopper cap. Remove the shock absorber dust seal. Remove the front bump stopper. Remove the shock absorber.
2. Inspect the dust seal for damage, if found replace.
3. Check the bush condition, if worn out please replace.
",
+ "file": null,
+ "display_order": 28
+ }
+ ]
+ },
+ {
+ "procedure_name": "Assembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Install the front bump stopper on the shock absorber. Install the shock absorber dust seal. Install the bump stopper cap. Install the shock absorber bush. Install the compressed spring. Install the coil spring seat. Install the coil spring bracket. Install the shock absorber washer & bush. Install the mounting nut. Install the top mounting nut. Torque tighten the nut to specified value. Torque : 40 \u2013 45 Nm Torque Wrench Type - Open end Torque wrench ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the spring compressor tool. Remove front wheel. For additional information refer to Front wheel \u2013 R&R; section. Using a cutting plier, remove the cotter pin from the ball joint. Never reuse the split pin, always replace with a new one. Using a 24 mm socket spanner, loosen and remove the upper control arm ball joint nut. Torque : 90 \u2013 110 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Detach the wheel speed sensor routing clips from the upper control arm. Using a 18 mm ring spanner, hold the mounting nut & using an 14 mm socket spanner loosen the bolt, remove the bolts & nuts. Torque : 97 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Detach and remove the upper control arm. Install in reverse order of removal. Pay attention while Installation. Bolt should be fitted in the direction of Arrow marks shown in illustration. Remove the Rear Shock Absorber. Place the rear shock absorber one end on the suitable base block. Place the suitable dolly on the rear shock absorber bush. Using a hydraulic press or hammer remove the rear shock absorber bush. Place the rear shock absorber one end on then base block and place the bush over the rear shock absorber. Place the bush & suitable dolly over the bush and Refit the bush by loading the hydraulic press. Refit the Rear Shock Absorber. Shock absorber is a tubular hydraulic device placed near each wheel to dampen the spring oscillations. One end of the shock absorber is attached to the frame and the other end on rear axle. The hydraulic shock absorber only dampens oscillations due to road irregularities. It does not support the weight of the vehicle. Shock absorber is Double Acting hydraulic telescopic Shock Absorber type. Support the rear axle using the appropriate hydraulic jack and lift the vehicle to compress the coil springs. Using a 17 mm socket spanners, loosen and remove the bottom mounting bolts and nuts of rear shock absorbers from the rear axle. Torque value : 110\u00b111 Nm Torque Wrench Type - Open end Torque Wrench Torque tightening should be done without load and with the tyres on level ground. While loosening the nut, hold the bolt using 15 mm ring spanner. Using a 14 mm socket spanner, loosen and remove the top mounting bolts of both rear shock absorbers from the chassis. Torque value : 65\u00b110Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Remove the shock absorber from the vehicle. Install in reverse order of removal. Pay attention while Installation. Bolt should be fitted in the direction of Arrow shown in illustration. Ensure the arrow on Rear Shock absorber should be on rear side of vehicle.
2. Inspect the shock absorber bushes for any damage.
",
+ "file": null,
+ "display_order": 22
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 135,
+ "sys_id": "THAR.AX-0006-Suspension",
+ "subsys_id": "THAR.AX-0006-Suspension-Wheel Alignment",
+ "systems": "Suspension",
+ "sub_systems": "Wheel Alignment",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.6,
+ "rts": null,
+ "mat": "J10-MAT-0510",
+ "cover_image": "/files/W4A170079.jpg",
+ "myid": 1250,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 21,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 55,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 110,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 149,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 179,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 232,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 275,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 301,
+ "kilometers_applicable": 1
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+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 358,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 394,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 427,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Wheel Alignment-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Wheel alignment (adjustment of Camber, Caster and Toe) is part of standard automobile maintenance that consists of adjusting the angles of the wheels so that they are set to the specification. The purpose of these adjustments is to reduce tyre wear, and to ensure that vehicle travel is straight and true (without pulling to one side). Wheel alignment consists of adjusting the angles of the wheels so that they are perpendicular to the ground and parallel to each other. The purpose of these adjustments is maximum tyre life and a vehicle that tracks straight and true when driving along a straight and level road. The symptoms of a vehicle that is out of alignment are: Uneven or rapid tyre wear, Pulling or drifting away from a straight line, Wandering on a straight level road, Spokes of the steering wheel off to one side while driving on a straight and level road. Wheel Alignment Sequence ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U3A130002.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "If above sequence is not followed, it will lead to incorrect wheel alignment even though individual adjustments are done correctly. Run Out Compensation ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Park the vehicle on 4 post wheel alignment equipment to do the run-out compensation. Refer wheel alignment equipment manufacturer's guide lines while doing run-out compensation. Refer the procedure given below for SAP setting ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "1. Keep the wheels on turntables of the wheel alignment machine.
2. Rotate the steering wheel to LHS lock position.
3. From LHS lock position, rotate steering wheel to RHS Lock position.
4. Count the number of turns of steering wheel from LHS to RHS lock position.
5. From RHS lock position, rotate steering wheel exactly half the number of turns towards LHS.
6. Lock the steering wheel.
7. If the steering straight ahead does not match the wheel straight ahead, then adjust the OBJ of the desired side.
8. Ensure that the silent bushes in the front suspension are in satisfactory condition.
9. Ensure that the front suspension fasteners are tightened to specified torque.
10. Ensure that there is no play in steering linkages and suspension ball joints.
11. Follow instruction manual of wheel aligning system manufacturer.
",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Wheel Alignment - Check & Adjust ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Wheel alignment consists of adjusting the angles of the wheels so that they are parallel to each other and perpendicular to the ground, thus maximizing tyre life and ensures straight and true tracking along a straight and level road. Specification for Wheel Alignment Front Suspension ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21715.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "Front Suspension Steering Angle Parameters ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21716.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Wheel alignment procedure to be done in vehicle unladen condition only. Do wheel alignment only according to manufacturer's specifications. Front tyre should have uniform wear and inflated to recommended pressure. Ensure that hub play is correct. Ensure that the front suspension fasteners are tightened to specified torque. Ensure that there is no play in steering linkages and suspension ball joints. Camber is defined as the inward or outward tilt of the top of the wheel as viewed from the front. While adjusting camber angle vehicle should be unladen and nobody should sit inside. The camber values should be within: 0\u2070 \u00b1 0.2\u2070 The difference between two wheels should be within: 0\u2070\u00b1 0.4\u2070. Using a 24 mm socket spanner, loosen the camber bolt locking nut. While loosening hold the bolt with the help of a 24 mm ring spanner. To adjust camber angle, rotate the camber bolt using 24 mm ring/socket , to clockwise or anti clockwise direction. Clockwise rotation will reduce the camber angle and anti-clockwise rotation will increase the camber angle. After adjusting camber angle tighten the camber bolt locking nut and recheck the camber angle. The angle between the vertical line and king pin, which fixes the steering knuckle and front axle, (steering column which connects the top and bottom ball joints in the independent axle type) when viewed the tyres from the side is called caster angle. While adjusting caster angle vehicle should be unladen. The values should be within: 4.2\u00b0 \u00b10.4\u00b0. The difference between two wheels should be within: 0\u00b0 \u00b1 0.4\u00b0. Adjust caster bolt until red zone becomes green. (Only if wheel alignment is out of specs). Using a 24 mm socket spanner, loosen the caster bolt locking nut. While loosening the nut, hold the bolt using 24 mm ring spanner. To adjust castor angle, rotate the caster bolt to clockwise or anti clockwise direction using 24 mm socket spanner. Clockwise rotation will decrease the caster angle and anti-clockwise rotation will increase the caster angle. Toe is the difference of measured distances between the front ends of the tyres (A) and the rear ends of the tyres (B) along the same axle when viewed the wheels from the top. Front Toe In to be adjusted individually on LH and RH side tie rod ends. Front Total toe between two wheels should be within: 0.23\u2070 \u00b1 0.1\u2070. The difference between two wheels should be within: 0\u00b0 \u00b1 0.4\u00b0. Using a 19 mm open end spanner, hold tie rod end first and then loosen tie rod end lock nut with the help of 19 mm open end spanner. Using a 14 mm open end spanner, Toe-in is adjusted by varying the length of tie rods. While adjusting toe-in, adjust the length of both the tie rods by rotating them in the same direction such that their lengths remain equal at all times. Perform steering angle sensor (SAS) calibration if steering wheel is removed and adjusted during straight ahead position setting and procedure as below. After adjusting the length of tie rods, recheck toe in and then hold tie rod end with 19 mm open end spanner and then tightening locknut with 19 mm open end spanner.
2. Connect the i-SMART diagnostic tester and turn the ignition ON .
3. Launch i-SMART Select ABS ECU and Navigate to Write Data .
4. Select the WRITE DATA tab.
",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170207.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": " 1. Click on \u201cROUTINE SELECTION\u201d drop down list and select \u201cSteering Angle Sensor Calibration\u201d . ",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170208.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Click on \u201cSTART ROUTINE\u201d to initiate the SAS Calibration. Ensure the Steering Wheel is at center and the front wheels are straight. The following pop up window appears once the SAS Calibration completed. Press \u201cOK\u201d button to complete SAS Calibration through i-SMART.
Front ride height : Front wheel arch center (Bottom Surface) to ground. Rear ride height : Rear wheel arch center (Bottom Surface) to ground.Ride Heights of different variants ",
+ "file": null,
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21732.jpg",
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "R16 SF 6S - Rim Size 16, Side Facing 6 Seater. R16 FF 4S - Rim Size 16, Front Facing 4 Seater. R18 FF 4S - Rim Size 18, Front Facing 4 Seater Prior to inspect the ball joint, inspect the wheel bearings for any play. Check 1 (On Vehicle) ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Position the vehicle on a 2 post lift and Raise the vehicle. Inspect the ball joint for relative movement by, grasp the top and bottom of the wheel and rock it in and out along the wheel\u2019s vertical axis.Observe any relative movement between the wheel knuckle and ball joints. Ensure wheel nuts/bolts are not in loosen condition while checking, as that may cause movement when rocking the wheel. If relative movement play is little or no play then the ball joint is in good condition. If relative movement play that seems excessive or noises, then Visual check the ball joints. Any noises or play heard towards the top are most likely indicative of a problem with the upper ball joint, while, any play or noise coming from the bottom of the wheel are probably indicative of a problem with the lower ball joint. Check 2 (On Vehicle) ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Take a pry bar and place it between the lower control arm and the steering knuckle, the two parts that are connected together by the ball joint and attempt to pry them apart. Loose ball joints will have an excessive amount of play and movement when you pry on them, may even make knocking or clicking sounds. Check 3 (On Vehicle) \u2013 Visual Inspection ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170172.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Inspect the ball joints for any signs of rust, damage to the dust boot, grease leakage, or other potential problems that may indicate a need for replacement. Check the looseness of ball joints in Control arms. Check 4 (Off Vehicle) ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the Ball joints from Vehicle. Refer Respective Ball Joints R&R; Section. Check the ball joint for free rotational torque by rotate the ball pin through the periphery of ball joint cup for checking the movement. Replace the ball joint only if movement is found jerky during rotation. Check the Axial lift by holding the ball Joint and lifting the ball pin in upward direction. If the play was observed more than 0.5 mm replace the ball joint. Lift the ball pin by one hand & hold the lower end of ball joint grounded by other hand. Rear Lower Link is used to provide articulation for rear suspension in vertical direction. It also supports the lower end of the axle. Using a 24 mm socket spanner loosen and remove the rear lower link front and rear mounting nuts and bolts. Torque value: 230 \u00b1 20 Nm Torque Wrench Type - Open end Torque Wrench for LH chassis side While loosening the nut, hold the bolt using 21 mm ring spanner. Torque tightening should be done without load and with the tyres on level ground. Detach the rear wheel speed sensor routing from the lower link. Remove the rear lower link from the vehicle. Install in reverse order of removal. Pay attention while Installation. Bolt should be fitted in the direction of Arrow shown in illustration.
2. Inspect the rear lower link bushes for any damage. If found replace.
",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 278,
+ "sys_id": "THAR.AX-0006-en-SM-Mechanisms",
+ "system_name": "Mechanisms",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1026,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 280,
+ "sys_id": "THAR.AX-0006-Mechanisms",
+ "subsys_id": "THAR.AX-0006-Mechanisms-Front Door Latch Assembly",
+ "systems": "Mechanisms",
+ "sub_systems": "Front Door Latch Assembly",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A380041.jpg",
+ "myid": 1393,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-0006-Front Door Latch Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380041.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12816.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12817.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Front Door Trim. For additional information refer to Front Door Trim R &R; section. Using 10 mm socket spanner, unscrew glass channel mounting nuts and detach the run channel beading from the channel and take out the channel from door. Torque :5\u00b11 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380042.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the door latch electrical connector. Detach the mounting link from latch to exterior door handle. Detach link from the handle lever. Using a 5 mm Allen key, Unscrew the latch to door mounting Allen screws. Torque : 7 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380046.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380047.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the front door latch assembly separately. 7 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the latch assembly for any damage, replace if found. Inspect the linkages for any damage or bend. Open the bonnet and lock it using bonnet stay rod. . Using a star screw driver, loosen and remove both side front splash shield mounting screw rivets. Remove both front splash shields from vehicle . Using a 10 mm socket spanner, loosen and remove the front stone guard front mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250064.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen and remove the rear stone guard rear mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250033.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the stone guard mounting screw rivets. Remove the stone guard from the vehicle. Disconnect the fog lamp electrical connectors LH & RH sides. Pull and remove the front bumper top panel trim clips and remove the panel. Using a 10 mm socket spanner, Unscrew front bumper mounting nuts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290005.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "using a 13 mm socket spanner, Unscrew front bumper bottom mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290006.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew front bumper top side mounting bolts. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290007.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front bumper top centre mounting screw rivets. Remove the front bumper assembly from the vehicle. Using a 13 mm socket spanner, Unscrew front bumper center bracket mounting bolts and remove the front bumper center mounting bracket. Torque : 10.0\u00b11 Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250060.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the front grill mounting screw rivets. Using a star screw driver, loosen and remove the bottom side front grill mounting screw rivets. Using a 10 mm socket spanner, loosen and remove the front grill mounting bolts. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250062.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Remove the front grill assembly from the vehicle. Using a 10 mm socket spanner, Unscrew hood catcher mounting nuts both the sides. Torque : 7 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380104.jpg",
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Remove the hood catchers from the vehicle. Install in the reverse order of removal. Inspect the hood catcher for any damages. Replace if found any Remove the Front Door Window Glass. For additional information refer to Front Door Window Glass R &R; section. Disconnect the front door window glass motor electrical connector. Using a 10 mm socket spanner, loosen and remove the front door window glass mechanism to door mounting nuts. Torque : 10.50 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380035.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380036.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the front door window glass mechanism separately. Install in the reverse order of removal. Inspect the glass for any damage. Replace if found. Inspect the regulator for any damages, Replace if found any Remove the Tail Door Trim. For additional information refer to Tail Door Trim R &R; section. Using a star screw drive, unscrew tail door handle top mounting screw and remove the cover. Carefully pull and detach the outer door handle from tail door. Using a star screw driver, unscrew handle inside support mounting screw from the tail gate. Torque : 1.3 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal. Inspect the rear door exterior handle for any damages. Replace if found any. Pull out the bonnet latch cable and open the bonnet. Lock it using bonnet stay rod. Disconnect cable guide and link from latch. Detach cable from routing clips. Press the lock and pull lever to detach bonnet cable lever with cable and take out the cable from the vehicle. Install in the reverse order of removal. Inspect the latch assembly for any damage, replace if found. Remove Tail Door Trim. For additional information refer to Tail Door Trim \u2013 R &R; section. For Softtop Variants, Remove the Tail Door Inner Handle. For additional information refer to Tail Door Inner Handle - R &R; Section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380052.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect tail door latch electrical connector. Disconnect latch lever from the key lock and handle. Using a 5mm allen key, unscrew the tail door latch mounting screw. Torque : 7 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380055.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380056.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully detach tail door latch. Install in the reverse order of removal. Inspect the latch assembly for any damage, replace if found. Remove the Front Door Window Glass Regulator LH. For additional information refer to Front Door Window Glass regulator LH R &R; section. Using a T20 torx socket spanner, unscrew the regulator motor mounting screws. Torque : 2.5 to 3 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the glass for any damage. Replace if found. Inspect the regulator for any damages, Replace if found any. Remove the Intercooler Assembly. Disconnect cable guide and link from latch. Using a 10 mm socket spanner, unscrew bonnet latch mounting nuts. Torque : 10.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380073.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the bonnet latch from hood. Install in the reverse order of removal. While Installation, hand tighten the latch mounting nuts first and align the latch in appropriate position And ensure smooth locking of latch in holding bracket , finally torque tighten the mounting nuts. Inspect the bonnet latch for any damage, replace if found. For additional information refer to the Wiper Washer Nozzle Front - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the stay rod. For additional information refer to the Stay Rod - R&R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280052.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the wiper hose routing clips from the bonnet.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280080.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the bonnet rubber beading from the bonnet.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W416.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W417.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the bonnet catcher bracket mounting bolts (Both sides).",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 13.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260054.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260053.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using T40 socket spanner, loosen and remove the bonnet mounting bolts.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 24\u00b14 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260061.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the bonnet from the vehicle.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the bonnet hinges for any crack or damage. Replace if found.",
+ "file": null,
+ "display_order": 21
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 274,
+ "sys_id": "THAR.AX-O-0007-Doors, Bonnet & Tail Gate",
+ "subsys_id": "THAR.AX-O-0007-Doors, Bonnet & Tail Gate-Tail Door Half Seal (Convertible Soft Top)",
+ "systems": "Doors, Bonnet & Tail Gate",
+ "sub_systems": "Tail Door Half Seal (Convertible Soft Top)",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A260063.jpg",
+ "myid": 1387,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Tail Door Half Seal (Convertible Soft Top)-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260063.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16771.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16772.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250124.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250123.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove Side window RH Velcro and Unzip the window.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250147.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Unhook the window from the vertical and horizontal belt rail and remove the window.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250125.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250122.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove Side window LH Velcro and Unzip the window.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250148.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Unhook the window from the vertical and horizontal belt rail and remove the window.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250126.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Open the tail door.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250127.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Unzip the tail gate window, detach the tail gate bar locking from rear RH & LH belt rails remove the tailgate window.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250129.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250128.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Unhook the \u2018C\u2019 pillar cover from rear RH & LH belt rails and fold the cover at top of the soft top.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Tail Door Half Seal (Convertible Soft Top).png",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a T30 socket spanner, loosen and remove the belt rear rail Mounting bolts and remove the belt rail from the vehicle.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": "Follow the same procedure for LH side.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260064.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260065.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the seal from the body.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 27
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the tail door half seal for any damage or wears. Replace if found any.",
+ "file": null,
+ "display_order": 28
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 277,
+ "sys_id": "THAR.AX-O-0007-Doors, Bonnet & Tail Gate",
+ "subsys_id": "THAR.AX-O-0007-Doors, Bonnet & Tail Gate-Mechanical Locks Set",
+ "systems": "Doors, Bonnet & Tail Gate",
+ "sub_systems": "Mechanical Locks Set",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A260121.jpg",
+ "myid": 1390,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Mechanical Locks Set-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260121.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16805.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove Front Door Trim RH. For additional information refer to Front Door Trim RH- R &R Section. ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260122.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Detach the key handle lever from the key lock set.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260123.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260124.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260132.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Detach lock holding bracket and remove key lock from the vehicle.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 10
+ }
+ ]
+ },
+ {
+ "procedure_name": "Tail Door Lock Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove Tail Door Trim. For additional information refer to Tail Door Trim RH- R &R; Section. ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260129.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Detach the key handle lever from the key lock set. ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260130.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260131.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260133.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Detach lock holding bracket and remove key lock from the tail door.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ },
+ {
+ "procedure_name": "Glove Box Lock Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove Glove Box Assembly.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1020,1341",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260127.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using Screw driver, remove Glove box Latch mounting screws and remove the latch from the glove box.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260128.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260136.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260135.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using Screw driver, Remove Lock from Latch by pressing lock locking clips.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 27
+ }
+ ]
+ },
+ {
+ "procedure_name": "Fuel Lid Door Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Screenshot 2023-04-20 181410.png",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using vehicle key open the fuel filler door. ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260125.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260126.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260134.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using Screw driver, detach lock holding bracket and remove key lock from the fuel lid door. ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. ",
+ "file": null,
+ "display_order": 34
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the key locks for any damage or wears. Replace if found any. ",
+ "file": null,
+ "display_order": 35
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 269,
+ "sys_id": "THAR.AX-O-0007-Doors, Bonnet & Tail Gate",
+ "subsys_id": "THAR.AX-O-0007-Doors, Bonnet & Tail Gate-Tail Gate Gas Strut",
+ "systems": "Doors, Bonnet & Tail Gate",
+ "sub_systems": "Tail Gate Gas Strut",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A380057.jpg",
+ "myid": 1382,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Tail Gate Gas Strut-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380057.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16730.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16731.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380078.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Lift and open the tail gate glass.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380058.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380077.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a screw driver carefully lift and open the gas strut lock at both the ends.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380060.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Carefully remove tail gate glass gas strut.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the gas strut assembly for any damage, replace if found.",
+ "file": null,
+ "display_order": 12
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 267,
+ "sys_id": "THAR.AX-O-0007-Doors, Bonnet & Tail Gate",
+ "subsys_id": "THAR.AX-O-0007-Doors, Bonnet & Tail Gate-Door Alignment Procedure",
+ "systems": "Doors, Bonnet & Tail Gate",
+ "sub_systems": "Door Alignment Procedure",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A260024cf7ce4.jpg",
+ "myid": 1380,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Door Alignment Procedure-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16713.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16714.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Door Alignment Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260024.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Pull the door outer handle and slowly close the door with outer door handle pulled in condition.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260027.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Check and feel for the condition of latch fouling with striker.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260025.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "If the latch fouling with the striker then loosen the striker mounting screws and align the striker so that there is no fouling.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260026.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Tighten the striker mounting screws to specific torque",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 23.5 \u00b1 2.5 ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "Ensure that door closing should be smooth and latch is not foul on the striker",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Follow the same procedure for other doors.",
+ "file": null,
+ "display_order": 13
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 266,
+ "sys_id": "THAR.AX-O-0007-Doors, Bonnet & Tail Gate",
+ "subsys_id": "THAR.AX-O-0007-Doors, Bonnet & Tail Gate-Front Door Assembly Removal",
+ "systems": "Doors, Bonnet & Tail Gate",
+ "sub_systems": "Front Door Assembly Removal",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A260034.jpg",
+ "myid": 1379,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Front Door Assembly Removal-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260034.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16703.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16704.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260035.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Lower the window glass to prevent from damage.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260036.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect door accessory electrical connector.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "Protect the electrical connectors to avoid water entry, which may leads to short circuit.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260044.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260045.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Detach the wiring harness bunch from holding bracket \u2018A\u2019 Pillar end.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260004.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew door stopper mounting bolts BIW end.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260038.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using T40 Torx Socket, Unscrew door hinge pin at bottom of the hinge.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260037.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully lift and remove the door assembly from vehicle.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Notice",
+ "content": "Key IN Reminder & Park Lamp Reminder will not function in case of driver door is removed.Torque : 23.5 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260006.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew door hinge mounting bolts from body.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 50 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260041.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the door assembly from vehicle.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Support the door while removing the bolts.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260008.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260042.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using star screw driver , Unscrew door hinge mounting screw door end.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 24\u00b1 4.0 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Before tightening the bolts align the door assembly correctly, else door operation won\u2019t be smooth..",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Do the door alignment, if required.",
+ "file": null,
+ "display_order": 22
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the door hinge for any damage. Replace if required.",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 272,
+ "sys_id": "THAR.AX-O-0007-Doors, Bonnet & Tail Gate",
+ "subsys_id": "THAR.AX-O-0007-Doors, Bonnet & Tail Gate-Tail Door Hinge",
+ "systems": "Doors, Bonnet & Tail Gate",
+ "sub_systems": "Tail Door Hinge",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A260028.jpg",
+ "myid": 1385,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Tail Door Hinge-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260028.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16753.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16754.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the tail door trim. For additional information refer to the Tail Door Trim- R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260030.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the tail door electrical connector and remove the wiring routing clips from the tail door.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260013.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a screws driver, loosen and remove the mounting screws from the hinges.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260018.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, loosen and remove the stopper mounting bolt from the Body.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 23.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260119.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the hinge mounting bolts inside tail door.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 50\u00b15 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260033.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the tail door.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Ensure to hold the tail door with spare wheel properly while remove, failing will lead door falling down which may lead to personal injuries.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260120.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260032.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the Hinge Mounting bolts from body.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque :27\u00b14 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the tail door hinges for any physical damage, replace if found.",
+ "file": null,
+ "display_order": 24
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 276,
+ "sys_id": "THAR.AX-O-0007-Doors, Bonnet & Tail Gate",
+ "subsys_id": "THAR.AX-O-0007-Doors, Bonnet & Tail Gate-Rear Windshield Glass",
+ "systems": "Doors, Bonnet & Tail Gate",
+ "sub_systems": "Rear Windshield Glass",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A260096.jpg",
+ "myid": 1389,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Rear Windshield Glass-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260096.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16791.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16792.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260081.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Disconnect the demister electrical connectors.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260114.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260115.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 4 mm Allen key, Unscrew glass hinge mounting screws.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260077.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260076.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260118.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using the screw driver Unlock the strut to detach the strut and remove the glass.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Ensure to hold the Rear Windshield glass while detach the struts, failing to hold leads to glass falling.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260084.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260085.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew strut bracket mounting bolts from glass.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Ensure not to over tigthen the strut bracket mounting bolts while Installation.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260116.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260117.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Rear Windshield Glass.png",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove strut mounting grommet and cap nuts from the glass.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 24
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the rear windshield glass for any damage or wears. Replace if found any.",
+ "file": null,
+ "display_order": 25
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 273,
+ "sys_id": "THAR.AX-O-0007-Doors, Bonnet & Tail Gate",
+ "subsys_id": "THAR.AX-O-0007-Doors, Bonnet & Tail Gate-Tail Door Assembly",
+ "systems": "Doors, Bonnet & Tail Gate",
+ "sub_systems": "Tail Door Assembly",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A260012.jpg",
+ "myid": 1386,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Tail Door Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260012.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16763.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16764.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the spare wheel carrier.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1014,1244",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the tail door trim. Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260018.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, loosen and remove the Stopper Mounting bolt from the Body.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Torque Value",
+ "content": "Torque : 50\u00b15 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260119.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, loosen and remove the hinge mounting bolts inside tail door.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Torque Value",
+ "content": "Torque : 50\u00b15 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260016.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Remove the tail door from vehicle.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 28
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the tail door for any physical damage, replace if found",
+ "file": null,
+ "display_order": 29
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 275,
+ "sys_id": "THAR.AX-O-0007-Doors, Bonnet & Tail Gate",
+ "subsys_id": "THAR.AX-O-0007-Doors, Bonnet & Tail Gate-Tail Door Half Seal (Hard Top)",
+ "systems": "Doors, Bonnet & Tail Gate",
+ "sub_systems": "Tail Door Half Seal (Hard Top)",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A260105.jpg",
+ "myid": 1388,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Tail Door Half Seal (Hard Top)-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260105.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16787.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the hard top assembly.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1024,1374",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260064.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260065.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the seal from the body.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 8
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the tail door half seal for any damage or wears. Replace if found any",
+ "file": null,
+ "display_order": 9
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 271,
+ "sys_id": "THAR.AX-O-0007-Doors, Bonnet & Tail Gate",
+ "subsys_id": "THAR.AX-O-0007-Doors, Bonnet & Tail Gate-Bonnet Hinge",
+ "systems": "Doors, Bonnet & Tail Gate",
+ "sub_systems": "Bonnet Hinge",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A260055.jpg",
+ "myid": 1384,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Bonnet Hinge-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260055.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16747.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16748.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the scuttle grill.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1024,1373",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260057.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using T40 socket spanner, loosen and remove the bonnet mounting bolts.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 24\u00b14 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260058.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the bonnet hinge mounting bolts from the body and detach hinge.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 24\u00b14 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260055.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the hood hinge from the bonnet.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the bonnet hinges for any crack or damage. Replace if found.",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 100,
+ "sys_id": "THAR.AX-O-0007-en-SM-Front Axle",
+ "system_name": "Front Axle",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1012,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 103,
+ "sys_id": "THAR.AX-O-0007-Front Axle",
+ "subsys_id": "THAR.AX-O-0007-Front Axle-Front LH Drive Shaft",
+ "systems": "Front Axle",
+ "sub_systems": "Front LH Drive Shaft",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A150025.jpg",
+ "myid": 1221,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Front LH Drive Shaft-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150025.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10296.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10297.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove Front LH wheel Hub. For additional information refer to Front LH wheel Hub \u2014 R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1014,1245",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Front Stabilizer Bar. For additional information refer to Front Stabilizer Bar \u2014 R&R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front LH wheel speed sensor mounting bolt and remove the sensor.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150026.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": " Torque : 9 \u00b1 1 Nm",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the wheel speed sensor routing clips from the upper control arm.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170123.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using cutting plier, remove upper arm ball joint cotter pin.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150027.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Never reuse the cotter pin, always replace with a new one.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 24 mm socket spanner, unscrew upper arm ball joint mounting nut.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150028.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": " Torque : 90 \u2013 110 Nm",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using suitable lever, partially detach the knuckle and remove the drive shaft.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150029.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Pull the drive shaft downwards and remove it.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150030.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150031.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 24
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Move the joint up, down, left, right, and in axial direction. Check for any rough movement or significant looseness.MST 0502AUA0002ST Front Axle Shaft Inboard Oil Seal Puller, remove the Oil seal from the housing",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W427.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Replace the Inboard Oil Seal once removed. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150050.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove E-Disconnect stone guard. For additional information refer to E-Disconnect stone guard - R &R section. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect E \u2014 Disconnect electric connector.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150016.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew electric disconnect housing mounting bolts and Carefully remove the E-Disconnect Housing with Fork .",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150264.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 17\u00b12 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150265.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using circlip plier remove the intermediate shaft circlip from housing.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150063.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Notice",
+ "content": "Tool should not damage the splines on the axle shaft this affects disconnect operation.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150268.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Pull out the axle shaft from wheel end side of e-disconnect housing. ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W428.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using MST 0502AUA0008ST Front Axle Tube Needle Bearing Puller, remove the Needle bearing from e-disconnect housing LH side.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150274.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150269.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150270.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150261.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "By using MST 0502AUA0007ST - F Axle Tube Needle Bearing Dolly, Install the LH Side needle bearing In the disconnect housing.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150228.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150275.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150274.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Clean and Insert the axle shaft through wheel end side of the disconnect housing.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150271.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Align the shifter sleeve on the intermediate shift through disconnect housing window and Install the circlip on the axle shaft with the help of circlip tool.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150272.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Notice",
+ "content": "Ensure there should not be excessive play between two shafts this affects the disconnect.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150273.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Install the new cover gasket while locating in the dowel on the disconnect housing.",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150141.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Notice",
+ "content": "Ensure to use New Gasket while Installation.* Ensure the cleanliness of disconnect housing cover face and cover resting face.* Do not bent the wrap the Gasket while installing.* Gasket orientation is fixed by dowel on the disconnect housing hence it will fit in one direction only.* Bent or warped cover gasket may lead to leak during running.",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Locate the disconnect cover on the dowel and install the bolts. Tighten the mounting bolts to specified torque value.",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150264.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Notice",
+ "content": "Ensure to use New bolts while Installation.* Apply locktite sealant on the bolts while installing, this avoid the leakthrough cover.",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Torque Value",
+ "content": "Torque : 17\u00b12 Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Connect e-Disconnect electrical connector.",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150016.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Connect e-Disconnect electrical connector. **For additional information refer to E-Disconnect stone guard \u2014 R &R section.**",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, refit the Oil seal on the housing.",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150047.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W429.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Refit Front LH drive shaft.",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1012,1517",
+ "file": null,
+ "display_order": 52
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the Front axle Tube Needle Bearing for any damage, Replace if necessary",
+ "file": null,
+ "display_order": 53
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 101,
+ "sys_id": "THAR.AX-O-0007-Front Axle",
+ "subsys_id": "THAR.AX-O-0007-Front Axle-Front Axle LH Drive Shaft Oil Seal",
+ "systems": "Front Axle",
+ "sub_systems": "Front Axle LH Drive Shaft Oil Seal",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A150054.jpg",
+ "myid": 1219,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Front Axle LH Drive Shaft Oil Seal-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150054.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11941.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11942.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1012,1517",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using MST 0502AUA0002ST Front Axle Shaft Inboard Oil Seal Puller, remove the Oil seal from the housing.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150046.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Replace the Inboard Oil Seal once removed.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150050.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, refit the Oil seal on the housing.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150047.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150051.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Refit Front LH drive shaft.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1012,1517",
+ "file": null,
+ "display_order": 13
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the axle shaft Inboard Oil Seal for any damage, Replace if necessary.",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 102,
+ "sys_id": "THAR.AX-O-0007-Front Axle",
+ "subsys_id": "THAR.AX-O-0007-Front Axle-Front Axle RH Drive Shaft Oil Seal",
+ "systems": "Front Axle",
+ "sub_systems": "Front Axle RH Drive Shaft Oil Seal",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A150055.jpg",
+ "myid": 1220,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Front Axle RH Drive Shaft Oil Seal-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150055.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11948.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11947.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove Front RH drive shaft.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1012,1518",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Position the Special tool support piece inside the axle housing and using MST 0502AUA0002ST Front Axle Shaft Inboard Oil Seal Puller, remove the Oil seal from the housing.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150048.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Replace the Inboard Oil Seal once removed.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150049.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, refit the Oil seal on the housing.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150056.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150051.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Refit Front RH drive shaft.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1012,1518",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the axle shaft Inboard Oil Seal for any damage, Replace if necessary.",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 105,
+ "sys_id": "THAR.AX-O-0007-Front Axle",
+ "subsys_id": "THAR.AX-O-0007-Front Axle-Front Axle Assembly",
+ "systems": "Front Axle",
+ "sub_systems": "Front Axle Assembly",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A150033.jpg",
+ "myid": 1223,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Front Axle Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150033.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11980.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11981.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 8 mm socket spanner, Unscrew front propeller shaft mounting bolts/nuts at front axle end.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130016.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 19\u00b13 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Front LH drive shaft.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1012,1517",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Drain the front differential oil. For additional information refer to Front differential oil draining and filling procedure. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove Front RH Wheel Hub.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1012,1518",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front RH wheel speed sensor mounting bolt and remove the sensor.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W425.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Detach the wheel speed sensor from routing bracket.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150034.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using cutting plier, Remove upper arm ball joint cotter pin.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150035.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Notice",
+ "content": "Never reuse the cotter pin, always replace with a new one.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 24 mm socket spanner, unscrew upper arm ball joint mounting nut and remove the ball joint.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150036.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque : 90 \u2013 110 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove E-Disconnect stone guard. For additional information refer to E-Disconnect stone guard \u2013 R &R section. ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Disconnect E \u2013 Disconnect electric connector.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150016.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Provide a jack to support front axle.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150037.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using 19 mm socket spanner, unscrew front axle mounting bolts and partially remove the axle downwards.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W426.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Torque Value",
+ "content": "Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Partially detach the knuckle an remove the drive shaft by using a suitable lever.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150039.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Pull the drive shaft downwards and remove it. ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150040.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Remove the front axle assembly from Vehicle.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150043.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Refill the front axle oil upto Max level. For additional information refer to Front differential oil draining and filling procedure. ",
+ "file": null,
+ "display_order": 39
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the axle shaft for straightness, cracks, damage, wear or distortion, replace it if necessary.Front Axle Oil \u2014 Mahindra 'MAXIMILE ELITE' New Generation Genuine Differential Fluid.
Capacity \u2014 1.25 Litres.
",
+ "file": null,
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Draining",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W422.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm square bit spanner, loosen and remove front axle filler plug.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": "Torque : 34 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": ", ",
+ "file": "/files/W4A150006.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refill specified quantity of recommended differential oil into differential assembly.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "Never reuse drained oil.
Always use recommended oil only.
Never mix different types of oil and use.
Clean filler plug area properly using a cloth before filling the oil.
",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": ", ",
+ "file": "/files/W4A150007.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Check the oil level and ensure its up to the level.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "Ensure that the oil level is up to lower most point of the filler plug. ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": ", ",
+ "file": "/files/W423.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Refit the filler plug back and torque tighten to specified value.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "Clean the filler plug with a clean cloth before refitting.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 34 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Recommend to use only Mahindra 'MAXIMILE Elite' new generation genuine differential fluid. Torque : 17\u00b12 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Carefully remove the E-Disconnect Housing with Fork.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150023.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150024.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "While Installation Apply Locktite sealant on the E-Disconnect Housing bolts to avoid the leak through cover.",
+ "file": null,
+ "display_order": 13
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the E-Disconnect motor, connector for any damage, Replace if necessary.",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 398,
+ "sys_id": "THAR.AX-O-0007-Front Axle",
+ "subsys_id": "THAR.AX-O-0007-Front Axle-Front Axle RH Drive shaft",
+ "systems": "Front Axle",
+ "sub_systems": "Front Axle RH Drive shaft",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1518,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Front Axle RH Drive shaft-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150032.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11978.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11966.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the front differential oil. For additional information refer to Front differential oil draining and filling procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Front LH wheel Hub.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1014,1245",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove Front Stabilizer Bar. For additional information refer to Front Stabilizer Bar \u2013 R &R; section. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front RH wheel speed sensor mounting bolt and remove the sensor. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W424.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque :9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the wheel speed sensor from routing bracket.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150034.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using cutting plier, remove upper arm ball joint cotter pin.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150035.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Notice",
+ "content": "Never reuse the cotter pin, always replace with a new one.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 24 mm socket spanner, unscrew upper arm ball joint mounting nut.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150036.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 90 \u2014 110 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove E-Disconnect stone guard. For additional information refer to E-Disconnect stone guard \u2014 R &R; section. ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Disconnect E \u2014 Disconnect electric connector.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150016.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Provide a jack to support front axle.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150037.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 19 mm socket spanner, unscrew front axle mounting bolts and partially down the axle.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150038.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Torque Value",
+ "content": "Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150037.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using suitable lever partially detach the knuckle and remove the drive shaft.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150040.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Pull the drive shaft downwards and remove it.",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150039.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150041.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Refill the front axle oil upto Max level. For additional information refer to Front differential oil draining and filling procedure. ",
+ "file": null,
+ "display_order": 35
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Move the joint up, down, left, right, and in axial direction. Check for any rough movement or significant looseness.* Check the drive shaft boot for cracks or other damage, and for grease leakage.* If damaged, disassemble the drive shaft to verify the damage, repair or replace if necessary.* Check the splines for wear and tear. ",
+ "file": null,
+ "display_order": 36
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 106,
+ "sys_id": "THAR.AX-O-0007-Front Axle",
+ "subsys_id": "THAR.AX-O-0007-Front Axle-E-Disconnect Motor",
+ "systems": "Front Axle",
+ "sub_systems": "E-Disconnect Motor",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A150020.jpg",
+ "myid": 1224,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-E-Disconnect Motor-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150020.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11995.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11996.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove E-Disconnect stone guard. For additional information refer to E-Disconnect stone guard \u2013 R &R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect E \u2013 Disconnect electric connector.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150016.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, unscrew E \u2013 Disconnect motor mounting bolts.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150017.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 12.5\u00b13.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the E-Disconnect motor",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150018.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150019.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150052.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "While Installation ensure to replace the New O Ring for E \u2013 Disconnect motor ",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the E-Disconnect motor, connector for any damage, Replace if necessary. ",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 397,
+ "sys_id": "THAR.AX-O-0007-Front Axle",
+ "subsys_id": "THAR.AX-O-0007-Front Axle-Front Axle LH Drive shaft",
+ "systems": "Front Axle",
+ "sub_systems": "Front Axle LH Drive shaft",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1517,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Front Axle LH Drive shaft-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150025.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11955.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11956.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove Front LH wheel Hub.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1014,1245",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Front Stabilizer Bar. For additional information refer to Front Stabilizer Bar \u2013 R &R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front LH wheel speed sensor mounting bolt and remove the sensor.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150026.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque: 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the wheel speed sensor routing clips from the upper control arm.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170123.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using cutting plier, remove upper arm ball joint cotter pin.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150027.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Never reuse the cotter pin, always replace with a new one.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 24 mm socket spanner, unscrew upper arm ball joint mounting nut.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150028.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "90 \u2014 110 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using suitable lever, partially detach the knuckle and remove the drive shaft.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150029.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Pull the drive shaft downwards and remove it.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150030.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150031.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 24
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Move the joint up, down, left, right, and in axial direction. Tools Required ",
+ "file": null,
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the Transmission fluid. For additional information refer to Transmission fluid Drain & Filling Section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Clutch Concentric Slave Cylinder. For additional information refer Clutch Concentric Slave Cylinder - R&R Section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1007,1137",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110019.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner remove the clutch housing mounting bolts and then gently tap using plastic mallet & remove clutch housing.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110167.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a screw driver/suitable oil seal remover, remove the input shaft oil seal from clutch housing.",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external cracks, if found replace.Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 38
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 71,
+ "sys_id": "THAR.AX-O-0007-Manual Transmission",
+ "subsys_id": "THAR.AX-O-0007-Manual Transmission-Transmission With Transfer Case",
+ "systems": "Manual Transmission",
+ "sub_systems": "Transmission With Transfer Case",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A110002.jpg",
+ "myid": 1151,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Transmission With Transfer Case-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110002.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21413.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/3013.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the battery negative terminal. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Rear Propeller Shaft Assembly. For additional information refer to Rear Propeller Shaft R &R; Session. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130015.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 8 mm socket spanner, loosen and remove the front propeller shaft mounting C clamp bolts from the transfer case.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque: 65 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110429.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110430.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the cross pin and detach the Shifter cable from the shifter control housing on transmission.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110453.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 0703AAD0009ST \u2013 Shifter and selector cable eye end removal tool, detach the Selector cable from the Shifter Control Housing ball pin.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110372.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110373.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110374.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110375.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Detach the Selector cable & Shifter cable abutments from the cable brackets on transmission by pressing locking clip and pull up the abutments.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Notice",
+ "content": "Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket.Torque: 44 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110008.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the transmission housing mounting bolts.",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Torque Value",
+ "content": "Torque: 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B110003.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Provide a jack to support the transmission.",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110011.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the transmission bed mounting bolts from transmission. ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Torque Value",
+ "content": "Torque: 25\u00b15 Nm ",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B110005.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using 14mm, 15mm socket and ring spanners, unscrew transmission cross member mounting bolts, nuts and detach it.",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Torque Value",
+ "content": "Torque: 65 \u00b110.0 Nm ",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B110004.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Lower the jack and remove the transmission along with the transfer case.",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110393.jpg",
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Carry-out clutch bleeding procedure. For additional information refer to clutch fluid Refilling and bleeding procedure. ",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Notice",
+ "content": "While refit Cables, Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install.",
+ "file": null,
+ "display_order": 57
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external oil leakage. Rectify if found.",
+ "file": null,
+ "display_order": 58
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 66,
+ "sys_id": "THAR.AX-O-0007-Manual Transmission",
+ "subsys_id": "THAR.AX-O-0007-Manual Transmission-Gear Cable Setting Procedure",
+ "systems": "Manual Transmission",
+ "sub_systems": "Gear Cable Setting Procedure",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A110443.jpg",
+ "myid": 1147,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Gear Cable Setting Procedure-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Gear Cable Setting",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110443.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Move the shifter cable quick adjuster outer cover in forward direction and unlock the QA clip in transmission end.",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110431.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Position the shifter control housing in Neutral Position on transmission.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110432.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Ensure the Selector cable is properly fitted on Shifter Control Housing ball pin on transmission. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110433.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110434.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Ensure the selector cable & shifter cable butments are properly fitted on transmission cable brackets.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110405.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the gear shifter lever knob with spring and 4WD selection knob. ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110406.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using trim removal tool, remove the Gear selection rod cover with trim.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110435.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Ensure the selector cable & shifter cable abutments are properly fitted on shifter lever bracket Inside passenger cabin.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110438.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Move the selector cable quick adjuster outer cover in forward direction and unlock the QA clip.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110439.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110448.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Insert the Neutral lock Special tool to shifter housing hole and lock the tool C profile to shifter lever as shown for ensuring selector & shifter arm in neutral position. ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110441.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "After Inserting the Neutral lock special tool, Shifter lever should not move in any direction. In this Condition press the selector cable QA clip as shown to lock it fully and release the quick adjuster outer cover.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Notice",
+ "content": "Ensure the proper locking by confirming/ hearing the click noise while install.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110389.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Ensure the shifter cable end is properly fitted on the shifter lever ball pin inside passenger cabin.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110431.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Ensure Transmission is in Neutral at transmission end.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110445.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "In this condition press the shifter cable QA clip towards arrow mark as shown to lock it fully and release the cable quick adjuster outer cover. ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Notice",
+ "content": "Ensure the proper locking by confirming/ hearing the click noise while install.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110446.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "After adjustment remove the special tool from shifter lever.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110449.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Refit the Gear selection rod cover with trim.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110405.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Refit the gear shifter level knob with spring and 4WD selection knob.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110450.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Inspect the shifter lever smooth shifting & gear engagement to all the gear range.",
+ "file": null,
+ "display_order": 38
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 85,
+ "sys_id": "THAR.AX-O-0007-Manual Transmission",
+ "subsys_id": "THAR.AX-O-0007-Manual Transmission-Manual Transmission System Technical Spec",
+ "systems": "Manual Transmission",
+ "sub_systems": "Manual Transmission System Technical Spec",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1163,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Manual Transmission System Technical Spec-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Technical Specification",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4023.pdf",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 79,
+ "sys_id": "THAR.AX-O-0007-Manual Transmission",
+ "subsys_id": "THAR.AX-O-0007-Manual Transmission-Transmission Rear End Oil Seal",
+ "systems": "Manual Transmission",
+ "sub_systems": "Transmission Rear End Oil Seal",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B110010.jpg",
+ "myid": 1159,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Transmission Rear End Oil Seal-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/files_VST-0059_Rear end oil seal installation.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B110010.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21542.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21543.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Remove the Transfer Case.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1008,1151",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110418.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a screw driver, remove the rear end oil seal from the Rear housing.",
+ "file": null,
+ "display_order": 8
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the oil seal for any damage. Replace if found any.",
+ "file": null,
+ "display_order": 9
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110098.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Position the rear end oil seal along with 0703BBA0002ST - Transmission Rear Housing Oil Seal Installer & install the oil seal using a mallet.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refit the Transfer Case.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1008,1151",
+ "file": null,
+ "display_order": 13
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 72,
+ "sys_id": "THAR.AX-O-0007-Manual Transmission",
+ "subsys_id": "THAR.AX-O-0007-Manual Transmission-Transmission",
+ "systems": "Manual Transmission",
+ "sub_systems": "Transmission",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B110001.jpg",
+ "myid": 1152,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Transmission-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B110001.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21442.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21443.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Transmission with Transfer case.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1008,1151",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110014.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Pull the clutch bleeder lock and detach the bleeder from CSC.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110015.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the CSC mounting bolts.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque: 25 \u00b1 3.5 Nm ( Step UP Torque \u2014 5, 15 , 25) ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110016.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110017.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 15 mm socket spanner/ combination spanner, loosen and remove the transfer case mounting nuts then detach the transfer case from the transmission.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque: 45 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carry-out clutch bleeding procedure. For additional information refer to clutch fluid Refilling and bleeding procedure. ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Check the Transmission oil level and topup if needed. ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1008,1146",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external oil leakage. Rectify if found.",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 82,
+ "sys_id": "THAR.AX-O-0007-Manual Transmission",
+ "subsys_id": "THAR.AX-O-0007-Manual Transmission-Sealant Specification",
+ "systems": "Manual Transmission",
+ "sub_systems": "Sealant Specification",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "",
+ "myid": 1162,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Sealant Specification-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Sealant Specification",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21653.jpg",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 80,
+ "sys_id": "THAR.AX-O-0007-Manual Transmission",
+ "subsys_id": "THAR.AX-O-0007-Manual Transmission-Shifter Control Housing Overhaul",
+ "systems": "Manual Transmission",
+ "sub_systems": "Shifter Control Housing Overhaul",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A11045500fdf4.jpg",
+ "myid": 1160,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Shifter Control Housing Overhaul-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21546.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21547.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Shifter Control Housing.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1008,1149",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110455.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110456.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "By Using 5 mm thin Punch & hammer, remove the Select lever guide locking pin and detach the guide.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110457.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Take out the control housing boot from the shift lever assembly.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110458.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "By using 3 mm Allen key, remove the Plug to access shift lever ball assembly locking pin.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110459.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110462.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "By Using 5 mm thin Punch and hammer, remove the shift lever ball assembly locking pin by accessing through plug hole.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110460.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the Shift lever assembly from the housing and remove the shift lever ball assembly as shown in the Illustration. ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110461.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the other side boot from the shift control housing.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110463.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "By using screw driver, remove the seal from the housing (One Side). ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110464.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "By using screw driver, remove the seal from the housing (Other Side).",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110465.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110466.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110467.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110468.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "By using M 8 flange headed bolt and 8 mm punch, remove the bush from the housing (One Side).",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Notice",
+ "content": "Position the M8 flange headed bolt on bush as shown above & hit the bolt by using punch and mallet.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110469.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110470.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110467.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110468.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "By using M 8 flange headed bolt and 8 mm punch, remove the bush from the housing (Other Side).",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Notice",
+ "content": "Position the M8 flange headed bolt on bush as shown above & hit the bolt by using punch and mallet.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110471.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "By using screw driver, remove the select lever circlip.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110473.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110474.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "By screw drive, hit the select lever shift pivot and remove the shaft.",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110475.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Detach select lever from the housing.",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110476.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "By using 15 mm ring/open end spanner, remove the breather from the housing.",
+ "file": null,
+ "display_order": 43
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110476.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "By using 15 mm ring/open end spanner,refit the breather on the housing.",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110477.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110478.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Position the select lever on housing and insert the select lever shaft on lever.",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110479.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Refit the select lever circlip on select lever by using nose plier.",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Shifter Control Housing Overhaulbdd090.png",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Shifter Control Housing Overhaul1823df6.png",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110481.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110465.jpg",
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Position the bush on housing (One side) and Install by using M8 flange headed bolt, 8 mm punch & mallet as shown illustration.",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "After Installation, Ensure bush face parallel to housing bore face as shown.",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110487.jpg",
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install the Oil seal by gently press by using hand or suitable dolly.",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110483.jpg",
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110484.jpg",
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110485.jpg",
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110469.jpg",
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Position the bush on housing (Other side) and Install by using M8 flange headed bolt, 8 mm punch & mallet as shown illustration.",
+ "file": null,
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Notice",
+ "content": "After Installation, Ensure bush face parallel to housing bore face as shown.",
+ "file": null,
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110488.jpg",
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install the Oil seal by gently press by using hand or suitable dolly (Other side).",
+ "file": null,
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110489.jpg",
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Refit the one side boot on shifter control housing.",
+ "file": null,
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110490.jpg",
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110492.jpg",
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Insert the shift lever assembly on housing and insert the Shift lever ball assembly to the shift lever assembly (As direction shown). ",
+ "file": null,
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110493.jpg",
+ "display_order": 72
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110494.jpg",
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110495.jpg",
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Align the Ball Assembly and shift lever shaft hole and Install the locking pin by using 5 mm punch and hammer. ",
+ "file": null,
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110496.jpg",
+ "display_order": 76
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Install the Plug on housing.",
+ "file": null,
+ "display_order": 77
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110497.jpg",
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Insert the other side control housing boot to the shift lever.",
+ "file": null,
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110498.jpg",
+ "display_order": 80
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Insert the lever guide on shift lever.",
+ "file": null,
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110499.jpg",
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Install the select lever guide locking pin by using 5 mm punch and hammer.",
+ "file": null,
+ "display_order": 83
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Refit the Shifter Control Housing. Torque: 21\u00b13 NM ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110365.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110368.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Refit the Selector cable & Shifter cable abutments on shift lever bracket.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": "Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110369.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Refit the Selector cable & Shifter cable on shift lever. ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110452.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Carry out Gear Cable Setting.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1008,1147",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Caution",
+ "content": "New Shifter Lever Assembly supplied with Gear shifter Neutral position tool, ensure to remove the tool from shifter housing after Gear cable setting.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Refit the Floor Console.",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1020,1340",
+ "file": null,
+ "display_order": 34
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the gear shift lever for any damage. Replace if found any.",
+ "file": null,
+ "display_order": 35
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 74,
+ "sys_id": "THAR.AX-O-0007-Manual Transmission",
+ "subsys_id": "THAR.AX-O-0007-Manual Transmission-Transmission Bed Mount",
+ "systems": "Manual Transmission",
+ "sub_systems": "Transmission Bed Mount",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B110008.jpg",
+ "myid": 1154,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Transmission Bed Mount-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B110008.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21532.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/53617.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B110003.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Support the transmission using jack. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110024.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 18 mm socket spanner, loosen and remove the transmission bed mount nuts.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110025.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 14 mm & 15 mm socket/ring spanner, loosen and remove the cross member mounting bolts & nuts then remove the transmission cross member.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque: 65\u00b1 10 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110021.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110085.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the transmission bed mounting bolts then remove the transmission bed mount from the vehicle",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque: 25\u00b15 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external oil leakage. Rectify if found.",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 73,
+ "sys_id": "THAR.AX-O-0007-Manual Transmission",
+ "subsys_id": "THAR.AX-O-0007-Manual Transmission-Gear Neutral Sensor (GNS)",
+ "systems": "Manual Transmission",
+ "sub_systems": "Gear Neutral Sensor (GNS)",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B110006.jpg",
+ "myid": 1153,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Gear Neutral Sensor (GNS)-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B110006.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21448.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21449.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110372.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110374.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110375.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Detach the Shifter cable abutment from the cable bracket on transmission by pressing locking clip and pull up the abutments.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket.* Do hold this cable damper to pull the cable from bracket.* Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110399.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the shifter cable bracket mounting bolts and remove the bracket.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110395.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the GNS electrical connection and detach the wiring routing clip.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110097.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 22 mm open end spanner, loosen & remove the Gear Neutral Sensor. ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110382.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "install in reverse order of removal.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "While Install cable, Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install.",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external damage, if found please replace.",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 83,
+ "sys_id": "THAR.AX-O-0007-Manual Transmission",
+ "subsys_id": "THAR.AX-O-0007-Manual Transmission-Sealant Application Pattern - MT",
+ "systems": "Manual Transmission",
+ "sub_systems": "Sealant Application Pattern - MT",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A110357.jpg",
+ "myid": 1515,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Sealant Application Pattern - MT-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Clutch Housing \u2013 Front Housing",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110357.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Bead width : 2\u00b10.5mm ",
+ "file": null,
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Front Housing \u2013 Intermediate Plate",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110276.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Bead width : 2\u00b10.5mm ",
+ "file": null,
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Intermediate Plate \u2013 Rear Housing",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110333.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Bead width : 2\u00b10.5mm ",
+ "file": null,
+ "display_order": 6
+ }
+ ]
+ },
+ {
+ "procedure_name": "Rear Housing \u2013 Gear Shift Control Housing",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110324.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Bead width : 2\u00b10.5mm ",
+ "file": null,
+ "display_order": 8
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 70,
+ "sys_id": "THAR.AX-O-0007-Manual Transmission",
+ "subsys_id": "THAR.AX-O-0007-Manual Transmission-Shifter And Selector Cable",
+ "systems": "Manual Transmission",
+ "sub_systems": "Shifter And Selector Cable",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A110408.jpg",
+ "myid": 1150,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Shifter And Selector Cable-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110408.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/VST-0069_SHIFTER & SELECTOR CABLE REMOVAL ( MT ) - NEW THAR.mp4",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21380.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21381.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Air Cleaner Assembly.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1000,1003",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Floor Console.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step 2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1020,1340",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110360.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110419.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 0703AAD0009ST \u2013 Shifter and selector cable eye end removal tool, detach the Selector cable & Shifter cable from the shift lever ball pins.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110361.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110364.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110362.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110363.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the Selector cable & Shifter cable abutments from the shifter bracket by pressing locking clip and pull up the abutments. ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket.* Do hold this cable damper to pull the cable from bracket.* Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110429.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110430.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the cross pin and detach the Shifter cable from the shifter control housing on transmission. ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Shifter and Selector Cable.png",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 0703AAD0009ST \u2013 Shifter and selector cable eye end removal tool, detach the Selector cable from the Shifter Control Housing ball pins. ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110373.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110372.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110374.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110375.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Detach the Selector cable & Shifter cable abutments from the cable brackets on transmission by pressing locking clip and pull up the abutments.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Notice",
+ "content": "Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket.* Do hold this cable damper to pull the cable from bracket.* Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110376.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the shifter & selector cable grommet mounting bolts.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110378.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110377.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Detach the shifter and selector cable from routing clips & take out from the vehicle.",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110379.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110377.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110380.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Routing the shifter and selector cable to the vehicle and position the cables on routing clips.",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Caution",
+ "content": "While routing the cable ensure to insert Selector cable in the left side of the Gear shifter lever and shifter cable in the right side.* Select & Shift cable should not cross each other.",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110376.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110381.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Refit the shifter & selector cable grommet mounting bolts and torque tighten the bolts.",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Torque Value",
+ "content": "Torque: 13\u00b1 2 Nm ",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Caution",
+ "content": "Ensure the cable grommet should get assemble from outside the cabin. ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110385.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110384.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110383.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Refit the selector cable & shifter cable abutments on transmission cable brackets.",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Notice",
+ "content": "Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install.",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110429.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Attach the Shifter cable on shifter control housing on transmission and refit the cross pin on Shifter control housing.",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110432.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Attach the Selector cable on Shifter Control Housing ball pins by hand.",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110361.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110362.jpg",
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Refit the selector cable & shifter cable abutments on shift lever bracket inside passenger cabin.",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Notice",
+ "content": "Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install.",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110454.jpg",
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Attach the Selector cable end on Shifter lever ball pin by hand. ",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110389.jpg",
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Refit the shifter cable end on Shifter lever ball pin by hand.",
+ "file": null,
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Carry out Gear Cable Setting.",
+ "file": null,
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1008,1147",
+ "file": null,
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Refit the Floor Console.",
+ "file": null,
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1020,1340",
+ "file": null,
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Refit the Air Cleaner Assembly.",
+ "file": null,
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1000,1003",
+ "file": null,
+ "display_order": 66
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the gear shift & select cables for any damage. Replace if found any.",
+ "file": null,
+ "display_order": 67
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 78,
+ "sys_id": "THAR.AX-O-0007-Manual Transmission",
+ "subsys_id": "THAR.AX-O-0007-Manual Transmission-Rear Housing",
+ "systems": "Manual Transmission",
+ "sub_systems": "Rear Housing",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A110072.jpg",
+ "myid": 1158,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Rear Housing-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110072.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B110009.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Rear housing is used to protect rear parts of transmission components from external environment. It is used to hold the Shifter Control Housing assembly & detent block.",
+ "file": null,
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21540.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21487.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the transmission oil.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1008,1146",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the transmission.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1008,1152",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110111.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110112.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, remove the gear control housing mounting bolts and then gently detach and remove the gear control housing assembly.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Yellow colored bolts are fitted with dowel inside, this bolts should be removed & refit first.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110114.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a T30 torx spanner, remove the torx bolt from the shift block actuator.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110116.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 22 mm socket spanner, remove the reverse switch. ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110119.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110120.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, remove the idler shaft front mounting bolt & using a 13 mm socket spanner remove the bottom idler shaft bolt.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110416.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the selector bracket mounting bolts.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110417.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the shifter bracket mounting bolts.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110121.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110122.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, remove the rear housing bolts from the front housing side.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Caution",
+ "content": "Ensure and take more care on not to breakage the front housing sealant while removing rear housing bolts from the front housing side.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110123.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner/Open end spanner, remove the rear housing mounting bolts. ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110124.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Turn the shift block actuator & release from the spring support.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110126.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110128.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110127.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110129.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "By using screw driver, release the rear housing dowels and using open end spanner detach the rear housing.",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Caution",
+ "content": "Release the dowels from the rear housing and ensure not to remove fully from the housing and it leads to touch the dowels on center housing projection as shown.* Use the open end spanner on both the side simultaneously.",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110130.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Lift the rear housing assembly along with the shift block actuator.",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110131.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Remove the rear housing assembly and take out shift block actuator from housing.",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110133.jpg",
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using a screw driver/suitable oil seal remover, remove the rear end oil seal from the Rear housing. ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110134.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, remove the H plate mounting bolts & the H plate assembly from the Rear housing. ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110135.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110037.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using hydraulic press, remove both the detents by pressing from outside to inside. ",
+ "file": null,
+ "display_order": 49
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external oil leakage. Rectify if found.",
+ "file": null,
+ "display_order": 50
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110319.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110135.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using suitable tool and hydraulic press, fit the detent (press from outside to inside)",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110320.jpg",
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Position the rear end oil seal along with 0703BBA0002ST - Transmission Rear Housing Oil Seal Installer & install the oil seal using a mallet.",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110321.jpg",
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Check for the rear end oil seal correct seating. ",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110134.jpg",
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Refit the H plate mounting bolts & torque tighten the bolts to specified value.",
+ "file": null,
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110333.jpg",
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110322.jpg",
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Apply loctite 5188 on Intermediate plate and insert the rear housing assembly.",
+ "file": null,
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110124.jpg",
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install the shift block actuator while installing the rear housing.",
+ "file": null,
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110123.jpg",
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Insert the rear housing mounting bolts,torque tighten the bolts specified value.",
+ "file": null,
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 30\u00b15 Nm ",
+ "file": null,
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110121.jpg",
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110122.jpg",
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Insert the rear housing mounting bolts,torque tighten the bolts specified value.",
+ "file": null,
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque : 30\u00b15 Nm ",
+ "file": null,
+ "display_order": 72
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110116.jpg",
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Refit the reverse light switch, torque tighten the switch to specified value. ",
+ "file": null,
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110119.jpg",
+ "display_order": 76
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110120.jpg",
+ "display_order": 77
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Insert the front & the bottom idler shaft mounting bolts, torque tighten the bolts to specified value.",
+ "file": null,
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque : Idler Shaft Bolts - 30\u00b15 Nm ",
+ "file": null,
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110417.jpg",
+ "display_order": 80
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Refit the shifter bracket with mounting bolts , torque tighten them to the specified value.",
+ "file": null,
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Torque Value",
+ "content": "Torque: 20.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110416.jpg",
+ "display_order": 83
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Refit the selector bracket with mounting bolts , torque tighten them to the specified value.",
+ "file": null,
+ "display_order": 84
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Torque Value",
+ "content": "Torque: 20.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 85
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110323.jpg",
+ "display_order": 86
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110114.jpg",
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Position the shift block actuator, apply Loctite 262 & insert the torx bolt and torque tighten the bolt to specified value.",
+ "file": null,
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Torque Value",
+ "content": "Torque : 10 - 15 Nm ",
+ "file": null,
+ "display_order": 89
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110324.jpg",
+ "display_order": 90
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110325.jpg",
+ "display_order": 91
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Apply 5188 loctite on the rear housing to fit gear control housing.",
+ "file": null,
+ "display_order": 92
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110111.jpg",
+ "display_order": 93
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110112.jpg",
+ "display_order": 94
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Refit the gear control housing & the mounting bolts. torque tighten the bolts to specified value.",
+ "file": null,
+ "display_order": 95
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Notice",
+ "content": "Yellow colored bolts are fitted with dowel inside, this bolts should be refit first. ",
+ "file": null,
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Torque Value",
+ "content": "Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 97
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 81,
+ "sys_id": "THAR.AX-O-0007-Manual Transmission",
+ "subsys_id": "THAR.AX-O-0007-Manual Transmission-Transmission Overhaul",
+ "systems": "Manual Transmission",
+ "sub_systems": "Transmission Overhaul",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A110111b846a2.jpg",
+ "myid": 1161,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Transmission Overhaul-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/VST-0070_TRANSMISSION 6RM320 OVERHAUL (MT) \u2013 NEW THAR.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21570.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21571.pdf",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Dis-assembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the Transmission fluid. For additional information refer to Transmission fluid Drain & Filling Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110111.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110112.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, remove the gear control housing mounting bolts and then gently detach and remove the gear control housing assembly.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Yellow colored bolts are fitted with dowel inside, this bolts should be removed & refit first.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110114.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a T30 torx spanner, remove the torx bolt from the shift block actuator.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110116.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 22 mm socket spanner, remove the reverse switch.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110117.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 22 mm open end spanner,remove the neutral sensor.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110119.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110120.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner,remove the idler shaft front mounting bolt & using a 13 mm socket spanner, remove the bottom idler shaft bolt.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110121.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110122.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, remove the rear housing bolts from the front housing side.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110123.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner/Open end spanner, remove the rear housing mounting bolts.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110124.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Turn the shift block actuator & release from the spring support.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110126.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110128.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110127.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110129.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "By using screw driver, release the rear housing dowels and using open end spanner, detach the rear housing.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Caution",
+ "content": "Release the dowels from the rear housing and ensure not to remove fully from the housing and it leads to touch the dowels on center housing projection as shown.Use the open end spanner on both the side simultaneously.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110130.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Lift the rear housing assembly along with the shift block actuator. ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110131.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Remove the rear housing assembly and take out shift block actuator from housing.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110133.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using a screw driver/suitable oil seal remover, remove the rear end oil seal from the Rear housing.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110134.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner remove the H plate mounting bolts & the H plate assembly from the Rear housing.",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110135.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using hydraulic press, remove both the detents by pressing from outside to inside.",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W390.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Remove the idler gear, shaft & the plastic support assembly.",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W391.jpg",
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Remove washer, idler gear & needle roller bearing from shaft.",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110138.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Remove main shift rod & the washers on both sides.",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Notice",
+ "content": "Ensure Gear in neutral position.",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110140.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Engage the 2nd gear.",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110141.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Engage the 4th gear.",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110142.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner remove the counter shaft lock bolt in clock wise direction.",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Notice",
+ "content": "The bolt is reverse threaded, hence rotate in clockwise for removing.",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110143.jpg",
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Using a MST 0703AD2720H116 \u2014 Lock Nut Dolly, loosen the output shaft lock nut.",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110144.jpg",
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110145.jpg",
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Using a bearing puller (SKF TMMR 120F), remove the counter shaft rear DGBB (Double Grove Ball Bearing).",
+ "file": null,
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Notice",
+ "content": "Use Counter shaft dummy bolt for support bearing puller. ",
+ "file": null,
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110146.jpg",
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110137.jpg",
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": "Using a puller (SKF TMMR 350F), remove the reverse driven gear, washer & CRB (Cylinder Roller Bearing) from output shaft.",
+ "file": null,
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110148.jpg",
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Remove reverse synchro ring and remove the reverse driven gear needle bearing & remove the bush. ",
+ "file": null,
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110149.jpg",
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110150.jpg",
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Remove reverse synchro stud and reverse fork & rail shift assembly along with reverse synchro sleeve from output shaft.",
+ "file": null,
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110152.jpg",
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Using a puller (SKF TMMR 350F) remove the reverse synchro hub from output shaft.",
+ "file": null,
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110153.jpg",
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110154.jpg",
+ "display_order": 72
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Using a puller (SKF TMMR 120F), remove the reverse drive gear, thrust washer & 5th drive gear from counter shaft.",
+ "file": null,
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110155.jpg",
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Description",
+ "content": "Remove the 5th drive gear NRB (Needle Roller Bearing) and 6th synchro ring.",
+ "file": null,
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110156.jpg",
+ "display_order": 76
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110157.jpg",
+ "display_order": 77
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "Description",
+ "content": "Using a suitable puller (SKF TMMR 350F) remove the 5th driven gear & bush from output shaft.",
+ "file": null,
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110158.jpg",
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110159.jpg",
+ "display_order": 80
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110160.jpg",
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "Description",
+ "content": "Remove the 5th & 6th synchro studs and remove the 5th & 6 th synchro sleeve along with fork & rail shift.",
+ "file": null,
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110161.jpg",
+ "display_order": 83
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110162.jpg",
+ "display_order": 84
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "Description",
+ "content": "Using a puller (SKF TMMR 120F) remove 5th drive gear bush, 5th & 6th synchro hub, synchro ring & 6th drive gear from counter shaft.",
+ "file": null,
+ "display_order": 85
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110163.jpg",
+ "display_order": 86
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "Description",
+ "content": "Remove the 6th drive gear NRB.",
+ "file": null,
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110164.jpg",
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, remove the clutch housing bolts.",
+ "file": null,
+ "display_order": 89
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110165.jpg",
+ "display_order": 90
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "Description",
+ "content": "Gently tap using plastic mallet & remove clutch housing.",
+ "file": null,
+ "display_order": 91
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110167.jpg",
+ "display_order": 92
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "Description",
+ "content": "Using a screw driver/suitable oil seal remover, remove the input shaft oil seal from clutch housing.",
+ "file": null,
+ "display_order": 93
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110168.jpg",
+ "display_order": 94
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "Description",
+ "content": "Using a snap ring removal tool/flat end screw driver, remove the input shaft snap ring from the front housing. ",
+ "file": null,
+ "display_order": 95
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110169.jpg",
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "Description",
+ "content": "Using a snap ring removal tool/flat end screw driver, remove the counter shaft snap ring from the front housing.",
+ "file": null,
+ "display_order": 97
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110170.jpg",
+ "display_order": 98
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "Description",
+ "content": "Using open end spanner, detach the front housing from the intermediate plate.",
+ "file": null,
+ "display_order": 99
+ },
+ {
+ "step_name": "Step-40",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110171.jpg",
+ "display_order": 100
+ },
+ {
+ "step_name": "Step-40",
+ "content_type": "Description",
+ "content": "Using a roll punch & hammer, remove the pin spring dowel from the 1st & 2nd shifter fork & rail assembly.",
+ "file": null,
+ "display_order": 101
+ },
+ {
+ "step_name": "Step-41",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110172.jpg",
+ "display_order": 102
+ },
+ {
+ "step_name": "Step-41",
+ "content_type": "Description",
+ "content": "Using a roll punch & hammer, remove the pin spring dowel from the 3rd & 4th shifter fork & remove fork rail assembly from intermediate plate. ",
+ "file": null,
+ "display_order": 103
+ },
+ {
+ "step_name": "Step-42",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110173.jpg",
+ "display_order": 104
+ },
+ {
+ "step_name": "Step-42",
+ "content_type": "Description",
+ "content": "By using snap ring removal tool,expand the output shaft snap ring and release the output shaft from intermediate plate.",
+ "file": null,
+ "display_order": 105
+ },
+ {
+ "step_name": "Step-43",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110174.jpg",
+ "display_order": 106
+ },
+ {
+ "step_name": "Step-43",
+ "content_type": "Description",
+ "content": "Using a mallet tap and remove the intermediate plate.",
+ "file": null,
+ "display_order": 107
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110175.jpg",
+ "display_order": 108
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "Description",
+ "content": "Remove the counter shaft assembly.",
+ "file": null,
+ "display_order": 109
+ },
+ {
+ "step_name": "Step-45",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110176.jpg",
+ "display_order": 110
+ },
+ {
+ "step_name": "Step-45",
+ "content_type": "Description",
+ "content": "Remove the output shaft assembly from the input shaft assembly.",
+ "file": null,
+ "display_order": 111
+ },
+ {
+ "step_name": "Step-46",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110177.jpg",
+ "display_order": 112
+ },
+ {
+ "step_name": "Step-46",
+ "content_type": "Description",
+ "content": "Remove the pilot bearing & Synchroring from input shaft.",
+ "file": null,
+ "display_order": 113
+ },
+ {
+ "step_name": "Step-47",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110179.jpg",
+ "display_order": 114
+ },
+ {
+ "step_name": "Step-47",
+ "content_type": "Description",
+ "content": "Using a circlip plier, remove the circlip from input shaft.",
+ "file": null,
+ "display_order": 115
+ },
+ {
+ "step_name": "Step-48",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110180.jpg",
+ "display_order": 116
+ },
+ {
+ "step_name": "Step-48",
+ "content_type": "Description",
+ "content": "By Using a puller (SKF TMBS 150E ) remove the DGBB from input shaft.",
+ "file": null,
+ "display_order": 117
+ },
+ {
+ "step_name": "Step-49",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110181.jpg",
+ "display_order": 118
+ },
+ {
+ "step_name": "Step-49",
+ "content_type": "Description",
+ "content": "Using a circlip plier, remove the circlip from counter shaft front end.",
+ "file": null,
+ "display_order": 119
+ },
+ {
+ "step_name": "Step-50",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110182.jpg",
+ "display_order": 120
+ },
+ {
+ "step_name": "Step-50",
+ "content_type": "Description",
+ "content": "By using a puller (SKF TMBS 150E) remove the DGBB from counter shaft front end.",
+ "file": null,
+ "display_order": 121
+ },
+ {
+ "step_name": "Step-51",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110183.jpg",
+ "display_order": 122
+ },
+ {
+ "step_name": "Step-51",
+ "content_type": "Description",
+ "content": "By using a puller (SKF TMMR 160F) remove the DGBB, 6th drive gear bush & thrust washer from counter shaft rear end.",
+ "file": null,
+ "display_order": 123
+ },
+ {
+ "step_name": "Step-52",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110184.jpg",
+ "display_order": 124
+ },
+ {
+ "step_name": "Step-52",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110185.jpg",
+ "display_order": 125
+ },
+ {
+ "step_name": "Step-52",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110228.jpg",
+ "display_order": 126
+ },
+ {
+ "step_name": "Step-52",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110186.jpg",
+ "display_order": 127
+ },
+ {
+ "step_name": "Step-52",
+ "content_type": "Description",
+ "content": "Using a puller (SKF TMBS 150E) remove the 1st driven gear, 2nd driven gear, 1st & 2nd synchro pack along with output shaft DGBB & 6th driven gear.",
+ "file": null,
+ "display_order": 128
+ },
+ {
+ "step_name": "Step-52",
+ "content_type": "Caution",
+ "content": "Engage puller legs in the 2nd driven gear. Remove in the sequence of 6th driven gear, output shaft DGBB, 1st driven gear with bush, 1st driven gear NRB, 1st & 2nd synchro pack, 2nd driven gear.",
+ "file": null,
+ "display_order": 129
+ },
+ {
+ "step_name": "Step-53",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110187.jpg",
+ "display_order": 130
+ },
+ {
+ "step_name": "Step-53",
+ "content_type": "Description",
+ "content": "Remove the 2nd driven gear NRB.",
+ "file": null,
+ "display_order": 131
+ },
+ {
+ "step_name": "Step-54",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110188.jpg",
+ "display_order": 132
+ },
+ {
+ "step_name": "Step-54",
+ "content_type": "Description",
+ "content": "Using a circlip plier remove the circlip from the output shaft.",
+ "file": null,
+ "display_order": 133
+ },
+ {
+ "step_name": "Step-55",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110189.jpg",
+ "display_order": 134
+ },
+ {
+ "step_name": "Step-55",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110190.jpg",
+ "display_order": 135
+ },
+ {
+ "step_name": "Step-55",
+ "content_type": "Description",
+ "content": "Remove the 3rd & 4th synchro studs & sleeve.",
+ "file": null,
+ "display_order": 136
+ },
+ {
+ "step_name": "Step-56",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110191.jpg",
+ "display_order": 137
+ },
+ {
+ "step_name": "Step-56",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110192.jpg",
+ "display_order": 138
+ },
+ {
+ "step_name": "Step-56",
+ "content_type": "Description",
+ "content": "Using puller (SKF TMMR 350F) remove the 3rd & 4th synchro hub, synchro ring & the 3rd driven gear assembly.",
+ "file": null,
+ "display_order": 139
+ },
+ {
+ "step_name": "Step-57",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110193.jpg",
+ "display_order": 140
+ },
+ {
+ "step_name": "Step-57",
+ "content_type": "Description",
+ "content": "Remove the 3rd driven gear NRB.",
+ "file": null,
+ "display_order": 141
+ },
+ {
+ "step_name": "Step-58",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110194.jpg",
+ "display_order": 142
+ },
+ {
+ "step_name": "Step-58",
+ "content_type": "Description",
+ "content": "Remove the output shaft.",
+ "file": null,
+ "display_order": 143
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110195.jpg",
+ "display_order": 144
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Shift Control Components ",
+ "file": null,
+ "display_order": 145
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check contact and sliding surfaces of shifter fork & rails for wear, scratches, projections and other damage. ",
+ "file": null,
+ "display_order": 146
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110196.jpg",
+ "display_order": 147
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110197.jpg",
+ "display_order": 148
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Heading",
+ "content": "Gear Components ",
+ "file": null,
+ "display_order": 149
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Check shafts for cracks, wear and bend. Synchronizers ",
+ "file": null,
+ "display_order": 152
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Check spline portion of coupling sleeves, synchronizer hubs, and gears for wear, chips, and racks.Bearings ",
+ "file": null,
+ "display_order": 155
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Make sure all bearings roll freely and are free from noise, cracks, pitting or wear.",
+ "file": null,
+ "display_order": 156
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 69,
+ "sys_id": "THAR.AX-O-0007-Manual Transmission",
+ "subsys_id": "THAR.AX-O-0007-Manual Transmission-Shifter Control Housing",
+ "systems": "Manual Transmission",
+ "sub_systems": "Shifter Control Housing",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A110076.jpg",
+ "myid": 1149,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Shifter Control Housing-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110076.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110054.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Shifter Control Housing is for gear selecting and shifting. It is connecting element between gear shift lever and shift rail through Shifter & Selector cables.",
+ "file": null,
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21373.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21374.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Transmission with Transfer case.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1008,1151",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110423.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110426.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110424.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110425.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, remove the gear control housing mounting bolts and then gently detach and remove the gear control housing assembly.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "Position the shifter lever in Natural Position on transmission.* Yellow colored bolts are fitted with dowel inside, this bolts should be removed & refit first.* While Installation, Apply sealant LOCTITE 5188 on the rear housing shifter control housing seating area .",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal, before installation apply the sealant if required.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Top up the transmission oil.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1008,1146",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the shift control housing for any damage. Replace if found any.",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 75,
+ "sys_id": "THAR.AX-O-0007-Manual Transmission",
+ "subsys_id": "THAR.AX-O-0007-Manual Transmission-Boot Gear Shifter Assembly",
+ "systems": "Manual Transmission",
+ "sub_systems": "Boot Gear Shifter Assembly",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A110404.jpg",
+ "myid": 1155,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Boot Gear Shifter Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110404.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21534.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/3015.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110405.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the gear shifter level knob with spring and 4WD selection knob.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110406.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using trim removal tool, remove the Gear selection rod cover with trim.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110407.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110415.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a screw driver , loosen and remove the gear selection rod cover mounting screw and detach boot from trim.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any damage. Rectify if found.",
+ "file": null,
+ "display_order": 12
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 67,
+ "sys_id": "THAR.AX-O-0007-Manual Transmission",
+ "subsys_id": "THAR.AX-O-0007-Manual Transmission-Transmission Oil - Replace",
+ "systems": "Manual Transmission",
+ "sub_systems": "Transmission Oil - Replace",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J10-MAT-0260",
+ "cover_image": "/files/W4B110001.jpg",
+ "myid": 1146,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 24,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 70,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 113,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 153,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 195,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 210,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 277,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 315,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 359,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 397,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 443,
+ "kilometers_applicable": 0
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Transmission Oil - Replace-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Transmission Oil - replace.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B110001.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "Description",
+ "content": "Position the vehicle on a 2 post /4 post lift.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "Description",
+ "content": "Transmission Oil \u2014 MAHINDRA \u201cMAXIMILE SYNTEC F2\u201d New Generation Genuine Transmission Fluid.\u2014 2.25 Litres.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21340.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Draining",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110342.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 8 mm square bit spanner, loosen and remove the filler plug.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110341.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 8 mm square bit spanner, loosen and remove the drain plug & allow the oil to drain out completely.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Place a tray or drain oil collecting bin under the drain plug to collect the oil.",
+ "file": null,
+ "display_order": 10
+ }
+ ]
+ },
+ {
+ "procedure_name": "Filling",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110341.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Install the drain plug. Torque tighten the drain plug to specified value.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Always replace the drain plug washer with a new one.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110343.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Fill recommended oil using an oil filling machine or by clean transparent pipe attached to the mechanical hand pump.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "Ensure that the oil level is up to lower most point of the filler plug.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110090.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Refit the filler plug. Torque tighten the filler plug to specified value.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Recommend to use only Mahindra MAXIMILE SYNTEC F2 new generation genuine transmission fluid.
Check for any damages on seat trims. Replace if required.
",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 240,
+ "sys_id": "THAR.AX-O-0007-Seat System",
+ "subsys_id": "THAR.AX-O-0007-Seat System-Driver Seat Back Rest Frame",
+ "systems": "Seat System",
+ "sub_systems": "Driver Seat Back Rest Frame",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B230126.jpg",
+ "myid": 1353,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Driver Seat Back Rest Frame-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230126.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12384.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12385.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Driver Seat Back Rest foam with Cover.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1022,1351",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew luggage hook mounting screw and remove it from the frame assy.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230127.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Separate the driver seat back rest frame.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230128.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 10
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the frame for any damages. Replace if required.",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 238,
+ "sys_id": "THAR.AX-O-0007-Seat System",
+ "subsys_id": "THAR.AX-O-0007-Seat System-Driver Seat Back Rest Foam with Cover",
+ "systems": "Seat System",
+ "sub_systems": "Driver Seat Back Rest Foam with Cover",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B230117.jpg",
+ "myid": 1351,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Driver Seat Back Rest Foam with Cover-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230117.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12370.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove Driver Seat Back Rest Assembly.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1022,1350",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Open the seat cover strip back side of back rest assy.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230146.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Unzip the seat cover LH & RH sides.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230075.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230076.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Press the lock and remove the head rest guide inside seat cover.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230119.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove foam with cover from back rest frame.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Excessive pull or improper removal may leads to damage the foam and seat cover. ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/Driver Seat Back Rest Foam with cover1.png",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any damages.Replace if required.For additional information refer to the Rear Seat Recliner Covers - R &R; section. ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Detach the seat folding cable from the lock and remove the cable.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230038.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the cable from the bottom cushion routing bracket.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230049.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the cable from the seat.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230050.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 10
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Check seat folding cable for any damages. Replace if found.",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 237,
+ "sys_id": "THAR.AX-O-0007-Seat System",
+ "subsys_id": "THAR.AX-O-0007-Seat System-Driver Seat Back Rest Assembly",
+ "systems": "Seat System",
+ "sub_systems": "Driver Seat Back Rest Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B230115.jpg",
+ "myid": 1350,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Driver Seat Back Rest Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230115.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12351.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12352.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove Diver Seat Assembly. For additional information refer to Driver Seat Assembly - R &R Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove seat recliner and height adjustment handle cover. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230102.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230100.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "By using star screw driver remove seat height adjustment handle mounting screws & remove the handle.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230101.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "By using star screw driver, remove LH & RH valance cover mounting screws and detach the covers.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230103.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230104.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230105.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230107.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230108.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230109.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach back cushion cover lock from seat bottom.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230071.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using T50 torx socket spanner, Unscrew back rest mounting bolts.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230110.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque: 47.5 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230111.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Detach the back rest from Seat assembly.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230112.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Press the Lock and remove the head rest from the back rest assembly.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230113.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230114.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 28
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any damages. Replace if required. Torque : 10 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the wiper motor separately.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A320051.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 13
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the motor for any damage. Replace if found any.Torque : 10.50 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the wiper motor and link assembly from vehicle.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A320035.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A320036.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the motor for any damage. Replace if found any.For additional information refer to Roof Speaker - R &R; section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Roof Tweeter LH & RH. For additional information refer to Roof Tweeter - R &R; section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a trim removal tool pull out center bow trim and disconnect roof lamp electrical connector.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240016.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240018.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the sound bar electrical connector.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280057.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew sound bar mounting bolts.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280058.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Detach the Wiring Harness from routing and remove from the sound bar assembly.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280051.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1036.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the Wiring Harness for any physical damage. Replace if found.For additional information refer to Driver Sun Visor - R &R; Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Co-Driver Sun Visor. For additional information refer to Co-Driver Sun Visor - R &R; Section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using Torx screw driver, Unscrew Centre bow trim mounting screw and detach the bow trim.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280010.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280011.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the MIC electrical.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W652.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the MIC from Centre bow trim.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280013.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280009.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the MIC unit for any damage.Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1015.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect Infotainment electrical connectors.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1016.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the Infotainment unit.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290007.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the infotainment unit for any damage.Torque Value: 3 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280048.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the antenna electrical connector through wheel arch.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280049.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1035.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the antenna assembly separately.",
+ "file": null,
+ "display_order": 13
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the antenna assembly and connector for any physical damage. Replace if found.",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 306,
+ "sys_id": "THAR.AX-O-0007-Infotainment Assembly",
+ "subsys_id": "THAR.AX-O-0007-Infotainment Assembly-USB And DOC Station",
+ "systems": "Infotainment Assembly",
+ "sub_systems": "USB And DOC Station",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/USB.png",
+ "myid": 1419,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-USB And DOC Station-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/USB.png",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1018.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12705.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console RH screvits and detach the panel from vehicle.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280032.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console LH screvits and detach the panel from vehicle.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1019.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew vertical ascent RH mounting screw and detach the vertical ascent RH from vehicle.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1020.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew vertical ascent LH mounting screw and detach the vertical ascent LH from vehicle.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1021.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "partially detach the switch bang assembly and remove electric connector to take out from the vehicle.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1022.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1023.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully pull and remove the Audio Unit port Assembly.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280037.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect the Audio Unit port electrical connectors and 12 volt electric connector.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280038.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the ,Audio Unit port mounting screws.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1024.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the USB and DOC station assembly from the trim.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1025.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 28
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the USB and DOC station assembly unit for any damage.
Brake and Clutch Fluid: Mahindra Maximile DOT 4 Genuine Brake fluid.
Brake and Clutch Fluid: 1.75 Liters (Including bleeding quantity)
Use recommended fluid & do not mix different brand fluids. *case fluid reservoir replaced, brake and clutch system needs bleeding.*the same brand fluid for top up; do not top up brake fluid from used and unsealed brake fluid container. *Brake fluid reservoir cap/ container should not be opened with dirty hands.*direct water spray on reservoir while washing engine compartment. *use Mahindra 'Maximile DOT 4' genuine Brake fluid.*Maximile DOT 4 brake fluid is not available and in emergency conditions, use Brake Fluid Meeting SAE J1703 FMVSS NO.116 DOT 4 OR IS 8654 TYPE-2 Specification. Change it at 30,000 km or 2 years whichever is earlier. ",
+ "file": null,
+ "display_order": 12
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 63,
+ "sys_id": "THAR.AX-O-0007-Clutch",
+ "subsys_id": "THAR.AX-O-0007-Clutch-Troubleshoot - Clutch",
+ "systems": "Clutch",
+ "sub_systems": "Troubleshoot - Clutch",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1458,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Troubleshoot - Clutch-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Unless the cause of a clutch problem is extremely obvious, accurate problem diagnosis will require a road test to confirm whether the problem exists or not.clutch slip is suspected then drive the vehicle in 1st or 2nd gear at the top speed (corresponding to the gear). Keeping the accelerator fully pressed; slowly apply the brake with your left feet. If the engine stalls then the clutch is not slipping.oil seal or transmission input shaft. The oil leaks from either of these areas will normally coat the housing interior or clutch cover or flywheel. Heat buildup due to slippage between the clutch plate and the flywheel or the pressure plate can result into the leaked oil literally getting baked. Visually this will result in a glazed residue varying from amber to black.loosen bolt or torn rubber boot. Normally the clutch housing misalignment is a result of:
1st and 2nd gear can be due to clutch not getting disengaged completely. To check, turn the engine OFF, shift the gear lever to 1st or 2nd gear and then jack up the rear axle till both the wheels gets lifted enough from the ground.wheels should not be spinning after that slowly release the pedal till it has moved about 10 mm, the wheel should still not be spinning. If some spinning is noticed then it indicates improper lift of the pressure plate.For additional information refer to Transmission Assembly With Transfer Case \u2014 R &R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1008,1151",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Put the dust cap/cotton cloth in CSC nozzle port during clutch or transmission service.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100053.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Pull the locking clip outwards using a small flat end screw driver and disconnect concentric slave cylinder upper part of bleeder.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100054.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "using a 12mm socket spanner remove concentric slave cylinder mounting bolts .",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 25\u00b13.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100055.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove concentric slave cylinder assembly.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carry-out clutch circuit bleeding. For additional information refer to Clutch Fluid Air Bleeding Procedure. ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1007,1133",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100101.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect clutch slave cylinder for any leakages.The push & pull gauge should be in line with the clutch pedal travel direction. Do not push the gauge by holding the top end. It would give us a wrong reading due to the extra force applied. New clutch assembly 9 -12 Kgf (88-118N). \ufeff Go to Step 2. Go to Step 3. Go to Step 4. Clutch Disc & Cover Inspection Procedure.
For additional information refer to Clutch Pressure Plate & Disc - R&R section.\ufeff ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B100017.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100099.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "using a MST 543 - Extractor flywheel bearing, remove the Flywheel Pilot Bearing.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B100019.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B100018.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B100020.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Refit the Flywheel Pilot Bearing by using MST 0312CBH0001ST - Flywheel Pilot Bearing Installer.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Refit the clutch pressure plate & disc . For additional information refer to Clutch Pressure Plate & Disc - R&R section. ",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the pilot bearing for any damage, crack. Replace if found any.",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 58,
+ "sys_id": "THAR.AX-O-0007-Clutch",
+ "subsys_id": "THAR.AX-O-0007-Clutch-Single Mass Flywheel (SMF)",
+ "systems": "Clutch",
+ "sub_systems": "Single Mass Flywheel (SMF)",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B100014.jpg",
+ "myid": 1139,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Single Mass Flywheel (SMF)-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B100014.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30861.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30862.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the clutch pressure plate & disc . For additional information refer to Clutch Pressure Plate & Disc - R&R; section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100084.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Lock the flywheel using MST 0307ABH0001ST \u2014 Flywheel Locking Tool.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B100024.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B100026.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 19 mm socket spanner, remove flywheel mounting bolts and detach the flywheel.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 50 \u00b1 3 Nm + 45\u00b0\u00b11\u00b0 ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100080.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the flywheel assembly.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Always replace flywheel mounting bolts with new one before installation.* Tighten the flywheel as per sequence and torque tighten the bolts to specified value.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 50 \u00b1 3 Nm + 45\u00b0\u00b11\u00b0 ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carry-out clutch circuit air bleeding. For additional information refer to Clutch Fluid Air Bleeding Procedure. ",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check Flywheel face-out and run-out.* Check Flywheel Surface Thermal Cracks Condition.* Check the flywheel ring gear for worn-out or damage.",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 57,
+ "sys_id": "THAR.AX-O-0007-Clutch",
+ "subsys_id": "THAR.AX-O-0007-Clutch-Clutch Cover Assembly",
+ "systems": "Clutch",
+ "sub_systems": "Clutch Cover Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A100002.jpg",
+ "myid": 1138,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Clutch Cover Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/VST-0064_Flywheel Locking & Clutch Centering.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100002.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B100013.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "The clutch cover is a diaphragm type with single-piece construction.For additional information refer to the transmission assembly with transfer case \u2014 R&R section. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1008,1151",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100084.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Lock the flywheel using MST 0307ABH0001ST \u2014Flywheel Locking Tool.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B100021.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B100022.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove clutch cover assembly mounting bolts.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "Insert MST 0801BUA0001ST \u2014 Clutch Disc Aligner Tool, before loosening the clutch cover bolts to prevent clutch plate falling down and getting damage. ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 5Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B100026.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100056.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the clutch cover assembly along with the clutch disc.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100059.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the clutch disc from clutch cove assembly.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100088.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B100022.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "While Installation, the projected part of clutch plate should come towards transmission side only, false installation can lead to clutch plate damage. *Installation, Using MST 0801BUA0001ST \u2014 Clutch Disc Aligner Tool, align the clutch cover assembly and clutch disc and fix the clutch cover assembly with the help of mounting bolts.2 post lift /4 post lift.
Clutch/Brake Fluid- Mahindra 'Maximile DOT 4' Genuine Brake fluid.Clutch/Brake FluidCapacity- 1.75 Liters (Including bleeding quantity).Entire bleeding operation should be done with engine ON condition. In case of fluid reservoir or brake fluid replacement, bleeding of brake circuit is required. Always use recommended fluid and do not mix different brand fluids. Always use fresh and clean fluid from a sealed container. Do not reuse the drained fluid. Fluid level in the reservoir must be at MAX level at the start of bleeding and should be checked after bleeding each brake circuit and top up as required. MAX mark on brake fluid reservoir.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100076.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Press and release the clutch pedal gently to full stroke a few times for the fluid to enter completely in the circuit.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100091.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100077.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove bleeder plug cap from clutch operating slave cylinder pipe. Attach a vinyl tube to bleeder plug and insert the other end into container. Ensure that the other end of the tube is fully immersed in the bottle having clean clutch /brake fluid.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "If the bleeding operation is done without connecting a tube and in the open air then the chance of air trapped in the system is high. Ensure that the other end of the tube is fully immersed in the bottle having clean brake fluid. Ensure to check any leakage in the bundy tube connector & bleeding plug cap, if leak found ensure to fit properly the bundy tube connector & bleeding plug cap. ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "If pedal sponginess is present do the entire bleeding procedure again.",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Caution",
+ "content": "Check clutch pedal for sponginess. If found spongy, repeat the entire procedure of bleeding. *and ensure there is no leakage from pipes and joints.*not spill brake fluid on the vehicle, it may damage the paint, if the brake fluid does contact the paint, wash it off immediately with water. *sure no dirt or other foreign matter is allowed to contaminate the brake fluid.*fluid reservoir cap should not be opened with dirty hands. *direct water spray on reservoir while washing engine compartment.*Maximile DOT 4 brake fluid is not available and in emergency conditions, use Brake Fluid Meeting SAE J1703 FMVSS NO.116 DOT 4 OR IS 8654 TYPE-2 Specification. Change it at 30,000 km or 2 years whichever is earlier. *the bleeding operation ensure the container and pipe used is of transparent for better visual.*all times during the bleeding process, it has to be ensured that the fluid level in the reservoir does not drop below minimum. ",
+ "file": null,
+ "display_order": 43
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 55,
+ "sys_id": "THAR.AX-O-0007-Clutch",
+ "subsys_id": "THAR.AX-O-0007-Clutch-Clutch Master Cylinder",
+ "systems": "Clutch",
+ "sub_systems": "Clutch Master Cylinder",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A100065.jpg",
+ "myid": 1136,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Clutch Master Cylinder-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100065.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B100009.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "The clutch master cylinder push rod is connected to clutch pedal. The clutch master cylinder converts driver's foot effort to hydraulic pressure and transmits the pressure to the slave cylinder through clutch bundy tube.",
+ "file": null,
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30832.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30833.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the transmission assembly with transfer case.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1008,1151",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B100008.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Detach clutch master cylinder(CMC) fluid inlet hose CMC end.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100044.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Pull the lock clip upwards and detach clutch high pressure pipe CMC end.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100042.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the clutch master cylinder.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carry-out clutch circuit bleeding. For additional information refer to Clutch Fluid Air Bleeding Procedure. ",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the clutch high pressure tube for any damage. Replace if found.more than 2 mm. ",
+ "file": null,
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Switch off the ignition.",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the clutch pedal box assembly. For additional information refer to Clutch Pedal box Assembly - R&R section. ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100073.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Loosen the sensor lock nut with the help of 13 mm open end spanner.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100074.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Insert a 2 mm spacer in the gap between magnetic holder and sensor body.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100071.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 12 mm open end spanner, adjust the magnetic holder till it touches the surface of spacer, thus maintain 2 \u00b10.5 mm gap between sensor body and magnetic holder.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100073.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Tighten the sensor lock nut.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refit he clutch pedal box assembly. For additional information refer to Clutch Pedal box Assembly - R &R section. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "After completing the clutch sensor setting, connect i-SMART and navigate to THAR \u2014 THAR_BS6.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Select \u201cEMS\u201d in the ECU List.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Click on \u201cLIVE DATA\u201d and select \u201cDriveability\u201d. ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Release the clutch pedal fully, the value of clutch status should be \u201c64\u201d. ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Press the clutch pedal to 10%, the value of clutch status should be \u201c65\u201d. ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Press the clutch pedal fully, the value of clutch status should be \u201c81\u201d. ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "If the clutch status value is not changing according to different clutch pedal position, re-adjust the clutch sensor.",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 310,
+ "sys_id": "THAR.AX-O-0007-en-SM-Bumpers",
+ "system_name": "Bumpers",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1029,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 310,
+ "sys_id": "THAR.AX-O-0007-Bumpers",
+ "subsys_id": "THAR.AX-O-0007-Bumpers-Front Bumper Assembly",
+ "systems": "Bumpers",
+ "sub_systems": "Front Bumper Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A290021.jpg",
+ "myid": 1423,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Front Bumper Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290021.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31379.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31378.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the front splash shield mounting screw rivets from both the sides of vehicle.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250019.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250119.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the front splash shield both the sides from vehicle.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250020.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250120.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the front stone guard front mounting bolts.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250032.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen and remove the rear stone guard rear mounting bolts.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250064.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the stone guard mounting screw rivets.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250033.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the stone guard from the vehicle.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250034.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect the fog lamp electrical connectors LH & RH sides.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270025.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W419.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Pull and remove the front bumper winch cover clips and remove the panel.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290002.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front bumper mounting nuts.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290003.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290004.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew front bumper bottom mounting bolts.",
+ "file": "/files/W4A290005.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front bumper top side mounting bolts.",
+ "file": "/files/W634.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front bumper top centre mounting screw rivets..",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W635.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Remove the front bumper assembly from the vehicle.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W636.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290022.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 39
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the front bumper assembly for any crack or damage. Replace if found.",
+ "file": null,
+ "display_order": 40
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 312,
+ "sys_id": "THAR.AX-O-0007-Bumpers",
+ "subsys_id": "THAR.AX-O-0007-Bumpers-Fender Assembly",
+ "systems": "Bumpers",
+ "sub_systems": "Fender Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A250179.jpg",
+ "myid": 1425,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Fender Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250179.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31420.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31419.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove Front Turn Indicator And DRL LH. For additional information refer to Remove Front Turn Indicator And DRL LH - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Splash Shield Front LH. For additional information refer to Splash Shield Front Lower LH - R&R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove Scuttle Grill.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1024,1373",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a screw driver, unscrew the antenna from the fender LH.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250181.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 3\u00b11 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the front grill mounting screw rivets.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W650.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm combination spanner, Unscrew show lock mounting nut fender end.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250140.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250139.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew fender top mounting bolts.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250142.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew fender side mounting bolts.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250143.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew fender bottom mounting bolts.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250180.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew fender mounting bolts door side.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250144.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the fender from vehicle.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250183.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250182.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 33
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the fender panel for any damage. Replace if found.",
+ "file": null,
+ "display_order": 34
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 311,
+ "sys_id": "THAR.AX-O-0007-Bumpers",
+ "subsys_id": "THAR.AX-O-0007-Bumpers-Rear Bumper Assembly",
+ "systems": "Bumpers",
+ "sub_systems": "Rear Bumper Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W420.jpg",
+ "myid": 1424,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Rear Bumper Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W420.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/53621.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/53622.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Cladding Rear Wheel Arch RH. For additional information refer to Cladding Rear Wheel Arch RH - R &R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Cladding Rear Wheel Arch LH. For additional information refer to Cladding Rear Wheel Arch LH - R &R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Open the tail gate.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260100.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the rear fender RH/ LH side mounting screws.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W637.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W638.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the rear bumper bottom side mounting screwrivets.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W639.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a star screw driver , loosen and remove the rear bumper side mounting screws.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W640.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W641.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew the rear bumper mounting bolts body end.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290040.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Flip the bumper and disconnect the electrical main connectors and remove rear bumper.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W642.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W643.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the wiring routing clips from the bumper assembly.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290043.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Disconnect the rear parking sensor electrical connectors.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W644.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Disconnect license plate electrical connector.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W645.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Remove the rear bumper wiring harness.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W646.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Remove the parking sensors with holder.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W647.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Remove the license plate lamp from rear bumper assembly.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W648.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W649.jpg",
+ "display_order": 34
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the rear bumper assembly for any crack or damage. Replace if found.",
+ "file": null,
+ "display_order": 35
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 322,
+ "sys_id": "THAR.AX-O-0007-en-SM-Electrical Components And Electrical Wiring Harness",
+ "system_name": "Electrical Components And Electrical Wiring Harness",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1034,
+ "active_status": true,
+ "Assets": [
+ {
+ "systemdisplayorder": 11,
+ "system_asset": "/files/CAN COMMUNICATION_V4.mp4",
+ "active_status": true
+ },
+ {
+ "systemdisplayorder": 13,
+ "system_asset": "/files/ELECTRONIC CONTROL UNIT (ECU)_V3.mp4",
+ "active_status": true
+ },
+ {
+ "systemdisplayorder": 14,
+ "system_asset": "/files/ElectricalComponents_G.mp4",
+ "active_status": true
+ },
+ {
+ "systemdisplayorder": 15,
+ "system_asset": "/files/Fusebox_V3.mp4",
+ "active_status": true
+ },
+ {
+ "systemdisplayorder": 12,
+ "system_asset": "/files/ECU IO - v9.mp4",
+ "active_status": true
+ },
+ {
+ "systemdisplayorder": 16,
+ "system_asset": "/files/WiringHarness_G.mp4",
+ "active_status": true
+ }
+ ],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 322,
+ "sys_id": "THAR.AX-O-0007-Electrical Components And Electrical Wiring Harness",
+ "subsys_id": "THAR.AX-O-0007-Electrical Components And Electrical Wiring Harness-DTC (Diagnostic Trouble Code) \u2013 Check",
+ "systems": "Electrical Components And Electrical Wiring Harness",
+ "sub_systems": "DTC (Diagnostic Trouble Code) \u2013 Check",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J10-MAT-0690",
+ "cover_image": "/files/W1E030251.jpg",
+ "myid": 1434,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 16,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 63,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 105,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 144,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 188,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 226,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 271,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 309,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 352,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 389,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 436,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-DTC (Diagnostic Trouble Code) \u2013 Check-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Preliminary Activities/ Conditions",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/DTC - Check.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Preliminary Activities/ Conditions",
+ "content_type": "Description",
+ "content": "2 post lift/ 4 post lift. \ufeff i-SMART diagnostic tester and turn the ignition ON. ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Click the VCI SELECTION. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1E030251.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Select Dearborn Electronics India Pvt Ltd. \u2013 Garuda and then click START. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1E030252.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Select THAR from the list of vehicles displayed as in following window then select the HAR_ BS6. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W653.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Click on the GENERATE button on the bottom right side of the Express View screen to generate DTC report. This will generate and store a report.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030246.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030247.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Once completed, i-SMART will prompt to open Excel file.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W654.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "If any DTC is active, Refer Diagnostic manual for more information. ",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "DTC \u2014 Check Procedure using miniSMART ANDROID",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Connect the miniSMART Bluetooth VCI on DLC and turn the ignition ON. ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Pair the Bluetooth of android tablet / smartphone with miniSMART VCI.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Launch the miniSMART App and select the THAR from the vehicle list.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Connect the miniSMART Android and select each \u201cECU\u201d from the list of controllers.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W655.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "From the list, select DTC Fetch. ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W656.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "The ECU will be analysed and the registered DTCs will be displayed, then take screen shots of all registered DTCs and their Freeze Frame data by clicking over the DTC / FF icon, for records.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "If any DTC is active, Refer Diagnostic manual for more information. ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Repeat the above steps 4 to 7 for other ECU\u2019s present in the vehicle.",
+ "file": null,
+ "display_order": 25
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 324,
+ "sys_id": "THAR.AX-O-0007-Electrical Components And Electrical Wiring Harness",
+ "subsys_id": "THAR.AX-O-0007-Electrical Components And Electrical Wiring Harness-Engine Wiring Harness",
+ "systems": "Electrical Components And Electrical Wiring Harness",
+ "sub_systems": "Engine Wiring Harness",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B370001.jpg",
+ "myid": 1436,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Engine Wiring Harness-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B370001.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31467.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31466.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect engine WH connector ECU end and detach harness from routing clips.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010078.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect AC compressor electrical connector.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010085.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew ignition coil ground connector mounting nut.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010227.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect Variable oil pump solenoid electrical connector.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010086.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect upstream Lambda sensor electrical connector and connector holder.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010093.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect Engine oil pressure sensor electrical connector and routing clip.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010090.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Disconnect WGTelectrical connector.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010091.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Disconnect Dump valve electrical connector and routing clip.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010194.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010234.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Disconnect VVT IN (Intake Phaser) electrical connector.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3112.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Disconnect VVT Out (Outlet Phaser) electrical connector.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3113.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Disconnect Throttle Valve Actuator & Position Sensor electrical connectors.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3114.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Disconnect Spark plug (4 nos) electrical connectors.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010094.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Disconnect Glow Plug inter-connector.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010195.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Disconnect downstream lambda sensor electrical connector and routing clip.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010089.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010233.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Disconnect Exhaust CAM sensor electrical connector.",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010134.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Disconnect Intake CAM phase sensor electrical connector.",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010095.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Disconnect Crankshaft Sensor electrical connectors.",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3115.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Disconnect Coolant temperature sensor electrical connector.",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010098.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Disconnect FIP electrical connector.",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010228.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Disconnect Common rail electrical connector.",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010096.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Disconnect Injector (4 nos) electrical connector.",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010099.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Disconnect Knock sensor electrical connector & routing clips.",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010100.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010105.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": "Disconnect Alternator connector & routing clip.",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010231.jpg",
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Using 8 mm socket spanner, Unscrew starter motor solenoid switch electrical connector.",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B090002.jpg",
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Disconnect reverse switch electrical connector.",
+ "file": "/files/W4A03C016_C 110.jpg",
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A03C017_C 110_1.jpg",
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Disconnect GNS electrical connector.",
+ "file": null,
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A03C007_C 12.jpg",
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Disconnect transfercase switch electrical connector.",
+ "file": null,
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120021.jpg",
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Description",
+ "content": "Detach WH routing clips.",
+ "file": null,
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W660.jpg",
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370020.jpg",
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "Description",
+ "content": "Detach Engine WH on intake manifold side.",
+ "file": null,
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W661.jpg",
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010132.jpg",
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew engine WH carrier mounting bolts.",
+ "file": null,
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010084.jpg",
+ "display_order": 72
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "Description",
+ "content": "Disconnect engine WH inter connector, Holding clip and routing clip fire wall end. ",
+ "file": null,
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010077.jpg",
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010130.jpg",
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "Description",
+ "content": "Detach the WH harness from engine assembly.",
+ "file": null,
+ "display_order": 76
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010104.jpg",
+ "display_order": 77
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010106.jpg",
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "Description",
+ "content": "Detach engine wiring harness from engine compartment.",
+ "file": null,
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370021.jpg",
+ "display_order": 80
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "Notice",
+ "content": "Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Torque tighten the earth mounting nuts to specified values.
\ufeff Connect diagnostic tool connector and clear any DTC\u2019s if registered.
",
+ "file": null,
+ "display_order": 82
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the wiring harness for any external damage, If any replace it.",
+ "file": null,
+ "display_order": 83
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 332,
+ "sys_id": "THAR.AX-O-0007-Electrical Components And Electrical Wiring Harness",
+ "subsys_id": "THAR.AX-O-0007-Electrical Components And Electrical Wiring Harness-Telltale Bank (Soft Top)",
+ "systems": "Electrical Components And Electrical Wiring Harness",
+ "sub_systems": "Telltale Bank (Soft Top)",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A220130.jpg",
+ "myid": 1446,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Telltale Bank (Soft Top)-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220130.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31666.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31665.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the cable.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W671.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove HVAC Control Panel (Manual).",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1017,1299",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Carefully pull the Telltale Bank from inside.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280037.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the Telltale Bank electrical connectors and 12 volt electric connector and remove the Assy from IP.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280038.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using star screw driver remove Telltale bank mounting screws.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220132.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 1.5 \u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the telltale bank.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220131.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Connect diagnostic tool connector and clear any DTC\u2019s if registered.",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the telltale bank for any external damage, If any replace it.",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 326,
+ "sys_id": "THAR.AX-O-0007-Electrical Components And Electrical Wiring Harness",
+ "subsys_id": "THAR.AX-O-0007-Electrical Components And Electrical Wiring Harness-Instrument Panel Wiring Harness",
+ "systems": "Electrical Components And Electrical Wiring Harness",
+ "sub_systems": "Instrument Panel Wiring Harness",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A370007.jpg",
+ "myid": 1439,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Instrument Panel Wiring Harness-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370007.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31563.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31562.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the cable.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W663.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Instrument Panel Assembly.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1015,1249",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew fuse box mounting bolts.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3119.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 4 .0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the RH side door to IP interconnector and holding clip.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3120.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect engine compartment to IP RH side inter-connector and holding clips.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3121.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect the MBFM electrical connectors.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3122.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3123.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3124.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew ground cable mounting nuts and detach the connectors.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3125.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Disconnect the ignition key barrel electrical connectors.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3126.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Disconnect the HVAC assembly electrical connectors.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3127.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Disconnect LH door electrical connector.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3128.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Disconnect the IP to Roof wiring harness inter-connector.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3129.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Disconnect LH side IP to engine interconnectors with holding clip.",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3130.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew earth cable mounting nuts.",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3131.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Remove the IP wiring routing clips from CCB.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3132.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Remove the front LH scuff Plate. For additional information refer to Front LH Scuff Plate - R &R section. ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Detach the LH B pillar partially.",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3133.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Disconnect the Pre tensioner electrical connectors LH side.",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3134.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Disconnect the LH seat electrical connector and routing clips.",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3135.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Disconnect the Airbag ECU electrical connector.",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3136.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3137.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew earth cable mounting nut and disconnect the cable.",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3138.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Disconnect the parking brake switch electrical connector.",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3139.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Remove the Front RH Scuff Plate. For additional information refer to Front RH Scuff Plate - R &R section. ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Detach the RHS B pillar partially.",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3140.jpg",
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": "Disconnect the Pre tensioner electrical connectors RH side.",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3141.jpg",
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Disconnect the floor console inside wiring Harness routing clips.",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3142.jpg",
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Disconnect the RH seat electrical connector and routing clips.",
+ "file": null,
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3143.jpg",
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Remove the wiring harness from vehicle.",
+ "file": null,
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3144.jpg",
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Notice",
+ "content": "Ensure proper engagement of all the connectors Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove A Pillar Upper Trim LH.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1015,1249",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect speaker electrical pigtail inter-connector.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3159.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3160.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach MIC wire from routing.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3161.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach roof wiring harness from routing clips.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280051.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect IP to roof WH inter-connector and holding clip with routing clips.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3162.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove IP TOP Cover with PAB Assembly LH.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Detach WH routing clip and from vehicle.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370039.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Notice",
+ "content": "Ensure proper engagement of all the connectors.* Ensure proper engagement of all the wiring harness mounting clips.* Ensure proper routing of wiring harness.diagnostic tool connector and clear any DTC\u2019s if registered. ",
+ "file": null,
+ "display_order": 22
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the wiring harness for any external damage, If any replace it.",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 329,
+ "sys_id": "THAR.AX-O-0007-Electrical Components And Electrical Wiring Harness",
+ "subsys_id": "THAR.AX-O-0007-Electrical Components And Electrical Wiring Harness-Tail Door Wiring Harness",
+ "systems": "Electrical Components And Electrical Wiring Harness",
+ "sub_systems": "Tail Door Wiring Harness",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A370013.jpg",
+ "myid": 1442,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Tail Door Wiring Harness-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370013.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31632.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31631.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Rear RH Tail Lamp Assembly. For additional information refer to Front RH Tail Lamp Assembly - R &R; section. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect floor to tail door interconnector and holding clips.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3163.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3164.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the tail door WH grommet.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370036.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect BIW pigtail inter-connector and connector holding clip.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3165.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the tail door Trim.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect door latch electrical connector.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3166.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the Tail Door Wiring Harness from vehicle.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370035.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Notice",
+ "content": "Ensure proper engagement of all the connectors.* Ensure proper engagement of all the wiring harness mounting clips.* Ensure proper routing of wiring harness.diagnostic tool connector and clear any DTC\u2019s if registered. ",
+ "file": null,
+ "display_order": 21
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the wiring harness for any external damage, If any replace it.",
+ "file": null,
+ "display_order": 22
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 331,
+ "sys_id": "THAR.AX-O-0007-Electrical Components And Electrical Wiring Harness",
+ "subsys_id": "THAR.AX-O-0007-Electrical Components And Electrical Wiring Harness-MBFM",
+ "systems": "Electrical Components And Electrical Wiring Harness",
+ "sub_systems": "MBFM",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A370056.jpg",
+ "myid": 1445,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-MBFM-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370056.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31657.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31656.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the cable.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect the MBFM electrical connectors.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370058.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Detach the IP wiring harness holding clip from MBFM bracket.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370066.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew MBFM bracket mounting bolts from BIW and remove MBFM with bracket from the vehicle.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370059.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew MBFM mounting bolts from the bracket and detach the MBFM.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370060.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370057.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the MBFM and bracket for any external damage, If any replace it.",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 323,
+ "sys_id": "THAR.AX-O-0007-Electrical Components And Electrical Wiring Harness",
+ "subsys_id": "THAR.AX-O-0007-Electrical Components And Electrical Wiring Harness-Service Reminder Indicator Reset",
+ "systems": "Electrical Components And Electrical Wiring Harness",
+ "sub_systems": "Service Reminder Indicator Reset",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J10-MAT-0580",
+ "cover_image": "/files/31461.jpg",
+ "myid": 1435,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 10,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 58,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 99,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 139,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 182,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 221,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 265,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 304,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 346,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 384,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 430,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Service Reminder Indicator Reset-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Heading",
+ "content": "Service Reminder Indicator Reset Procedure ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Service Reminder Indicator - Reset.mp4",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "In the instrument cluster, the service reminder alert will start popping up in the cluster screen at 200 kms before the actual kilometers at which the service is due. This will continue at every ignition cycle. It is necessary to reset the service reminder once the service is rendered to the vehicle. If not reset, the service alert will continue to pop up at every ignition cycle, till it is reset by using recommended procedures.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31461.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Reset using OK button on Switch Bank",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Switch OFF the ignition.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Press the OK button on Driver side switch bank and simultaneously turn the ignition ON.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W657.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W658.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Release the OK button within 5 seconds after ignition on.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W659.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Check and ensure that the service reminder alert is OFF in the cluster.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "The above procedure would reset the Service Reminder Alert till the next scheduled maintenance.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Service reminder alert is provided with the intent of reminding the customer about a pending service visit hence, perform this SOP only after the vehicle has actually undergone servicing. ",
+ "file": null,
+ "display_order": 13
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 325,
+ "sys_id": "THAR.AX-O-0007-Electrical Components And Electrical Wiring Harness",
+ "subsys_id": "THAR.AX-O-0007-Electrical Components And Electrical Wiring Harness-Engine Compartment Wiring Harness",
+ "systems": "Electrical Components And Electrical Wiring Harness",
+ "sub_systems": "Engine Compartment Wiring Harness",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W723.jpg",
+ "myid": 1438,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Engine Compartment Wiring Harness-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W723.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31512.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31511.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect the EMS ECU GASOLINE-K connector.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3116.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the HFM sensor C 19 connector.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C001_C 19.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the front splash shield. For additional information refer to splash shield Front RH -R &R section. ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner remove earth cable mount nut and a routing clip.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C055_G 5.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove LH Side marker lamp connector with a routing clip.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C046_C 573.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect LH side turn lamp electrical connector.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C048_C 576.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Disconnect LH DRL connector and detach grow mat to take out connector.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C027_C 90.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Disconnect LH Head lamp and levelling motor(HLLD) electrical connectors.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C023_C 83.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Disconnect Horn electrical Connectors (2Nos) and 3 routing clip.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3117.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3117.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Disconnect Electrical fan electrical connector.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C012_C 71.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Disconnect LH Crash sensor electrical connector.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C039_C 296.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Disconnect fog lamp electrical connector routing clips.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C010_C 68.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Disconnect ambient temperature sensor electrical connector.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C035_C 128.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew engine compartment fuse box mounting bolts.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370026.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Torque Value",
+ "content": "Torque : 10\u00b11 Nm ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using 8 mm socket spanner remove fuse box positive cable mounting nut and disconnect from battery fuse connection.",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370065.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Disconnect engine WH inter connector, Holding clip.",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010077.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010130.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Detach WH routing clips from fire wall.",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370027.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370028.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner unscrew earth cable mounting nut from fire wall and detach cable.",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C055_G 5.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Remove Air Cleaner Assembly.",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1017,1295",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Using 10 mm combination spanner Remove LH fender ground mounting nut and detach it.",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C059_G 12.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Disconnect brake fluid level sensor electrical connector.",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C003_C 53.jpg",
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Disconnect ABS ECU electrical connector.",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C011_C 69.jpg",
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": "Disconnect HVAC triple pressure switch electrical connector.",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C006_C 57.jpg",
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Disconnect RH Crash sensor electrical connector.",
+ "file": null,
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C038_C 295.jpg",
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Remove the Splash Shield Front RH. **For additional information refer to splash shield Front RH -R &R section.**",
+ "file": null,
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Disconnect RH fog lamp electrical connector routing clips.",
+ "file": null,
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C009_C 67.jpg",
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Disconnect RH head lamp electrical connector.",
+ "file": null,
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3118.jpg",
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Description",
+ "content": "Disconnect RH head lamp levelling motor(HLLD) electrical connector.",
+ "file": null,
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C033_C 99.jpg",
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "Description",
+ "content": "Disconnect RH side marker lamp electrical connector with a routing clip.",
+ "file": null,
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C037_C 202.jpg",
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "Description",
+ "content": "Disconnect Front RH indicator and DRL connector and detach grow mat to take out connector.",
+ "file": null,
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C050_C 590.jpg",
+ "display_order": 72
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner unscrew earth cable mounting nut from RH fender and detach cable.",
+ "file": null,
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C058_G 11.jpg",
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "Description",
+ "content": "Detach WH routing clips from fender.",
+ "file": null,
+ "display_order": 76
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370030.jpg",
+ "display_order": 77
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370029.jpg",
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "Description",
+ "content": "Disconnect engine compartment to IP electrical connectors.",
+ "file": null,
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C040_C 404 F.jpg",
+ "display_order": 80
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C041_C 405 F.jpg",
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C042_C 406 M.jpg",
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C043_C 407 F.jpg",
+ "display_order": 83
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "Description",
+ "content": "Disconnect accelerator pedal electrical connector.",
+ "file": null,
+ "display_order": 84
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C025_C 86.jpg",
+ "display_order": 85
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "Description",
+ "content": "Disconnect brake switch electrical connector with a routing clip.",
+ "file": null,
+ "display_order": 86
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C024_C 85.jpg",
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "Description",
+ "content": "Disconnect clutch sensor electrical connector.",
+ "file": null,
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C026_C 87.jpg",
+ "display_order": 89
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "Description",
+ "content": "Detach WH routing clips and take out wiring.",
+ "file": null,
+ "display_order": 90
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370031.jpg",
+ "display_order": 91
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "Description",
+ "content": "Detach WH from inside to outside.",
+ "file": null,
+ "display_order": 92
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370032.jpg",
+ "display_order": 93
+ },
+ {
+ "step_name": "Step-40",
+ "content_type": "Description",
+ "content": "Remove the scuttle Grill.",
+ "file": null,
+ "display_order": 94
+ },
+ {
+ "step_name": "Step-40",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1015,1250",
+ "file": null,
+ "display_order": 95
+ },
+ {
+ "step_name": "Step-41",
+ "content_type": "Description",
+ "content": "Disconnect Wiper motor electrical connector and a routing clip.",
+ "file": null,
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-41",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C004_C 54.jpg",
+ "display_order": 97
+ },
+ {
+ "step_name": "Step-42",
+ "content_type": "Description",
+ "content": "Disconnect IP to Engine compartment wiring harness inter-connectors.",
+ "file": null,
+ "display_order": 98
+ },
+ {
+ "step_name": "Step-42",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370017.jpg",
+ "display_order": 99
+ },
+ {
+ "step_name": "Step-43",
+ "content_type": "Description",
+ "content": "Disconnect engine compartment to chassis WH inter-connector.",
+ "file": null,
+ "display_order": 100
+ },
+ {
+ "step_name": "Step-43",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C044_C 424 M.jpg",
+ "display_order": 101
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "Description",
+ "content": "Disconnect washer tank electrical connector.",
+ "file": null,
+ "display_order": 102
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A320038.jpg",
+ "display_order": 103
+ },
+ {
+ "step_name": "Step-45",
+ "content_type": "Description",
+ "content": "Detach Engine compartment Wiring Harness from engine compartment.",
+ "file": null,
+ "display_order": 104
+ },
+ {
+ "step_name": "Step-45",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W662.jpg",
+ "display_order": 105
+ },
+ {
+ "step_name": "Step-46",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 106
+ },
+ {
+ "step_name": "Step-46",
+ "content_type": "Notice",
+ "content": "Ensure proper engagement of all the connectors.* Ensure proper engagement of all the wiring harness mounting clips.* Ensure proper routing of wiring harness.* Torque tighten the earth mounting nuts to specified values.* Connect diagnostic tool connector and clear any DTC\u2019s if registered.",
+ "file": null,
+ "display_order": 107
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the wiring harness for any external damage, If any replace it.",
+ "file": null,
+ "display_order": 108
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 327,
+ "sys_id": "THAR.AX-O-0007-Electrical Components And Electrical Wiring Harness",
+ "subsys_id": "THAR.AX-O-0007-Electrical Components And Electrical Wiring Harness-Chassis Wiring Harness",
+ "systems": "Electrical Components And Electrical Wiring Harness",
+ "sub_systems": "Chassis Wiring Harness",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W665.jpg",
+ "myid": 1440,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Chassis Wiring Harness-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W665.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31593.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31592.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the e-disconnect stone guard.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the Front RH wheel speed sensor C 361 connector.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A16C005_C 361.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach wiring harness routing clips on front cross member.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W666.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370009.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W667.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect the e-disconnect motor C 231 connector.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3145.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect the front LH wheel speed sensor C 360 connector.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Chassis Wiring Harness.PNG",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Detach wiring harness routing clips on chassis.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370011.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Disconnect engine compartment WH to Chassis WH inter-connector.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3146.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Detach routing clips on chassis LH side.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W668.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Disconnect the chassis to FDM C 485 F inter-connector.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3147.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Disconnect the rear LH wheel speed sensor C 362 connector.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3148.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Detach routing clips on chassis rear LH side .",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370014.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Disconnect the chassis to bumper C 434 F inter-connector.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3149.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Disconnect the DEF pigtail C 707 F inter-connector.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3150.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Detach rear chassis routing clips.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370040.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Disconnect the rear RH Wheel Speed Sensor C363 connector.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3151.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Detach routing clips on chassis rear RH side.",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3152.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Remove the Rear LH Tail Lamp Assembly. ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner unscrew LH tail lamp earth cable mounting nut and detach it.",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3153.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Detach routing clip and grow mate.",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W669.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370015.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Remove the Rear RH Tail Lamp Assembly. ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner unscrew RH tail lamp earth cable mounting nut and detach it.",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3154.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Disconnect the tail lamp RH C 153 connector.",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3155.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": "Disconnect the tail lamp LH C 154 connector.",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3156.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Disconnect the chassis to tail gate-2 C 708 F inter- connector.",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3157.jpg",
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Disconnect the chassis to tailgate-3 C 709 F inter-connector.",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3158.jpg",
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Remove the chassis wiring harness from vehicle.",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Notice",
+ "content": "Ensure proper engagement of all the connectors.
Remove the HVAC Control Panel.
Connect diagnostic tool connector and clear any DTC\u2019s if registered.
Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the sensor from the routing slot.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370064.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Take out the sensor and disconnect the electrical connector.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370063.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370062.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the ambient temperature sensor for any external damage, If any replace it.",
+ "file": null,
+ "display_order": 12
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 245,
+ "sys_id": "THAR.AX-O-0007-en-SM-Interior System",
+ "system_name": "Interior System",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1023,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 247,
+ "sys_id": "THAR.AX-O-0007-Interior System",
+ "subsys_id": "THAR.AX-O-0007-Interior System-Hard Top Quarter Glass",
+ "systems": "Interior System",
+ "sub_systems": "Hard Top Quarter Glass",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A240055.jpg",
+ "myid": 1360,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Hard Top Quarter Glass-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240055.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12451.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12452.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew hard top quarter glass frame mounting screws from the rear window.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240056.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Pull - out the glass beading from Quarter Glass.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240057.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Carefully push from inside to outside and remove the rear window from the vehicle.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240058.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240059.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240060.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "While Installation always replace with New frame mounting screws",
+ "file": null,
+ "display_order": 13
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the hard top quarter glass for any damage/crack etc. Replace if found any.
Follow the below steps for replacement of Hard-Top windshield upper frame Seal
For additional information refer into B pillar lower trim R &R- Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the centre roof bow trim.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1023,1359",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Open the top cover and Using a 14 mm socket spanner, loosen and remove the seat belt upper mounting bolt.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210069.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "38 \u00b16 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210071.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the upper trim from vehicle.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240040.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240063.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner unscrew front lateral trim mounting bolt.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240066.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "2 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the Front lateral trim.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240067.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240068.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the Front Lateral trim for any damage/crack/cut etc. Replace if found any.For additional information refer Driver Sun Visor \u2014 R &R.; ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove co-driver sun visor. For additional information refer Driver Sun Visor \u2014 R &R.; ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a T40 Torx Socket spanner unscrew centre bow trim mounting screws.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240011.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a trim removal tool carefully detach the trim and remove electrical connector.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240012.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240076.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the MIC carefully from the trim..",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240013.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240010.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "install in the reverse order of removal.",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the trim for any damage/crack/cut etc. Replace it if found .",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 248,
+ "sys_id": "THAR.AX-O-0007-Interior System",
+ "subsys_id": "THAR.AX-O-0007-Interior System-A Pillar Upper Trim",
+ "systems": "Interior System",
+ "sub_systems": "A Pillar Upper Trim",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A240031.jpg",
+ "myid": 1361,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-A Pillar Upper Trim-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240031.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12460.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12461.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove Front Roof Bow Trim.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1023,1358",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Front Lateral Trim.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1023,1363",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner unscrew A pillar trim mounting bolt.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240032.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 2 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the A pillar upper trim from vehicle.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240033.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240034.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "
The driver airbag module connects to the steering column wiring harness via a rotary coupler called as clock spring. Within the driver airbag module there is a squib which, when given the correct current by the airbag ECU, inflates the airbag by initiating a chemical reaction. In deployment, the airbag inflates within a fraction of a second and then deflate at a controlled rate as the driver body regions; typically head and chest interact with airbag. Vents in the airbag control its deflation.
",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": ", ",
+ "file": "/files/W4A210041.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210029.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/32033.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/32034.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Steering Column Shrouds.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1017,1299",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Turn the steering wheel to 90\u00b0 counter clockwise direction from the steering wheel straight position and using a screw driver press the RHS DAB lock then release the lock.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "DAB locks are made up of plastic, ensure to press the locks softly by screwdriver. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210042.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210112.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Turn the steering wheel to 90\u00b0 clockwise direction from the steering wheel straight position and using a screw driver press the LHS DAB lock then release the lock.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "DAB locks are made up of plastic, ensure to press the locks softly by screwdriver. ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210110.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210111.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Gently pull-out the DAB module from the steering wheel.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210106.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a small flat end screw driver release the lock of the DAB electrical connector, then disconnect the DAB and horn electrical connectors.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "While refit ensure wires are routed out of the snapping zones to avoid damage. ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210043.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the DAB module separately.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210044.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 26
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the DAB module for any physical damage. Replace if found anywait for atleast 2 mins before starting the work.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080024.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Glove Box Assembly.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1020,1341",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the IP grab handle cover.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220022.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Passenger_airbag_module.png",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting screws.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220024.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220025.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Partially detach the door edge beading and using a trim removal tool, remove the IP LH side cover.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220139.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220065.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque : 8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220076.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220066.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220077.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Take out the IP LH side top cover with Passenger air bag from the IP.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220134.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using a 10 mm ring spanner, loosen and remove the air bag mounting bolt from IP top cover.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Torque Value",
+ "content": "Torque :4.5\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210046.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Expand the PAB module holder both sides using screw driver and detach the PAB separately from IP top cover.",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210047.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210048.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 40
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the PAB module for any damage. Replace if found any. wait for atleast 2 mins before starting the work.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Front console assembly. For additional information refer to Front Console Assembly R&R; section.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver remove the Airbag ECU Cover screw from airbag ECU.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/32005.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the SRS/ Airbag ECU electrical connectors.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210051.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen the SRS/ Airbag ECU mounting nuts on the floor panel.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque :8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210052.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the SRS/ Airbag ECU from the body.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210053.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210054.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Inspect the airbag ECU for any damage, replace if found any.Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front splash shield lower mounting screws.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250193.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250191.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect the front Crash sensor electrical connector.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210056.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the front Crash sensor mounting bolt from the vehicle.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque :8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210057.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the front crash sensor from the vehicle.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210058.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the front crash sensor for any damage. Replace if found.",
+ "file": null,
+ "display_order": 21
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 34,
+ "sys_id": "THAR.AX-O-0007-en-SM-Charging System",
+ "system_name": "Charging System",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1005,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 38,
+ "sys_id": "THAR.AX-O-0007-Charging System",
+ "subsys_id": "THAR.AX-O-0007-Charging System-Dark Current Test",
+ "systems": "Charging System",
+ "sub_systems": "Dark Current Test",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B080004.jpg",
+ "myid": 1119,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Dark Current Test-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Dark Current Test ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "When the engine is stopped and the ignition switched off, the battery feeds accessories which are directly connected to battery, such as alarms, clock, radio code and certain computers that operate continuously. Dark currents are considered normal if they do not exceed a few tens of milli amperes. If the value is more than that, one or more permanent electrical component is drawing too much current. They can be isolated by withdrawing the fuses one by one until the faulty circuit is identified. ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "A multi-meter is the best tool for these measurements. A current clamp cannot accurately measure currents of less than 1 A. The measurement must be taken at the battery itself. ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "Before carrying out leakage current test,
(For MT Variants \u2014 7 mA (Max) & for AT Variants \u2014 12 mA (Max)) ,check for any: Check for any active loads ( like roof lamp,etc;).
",
+ "file": null,
+ "display_order": 12
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 35,
+ "sys_id": "THAR.AX-O-0007-Charging System",
+ "subsys_id": "THAR.AX-O-0007-Charging System-Alternator",
+ "systems": "Charging System",
+ "sub_systems": "Alternator",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B080011.jpg",
+ "myid": 1116,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Alternator-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Component Location Index",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080011.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25367.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25368.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the cable.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen and remove the engine feed cover mounting bolts.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080012.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 11 \u00b1 1Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, rotate the auto tensioner in anti-clockwise direction and detach the accessory belt. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080013.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the alternator electrical connector. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080014.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove alternator positive cable cover. ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080011.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the alternator positive cable nut.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080034.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 15 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 12 mm socket and ring spanner, Remove the alternator top mounting bolt and nut. ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080015.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the alternator bottom mounting bolt and nut. ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080016.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080017.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Carefully remove the alternator from engine compartment. ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080019.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080017.jpg",
+ "display_order": 29
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "The specific gravity for fully charged battery is as follows: AMARON -1.270 \u00b1 0.010 at 27\u00b0C ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Specific gravity readings. * By measuring the specific gravity of the electrolyte, you can identify whether the battery is fully charged, requires charging, or must be replaced. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080030.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Specific gravity varies with the temperature. If the electrolyte temperature is substantially above 27\u00b0 C add seven points (0.007) to the observed specific gravity reading for every 10\u00b0 C by which the actual temperature is above 27\u00b0 C. * Deduct seven points per 10\u00b0 C where the observed reading is below 27\u00b0 C to obtain the temperature corrected reading at 27\u00b0 C. * Inspect battery electrolyte specific gravity whenever required. ",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 34,
+ "sys_id": "THAR.AX-O-0007-Charging System",
+ "subsys_id": "THAR.AX-O-0007-Charging System-Battery Health Checkup",
+ "systems": "Charging System",
+ "sub_systems": "Battery Health Checkup",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J10-MAT-0550",
+ "cover_image": "/files/W4B080001ac0d5f.jpg",
+ "myid": 1115,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 36,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 56,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 97,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 137,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 180,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 219,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 263,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 302,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 344,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 382,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 428,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Battery Health Checkup-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "Description",
+ "content": "MDX - 650P battery tester to battery terminals connecting probes on the battery posts respectively. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Press the Enter button and confirm the BATTERY LOCATION by selecting the \u201cIN VEHICLE\u201d in the tester using navigation button Up or Down . ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25354.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Press the Enter button and confirm the POST TYPE by selecting the \u201cTOP POST\u201d in the tester using navigation button Up or Down . ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25355.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Press the Enter button and confirm the APPLICATION by selecting the \u201cAUTOMOTIVE\u201d in the tester using navigation button Up or Down . ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25356.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Press the Enter button and confirm the BATTERY TYPE by selecting the \u201cREGULAR FLOODED\u201d in the tester using navigation button Up or Down . ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25357.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Press the Enter button and confirm the BATTERY STANDARD by selecting the \u201cJIS\u201d in the tester using navigation button Up or Down . ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25358.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Press the Enter button and get the recommended JIS Number value by pressing button Up or Down . ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25359.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25360.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Press the Enter button and perform the TESTING. ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25361.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Once the TESTING done, the initial battery result will be display. ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25362.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Press the PRINT button to get the hard copy print out. ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25363.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25364.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Disconnect the battery tester probes from battery terminals. ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "Follow the below table for Battery Testing test results condition and remedial action ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25365.jpg",
+ "display_order": 29
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 41,
+ "sys_id": "THAR.AX-O-0007-Charging System",
+ "subsys_id": "THAR.AX-O-0007-Charging System-Charging System Technical Spec",
+ "systems": "Charging System",
+ "sub_systems": "Charging System Technical Spec",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1122,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Charging System Technical Spec-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Battery Specifications",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/17514.jpg",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 37,
+ "sys_id": "THAR.AX-O-0007-Charging System",
+ "subsys_id": "THAR.AX-O-0007-Charging System-Open Circuit Voltage Test",
+ "systems": "Charging System",
+ "sub_systems": "Open Circuit Voltage Test",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/open circuit voltage test1.png",
+ "myid": 1118,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Open Circuit Voltage Test-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Open Circuit Voltage Test ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Turn ON the head lamp high beam for 30 seconds to remove any surface charge. ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Digital voltmeter checks the battery\u2019s open circuit voltage. Analogue meters do not show accurate readings and should be avoided. ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Turn OFF the head lamp, disconnect the battery and connect the digital voltmeter across the battery terminals. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/open circuit voltage test1.png",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Note the readings in the voltmeter. A fully charged battery will have an open-circuit voltage based on below table value. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25382.jpg",
+ "display_order": 7
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 42,
+ "sys_id": "THAR.AX-O-0007-Charging System",
+ "subsys_id": "THAR.AX-O-0007-Charging System-Troubleshoot - Charging System",
+ "systems": "Charging System",
+ "sub_systems": "Troubleshoot - Charging System",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1456,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Troubleshoot - Charging System-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/17515.pdf",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Component Inspection and Action Table",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/17516.pdf",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection and Verification",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Torque : 5 \u00b1 1.0 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner loosen hose clamp and remove fuel filler hose pipe end and detach the hose.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040094.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 6 \u00b1 1.0 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect fuel vent and fuel vapour line quick couplers.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040100.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040138.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect fuel filler hose routing clip and remove the hose from vehicle.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040101.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040102.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect fuel filler pipe assembly for any physical damage, replace if found any.* Inspect fuel filler pipe assembly for any leakage. Rectify if found any.",
+ "file": null,
+ "display_order": 21
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 361,
+ "sys_id": "THAR.AX-O-0007-Fuel System",
+ "subsys_id": "THAR.AX-O-0007-Fuel System-Fuel Delivery Module",
+ "systems": "Fuel System",
+ "sub_systems": "Fuel Delivery Module",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B040016.jpg",
+ "myid": 1043,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Fuel Delivery Module-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Fuel Delivery Module delivers the fuel to the low pressure line and to measure the fuel level in the tank.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040016.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Heading",
+ "content": "Fuel delivery module consists ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040092.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Fuel System Low Pressure Circuit Test Gauge ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040231.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Fuel System Low Pressure Circuit Test Gauge tool kit is used to diagnose Fuel System Low pressure circuit related concerns only.5.2 to 5.4 bar. ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Turn the Ignition OFF and remove the Fuel Gauge.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040231.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Connect the fuel line to FIP Inlet pipe and fuel supply pipe interconnection.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040114.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040050.jpg",
+ "display_order": 27
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 360,
+ "sys_id": "THAR.AX-O-0007-Fuel System",
+ "subsys_id": "THAR.AX-O-0007-Fuel System-Fuel Tank Assembly",
+ "systems": "Fuel System",
+ "sub_systems": "Fuel Tank Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B040015.jpg",
+ "myid": 1042,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Fuel Tank Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The fuel tank is a reservoir for the fuel and incorporates the Fuel delivery module inside",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040015.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040147.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30509.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30510.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Disconnect fuel vent hose quick coupler from gasoline tank.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040136.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using hose clamp plier release fuel filler hose spring band clamp and disconnect the hose fuel tank endr.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040137.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect fuel vapour hose quick coupler from gasoline tank fuel filter side.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040138.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the fuel vapour quick couplers in the tank supply end.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040140.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040141.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect the fuel tank supply pipe quick coupler.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040135.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect the fuel tank return hose quick coupler.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040146.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect fuel tank electrical connector.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040142.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Provide Jack to support the fuel tank.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040143.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner unscrew fuel tank mounting bolts.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040144.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 55 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the tank Assembly from vehicle.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040145.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040148.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 29
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for fuel leakage in the fuel tank.Torque : 25 \u00b1 3.0 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040026.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Fuel Rail sensor should be remove & refit only 5 times, ensure to replace New Assembly beyond 5 times",
+ "file": null,
+ "display_order": 13
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the rail sensor for any damage. Replace if found.Torque : 22.5 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040061.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before working on the high pressure side fuel components (Fuel Injection Pump, High Pressure Pipe, Fuel Rail & Injectors) turn the engine off, disconnect fuel supply hose quick coupler at FIP end and wait for Ten minutes
Inspect the high pressure fuel pipe for leakage, rectify if found.
",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 374,
+ "sys_id": "THAR.AX-O-0007-Fuel System",
+ "subsys_id": "THAR.AX-O-0007-Fuel System-Fuel System Technical Spec",
+ "systems": "Fuel System",
+ "sub_systems": "Fuel System Technical Spec",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1059,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Fuel System Technical Spec-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30668.pdf",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 371,
+ "sys_id": "THAR.AX-O-0007-Fuel System",
+ "subsys_id": "THAR.AX-O-0007-Fuel System-Fuel Level Sensor",
+ "systems": "Fuel System",
+ "sub_systems": "Fuel Level Sensor",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B040201.jpg",
+ "myid": 1044,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Fuel Level Sensor-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040201.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30653.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30654.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Fuel Delivery Module Assembly.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1002,1043",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Press the clip and unlock the sensor from the mount, move the level sensor in upward direction with moderate strength & remove the sensor assembly from the FDM.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040204.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040203.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Detach the wiring from the level sensor housing.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040205.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "By Using suitable pin take out the wiring pins from sensor.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040206.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Pressing the both sided snap-on tabs of the cable connector through the opening of the housing and cover carefully and simultaneously pull out the wire connectors from float unit.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/fuel level 1.PNG",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/fuel level 2.PNG",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Take out the Sensor.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040202.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Prior to the Installation, both the wiring connector snap-on tabs have to be bent back to the right position as shown below (By using Knife or suitable tool).",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040241.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Plug the wiring connectors pins on the New sensor housing at appropriate place with moderate force.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040242.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Ensure to Plug the wiring connectors pins on the New sensor housing at appropriate slots based on wiring colours as shownFuel System Low Pressure Circuit Test Gauge ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040231.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Fuel System Low Pressure Circuit Test Gauge tool kit is used to diagnose Fuel System Low pressure circuit related concerns only.2 post lift/ 4 post lift and turn engine OFF.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Preliminary Activities/Conditions",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040001.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Press the lock and disconnect the filter inlet hose quick coupler from the filter.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040003.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "All are quick fix connectors, press gently and remove it carefully; avoid seal damages.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Press the lock and disconnect the filter outlet hose quick coupler from the filter.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040002.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the fuel filter from mounting bracket lock and remove the filter from the vehicle.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040004.jpg",
+ "display_order": 9
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Refit the fuel filter in the vehicle on mounting bracket lock.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040005.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Ensure arrow mark on the fuel filter assembly should be pointing towards vehicle front (Arrow mark indicating that the fuel flow direction towards engine).",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040007.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Always use recommended filter only.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Reconnect the fuel filter fuel outlet line quick coupler.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040002.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "All are quick fix connectors, press gently and remove it carefully; avoid seal damages.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Reconnect the fuel filter fuel inlet quick coupler.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040003.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "Check and ensure proper fitment of fuel lines, any leakage can lead to fire.",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 368,
+ "sys_id": "THAR.AX-O-0007-Fuel System",
+ "subsys_id": "THAR.AX-O-0007-Fuel System-Fuel Rail Assembly",
+ "systems": "Fuel System",
+ "sub_systems": "Fuel Rail Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B040122.jpg",
+ "myid": 1477,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Fuel Rail Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040122.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30592.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30593.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove High Pressure Pipe (Pump to Rail).",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040050.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1002,1049",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before working on the high pressure side fuel components (Fuel Injection Pump, High Pressure Pipe, Fuel Rail & Injectors) turn the engine off, disconnect fuel supply hose quick coupler at FIP end and wait for Ten minutes.Torque : 11 \u00b11.0 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect fuel rail electrical connector.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040119.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect injector electrical connectors.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040120.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner loosen and remove the fuel rail mounting bolts.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040121.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully remove the Fuel Rail Assembly with injectors.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040123.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Injectors Combustion Seals should be replaced with new ones when ever removing & refitting the Fuel Rail Assembly from the cylinder head.",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal of Injector Combustion Seal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Combustion Seal by using plastic lever or plastic pliers or Nose plier. The Combustion Seal can be stretched until it breaks or can be removed off the component.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040028.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "When removing Combustion Seal, no metallic fixtures (pliers, fork, scissors, cutter, trimmer) are allowed to be used, which may damage injector sealing surface. Only plastic fixtures can be used* Take care not to damage the surface of the injector* Inspect the sealing surface and replace the complete injector in case there is a defect on sealing surface (such as a tool mark)",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040030.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040032.jpg",
+ "display_order": 25
+ }
+ ]
+ },
+ {
+ "procedure_name": "Assembly of the New Injector Combustion Seal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "properly Clean the Combustion Seal groove & injector tip by bathing it in an appropriate cleaning fluid, before assembling the Combustion Seal.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040033.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Position the injector in vertical position (O-ring in the upper side) in the cleaning bath for 10 to 15 min, not above the middle of the Valve Body* Cleaning fluid must not content acids and/or substances not recommended to get in contact with steel or PA and avoid oil, lubricant, grease* Can use P3-Galvaclean20 (Henkel) cleaning fluid with a concentration of 20 to 80 g/l diluted in demineralized water pre heated at 50\u00b0C* Cleaning fluid must not get in the connector and/or inside the injector and non metallic parts of the injector* Does not use brush, emery paper or ultrasonic device on clean the injector* Inspect the sealing surface and replace the complete injector in case there is a defect on sealing surface (such as a tool mark)",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040034.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "The surfaces of the new Combustion Seal must be clean and free of grease.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "The geometry of the groove must not be damaged or modified.",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Place the Combustion Seal installation special tool on the injector tip.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040183.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040200.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Insert and push the sealing ring by using pushing tool over the sealing ring tool until it snaps into the groove.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040198.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "The seal must be completely free of grease and oil",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040199.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040189.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the Combustion Seal installation special tool from injector tip.",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040187.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Insert the injector to the sizing special tool and turn 180\u00e2\u0081\u00b0 so that the seal fits well in the groove. Remove Injector from the sizing tool by turning it in the reverse direction.",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040035.jpg",
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Notice",
+ "content": "Check that the Combustion Seal has not been damaged during assembly to the injector and ensure seal must fit properly in the relative groove.",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040194.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040191.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040190.jpg",
+ "display_order": 47
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the Fuel rail for any damage. Replace if found.Torque : 22.5 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040061.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before working on the high pressure side fuel components (Fuel Injection Pump, High Pressure Pipe, Fuel Rail & Injectors) turn the engine off, disconnect fuel supply hose quick coupler at FIP end and wait for Ten minutes.Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect FIP electrical connector.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040054.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Notice",
+ "content": "Replace the FIP O Ring with a new one when installing.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040056.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove roller tappet from the high pressure pump housing",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040192.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040193.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": "While Installation, Ensure that the projection in the roller tappet should be matched with slot in the cylinder head for correct orientation.",
+ "file": null,
+ "display_order": 29
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the FIP for any physical damage, replace if found any.For additional information refer to Wheel R &R; Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the tyre from the rim. For additional information refer to Tyre - R &R; Section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a T10 Socket Spanner, loosen and remove the TPMS sensor mounting screw and detach the sensor.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160076.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "The TPMS and Valve cannot be replaced separately.These can be replaceable as assembly.* The valve must be positioned just left of the start position to avoid sensor damage. Do not touch the sensor with the tyre tool.* Starting to mount the tyre from the valve location is a wrong fitment. The fixing tool/ stem may hit the sensor and damage it. Start from the opposite direction.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160064.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "By using suitable TPMS removal/Installer tool, remove the valve from the rim.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160079.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 12
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Ensure that the TPMS Sensor is not damaged while removing the tyre.* Check the tyre inner surface for cuts and punctures.",
+ "file": null,
+ "display_order": 13
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 317,
+ "sys_id": "THAR.AX-O-0007-Tyre Pressure Monitoring System",
+ "subsys_id": "THAR.AX-O-0007-Tyre Pressure Monitoring System-TPMS Manual Learning",
+ "systems": "Tyre Pressure Monitoring System",
+ "sub_systems": "TPMS Manual Learning",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A090057.jpg",
+ "myid": 1430,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-TPMS Manual Learning-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "TPMS Manual Learning is the process by which the identities of 5 sensors installed inside the tyres are learnt & programmed in to the memory of receiver module.* It should be mandatory to performe on any of the following conditions or operations done. * Any of the old TPMS sensors are damaged & sensors are replaced.* Any of the tyre among 5 tyres are replaced.* if any of the tyres or set of tyres are shuffled or swapped in position.* If tyres rotation operation is performed.* If observed that the alert indications in TPMS screen are not correlating with respect to their actual position in vehicle.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Once the manual learning is initiated the sensors inside the tires needs to triggered by leaking the air from each tire one at a time and should be completed within 90 secs post to each event for learning all 5 tires. * Do not perform Manual learning process at the same time on two vehicles with in the radius of 20 meters. *is mandatory that manual learning of tyres should follow the sequence of \u2018front left tyre position, front right tyre, rear right tyre, rear left tyre and spare tyre\u2019.*is required to ensure the tires are having pressure > 32 psi & < 36 psi before initiating the manual learning process. *is mandatory that manual learning of tyres should follow the sequence of \u2018front left tyre position, front right tyre, rear right tyre, rear left tyre and spare tyre\u2019.*is required to ensure the tires are having pressure > 32 psi & < 36 psi before initiating the manual learning process. *to manual learning all tire should be filled with recommended tyre pressure value.*any point of time during the learning process if learning takes more than 90 secs of time for each tire position then the system shall exit the learning mode and show the Learning not successful screen. *a time, only one tyre can be swapped with the spare wheel and then follow the learning procedure.If failed to enter in to manual learning mode. Try initiating the manual learning once again. Check if reverse gear is engaged, if engaged disengage it. Check MBFM, Infotainment & Cluster software versions. Check if variant coding is done in all three. Check if Scroll Up arrow button on Driver side switch bank button is working fine. ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "TPMS learning procedure must be done in the below sequence:Front left tyreFront right tyreRear right tyreRear left tyreSpare tyre",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Start leaking the air from front left tyre for 30 to 40 seconds & stop for 5 seconds.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160044.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Repeat until the tyre gets learnt. *front left tyre is learned 1 siren chirp sound is heard and FL tyre shows learned in infotainment system.Repeat until the tyre gets learnt. *front right tyre is learned 1 siren chirp sound is heard and FR tyre shows learned in infotainment system.Repeat until the tyre gets learnt. *rear right tyre is learned 1 siren chirp sound is heard and RR tyre shows learned in infotainment system.Repeat until the tyre gets learnt. *Rear left tyre is learned 1 siren chirp sound is heard and RL tyre shows learned in infotainment system.Repeat until the tyre gets learnt. *spare tyre is also learned then 1 siren chirp sound is heard and ALL tyres show learned at respective tyre positions and \u2018All tyres Learned successfully\u2019 in the center of the screen.\u201cLearning not successful\u201d screen.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160050.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Caution",
+ "content": "After tyre rotation or TPMS sensor replacement, TPMS must be learnt,otherwise the system will show TPMS malfunction indicator. *learning need to be carried out whenever : Tyre rotation happens. 2 or more wheels are swapped. TPMS sensor is replaced. MBFM is replaced.*TPMS should not be used as a tyre pressure gauge while adjusting vehicle tyre pressure. ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Notice",
+ "content": "No two vehicles should be done with manual learning process at a time in same location with in radius of 20 meters. *to manual learning all tire should be filled with recommended tyre pressure valueMechanical ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Check for any oil leakage in the transfer case.For AT Variants top trim removal follow (Steps 3 - 8) : , Remove the 4WD selection knob by rotating it in anti-clock wise direction.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110306.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Pull and fold the gear shifter boot from gear shifter bezel .",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110269.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Partially detach the bezel from the console.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110134.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Excessive pull may leads to damage of the electrical connector. ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect the AT gaiter electrical connector from the bezel.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110135.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Carefully remove the bezel trim from the TGS lever.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110134.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Handle bezel assembly carefully to prevent it from damage or scratches.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using trim removal tool, carefully remove the floor console top trim with transfer case shifter boot.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110269.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Detach the transfer case cable abutment from the shifter bracket by pressing locking clip and pull up the abutments.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120003.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Caution",
+ "content": "Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner unscrew transfer case shifter lever assembly mounting nuts.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120004.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Take out the shifter and tilt the lever assembly gear shifter lever side to remove the TC shifter cable 'R' clip.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120002.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Detach the TC shifter cable from shifter assembly.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120009.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Remove the transfer case shifter from the vehicle.",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120005.jpg",
+ "display_order": 32
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the transfer case shifter for any damage. Replace if found any.",
+ "file": null,
+ "display_order": 33
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Position the transfer case cable on shift lever bracket.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120009.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Install the shifter cable locking R clip.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120002.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Position the transfer case shifter lever assembly.",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120006.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Position the transfer case shifter lever at 2H position.",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120007.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "Ensure that the transfer case link should be in 2H position on transfer case (Extreme Rear end position from front of the vehicle).",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120013.jpg",
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Refit the transfer case cable abutments on shift lever bracket.",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120003.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install.",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit the shifter lever assembly mounting nuts. Tighten the mounting nuts to specified torque value. ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120004.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque value :22.51\u00b14 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from '2H' to other range. If Shifting not smooth Carry-out Transfer Cable setting.",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120007.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120048.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "For AT Variants top trim Installation follow (Steps 8 \u2014 12) : , Refit the floor console top trim with transfer case shifter boot.",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110269.jpg",
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Connect the AT gaiter electrical connector with the bezel.",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110135.jpg",
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Refit the bezel trim with shifter bezel.",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110311.jpg",
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Caution",
+ "content": "Handle bezel assembly carefully toprevent it from damage or scratches",
+ "file": null,
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Unfold the gear shifter boot and refit the boot with gear shifter bezel.",
+ "file": null,
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110269.jpg",
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Refit the 4WD selection knob by rotating it in clock wise direction.",
+ "file": null,
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110308.jpg",
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Refit the Manual transmission gear selection rod cover with trim.",
+ "file": null,
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110310.jpg",
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Refit gear shifter level knob and 4WD selection knob by rotating them in clock wise direction.",
+ "file": null,
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110405.jpg",
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Notice",
+ "content": "Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from 'N' to other range.MST 0703AAD0009ST \u2013 Shifter and selector cable eye end removal tool, detach the transfer case shifter cable from the transfer case ball pins.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Transfer Case Cable.png",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Detach the transfer case cable abutment from the cable bracket on transmission by pressing locking clip and pull up the abutments.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110392.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket.Keep the Transfercase shifter in 4L position while refit R Clip. ",
+ "file": null,
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120007.jpg",
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Attach the transfer case cable abutment with the shifter bracket by pressing locking clip.",
+ "file": null,
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120003.jpg",
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket.",
+ "file": null,
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Attach the transfer case cable with the cable bracket routing clamp.",
+ "file": null,
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120061.jpg",
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit the floor console side trim and install the mounting screw rivet.",
+ "file": null,
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110219.jpg",
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110178.jpg",
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refit the gear selection rod cover with trim.",
+ "file": null,
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110310.jpg",
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Refit gear shifter level knob and 4WD selection knob by rotating them in clock wise direction.",
+ "file": null,
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110405.jpg",
+ "display_order": 72
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "For AT Variants top trim Installation follow (Steps 9 \u2014 13) : , Refit the floor console top trim with transfer case shifter boot.",
+ "file": null,
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110269.jpg",
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Connect the AT gaiter electrical connector with the bezel.",
+ "file": null,
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110135.jpg",
+ "display_order": 76
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Refit the bezel trim with shifter bezel.",
+ "file": null,
+ "display_order": 77
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110311.jpg",
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Caution",
+ "content": "Handle bezel assembly carefully to prevent it from damage or scratches.",
+ "file": null,
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Unfold the gear shifter boot and refit the boot with gear shifter bezel.",
+ "file": null,
+ "display_order": 80
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110269.jpg",
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Refit the 4WD selection knob by rotating it in clock wise direction.",
+ "file": null,
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110308.jpg",
+ "display_order": 83
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Refit shifter cable grommet and install the mounting bolts on fire wall.",
+ "file": null,
+ "display_order": 84
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120010.jpg",
+ "display_order": 85
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Caution",
+ "content": "Ensure the cable grommet should get assemble from outside of the cabin.",
+ "file": null,
+ "display_order": 86
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Torque Value",
+ "content": "Torque Value : 10 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Position the transfer case lever at 2H position on transfer case (Extreme Rear end position from front of the vehicle).",
+ "file": null,
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120013.jpg",
+ "display_order": 89
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Refit the transfer case cable abutments on transmission cable brackets.",
+ "file": null,
+ "display_order": 90
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110393.jpg",
+ "display_order": 91
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Notice",
+ "content": "Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install.",
+ "file": null,
+ "display_order": 92
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "For adjust cable length, move the cable quick adjuster outer cover in forward direction and unlock the QA clip.",
+ "file": null,
+ "display_order": 93
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120014.jpg",
+ "display_order": 94
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Adjust the cable length to fix the cable on link ball pin. After adjusting the length, position the quick adjuster body on link ball pin.",
+ "file": null,
+ "display_order": 95
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120047.jpg",
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Once quick adjuster body snap on ball pin, press the QA clip towards arrow mark shown to lock it fully and release the cable quick adjuster outer cover.",
+ "file": null,
+ "display_order": 97
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120046.jpg",
+ "display_order": 98
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Notice",
+ "content": "Ensure the proper locking by confirming/ hearing the click noise while install.",
+ "file": null,
+ "display_order": 99
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from '2H' to other range.",
+ "file": null,
+ "display_order": 100
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120007.jpg",
+ "display_order": 101
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120048.jpg",
+ "display_order": 102
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 89,
+ "sys_id": "THAR.AX-O-0007-Transfer Case",
+ "subsys_id": "THAR.AX-O-0007-Transfer Case-Transfer Case",
+ "systems": "Transfer Case",
+ "sub_systems": "Transfer Case",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A110028.jpg",
+ "myid": 1209,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Transfer Case-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110028.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30929.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30928.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the cable.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Rear Propeller Shaft Assembly. For additional information refer to Rear Propeller Shaft R &R; Session. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 8 mm socket spanner, loosen and remove the front propeller shaft mounting C clamp bolts from the transfer case.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130015.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the transfer case electrical connector.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120021.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 0703AAD0009ST \u2013 Shifter and selector cable eye end removal tool , detach the transfer case cable from the transfer case ball pins.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110390.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Pressing locking clip and detach the transfer case cable abutment from the cable bracket on transmission and pull up the abutments.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110392.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Notice",
+ "content": "Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. * Do hold this cable damper to pull the cable from bracket.* Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110391.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110393.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110394.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Provide a jack to support the transmission.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110010.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the transmission bed mounting bolts.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110011.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque: 70\u00b15 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 14 mm, 15 mm socket and ring spanners, unscrew transmission cross member mounting bolts, nuts and detach it.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110012.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque: 65 \u00b110.0 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using a 15 mm socket spanner, loosen and remove the transfer case mounting nuts",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110030.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque: 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the transfer case from the vehicle.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110029.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110393.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Notice",
+ "content": "While Installation of transfer case cable abutments on transmission cable brackets, Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "After Installation of Transfer Case Assembly on vehicle, Carry-out below cable setting Procedure. , Ensure that the transfer case link should be in 2H position on transfer case (Extreme Rear end position from front of the vehicle).",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120013.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "For adjust cable length, move the cable quick adjuster outer cover in forward direction and unlock the QA clip.",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120014.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Adjust the cable length to fix the cable on link ball pin. After adjusting the length position the quick adjuster body on link ball pin.",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120047.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Once quick adjuster body snap on ball pin, press the QA clip towards arrow mark shown to lock it fully and release the cable quick adjuster outer cover.",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120046.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Notice",
+ "content": "Ensure the proper locking by confirming/ hearing the click noise while install.",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from '2H' to other range.",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120007.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120048.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Check transfer case oil level & top up if required.",
+ "file": null,
+ "display_order": 49
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the transfer case for any damage. Replace if found any.",
+ "file": null,
+ "display_order": 50
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 92,
+ "sys_id": "THAR.AX-O-0007-Transfer Case",
+ "subsys_id": "THAR.AX-O-0007-Transfer Case-Transfer Case Overhual",
+ "systems": "Transfer Case",
+ "sub_systems": "Transfer Case Overhual",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "",
+ "myid": 1212,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Transfer Case Overhual-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/VST-0077_Transfer Case Overhaul.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/3078.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/3079.pdf",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Dis-assembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the Transfer case fluid. For additional information refer to Transfer case fluid Drain & Filling Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Transfer case from the vehicle. For additional information refer to Transfer case - R &R; Section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1010,1209",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Position the transfer case on the suitable Wooden/ Nylon blocks.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120063.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "Ensure the oil is drained prior to disassembly of the transfer case.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a Special tool MST 203 Companion Flange Holding Tool, hold the transfer rear flange.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120064.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W393.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 30 mm socket spanner, loosen and remove rear flange center nut. ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120065.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque Value : 340 - 370 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120130.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a magnetic stick, take out flange washer and remove seal from transfer case rear flange.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120066.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Notice",
+ "content": "Ensure the use New washer & Seal while installation.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120131.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120132.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120067.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a mallet, remove the transfer case rear flange.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120068.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Notice",
+ "content": "Use suitable 2 Jaw puller to remove the flange, In case of flange not able to remove by mallet.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120027.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 10 mm square bit spanner, remove the transfer case draining & filling oil plugs from the cover.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120069.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 15 mm socket spanner remove the assembly cover mounting bolts and remove the mounting bolts & identification tag.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120070.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120071.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Separate the front assembly cover and the rear case assembly.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120074.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Caution",
+ "content": "To avoid damage of the metal surface, apply limited force to the bosses on the cover and the transfer case while breaking the sealant bond.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120072.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120073.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a flat end screw driver, remove transfer case Rear output shaft oil seal from the cover.",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120078.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Remove the Spacer from the cover.",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120075.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Separate the return spring from the front assembly cover by pulling them outwards.",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120076.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using flat screw driver& circlip plier, remove the ball bearing snap ring.",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120077.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Rotate the cover and by using MST 0707BBA0003ST - Universal Mandtral remove the ball bearing from the cover.",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120079.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "By using suitable Internal puller, pull out the needle bearing from the cover.",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120080.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Caution",
+ "content": "Care must be taken not to damage the metal surface while removing the needle bearing.",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120133.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Position the transfer case casing and remove the shift collar hub from the output shaft.",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120134.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Remove the 2W-4W lock up assembly and lock up fork together from output shaft and separate lock up fork from the 2W-4W lock up assembly.",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120082.jpg",
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120083.jpg",
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "To dismantle 2W-4W lockup assembly, remove snap ring, lock up hub return spring from lock up collar.",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120135.jpg",
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120136.jpg",
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120091.jpg",
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120137.jpg",
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Using a circlip plier & flat screw driver, remove the snap ring from the output shaft and remove the spacer.",
+ "file": null,
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120085.jpg",
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120086.jpg",
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Remove the drive chain with sprocket and drive sprocket from the output shaft.",
+ "file": null,
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120087.jpg",
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120138.jpg",
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Separate the drive chain, driven sprocket and drive sprocket.",
+ "file": null,
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120139.jpg",
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120088.jpg",
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Remove the magnet from the slot in the case.",
+ "file": null,
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120089.jpg",
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": "Remove the coupler from the case.",
+ "file": null,
+ "display_order": 72
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120090.jpg",
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Remove the output shaft and the gear rotor (Gearotor) pump from the case.",
+ "file": null,
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120092.jpg",
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Rotate and align the guide pin of the shaft to the slot on the pump body and Separate the gear rotor pump and strainer assembly from the output shaft.",
+ "file": null,
+ "display_order": 76
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120093.jpg",
+ "display_order": 77
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "By using nose plier, remove the hose clip and remove the hose from pump and remove the strainer.",
+ "file": null,
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120094.jpg",
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Remove the rail shaft assembly from the case.",
+ "file": null,
+ "display_order": 80
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120095.jpg",
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Description",
+ "content": "Remove the reduction hub and the reduction fork from the case.",
+ "file": null,
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120096.jpg",
+ "display_order": 83
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "Description",
+ "content": "Separate the reduction hub and the reduction fork.",
+ "file": null,
+ "display_order": 84
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120097.jpg",
+ "display_order": 85
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "Description",
+ "content": "Remove the two shift fork facings from the shift fork assembly (if required).",
+ "file": null,
+ "display_order": 86
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120240.jpg",
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "Description",
+ "content": "Using a Special tool MST 203 Companion Flange Holding Tool, hold the transfer case output shaft yoke. ",
+ "file": null,
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120214.jpg",
+ "display_order": 89
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W392.jpg",
+ "display_order": 90
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "Description",
+ "content": "Using a 30 mm socket spanner, loosen and remove rear output shaft yoke center nut.",
+ "file": null,
+ "display_order": 91
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120215.jpg",
+ "display_order": 92
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "Torque Value",
+ "content": "Torque Value : 340 - 370 Nm ",
+ "file": null,
+ "display_order": 93
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120141.jpg",
+ "display_order": 94
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "Description",
+ "content": "Using a magnetic stick & flat screw drive , take out flange washer and remove seal from transfer case output shaft yoke.",
+ "file": null,
+ "display_order": 95
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120142.jpg",
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "Notice",
+ "content": "Ensure the use New washer & Seal while installation. ",
+ "file": null,
+ "display_order": 97
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120143.jpg",
+ "display_order": 98
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "Description",
+ "content": "Using a mallet, remove the transfer case rear flange.",
+ "file": null,
+ "display_order": 99
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120101.jpg",
+ "display_order": 100
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "Notice",
+ "content": "Use suitable 2 Jaw puller to remove the flange, In case of flange not able to remove by mallet. ",
+ "file": null,
+ "display_order": 101
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120029.jpg",
+ "display_order": 102
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "Description",
+ "content": "Remove the lower output shaft from the casing.",
+ "file": null,
+ "display_order": 103
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120102.jpg",
+ "display_order": 104
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "Description",
+ "content": "Using a 15 mm socket spanner, remove the adapter assembly, input shaft and carrier assembly bolts.",
+ "file": null,
+ "display_order": 105
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120103.jpg",
+ "display_order": 106
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "Description",
+ "content": "Take out the adapter assembly with input shaft and carrier assembly.",
+ "file": null,
+ "display_order": 107
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120104.jpg",
+ "display_order": 108
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "Description",
+ "content": "Using an outer circlip plier, Expanding the long ends snap ring unlock the bearing lock circlip and remove the input shaft and carrier assembly.",
+ "file": null,
+ "display_order": 109
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120112.jpg",
+ "display_order": 110
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120107.jpg",
+ "display_order": 111
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120144.jpg",
+ "display_order": 112
+ },
+ {
+ "step_name": "Step-40",
+ "content_type": "Description",
+ "content": "Remove snap ring and oil seal from adapter assembly.",
+ "file": null,
+ "display_order": 113
+ },
+ {
+ "step_name": "Step-40",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120281.jpg",
+ "display_order": 114
+ },
+ {
+ "step_name": "Step-40",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120113.jpg",
+ "display_order": 115
+ },
+ {
+ "step_name": "Step-41",
+ "content_type": "Description",
+ "content": "Remove the input shaft bearing retaining ring.",
+ "file": null,
+ "display_order": 116
+ },
+ {
+ "step_name": "Step-41",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120191.jpg",
+ "display_order": 117
+ },
+ {
+ "step_name": "Step-42",
+ "content_type": "Description",
+ "content": "Remove the input shaft bearing retaining ring.",
+ "file": null,
+ "display_order": 118
+ },
+ {
+ "step_name": "Step-42",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120283.jpg",
+ "display_order": 119
+ },
+ {
+ "step_name": "Step-42",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120284.jpg",
+ "display_order": 120
+ },
+ {
+ "step_name": "Step-42",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120186.jpg",
+ "display_order": 121
+ },
+ {
+ "step_name": "Step-43",
+ "content_type": "Description",
+ "content": "Remove the ASM Carrier from the input shaft.",
+ "file": null,
+ "display_order": 122
+ },
+ {
+ "step_name": "Step-43",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120282.jpg",
+ "display_order": 123
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "Description",
+ "content": "Remove the sun gear snap ring from ASM Carrier.",
+ "file": null,
+ "display_order": 124
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120286.jpg",
+ "display_order": 125
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120287.jpg",
+ "display_order": 126
+ },
+ {
+ "step_name": "Step-45",
+ "content_type": "Description",
+ "content": "Remove the thrust plate & sun gear from ASM Carrier.",
+ "file": null,
+ "display_order": 127
+ },
+ {
+ "step_name": "Step-45",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120288.jpg",
+ "display_order": 128
+ },
+ {
+ "step_name": "Step-45",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120289.jpg",
+ "display_order": 129
+ },
+ {
+ "step_name": "Step-46",
+ "content_type": "Description",
+ "content": "By using suitable Internal puller, remove the copper bush from the input shaft.",
+ "file": null,
+ "display_order": 130
+ },
+ {
+ "step_name": "Step-46",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120145.jpg",
+ "display_order": 131
+ },
+ {
+ "step_name": "Step-46",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120146.jpg",
+ "display_order": 132
+ },
+ {
+ "step_name": "Step-47",
+ "content_type": "Description",
+ "content": "By using suitable Internal puller, remove the needle bearing from the input shaft.",
+ "file": null,
+ "display_order": 133
+ },
+ {
+ "step_name": "Step-47",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120147.jpg",
+ "display_order": 134
+ },
+ {
+ "step_name": "Step-47",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120148.jpg",
+ "display_order": 135
+ },
+ {
+ "step_name": "Step-48",
+ "content_type": "Description",
+ "content": "By using 17 mm Open end spanner, remove the Breather (For MT variants located at Adapter plate & for AT variants at Adapter case assembly).",
+ "file": null,
+ "display_order": 136
+ },
+ {
+ "step_name": "Step-48",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120149.jpg",
+ "display_order": 137
+ },
+ {
+ "step_name": "Step-48",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120129.jpg",
+ "display_order": 138
+ },
+ {
+ "step_name": "Step-49",
+ "content_type": "Description",
+ "content": "By using 13 mm socket spanner, remove the hexagonal nut of the shift shaft. ",
+ "file": null,
+ "display_order": 139
+ },
+ {
+ "step_name": "Step-49",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120116.jpg",
+ "display_order": 140
+ },
+ {
+ "step_name": "Step-50",
+ "content_type": "Description",
+ "content": "By using T25 torx spanner, remove the transfer case and shift cam torx screws.",
+ "file": null,
+ "display_order": 141
+ },
+ {
+ "step_name": "Step-50",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120127.jpg",
+ "display_order": 142
+ },
+ {
+ "step_name": "Step-51",
+ "content_type": "Description",
+ "content": "By using flat end screw driver & mallet, remove the clip ring and pull out shift shaft & lever.",
+ "file": null,
+ "display_order": 143
+ },
+ {
+ "step_name": "Step-51",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120126.jpg",
+ "display_order": 144
+ },
+ {
+ "step_name": "Step-51",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120150.jpg",
+ "display_order": 145
+ },
+ {
+ "step_name": "Step-52",
+ "content_type": "Description",
+ "content": "Remove shift lever from shift shaft.",
+ "file": null,
+ "display_order": 146
+ },
+ {
+ "step_name": "Step-52",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120290.jpg",
+ "display_order": 147
+ },
+ {
+ "step_name": "Step-53",
+ "content_type": "Description",
+ "content": "By using flat end screw driver, remove the \u2018o\u2019 ring from shift shaft.",
+ "file": null,
+ "display_order": 148
+ },
+ {
+ "step_name": "Step-53",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120167.jpg",
+ "display_order": 149
+ },
+ {
+ "step_name": "Step-54",
+ "content_type": "Description",
+ "content": "Remove 4L assist spring and roller, shifter cam.",
+ "file": null,
+ "display_order": 150
+ },
+ {
+ "step_name": "Step-54",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120175.jpg",
+ "display_order": 151
+ },
+ {
+ "step_name": "Step-54",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120120.jpg",
+ "display_order": 152
+ },
+ {
+ "step_name": "Step-55",
+ "content_type": "Description",
+ "content": "Remove plunger and spring from the transfer case. ",
+ "file": null,
+ "display_order": 153
+ },
+ {
+ "step_name": "Step-55",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120121.jpg",
+ "display_order": 154
+ },
+ {
+ "step_name": "Step-55",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120122.jpg",
+ "display_order": 155
+ },
+ {
+ "step_name": "Step-55",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120123.jpg",
+ "display_order": 156
+ },
+ {
+ "step_name": "Step-56",
+ "content_type": "Description",
+ "content": "By using 24 mm ring spanner, remove 4WD indicator switch from the transfer case (If required). ",
+ "file": null,
+ "display_order": 157
+ },
+ {
+ "step_name": "Step-56",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120151.jpg",
+ "display_order": 158
+ },
+ {
+ "step_name": "Step-57",
+ "content_type": "Description",
+ "content": "By using flat end screw driver, remove the oil seal from the assembly case.",
+ "file": null,
+ "display_order": 159
+ },
+ {
+ "step_name": "Step-57",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120154.jpg",
+ "display_order": 160
+ },
+ {
+ "step_name": "Step-58",
+ "content_type": "Description",
+ "content": "By using flat end screw driver, remove the retaining ring from the assembly case.",
+ "file": null,
+ "display_order": 161
+ },
+ {
+ "step_name": "Step-58",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120152.jpg",
+ "display_order": 162
+ },
+ {
+ "step_name": "Step-59",
+ "content_type": "Description",
+ "content": "By using MST 0707BBA0003ST \u2013 Universal Mandtral remove the ball bearing from the case. ",
+ "file": null,
+ "display_order": 163
+ },
+ {
+ "step_name": "Step-59",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120153.jpg",
+ "display_order": 164
+ },
+ {
+ "step_name": "Step-60",
+ "content_type": "Description",
+ "content": "By using cutting plier, remove the dowel pin from transfer case.",
+ "file": null,
+ "display_order": 165
+ },
+ {
+ "step_name": "Step-60",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120158.jpg",
+ "display_order": 166
+ },
+ {
+ "step_name": "Step-60",
+ "content_type": "Caution",
+ "content": "Do not remove the ring gear shown in the below figure from the case.",
+ "file": null,
+ "display_order": 167
+ },
+ {
+ "step_name": "Step-60",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120157.jpg",
+ "display_order": 168
+ }
+ ]
+ },
+ {
+ "procedure_name": "Cleaning",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Before cleaning, check the magnet for the presence of metal particles which indicate internal chipping of the transfer case.",
+ "file": null,
+ "display_order": 169
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a cleaning solvent, clean the old oil and dirt deposits.",
+ "file": null,
+ "display_order": 170
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120159.jpg",
+ "display_order": 171
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "Before cleaning, check the magnet for the presence of metal particles which indicate internal chipping of the transfer case.* After cleaning dry the parts with low pressure (20 psi maximum) compressed air.* Lubricate the ball bearings and needle bearing with ATF oil. Protect lubricated bearings from dust. ",
+ "file": null,
+ "display_order": 172
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Always replace the hose coupling, O-ring , oil seal and flange/Yoke Nut with new parts.",
+ "file": null,
+ "display_order": 173
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Visually check all the parts for damage.",
+ "file": null,
+ "display_order": 174
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "Referring to normal gear tooth face, specifically inspect the uneven wear and chips of gear tooth. Replace or repair if necessary",
+ "file": null,
+ "display_order": 175
+ }
+ ]
+ },
+ {
+ "procedure_name": "Assembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Insert dowel pins to the ring gear casing",
+ "file": null,
+ "display_order": 176
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120160.jpg",
+ "display_order": 177
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Warning",
+ "content": "Dropping of heavy/large objects will damage the part and cause personal injury.",
+ "file": null,
+ "display_order": 178
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Press the ball bearing to the front casing by using MST\u2019s (0707AUA0005ST - Trasfer case Case Covers Ball Bearing Pressing tool) & 0707BBA0003ST \u2013 Universal Mandtral - Oil Seal/ Bearing Installer. ",
+ "file": null,
+ "display_order": 179
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120161.jpg",
+ "display_order": 180
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "Check the ball bearing for functionality prior to installation.",
+ "file": null,
+ "display_order": 181
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120162.jpg",
+ "display_order": 182
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120163.jpg",
+ "display_order": 183
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a snap ring removal tool/screw driver install the retainer ring to the front casing.",
+ "file": null,
+ "display_order": 184
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120164.jpg",
+ "display_order": 185
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install the new output oil seal into the case by using 0707BBA0001ST-Transfer Case Output Shafts Oil Seal Installer & 0707BBA0003ST \u2013 Universal Mandtral - Oil Seal/ Bearing Installer.",
+ "file": null,
+ "display_order": 186
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120165.jpg",
+ "display_order": 187
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "Check the oil seal prior to installation. In case of any external damages are observed, then replace the oil seal.",
+ "file": null,
+ "display_order": 188
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120166.jpg",
+ "display_order": 189
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install new \u2018O\u2019 ring on the shift shaft and lubricate it.",
+ "file": null,
+ "display_order": 190
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120167.jpg",
+ "display_order": 191
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120168.jpg",
+ "display_order": 192
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit the shift shaft in to the shift lever.",
+ "file": null,
+ "display_order": 193
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120169.jpg",
+ "display_order": 194
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Position spring and plunger in the hole of the transfer case. ",
+ "file": null,
+ "display_order": 195
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W394.jpg",
+ "display_order": 196
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120122.jpg",
+ "display_order": 197
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120121.jpg",
+ "display_order": 198
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Partially Insert star splined end of the shift shaft into the transfer case.",
+ "file": null,
+ "display_order": 199
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120170.jpg",
+ "display_order": 200
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Position shift cam into transfer case with flat end of cam approximately parallel with front face of case (as shown in the picture).",
+ "file": null,
+ "display_order": 201
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120172.jpg",
+ "display_order": 202
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120173.jpg",
+ "display_order": 203
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Install clip ring in groove near inside end of shift shaft.",
+ "file": null,
+ "display_order": 204
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120174.jpg",
+ "display_order": 205
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Install 4L assist spring in groove of shift cam and slot of transfer case.",
+ "file": null,
+ "display_order": 206
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120175.jpg",
+ "display_order": 207
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120176.jpg",
+ "display_order": 208
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Refit the transfer case and shift cam torx screws by using screwdriver.",
+ "file": null,
+ "display_order": 209
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W395.jpg",
+ "display_order": 210
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Notice",
+ "content": "Make sure that shift shaft is fully engaged so that second screw end enters groove in shaft.",
+ "file": null,
+ "display_order": 211
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W396.jpg",
+ "display_order": 212
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Refit the hex nut of the shift shaft, Torque tighten mounting nut to specified value.",
+ "file": null,
+ "display_order": 213
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120116.jpg",
+ "display_order": 214
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Install 4WD indicator switch to transfer case.",
+ "file": null,
+ "display_order": 215
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120178.jpg",
+ "display_order": 216
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Press the needle bearing into the input shaft by using MST 0707AUA0003ST - T Case Input Shaft Sleeve Pressing tool & 0707BBA0003ST \u2013 Universal Mandtral - Oil Seal/ Bearing Installer.",
+ "file": null,
+ "display_order": 217
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120180.jpg",
+ "display_order": 218
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120179.jpg",
+ "display_order": 219
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Press the new sleeve bearing into the input shaft by using MST 0707AUA0004ST - T Case Input Shaft NRB Pressing tool & 0707BBA0003ST \u2013 Universal Mandtral - Oil Seal/ Bearing Installer.",
+ "file": null,
+ "display_order": 220
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120181.jpg",
+ "display_order": 221
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120182.jpg",
+ "display_order": 222
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Refit the input shaft to the carrier assembly by matching the splines.",
+ "file": null,
+ "display_order": 223
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120183.jpg",
+ "display_order": 224
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120185.jpg",
+ "display_order": 225
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Install the thrust plate, thrust washer onto the input shaft.",
+ "file": null,
+ "display_order": 226
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120186.jpg",
+ "display_order": 227
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Position and press the bearing onto the input shaft by using a MST 0707AUA0002ST - T Case Input Shaft Ball Brg Pressing tool. ",
+ "file": null,
+ "display_order": 228
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120187.jpg",
+ "display_order": 229
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120188.jpg",
+ "display_order": 230
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120189.jpg",
+ "display_order": 231
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Install the retaining on the input shaft assembly by using circlip plier. ",
+ "file": null,
+ "display_order": 232
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120190.jpg",
+ "display_order": 233
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120191.jpg",
+ "display_order": 234
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Invert from adapter assembly. Install snap ring by making sure that snap ring is correctly install in the groove.",
+ "file": null,
+ "display_order": 235
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120192.jpg",
+ "display_order": 236
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Using a circlip plier expand the snap ring and insert the carrier assembly with input shaft to the adapter case.",
+ "file": null,
+ "display_order": 237
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120193.jpg",
+ "display_order": 238
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Notice",
+ "content": "(Ensure that planet carrier assembly on the work bench is such that the retaining rings\u2019 mounting groove faces upward.",
+ "file": null,
+ "display_order": 239
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120107.jpg",
+ "display_order": 240
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120194.jpg",
+ "display_order": 241
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Press spiral the pin into the front adapter.",
+ "file": null,
+ "display_order": 242
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": "Using a suitable MST, refit an oil seal from the carrier assembly body by using a MST 0707BAJ0001ST \u2013 Transfer Case Input Shaft Oil Seal Installer - MT (or) 0707BAJ0001ST \u2013 Transfer Case Input Shaft Oil Seal Installer - AT & 0707BBA0003ST \u2013 Universal Mandtral - Oil Seal/ Bearing Installer.",
+ "file": null,
+ "display_order": 243
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120195.jpg",
+ "display_order": 244
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120196.jpg",
+ "display_order": 245
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120197.jpg",
+ "display_order": 246
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120198.jpg",
+ "display_order": 247
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Apply a 1.6 mm bead of sealant on the mounting face for the transfer case. ",
+ "file": null,
+ "display_order": 248
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W397.jpg",
+ "display_order": 249
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W398.jpg",
+ "display_order": 250
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120201.jpg",
+ "display_order": 251
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Refit the adapter input shaft and carrier assembly to the case, and using a 16 mm socket spanner, tighten the mounting nuts to specified torque.",
+ "file": null,
+ "display_order": 252
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120202.jpg",
+ "display_order": 253
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120203.jpg",
+ "display_order": 254
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Refit the breather nipple.",
+ "file": null,
+ "display_order": 255
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120204.jpg",
+ "display_order": 256
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Position the output shaft in the transfer case.",
+ "file": null,
+ "display_order": 257
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120205.jpg",
+ "display_order": 258
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120206.jpg",
+ "display_order": 259
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Description",
+ "content": "Position the output shaft in transfer case, and install the end yoke assembly, seal, washer and the lock nut.",
+ "file": null,
+ "display_order": 260
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120207.jpg",
+ "display_order": 261
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120208.jpg",
+ "display_order": 262
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120209.jpg",
+ "display_order": 263
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120210.jpg",
+ "display_order": 264
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120211.jpg",
+ "display_order": 265
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "Description",
+ "content": "Using a suitable MST yoke holder, socket spanner and torque wrench, tighten the front flange mounting lock nut to specified torque.",
+ "file": null,
+ "display_order": 266
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W399.jpg",
+ "display_order": 267
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W400.jpg",
+ "display_order": 268
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120214.jpg",
+ "display_order": 269
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120215.jpg",
+ "display_order": 270
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "Description",
+ "content": "Install the two forks facing on the reduction shift fork assembly.",
+ "file": null,
+ "display_order": 271
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120216.jpg",
+ "display_order": 272
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "Description",
+ "content": "Install the reduction hub in to the fork.",
+ "file": null,
+ "display_order": 273
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120217.jpg",
+ "display_order": 274
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120218.jpg",
+ "display_order": 275
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "Description",
+ "content": "Refit the reduction hub and reduction shift fork into the planet carrier.",
+ "file": null,
+ "display_order": 276
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120219.jpg",
+ "display_order": 277
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "Description",
+ "content": "Slide roller of fork in to the cam groove. ",
+ "file": null,
+ "display_order": 278
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120220.jpg",
+ "display_order": 279
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "Description",
+ "content": "Insert shift rail in reduction fork bore, to match with case bore.",
+ "file": null,
+ "display_order": 280
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120095.jpg",
+ "display_order": 281
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "Description",
+ "content": "Align rotor slot of the pump and slot of the pump body in line.",
+ "file": null,
+ "display_order": 282
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120222.jpg",
+ "display_order": 283
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "Description",
+ "content": "Align the slide the pump assembly on output shaft over pump pin.",
+ "file": null,
+ "display_order": 284
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120223.jpg",
+ "display_order": 285
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "Notice",
+ "content": "Align the guide pin of the shaft to the slot on the pump body and slide the pump assembly onto the output shaft over pump pin.",
+ "file": null,
+ "display_order": 286
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120224.jpg",
+ "display_order": 287
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "Description",
+ "content": "Assemble the strainer and hose to the gear rotor pump.",
+ "file": null,
+ "display_order": 288
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120225.jpg",
+ "display_order": 289
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120226.jpg",
+ "display_order": 290
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120227.jpg",
+ "display_order": 291
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120228.jpg",
+ "display_order": 292
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "Description",
+ "content": "Install the output shaft and gear rotor pump assembly into the reduction hub housing by matching the splines.",
+ "file": null,
+ "display_order": 293
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120229.jpg",
+ "display_order": 294
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120230.jpg",
+ "display_order": 295
+ },
+ {
+ "step_name": "Step-40",
+ "content_type": "Description",
+ "content": "Couple strainer with case and insert the magnet into the transfer case slot.",
+ "file": null,
+ "display_order": 296
+ },
+ {
+ "step_name": "Step-40",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120232.jpg",
+ "display_order": 297
+ },
+ {
+ "step_name": "Step-41",
+ "content_type": "Description",
+ "content": "Refit the magnet into body.",
+ "file": null,
+ "display_order": 298
+ },
+ {
+ "step_name": "Step-41",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120234.jpg",
+ "display_order": 299
+ },
+ {
+ "step_name": "Step-41",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120235.jpg",
+ "display_order": 300
+ },
+ {
+ "step_name": "Step-42",
+ "content_type": "Description",
+ "content": "Position the drive sprocket to the rear output shaft end and driven sprocket to the front output shaft end.",
+ "file": null,
+ "display_order": 301
+ },
+ {
+ "step_name": "Step-43",
+ "content_type": "Description",
+ "content": "Install the drive chain onto the sprockets.",
+ "file": null,
+ "display_order": 302
+ },
+ {
+ "step_name": "Step-43",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120238.jpg",
+ "display_order": 303
+ },
+ {
+ "step_name": "Step-43",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120111.jpg",
+ "display_order": 304
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "Description",
+ "content": "Holding each sprocket with drive chain tight and parallel with transfer case, install the drive chain assembly to the output shaft. ",
+ "file": null,
+ "display_order": 305
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120236.jpg",
+ "display_order": 306
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "Notice",
+ "content": "Holding each sprocket with the drive chain tight and parallel with the transfer case, install the drive chain assembly to the output shaft. Rotate the driven sprocket slightly to engage splines on the front output shaft.",
+ "file": null,
+ "display_order": 307
+ },
+ {
+ "step_name": "Step-45",
+ "content_type": "Description",
+ "content": "Install the spacer to the front output shaft.",
+ "file": null,
+ "display_order": 308
+ },
+ {
+ "step_name": "Step-45",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120086.jpg",
+ "display_order": 309
+ },
+ {
+ "step_name": "Step-46",
+ "content_type": "Description",
+ "content": "Install the snap ring into the groove of the front output shaft.",
+ "file": null,
+ "display_order": 310
+ },
+ {
+ "step_name": "Step-46",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120085.jpg",
+ "display_order": 311
+ },
+ {
+ "step_name": "Step-46",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120237.jpg",
+ "display_order": 312
+ },
+ {
+ "step_name": "Step-47",
+ "content_type": "Description",
+ "content": "Install the lockup hub and return spring to the lockup collar and insert the snap ring.",
+ "file": null,
+ "display_order": 313
+ },
+ {
+ "step_name": "Step-47",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120137.jpg",
+ "display_order": 314
+ },
+ {
+ "step_name": "Step-47",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120091.jpg",
+ "display_order": 315
+ },
+ {
+ "step_name": "Step-47",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120136.jpg",
+ "display_order": 316
+ },
+ {
+ "step_name": "Step-48",
+ "content_type": "Description",
+ "content": "Install new facings to the fork.",
+ "file": null,
+ "display_order": 317
+ },
+ {
+ "step_name": "Step-48",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120239.jpg",
+ "display_order": 318
+ },
+ {
+ "step_name": "Step-48",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120240.jpg",
+ "display_order": 319
+ },
+ {
+ "step_name": "Step-49",
+ "content_type": "Description",
+ "content": "Engage the lockup fork in the groove in 2WD-4WD lockup assembly and slide this group down over output shaft and rail shaft.",
+ "file": null,
+ "display_order": 320
+ },
+ {
+ "step_name": "Step-49",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120241.jpg",
+ "display_order": 321
+ },
+ {
+ "step_name": "Step-49",
+ "content_type": "Notice",
+ "content": "Check the ball bearing prior to installation. In case of any external damages are observed, then replace the ball bearing.",
+ "file": null,
+ "display_order": 322
+ },
+ {
+ "step_name": "Step-49",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120242.jpg",
+ "display_order": 323
+ },
+ {
+ "step_name": "Step-49",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120243.jpg",
+ "display_order": 324
+ },
+ {
+ "step_name": "Step-50",
+ "content_type": "Description",
+ "content": "Install shift collar engaging splines on output shaft and in 2WD-4WD lockup assembly.",
+ "file": null,
+ "display_order": 325
+ },
+ {
+ "step_name": "Step-50",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120244.jpg",
+ "display_order": 326
+ },
+ {
+ "step_name": "Step-51",
+ "content_type": "Description",
+ "content": "Position the cover with the open end facing up on the table.",
+ "file": null,
+ "display_order": 327
+ },
+ {
+ "step_name": "Step-51",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120247.jpg",
+ "display_order": 328
+ },
+ {
+ "step_name": "Step-52",
+ "content_type": "Description",
+ "content": "Position the end of the needle bearing with the identification mark and up the press into the cover by using a suitable MST 0707AUA0006ST\u2013 T Case Rear Cover NRB Pressing tool & 0707BBA0003ST \u2013 Universal Mandtral - Oil Seal/ Bearing Installer.",
+ "file": null,
+ "display_order": 329
+ },
+ {
+ "step_name": "Step-52",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120249.jpg",
+ "display_order": 330
+ },
+ {
+ "step_name": "Step-52",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120250.jpg",
+ "display_order": 331
+ },
+ {
+ "step_name": "Step-52",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120251.jpg",
+ "display_order": 332
+ },
+ {
+ "step_name": "Step-53",
+ "content_type": "Description",
+ "content": "Press the ball bearing into cover by using MST 0707AUA0005ST \u2013 T Case Covers Ball Brg Pressing tool & 0707BBA0003ST \u2013 Universal Mandtral - Oil Seal/ Bearing Installer.",
+ "file": null,
+ "display_order": 333
+ },
+ {
+ "step_name": "Step-53",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120252.jpg",
+ "display_order": 334
+ },
+ {
+ "step_name": "Step-53",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120253.jpg",
+ "display_order": 335
+ },
+ {
+ "step_name": "Step-53",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120254.jpg",
+ "display_order": 336
+ },
+ {
+ "step_name": "Step-53",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120255.jpg",
+ "display_order": 337
+ },
+ {
+ "step_name": "Step-54",
+ "content_type": "Description",
+ "content": "Install snap ring over the ball bearing into cover by using screw driver or circlip plier.",
+ "file": null,
+ "display_order": 338
+ },
+ {
+ "step_name": "Step-54",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120256.jpg",
+ "display_order": 339
+ },
+ {
+ "step_name": "Step-55",
+ "content_type": "Description",
+ "content": "Install the return spring over rail shaft in the transfer case. ",
+ "file": null,
+ "display_order": 340
+ },
+ {
+ "step_name": "Step-55",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120266.jpg",
+ "display_order": 341
+ },
+ {
+ "step_name": "Step-56",
+ "content_type": "Description",
+ "content": "Position the cover with the open end facing down on the table.",
+ "file": null,
+ "display_order": 342
+ },
+ {
+ "step_name": "Step-56",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120257.jpg",
+ "display_order": 343
+ },
+ {
+ "step_name": "Step-57",
+ "content_type": "Description",
+ "content": "Install the spacer over output shaft spline in the cover assembly.",
+ "file": null,
+ "display_order": 344
+ },
+ {
+ "step_name": "Step-57",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120258.jpg",
+ "display_order": 345
+ },
+ {
+ "step_name": "Step-57",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120259.jpg",
+ "display_order": 346
+ },
+ {
+ "step_name": "Step-58",
+ "content_type": "Description",
+ "content": "Press the new oil seal into the cover assembly by using MST 0707BBA0001ST \u2013 Transfer Case Output Shafts Oil Seal Installer & 0707BBA0003ST \u2013 Universal Mandtral - Oil Seal/ Bearing Installer.",
+ "file": null,
+ "display_order": 347
+ },
+ {
+ "step_name": "Step-58",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W401.jpg",
+ "display_order": 348
+ },
+ {
+ "step_name": "Step-58",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W402.jpg",
+ "display_order": 349
+ },
+ {
+ "step_name": "Step-58",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120262.jpg",
+ "display_order": 350
+ },
+ {
+ "step_name": "Step-58",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120263.jpg",
+ "display_order": 351
+ },
+ {
+ "step_name": "Step-58",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120264.jpg",
+ "display_order": 352
+ },
+ {
+ "step_name": "Step-58",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120265.jpg",
+ "display_order": 353
+ },
+ {
+ "step_name": "Step-59",
+ "content_type": "Description",
+ "content": "Apply 1.6 mm bead of Loctite RTV598 to the transfer case mounting surface.",
+ "file": null,
+ "display_order": 354
+ },
+ {
+ "step_name": "Step-59",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120267.jpg",
+ "display_order": 355
+ },
+ {
+ "step_name": "Step-60",
+ "content_type": "Description",
+ "content": "Installation of cover, align the transfer case with cover. Do not use excessive force.",
+ "file": null,
+ "display_order": 356
+ },
+ {
+ "step_name": "Step-60",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120268.jpg",
+ "display_order": 357
+ },
+ {
+ "step_name": "Step-60",
+ "content_type": "Notice",
+ "content": "Align the cover holes with the transfer case dowel pins.* Align the cover bearing with output shaft.* Align the cover blind hole with rail shaft and make sure that return spring is not cocked.",
+ "file": null,
+ "display_order": 358
+ },
+ {
+ "step_name": "Step-60",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120269.jpg",
+ "display_order": 359
+ },
+ {
+ "step_name": "Step-61",
+ "content_type": "Description",
+ "content": "Refit the front and rear housing cover mounting bolts along with identification tag and torque tighten the bolt to specified value.",
+ "file": null,
+ "display_order": 360
+ },
+ {
+ "step_name": "Step-61",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120270.jpg",
+ "display_order": 361
+ },
+ {
+ "step_name": "Step-61",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120271.jpg",
+ "display_order": 362
+ },
+ {
+ "step_name": "Step-61",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120272.jpg",
+ "display_order": 363
+ },
+ {
+ "step_name": "Step-61",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120273.jpg",
+ "display_order": 364
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "Description",
+ "content": "Install the two oil plugs to the cover, torque tighten the nut to specified value.",
+ "file": null,
+ "display_order": 365
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120274.jpg",
+ "display_order": 366
+ },
+ {
+ "step_name": "Step-63",
+ "content_type": "Description",
+ "content": "Install the flange and washer and lock nut to the output shaft.",
+ "file": null,
+ "display_order": 367
+ },
+ {
+ "step_name": "Step-63",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W403.jpg",
+ "display_order": 368
+ },
+ {
+ "step_name": "Step-63",
+ "content_type": "Notice",
+ "content": "Do not fully tighten the bolts at this stage.",
+ "file": null,
+ "display_order": 369
+ },
+ {
+ "step_name": "Step-63",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120276.jpg",
+ "display_order": 370
+ },
+ {
+ "step_name": "Step-63",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120277.jpg",
+ "display_order": 371
+ },
+ {
+ "step_name": "Step-63",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120278.jpg",
+ "display_order": 372
+ },
+ {
+ "step_name": "Step-64",
+ "content_type": "Description",
+ "content": "Holding the flange by flange holder torque tighten the nut to specified value.",
+ "file": null,
+ "display_order": 373
+ },
+ {
+ "step_name": "Step-64",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120279.jpg",
+ "display_order": 374
+ },
+ {
+ "step_name": "Step-64",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120280.jpg",
+ "display_order": 375
+ },
+ {
+ "step_name": "Step-65",
+ "content_type": "Description",
+ "content": "Refit the Transfer case on the vehicle.",
+ "file": null,
+ "display_order": 376
+ },
+ {
+ "step_name": "Step-65",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1010,1209",
+ "file": null,
+ "display_order": 377
+ },
+ {
+ "step_name": "Step-66",
+ "content_type": "Description",
+ "content": "Refill the Transfer case fluid. For additional information refer to Transfer case fluid Drain & Filling Section. ",
+ "file": null,
+ "display_order": 378
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 87,
+ "sys_id": "THAR.AX-O-0007-Transfer Case",
+ "subsys_id": "THAR.AX-O-0007-Transfer Case-Transfer Cable Setting",
+ "systems": "Transfer Case",
+ "sub_systems": "Transfer Cable Setting",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A120016.jpg",
+ "myid": 1207,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Transfer Cable Setting-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Transfer Cable Setting",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Position the transfer case shifter lever at 2H position.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120016.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Ensure cable cross pin is properly fitted on transfer case shifter.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120002.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Ensure the transfer case cable abutment is properly fitted on shifter bracket.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120003.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Ensure the transfer case cable abutment is properly fitted on transmission cable bracket.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110392.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 0703AAD0009ST \u2013 Shifter and selector cable eye end removal tool, detach the transfer case cable from the transfer case ball pins.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110390.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Ensure that the transfer case link should be in 2H position on transfer case (Extreme Rear end position from front of the vehicle).",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120013.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "For adjust cable length, move the cable quick adjuster outer cover in forward direction and unlock the QA clip.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120014.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Adjust the cable length to fix the cable on link ball pin. After adjusting the length, position the quick adjuster body on link ball pin.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120047.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Once quick adjuster body snap on ball pin, press the QA clip towards arrow mark shown to lock it fully and release the cable quick adjuster outer cover.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120046.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Notice",
+ "content": "Ensure the proper locking by confirming/ hearing the click noise while install.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from '2H' to other range.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120016.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120048.jpg",
+ "display_order": 22
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 88,
+ "sys_id": "THAR.AX-O-0007-Transfer Case",
+ "subsys_id": "THAR.AX-O-0007-Transfer Case-Transfer Case Oil - Replace",
+ "systems": "Transfer Case",
+ "sub_systems": "Transfer Case Oil - Replace",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J10-MAT-0270",
+ "cover_image": "/files/W4A11040988c3af.jpg",
+ "myid": 1208,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 20,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 68,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 109,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 148,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 192,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 230,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 274,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 313,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 356,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 393,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 417,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Transfer Case Oil - Replace-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Transfer Case Oil - Replace.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30920.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "Description",
+ "content": "Position the vehicle on a 2 post /4 post lift. Transfer case Oil \u2014 MAHINDRA 'MAXIMILE POWER STEERING FLUID' Genuine Power Steering Fluid.*\u2014 1.2 Litres. ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110409.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Draining Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm square bit spanner, remove the oil filling plug from the transfer case.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110410.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Place a tray beneath the drain plug for collecting the oil while draining.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 10 mm square bit spanner, loosen and remove the drain plug.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110411.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Collect the drained oil in a suitable container.",
+ "file": null,
+ "display_order": 10
+ }
+ ]
+ },
+ {
+ "procedure_name": "Filling Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Refit the drain plug. Torque tighten the drain plug to specified value.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110411.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "34\u00b16 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Fill recommended transfer case fluid with the help of a mechanical pump through filler plug.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110414.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "Ensure that the oil level by insert the 8 mm allen key and check the oil level mark.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110412.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Refit the filler plug and torque tighten the filler plug to specified torque value.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110410.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "34\u00b16 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Recommend to use only MAHINDRA 'MAXIMILE POWER STEERING FLUID' Genuine Power Steering Fluid.* In case of non-availability of Genuine fluid, SHELL MAKE 'SPIRAX S3 ATF MD3' can be used. In emergency conditions, fluid meeting DEXRON III specification can be used and oil change interval should be at every 40000 km.",
+ "file": null,
+ "display_order": 21
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 338,
+ "sys_id": "THAR.AX-O-0007-en-SM-Air Intake",
+ "system_name": "Air Intake",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1000,
+ "active_status": true,
+ "Assets": [
+ {
+ "systemdisplayorder": 1,
+ "system_asset": "/files/Air intake_System(G).mp4",
+ "active_status": true
+ }
+ ],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 348,
+ "sys_id": "THAR.AX-O-0007-Air Intake",
+ "subsys_id": "THAR.AX-O-0007-Air Intake-Intake Manifold",
+ "systems": "Air Intake",
+ "sub_systems": "Intake Manifold",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B020019.jpg",
+ "myid": 1005,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Intake Manifold-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "It is a structure of a pipe, which carries air into the combustion chamber in an engine. The primary function of the intake manifold is to evenly distribute the air to each intake port in the cylinder head. Even distribution is important to optimize the efficiency and performance of the engine",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020019.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020218.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30396.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30395.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Throttle Valve",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1008,1152",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the purge valve vapor hose quick coupler and disconnect the hose intake manifold end.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020264.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Pull out the purge valve from holding bracket and hose routing to partially detach purge valve vapor hose.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020266.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release breather hose clamp, routing clip and detach hose intake manifold end.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020271.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect MAP sensor electrical connector.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020272.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using T25 Torx socket spanner, Unscrew boost pressure & temperature sensor mounting bolt and remove it.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020273.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 4 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew engine oil dipstick guide routing bracket mounting bolt.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020269.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew intake manifold support bracket mounting bolt manifold end.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020270.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 16 mm ring spanner, Loosen and remove NVH cover mounting stud on intake manifold.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020274.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew intake manifold mounting bolts.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020275.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Carefully remove the intake manifold from engine compartment.",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020228.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Notice",
+ "content": "Replace the gaskets to the intake manifold whenever removed from the engine.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 36
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the intake manifold for the external damage. If any damage found replace it.",
+ "file": null,
+ "display_order": 37
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 342,
+ "sys_id": "THAR.AX-O-0007-Air Intake",
+ "subsys_id": "THAR.AX-O-0007-Air Intake-Intercooler Assembly",
+ "systems": "Air Intake",
+ "sub_systems": "Intercooler Assembly",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B020210.jpg",
+ "myid": 1504,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Intercooler Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The intercooler typically an air-to-air heat exchanger. Intercooler cools the air compressed by the turbocharger by reducing its temperature and increasing the density of the air supplied to the engine and thus improving the volumetric efficiency by increasing intake air charge density through nearly isobaric (constant pressure) cooling. The cooled air density improves, helping in increasing the power output and improving the fuel consumption.Torque : 6.5 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020279.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect boost pressure & temperature sensor electrical connector",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020280.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, remove boost pressure & temperature sensor mounting bolt and detach it",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020281.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect intercooler electric fan electric connector",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020285.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew degassing tank mounting bolts to partially detach the tank",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020282.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.5\u00b10.5Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew intercooler fan mounting nuts",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020286.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the Intercooler fan from intercooler assembly",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020287.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Notice",
+ "content": "While installing the fan, Ensure to align the arrow mark on Top side as shown below",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020288.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020043.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew Intercooler mounting bolts",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/intercooler assembly1111.png",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew Intercooler mounting bolts",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020284.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Torque Value",
+ "content": "Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020227.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal",
+ "file": null,
+ "display_order": 37
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for the intercooler for external damage. If found replace itTorque : 2.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the boost pressure & temperature sensor.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020089.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external cracks or damage, replace if found any.",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 343,
+ "sys_id": "THAR.AX-O-0007-Air Intake",
+ "subsys_id": "THAR.AX-O-0007-Air Intake-Air Cleaner Assembly",
+ "systems": "Air Intake",
+ "sub_systems": "Air Cleaner Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B020031.jpg",
+ "myid": 1003,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Air Cleaner Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020031.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30355.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30356.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect HFM sensor electrical connector and routing clip.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020249.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020253.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew HFM sensor mounting bolts and detach sensor from air clear assembly.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020251.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020252.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew air cleaner assembly mounting bolts from BIW.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020032.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully take out the air cleaner assembly and air intake dirty duct.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020033.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 5 mm Allen key, loosen and remove the dirty side duct mounting bolts from the air cleaner assembly then separate the air cleaner assembly.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020068.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020111.jpg",
+ "display_order": 21
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the air cleaner housing for the external damage. If any damage found replace it.",
+ "file": null,
+ "display_order": 22
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 341,
+ "sys_id": "THAR.AX-O-0007-Air Intake",
+ "subsys_id": "THAR.AX-O-0007-Air Intake-Intercooler Fan Assembly",
+ "systems": "Air Intake",
+ "sub_systems": "Intercooler Fan Assembly",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B020221.jpg",
+ "myid": 1503,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Intercooler Fan Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020221.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30327.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30328.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the NVH cover",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010045.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect Intercooler fan electrical connector",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020285.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew intercooler electric fan mounting nuts",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020286.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully remove the fan assembly",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020287.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020288.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020043.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Notice",
+ "content": "While installing the fan, Ensure to align the arrow mark on Top side as shown below",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the Intercooler Fan Assembly for any external damage, Replace the fan assembly if required.",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 339,
+ "sys_id": "THAR.AX-O-0007-Air Intake",
+ "subsys_id": "THAR.AX-O-0007-Air Intake-Air Filter Element Replace",
+ "systems": "Air Intake",
+ "sub_systems": "Air Filter Element Replace",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J10-MAT-0120",
+ "cover_image": "/files/W4B020017.jpg",
+ "myid": 1001,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 41,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 82,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 123,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 127,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 205,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 246,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 252,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 328,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 369,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 373,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 440,
+ "kilometers_applicable": 0
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Air Filter Element Replace-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The air cleaner element is Non woven +Pleated Media type (Dry Type). Filtration happens in two stages. Coarser particles are filtered in first stage by foam media and fine particles are filtered by Paper media in second stage. The dust and other fine particles which are sucked inside along with air gets trapped in the air cleaner while passing through the filter element.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Air Filter Element - Replace.mp4",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Notice",
+ "content": "Don\u2019t tap or hit the filter element.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020017.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020001.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "Description",
+ "content": "Torque : 10 Nm ",
+ "file": null,
+ "display_order": 25
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 340,
+ "sys_id": "THAR.AX-O-0007-Air Intake",
+ "subsys_id": "THAR.AX-O-0007-Air Intake-HFM Sensor Cleaning",
+ "systems": "Air Intake",
+ "sub_systems": "HFM Sensor Cleaning",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B020018.jpg",
+ "myid": 1502,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-HFM Sensor Cleaning-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The HFM sensor is used to find out the mass flow rate of air entering into fuel injection internal combustion engine.Possible Customer Complaints/ Symptoms ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Poor pickup",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Root Cause ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Wrong indication of the air flow to the ECU from the HFM sensor. This is due to the deposition of oil & dust particles on sensor element",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Logic ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Under normal driving conditions, if required boost pressure is not generated by the turbocharger, the smoke limitation map limits the fueling to avoid smoke due to lack of airTorque : 4 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully remove the sensor from intake manifold.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A020089.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external cracks, replace if found any.",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 350,
+ "sys_id": "THAR.AX-O-0007-Air Intake",
+ "subsys_id": "THAR.AX-O-0007-Air Intake-Troubleshoot - Air Intake",
+ "systems": "Air Intake",
+ "sub_systems": "Troubleshoot - Air Intake",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1010,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Troubleshoot - Air Intake-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Symptom Possible Causes",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30409.pdf",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Component Inspection and Action Table",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30408.pdf",
+ "display_order": 2
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 347,
+ "sys_id": "THAR.AX-O-0007-Air Intake",
+ "subsys_id": "THAR.AX-O-0007-Air Intake-Throttle Valve",
+ "systems": "Air Intake",
+ "sub_systems": "Throttle Valve",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B020034.jpg",
+ "myid": 1006,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Throttle Valve-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020034.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4779.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4780.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the NVH cover.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010903.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the throttle valve electrical connector.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020289.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner, loosen intercooler outlet hose clip and detach the hose throttle end.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020257.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.5 \u00b1 0.6Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew throttle valve mounting bolts.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020290.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully remove throttle body from intake manifold.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020291.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020233.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external cracks, replace if found any.",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 344,
+ "sys_id": "THAR.AX-O-0007-Air Intake",
+ "subsys_id": "THAR.AX-O-0007-Air Intake-HFM Sensor",
+ "systems": "Air Intake",
+ "sub_systems": "HFM Sensor",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B020018.jpg",
+ "myid": 1004,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-HFM Sensor-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The HFM sensor is used to find out the mass flow rate of air entering into fuel injection internal combustion engine.Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew the HFM sensor mounting bolts.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020251.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew the HFM sensor mounting bolts.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020252.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020232.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external cracks, replace if found any.Torque : 10 Nm ",
+ "file": null,
+ "display_order": 28
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 123,
+ "sys_id": "THAR.AX-O-0007-en-SM-Wheel & Tyre",
+ "system_name": "Wheel & Tyre",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1014,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 130,
+ "sys_id": "THAR.AX-O-0007-Wheel & Tyre",
+ "subsys_id": "THAR.AX-O-0007-Wheel & Tyre-Front Wheel",
+ "systems": "Wheel & Tyre",
+ "sub_systems": "Front Wheel",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A160002.jpg",
+ "myid": 1511,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Front Wheel-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160002.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/56070.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/56071.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 21 mm Wheel spanner/ deep socket spanner, loosen and remove the wheel mounting bolts.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160003.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque :140\u00b110 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the mounting bolts and then remove the wheel.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160004.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160005.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 10
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external damage in the tyre or the rim, if found replace.Torque :50\u00b17.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the spare wheel carrier from the vehicle.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160024.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160025.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 12
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external damage in the spare wheel carrier , if found replace.",
+ "file": null,
+ "display_order": 13
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 132,
+ "sys_id": "THAR.AX-O-0007-Wheel & Tyre",
+ "subsys_id": "THAR.AX-O-0007-Wheel & Tyre-Spare Wheel",
+ "systems": "Wheel & Tyre",
+ "sub_systems": "Spare Wheel",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A160019.jpg",
+ "myid": 1513,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Spare Wheel-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160019.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/56034.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/56035.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 21 mm socket spanner, loosen and remove the wheel nuts on the spare wheel carrier.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160021.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque :70\u00b110 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the spare wheel from the vehicle.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160020.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160005.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 10
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external damage in the tyre or the rim, if found replace.* Check for any foreign material on tyre or rim, remove if found.",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 124,
+ "sys_id": "THAR.AX-O-0007-Wheel & Tyre",
+ "subsys_id": "THAR.AX-O-0007-Wheel & Tyre-Tyre Rotation",
+ "systems": "Wheel & Tyre",
+ "sub_systems": "Tyre Rotation",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J10-MAT-0530",
+ "cover_image": "",
+ "myid": 1242,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 18,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 48,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 89,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 130,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 171,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 212,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 255,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 294,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 336,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 375,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 419,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Tyre Rotation-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Tyre Rotation.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "Description",
+ "content": "Position the vehicle on 2 post lift.",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/tyre_rotation.png",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Tyre Rotation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Tyres on the front and rear side of vehicles operate at different loads and perform different steering, handling, and braking functions. For these reasons, they wear at unequal rates and develop irregular wear patterns. Rotation will increase tread life. help to maintain mud, snow, and wet traction levels, and contribute to a smooth quiet ride Follow the recommended tyre rotation frequency for your type of driving more frequent rotation is permissible f desired. The reasons for any rapid or unusual wear should be corrected prior to rotation being performed It is recommended to rotate the tyres as per Maintenance Schedule.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S2B110007.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "TPMS Learning needs to be carried out for vehicle models equipped with TPMS (Tyre Pressure Monitoring System), procedure as below.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21664.jpg",
+ "display_order": 7
+ }
+ ]
+ },
+ {
+ "procedure_name": "TPMS Learning",
+ "steps": [
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "Description",
+ "content": "Position the vehicle on a flat surface.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Press the Scroll Up arrow button on Driver side switch bank and simultaneously turn the ignition ON.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090057.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W414.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Wait for cluster\u2019s tachometer & speedometer self-check rotation and then release the arrow button.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160055.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160056.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Identifying weather the learning is initiated. For additional information refer to front WHEEL - R &R Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using chisel Remove the drive shaft mounting nut caulking. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150055.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 36 mm socket spanner, loosen and remove Drive shaft mounting nut by Applying brake.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150027.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 240 \u2014 260 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the caliper stem mounting bolts then hang the caliper. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130167.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 31 \u2014 38 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Pull the Brake Pad outwards upto pad contact with clip as shown in the illustration.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130294.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Twist the pad in anti clock wise direction, lift the pad upwards and remove the pad. ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Front Wheel Hub.png",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Front Wheel Hub1.png",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 19 mm socket spanner, loosen and remove the caliper bracket mounting bolts then remove the caliper bracket.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130331.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 90 \u2014 100 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using star screw driver, remove the brake disc mounting screw and detach the disc from the front wheel hub.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130173.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the disc separately.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130174.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 19 mm socket spanner, loosen and remove Hub mounting bolts and remove the hub with carrier plate.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150029.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque : 87 - 90 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Front Wheel Hub2.png",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Front Wheel Hub3.png",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Caution",
+ "content": "Before assembly clean the mating faces of the front wheel hub and brake disc.",
+ "file": null,
+ "display_order": 31
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external damage in the wheel hub, if found replace.Torque :140\u00b110 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the mounting bolts and then remove the wheel.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160053.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160054.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 10
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external damage in the tyre or the rim, if found replace.* Check for any foreign material on tyre or rim, remove if found.",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 125,
+ "sys_id": "THAR.AX-O-0007-Wheel & Tyre",
+ "subsys_id": "THAR.AX-O-0007-Wheel & Tyre-Tyre Pressure - Check & Adjust",
+ "systems": "Wheel & Tyre",
+ "sub_systems": "Tyre Pressure - Check & Adjust",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J10-MAT-0610",
+ "cover_image": "/files/W4A160038.jpg",
+ "myid": 1243,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 13,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 61,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 102,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 142,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 185,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 224,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 268,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 307,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 349,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 387,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 433,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Tyre Pressure - Check & Adjust-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Heading",
+ "content": "Tyre Pressure- Inspect & Adjust ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Proper Tyre inflation pressure is essential to the safe and satisfactory operation of your vehicle.Three primary areas are affected by improper Tyre pressure:
TYRE PRESSURE LABEL ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160038.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Tyre Label is located on the driver side inner B-pillar. This label tells you important information about tyre size designed for your vehicle, and the tyre inflation pressures for the front & rear tyres.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21677.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Never overload the vehicle. Overloading can cause tyre failure, affect vehicle handling, and increase your stopping distance, resulting in an accident and/ or personal injury.Static Balance ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A180032.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "When the free rotation of the wheel is allowed, the heavier part is stopped on the bottom if the wheel weight is unbalanced and this is called Static Unbalance . Also, the state at which tyre's stop position is not same is called Static Balance when the wheel is rotated again. If the part A is heavier as shown in the figure, add the balance weight corresponding to unbalanced weight from B to A to maintain the static balance. If the static balance is not maintained, tramping, up and down vibration of the wheels, occurs. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Heading",
+ "content": "Dynamic Balance ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A180033.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "The static unbalance of the wheel creates the vibration in the vertical direction, but the dynamic unbalance creates the vibration in the lateral direction. As shown in the figure (A) , if two parts, (2) and (3), are heavier when the wheels are under the static balance condition, dynamic unbalance is created, resulting in shimmy, left and right vibration of the wheels, and the torque Fxa is applied in the axial direction. To correct the dynamic unbalance, add the balance weight of a same weight for two points of the circumference of the rim, M1 and M2, as shown in the figure (B) , and apply the torque in the opposite direction to the torque Fxa to offset in order to ensure smooth rotation of the wheel.
The wheel should always be balanced and aligned in order to provide:
Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270121.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Detach the IP driver side switch bank from the Instrumental Panel Assembly.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the IP driver side switch bank condition, if required replace.",
+ "file": null,
+ "display_order": 12
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 297,
+ "sys_id": "THAR.AX-O-0007-Interior & Exterior Lighting",
+ "subsys_id": "THAR.AX-O-0007-Interior & Exterior Lighting-Switch ORVM",
+ "systems": "Interior & Exterior Lighting",
+ "sub_systems": "Switch ORVM",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A270006.jpg",
+ "myid": 1410,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Switch ORVM-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270006.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12638.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12639.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270007.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "By using Trim Removal tool, remove the bezel rest from front door RH.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270098.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect the electrical connector from the bezel.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270009.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270010.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using flat screw driver detach the switch from the bezel. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the mounting clips condition to avoid rattling and falling down.Torque : 4 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270044.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect tail lamp electrical connector.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270045.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove tail lamp from vehicle.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the tail lamp/ rear lamp assembly for any physical damage/crack etc.Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270005.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the center switch from IP center switch bank assembly.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the mounting clips condition to avoid rattling and falling down.Torque : 6 \u00b11Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270022.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the head lamp assembly separately.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270023.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the head lamp for any damage, crack and glass fading.Torque : 6.5 \u00b10.7Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270037.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the electrical connector.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270038.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using hand, Push the side marker lamp assembly from the cladding and remove.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270039.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the Side Marker Lamp from vehicle.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the side marker lamp assembly for any physical damage/crack etc.* Inspect the glass for fading.* Inspect the condition of bulbs.* Inspect the connectors for proper fitment.",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 289,
+ "sys_id": "THAR.AX-O-0007-Interior & Exterior Lighting",
+ "subsys_id": "THAR.AX-O-0007-Interior & Exterior Lighting-Front Turn Indicator And DRL",
+ "systems": "Interior & Exterior Lighting",
+ "sub_systems": "Front Turn Indicator And DRL",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A270113.jpg",
+ "myid": 1402,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Front Turn Indicator And DRL-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270113.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12561.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12562.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250193.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front splash shield lower mounting screws (Front side screws).",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250191.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nut.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the front side of shield to access front turn indicator and DRL.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270110.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the front turn indicator and DRL electrical connectors.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270111.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner loosen and remove the front turn indicator and DRL mounting bolts.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 4\u00b11 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270112.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully remove front turn indicator and DRL.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the front turn indicator and DRL for any damage, replace if required.",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 292,
+ "sys_id": "THAR.AX-O-0007-Interior & Exterior Lighting",
+ "subsys_id": "THAR.AX-O-0007-Interior & Exterior Lighting-Side Marker Lamp Bulb",
+ "systems": "Interior & Exterior Lighting",
+ "sub_systems": "Side Marker Lamp Bulb",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A270046.jpg",
+ "myid": 1405,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Side Marker Lamp Bulb-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270046.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12591.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12592.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250193.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front splash shield lower mounting screws.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250191.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.5 \u00b10.7 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270047.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Rotate the bulb holder in anti clock wise direction and remove the holder with bulb.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270048.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the bulb from the holder.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the bulb condition to avoid rattling and falling down.Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270044.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect tail lamp electrical connector.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270081.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove and turn the backup lamp bulb socket in the direction of the arrow.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270082.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the reverse lamp bulb from holder.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the bulb condition to avoid rattling and falling down.Torque :4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270044.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect tail lamp electrical connector.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270078.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the bulb from holder by turning the bulb in counter clock wise direction. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270082.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Gently pull out the bulb from holder.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the bulb condition to avoid rattling and falling down.Torque : 6.5 \u00b1 0.7 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270058.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect parking lamp electrical connector.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270059.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Rotate and remove the bulb holder from vehicle.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270060.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove bulb from holder by turning the bulb in counter clock wise direction.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Detach the bulb from holder.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the bulb condition to avoid rattling and falling down.RIGHT TURN INDICATOR ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "For inspection, push the lighting control stalk clockwise (to stop position B) to indicate a right turn. The instrument cluster arrow lamp pointing towards the right flashes along with the right side turn signal lamps with chime indicating your intention of turning towards rightLEFT TURN INDICATOR ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "For inspection, push the lighting control stalk anti-clockwise (to stop position A) to indicate a left turn. The instrument cluster arrow lamp pointing towards the left flashes along with the left side turn signal lamps with chime indicating your intention of turning towards left.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270062.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Heading",
+ "content": "LAMPS OFF ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "For inspection, rotate the outer rotary switch on the lighting control stalk aligning the \u2018Arrow\u2019 on the switch to \u2018O\u2019 on the stalk to switch OFF all lamps.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270066.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "LANE CHANGING ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "For inspection of signal a lane change, move the light control stalk clockwise or anti-clockwise to the limit point of free movement of the lever and release. The turn signals will flash three times and stop.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270064.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "PARKING LAMPS ON ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "For inspection, rotate the outer rotary switch on the lighting control stalk aligning the \u2018arrow\u2019 on the switch to the \u20181st d\u00c3\u00a9tente\u2019 position on the stalk to switch ON the parking lamps.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270066.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "HEAD LAMP ON ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "For inspection, rotate the outer rotary switch on the lighting control stalk aligning the \u2018Arrowt\u2019 on the switch to the \u20182nd d\u00c3\u00a9tente\u2019 position on the stalk to switch ON the head lamps.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270067.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12526.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Heading",
+ "content": "HEAD LAMP HIGH BEAM/LOW BEAM ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "For inspection, with the head lamp ON, push the lighting control stalk down (away) from steering wheel to switch ON the head lamp high beam. The head lamp high beam tell-tale lamp in the instrument cluster illuminates indicating high beam option selected.HEAD LAMP FLASH ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "For inspection, pull the lighting control stalk (from the head lamp low beam position) towards the steering wheel to instantaneously flash the head lamp high beam.* The head lamp flash works even when the head lamp is OFF.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270071.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Heading",
+ "content": "FOG LAMPS OFF ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "For inspection, align the inner rotary switch on the lighting control stalk to the fog lamp off \u2018dot\u2019 on the inner fixed stalk as shown to switch OFF the fog lamps.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270070.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Heading",
+ "content": "FRONT FOG LAMPS ON ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "To inspect the front fog lamps, switch ON the ignition and the parking lamps. Turn the inner rotary switch on the lighting control stalk to align to the fog lamp symbol on the inner fixed stalk as shown.* The front fog lamp indicator in the instrument cluster indicates the operation status.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270072.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Heading",
+ "content": "HAZARD WARNING LAMP ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "For inspection, press the hazard switch ON, All the turn signal lamps flash. To turn OFF, press the switch again.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270073.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "CENTER ROOF LAMP ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "The Roof lamp switch has three operation modes to choose from;
WIPER CONTROL STALK ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Wiper Off inspection, move the wipe stalk in neutral position (B). Wiper remains OFF. 2.(Mist)inspection, push the wipe control stalk to position A for a flick-wipe, hold to operate the wipe continuously (simultaneously lift the wiper stalk towards the steering wheel to operate the wash). The stalk automatically comes back to position B when released. 3.(INT) Mode inspection, push down the stalk down to position C. In the INT mode, the wiper operates on preset intervals. 4.Speed Wipinginspection, push the wipe control stalk up to the position D to operate the wiper at a fixed low speed. 5.Speed Wiping inspection, push the wiper control stalk up to position E to operate the wiper at a fixed high speed. ",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A320002.jpg",
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "FRONT WIPE/WASH ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "For inspection, pull/lift the wiper control stalk towards the steering wheel from any position to activate the front wipe/wash function. Washer fluid is sprayed on the front windshield and the wipers wipe the windshield 3 times after the washer spray is stopped and wipe once after 4 sec. Hold the stalk in position for continuous spray of washer fluid.",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210020.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Heading",
+ "content": "HORN ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "For inspection, press the pad on the steering wheel to sound the horn. The horn functions even when the ignition has been switched OFF.",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270076.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Heading",
+ "content": "STOP LAMP/HIGH MOUNTED STOP LAMP ",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "For inspection, Press the brake pedal and the Stop Lamp /high mounted stop lamp will illuminate.",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270040.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Heading",
+ "content": "REVERSE LAMP ",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "For inspection, Engage the reverse gear and the reverse lamp will illuminate.",
+ "file": null,
+ "display_order": 54
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 287,
+ "sys_id": "THAR.AX-O-0007-Interior & Exterior Lighting",
+ "subsys_id": "THAR.AX-O-0007-Interior & Exterior Lighting-Head Light Aiming - Check & Adjust",
+ "systems": "Interior & Exterior Lighting",
+ "sub_systems": "Head Light Aiming - Check & Adjust",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J10-MAT-0570",
+ "cover_image": "/files/W4A270085927bd3.jpg",
+ "myid": 1400,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 11,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 71,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 114,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 154,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 196,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 234,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 278,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 316,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 361,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 399,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 444,
+ "kilometers_applicable": 0
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Head Light Aiming - Check & Adjust-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Check & Adjust",
+ "steps": [
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "Description",
+ "content": "10 meters or 3 meters away from the aiming board. (L = 10 meters / 3 meters which is the distance from starting point of front tyre to the aiming board as shown in illustration below).Refer below illustration for \u201cL= 10 Meters\u201d. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270086.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refer illustration for \u201cL= 3 Meters\u201d. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270091.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Refer the illustration for the head lamp adjustment arrangement ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270087.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270088.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Refer the illustration for the head lamp aiming board dimensions of Head Lamps ",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ },
+ {
+ "procedure_name": "Low Beam Setting Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270089.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270090.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Refer below illustration for the head lamp aiming board dimensions of Head Lamps ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Low beam & high beam aiming settings are common. Hence if adjust low beam, high beam will also get aligned with low beam.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1A270096.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1A270097.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 5 mm socket spanner, rotate the adjusting screw on motor to vary the Low beam cut-off pattern in vertical direction. Downwards. * Anti-clockwise rotation \u2014 Upwards. horizontal direction. Left Side * Anti-clockwise rotation \u2014 Right Side. horizontal direction. Right side. * Anti-clockwise rotation \u2014 Left side. Torque :6.5\u00b10.7 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270033.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect front indicator electrical connector.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270034.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Rotate and remove the bulb holder from vehicle.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270035.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove bulb from holder by turning the bulb in counter clock wise direction. ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the bulb holder condition to avoid rattling and falling down.
Check the bulb condition. If required replace.
",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 299,
+ "sys_id": "THAR.AX-O-0007-Interior & Exterior Lighting",
+ "subsys_id": "THAR.AX-O-0007-Interior & Exterior Lighting-IP Center Switch Bank Assembly",
+ "systems": "Interior & Exterior Lighting",
+ "sub_systems": "IP Center Switch Bank Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A270130.jpg",
+ "myid": 1412,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-IP Center Switch Bank Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270130.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12651.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12652.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290032.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console RH screvits and detach the panel from vehicle.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290031.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console LH screvits and detach the panel from vehicle.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290034.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew vertical ascent RH mounting screw and detach the vertical ascent RH from vehicle.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290033.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew vertical ascent LH mounting screw and detach the vertical ascent LH from vehicle.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290035.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290036.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290036.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "partially detach the switch bank assembly and remove electric connector to take out from the vehicle.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the center switch for any physical damage. Replace if found.",
+ "file": null,
+ "display_order": 21
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 254,
+ "sys_id": "THAR.AX-O-0007-en-SM-Exterior System",
+ "system_name": "Exterior System",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1024,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 265,
+ "sys_id": "THAR.AX-O-0007-Exterior System",
+ "subsys_id": "THAR.AX-O-0007-Exterior System-Convertible Soft Top Frame Complete",
+ "systems": "Exterior System",
+ "sub_systems": "Convertible Soft Top Frame Complete",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A250267.jpg",
+ "myid": 1378,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Convertible Soft Top Frame Complete-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250267.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16689.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16690.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Convertible Soft top Canopy.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1024,1367",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250255.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the support centre Rexine rivets other side.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250257.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250256.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250258.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250259.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the Support Side Rexines rivets RH & LH.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250260.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250261.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using star screw driver, loosen and remove the Bow 1 Injection Mould mounting screws (locate 1 screw at bottom side of centre rexine support).",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250262.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250263.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using star screw driver, loosen and remove the Latch mounting screws.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250264.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250265.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the Bow 1 Injection mould from front side bow and remove the Convertible Soft top Frame Complete assembly.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 22
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the Convertible Soft top Frame Complete assembly for any crack or damage. Replace if any.",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 254,
+ "sys_id": "THAR.AX-O-0007-Exterior System",
+ "subsys_id": "THAR.AX-O-0007-Exterior System-Convertible Soft Top Assembly",
+ "systems": "Exterior System",
+ "sub_systems": "Convertible Soft Top Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A250121.jpg",
+ "myid": 1367,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Convertible Soft Top Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250121.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16471.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250124.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250123.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove Side window RH Velcro and Unzip the window.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250147.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Unhook the window from the vertical and horizontal belt rail and remove the window.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250125.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250122.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove Side window LH Velcro and Unzip the window.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250148.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Unhook the window from the vertical and horizontal belt rail and remove the window.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250126.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Open the tail door.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250127.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250150.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250149.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Unzip the tail gate window, detach the tail gate bar locking from rear RH & LH belt rails remove the tailgate window.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250129.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250128.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250151.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Unhook the \u2018C\u2019 pillar cover from rear RH & LH belt rails and fold the cover at top of the soft top.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250130.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250155.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250131.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250156.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250177.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Slide the Sun visors and Remove the Footman's loops from front header.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Notice",
+ "content": "While unlock the Footman loop hook from the front header metal bracket, ensure to press & move the softtop assembly slightly in forward direction and release the hook from the bracket.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250132.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250152.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Slide back the convertible top from front header to rear and roll up properly.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250154.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250153.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Properly Roll up the convertible soft top assembly in the rear side as shown in fig .",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250134.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250133.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Unlock two Quick release knuckle RH & LH from main pivot brackets .",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250135.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250157.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Lift the convertible soft top assembly upwards (both sides) , silding towards rear and take out assembly from the vehicle.",
+ "file": null,
+ "display_order": 41
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250157.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250153.jpg",
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Lift the convertible soft top assembly upwards (both sides), sliding towards front and position on the vehicle as shown.",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250134.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250133.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Align the convertible soft top assembly both sides & Lock the two Quick release knuckle to RH & LH main pivot brackets.",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250153.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250154.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Properly open rolled convertible soft top assembly from the rear side.",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250152.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250159.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Slide convertible top from rear end to front header and position on front header properly.",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250163.jpg",
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250175.jpg",
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250164.jpg",
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250176.jpg",
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250177.jpg",
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250178.jpg",
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Lock the Footman's loops to the front header and slide the Sun visors.",
+ "file": null,
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Lock the Footman loop hook on the front header metal bracket & press the loop handle.Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250214.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250215.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250216.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250217.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Rear Roof caps using trim remover and Using a T30 socket spanner, loosen and remove the roof rear top mounting bolts.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240016.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240018.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a trim remover pull out center bow trim and disconnect roof lamp electrical connector.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "Ensure to use trim remover while removing centre roof bow trim, and avoid the press clip damage. *the press clip for proper fixing, if it is damaged.Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250102.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250103.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "By Using T30 Torx Socket Spanner remove the RH & LH roof side upper frame mounting bolts.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250104.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250104.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "By Using T30 Torx Socket Spanner remove the RH & LH roof side lower frame mounting bolts",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250206.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250207.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "By Using T30 Torx Socket Spanner remove the RH & LH rear lower bracket mounting bolts.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250208.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250209.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a T30 socket spanner, loosen and remove the roof top mounting bolts from roll cage.",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250108.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Disconnect the HMSL electrical connector.",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250230.jpg",
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Insert and split the panel with trim remover, in between Hard-Top and frame mounting plate.",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250223.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250107.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Lift and Carefully remove the hard top assembly from the vehicle with sufficient manpower and keep it in Trolly bench or flat working bay.",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Notice",
+ "content": "Use the recommended safety equipment\u2019s; Safety goggles, Cotton gloves, Safety shoes etc. while lifting the Hard-Top.",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250107.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250225.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Prepare the Hard-Top assembly for installation
Don't use ordinary solvent for HardTop cleaning. (it may result some undefined problems in Hard-Top). ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250222.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250227.jpg",
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250229.jpg",
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Inspect the Hard-Top windshield upper frame Seal and replace if needed when the seal loses its softness or if found any damages.
The Seal must be replaced along with X-mas tree clips, when the seal loses its softness or if found any damages, don't reused the X-mas tree clips. ",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Caution",
+ "content": "This seal is for preventing the water leakage and wind noise only. Seal coming with Two-way pasting tape.
Silicon sealant must be applied for water leakage and wind noise prevention. ",
+ "file": null,
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250224.jpg",
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250220.jpg",
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250221.jpg",
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Notice",
+ "content": "While Installation hand tighten all the Hard top mounting bolts first for proper positioning and finally torque tighten all the bolts. *over tighten the screws to avoid the thread slipping and other damages.*Installation properly position the Hard top dowels in the body for proper positioning & fitment. ",
+ "file": null,
+ "display_order": 66
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the hard top assembly for any damage. Replace if found.",
+ "file": null,
+ "display_order": 67
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 258,
+ "sys_id": "THAR.AX-O-0007-Exterior System",
+ "subsys_id": "THAR.AX-O-0007-Exterior System-Foot Step Assembly",
+ "systems": "Exterior System",
+ "sub_systems": "Foot Step Assembly",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A250189.jpg",
+ "myid": 1371,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Foot Step Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250189.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16591.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16592.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250184.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 12 mm socket and 13 mm combination spanner, Unscrew front bracket mounting bolt and nut.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250185.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 12 mm socket and 13 mm combination spanner, Unscrew front centre bracket mounting bolt and nut.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250186.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 13 mm socket combination spanner, Unscrew rear bracket mounting bolt.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250187.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250188.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250001.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the front foot step assembly from vehicle.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "Front extreme portion of foot step is not to stand, Since front portion is aesthetic part to merge the design theme with cladding.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any damages or crack in foot step assembly. Replace if found.",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 260,
+ "sys_id": "THAR.AX-O-0007-Exterior System",
+ "subsys_id": "THAR.AX-O-0007-Exterior System-Scuttle Grill",
+ "systems": "Exterior System",
+ "sub_systems": "Scuttle Grill",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A250006.jpg",
+ "myid": 1373,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Scuttle Grill-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250006.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16614.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16615.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250007.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Pull out cover cap from the wiper arm.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250008.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 13mm socket spanner, loosen and remove the Wiper arm mounting nuts.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 15 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250009.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the wiper arms from vehicle.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250011.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the Scuttle Grill mounting screws .",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 1.9\u00b10.5Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250010.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the Scuttle Grill mounting Scrivets .",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250012.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the Scuttle Grill from the vehicle.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the Scuttle grill for any damage. Replace if found.Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250064.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen and remove the rear stone guard rear mounting bolts.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250033.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the stone guard mounting screw rivets.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250034.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the stone guard from the vehicle.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270025.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W415.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect the fog lamp electrical connectors LH & RH sides.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290002.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Pull and remove the front bumper top panel trim clips and remove the panel.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290003.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290004.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew front bumper mounting nuts.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290005.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "using a 13 mm socket spanner, Unscrew front bumper bottom mounting bolts.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290006.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew front bumper top side mounting bolts.",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290007.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front bumper top centre mounting screw rivets.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290008.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Remove the front bumper assembly from the vehicle.",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290010.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, Unscrew front bumper center bracket mounting bolts and remove the front bumper center mounting bracket.",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Torque Value",
+ "content": "Torque : 10.0\u00b11 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250060.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the front grill mounting screw rivets.",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290011.jpg",
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the bottom side front grill mounting screw rivets.",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250061.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the front grill mounting bolts.",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250062.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250063.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Remove the front grill assembly from the vehicle.",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290012.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290013.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Using star screw driver, Remove centre grill mounting screws and locking clips from front facia.",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290015.jpg",
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290014.jpg",
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Remove the centre grill from front facia.",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 58
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the front bumper assembly for any crack or damage, Replace if found any.
Check the front grill assembly for any external cracks, replace if found any.
",
+ "file": null,
+ "display_order": 59
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 257,
+ "sys_id": "THAR.AX-O-0007-Exterior System",
+ "subsys_id": "THAR.AX-O-0007-Exterior System-Soft Top Canopy Rear Tube Structure",
+ "systems": "Exterior System",
+ "sub_systems": "Soft Top Canopy Rear Tube Structure",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A250077.jpg",
+ "myid": 1370,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Soft Top Canopy Rear Tube Structure-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250077.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16573.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16574.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Soft top canopy.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1024,1369",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250082.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the rear side cover LH mounting bolts.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250083.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the rear side cover RH mounting bolts.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250090.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250091.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the rear side covers LH and RH sides.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250079.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250081.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the rear side member RH mounting bolts.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250088.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully remove the rear side member RH from vehicle.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250078.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250080.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the rear side member LH mounting bolts.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250089.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Carefully remove the rear side member LH from vehicle.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250084.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250085.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the rear centre panel assembly mounting bolts.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250086.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250087.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using a T40 torx socket spanner, loosen and remove the rear structure frame mounting torx bolts.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250099.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the rear structure frame from vehicle.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 31
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the rear structure frame for any external cracks and damages, replace if found any.",
+ "file": null,
+ "display_order": 32
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 264,
+ "sys_id": "THAR.AX-O-0007-Exterior System",
+ "subsys_id": "THAR.AX-O-0007-Exterior System-Convertible Soft Top Canopy",
+ "systems": "Exterior System",
+ "sub_systems": "Convertible Soft Top Canopy",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A250252.jpg",
+ "myid": 1377,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Convertible Soft Top Canopy-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250252.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16670.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16671.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the convertible soft top assembly.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1024,1367",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250240.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250239.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove Canopy mounting screws from the front side bow assembly RH and LH.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250241.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250242.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the lock from the RH and LH Front side bow assembly.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250243.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using star screw driver, loosen and remove Canopy mounting screws from Front side bow assembly inner side.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250244.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the Canopy from the front side bow assembly.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250245.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250246.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Detach or unlock the spring from the Bow 2 Pivot assembly & remove Canopy from Bow 2 Pivot assembly .",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250247.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250248.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using star screw driver, loosen and remove the canopy mounting screws from bow 2 pivot assembly and detach canopy.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250249.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250250.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using star screw driver, loosen and remove the canopy mounting screws from bow 3 assembly and detach canopy.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250251.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the Center Support Rexine Rivets.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250254.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the Canopy from the Frame.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250253.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250254.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the Cable with Spring from the Canopy (RH &LH;).",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Caution",
+ "content": "While Installation, Insert the cable from bracket side to Spring side (Insert spring inside from top)",
+ "file": null,
+ "display_order": 33
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the convertible soft top canopy for any crack or damage. Replace if any.",
+ "file": null,
+ "display_order": 34
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 262,
+ "sys_id": "THAR.AX-O-0007-Exterior System",
+ "subsys_id": "THAR.AX-O-0007-Exterior System-ORVM",
+ "systems": "Exterior System",
+ "sub_systems": "ORVM",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A250277.jpg",
+ "myid": 1375,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-ORVM-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250277.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16659.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16660.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the front door inner trim. For additional information refer to the Front Door Inner Trim - R &R; section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250274.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen and remove the mounting nuts from the ORVM.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250275.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250276.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the ORVM from the vehicle completely.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the ORVM for any crack or damage. Replace if any.",
+ "file": null,
+ "display_order": 12
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 259,
+ "sys_id": "THAR.AX-O-0007-Exterior System",
+ "subsys_id": "THAR.AX-O-0007-Exterior System-Roller Gage Bar Assembly",
+ "systems": "Exterior System",
+ "sub_systems": "Roller Gage Bar Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A250022.jpg",
+ "myid": 1372,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Roller Gage Bar Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250022.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16600.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16601.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove front lateral trim.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1023,1363",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Roof Speaker trim assembly.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1028,1422",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210079.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210080.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Open the top cover and Using a 14 mm socket spanner, loosen and remove the seat belt upper mounting bolt.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque :38 \u00b16 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210081.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the seat belt lower mounting bolt.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque :38 \u00b16 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250023.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the hand support belt.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250024.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the floor mate partially from the vehicle.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250025.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 13mm socket spanner, loosen and remove the roller gage bar rear mounting bolt.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 4Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250026.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 13mm socket spanner, loosen and remove the roller gage bar front mounting bolt.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 4Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250027.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 13mm socket spanner, Unscrew roller gage bar side mounting bolts.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 4Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250028.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the roller gage bar from vehicle.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250029.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250030.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the roller bar cover and separate roller gage bar.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 33
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any damages or crack in roller gage bar assembly. Replace if found.",
+ "file": null,
+ "display_order": 34
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 256,
+ "sys_id": "THAR.AX-O-0007-Exterior System",
+ "subsys_id": "THAR.AX-O-0007-Exterior System-Soft Top Canopy",
+ "systems": "Exterior System",
+ "sub_systems": "Soft Top Canopy",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A250065.jpg",
+ "myid": 1369,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Soft Top Canopy-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250065.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16555.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16556.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250066.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250067.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the rear mounting tube pipe structure mounting bolts.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250068.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250072.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the welcro from the rear tubes .",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250075.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250092.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the side cover from window bracket LH and RH sides.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250069.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250070.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the front mounting tube pipe structure mounting bolts.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250071.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the welcro from the front tubes .",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250073.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250074.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a star screw, loosen and remove the canopy front LH and RH screw rivets.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250118.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250117.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250116.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 10mm socket spanner, Unscrew canopy front end mounting bolts.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250076.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the Canopy from the vehicle.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 27
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the canopy assembly for any external cracks, replace if found any.",
+ "file": null,
+ "display_order": 28
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 198,
+ "sys_id": "THAR.AX-O-0007-en-SM-Heating, Ventilation And Air Conditioning (HVAC) ",
+ "system_name": "Heating, Ventilation And Air Conditioning (HVAC) ",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1018,
+ "active_status": true,
+ "Assets": [
+ {
+ "systemdisplayorder": 8,
+ "system_asset": "/files/HVAC.mp4",
+ "active_status": true
+ }
+ ],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 218,
+ "sys_id": "THAR.AX-O-0007-Heating, Ventilation And Air Conditioning (HVAC)",
+ "subsys_id": "THAR.AX-O-0007-Heating, Ventilation And Air Conditioning (HVAC)-Plate Mode Main Link",
+ "systems": "Heating, Ventilation And Air Conditioning (HVAC)",
+ "sub_systems": "Plate Mode Main Link",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A200178.jpg",
+ "myid": 1331,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Plate Mode Main Link-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200178.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/50023.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/50024.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the HVAC Mode Actuator.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1018,1323",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew plate mode main link mounting screws and remove the link.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200179.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200180.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the lever sub assembly and lever foot from the plate mode main link.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200181.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200182.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 12
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Inspect the plate mode main link for any damage. Replace if found.",
+ "file": null,
+ "display_order": 13
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 205,
+ "sys_id": "THAR.AX-O-0007-Heating, Ventilation And Air Conditioning (HVAC)",
+ "subsys_id": "THAR.AX-O-0007-Heating, Ventilation And Air Conditioning (HVAC)-Compressor",
+ "systems": "Heating, Ventilation And Air Conditioning (HVAC)",
+ "sub_systems": "Compressor",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A200092.jpg",
+ "myid": 1318,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Compressor-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200092.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/52023.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/52024.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Recover the AC gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Air Cleaner Assembly.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1000,1003",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the Steering Lower Intermediate Shaft.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1017,1302",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 12 mm open end spanner, Remove suction and discharge hose mounting nut from compressor.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 14.0+1.0 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200093.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the AC/water pump belt. For additional information refer to AC/Water Pump Belt - R&R Section. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect the AC compressor electrical connector.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200094.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Remove the compressor mounting nuts from the crank case.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Screenshot 2023-04-20 181129.png",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the compressor from the vehicle.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200095.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Refit the Steering Lower Intermediate Shaft.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1017,1302",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Refit the Air Cleaner Assembly.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1000,1003",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Remove the AC/water pump belt. For additional information refer to AC/Water Pump Belt - R&R Section. ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Recharge the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both liquid tube and discharge hose mounting joints without any damage. Damage to the O-ring may cause A/C refrigerant leakage which leads to A/c failure.",
+ "file": null,
+ "display_order": 27
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the compressor for any physical damage. Replace if found.Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220004.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220005.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the floor console LH panel assembly scrivet and detach the panel from vehicle.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220006.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220007.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the RH vertical ascent mounting screw and detach it from vehicle.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1547.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1549.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the LH vertical ascent mounting screw and detach it from vehicle.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220010.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1548.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Partially detach bezel HAVC control panel assembly and disconnect electrical connectors.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1550.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect Heater, Mode selection control cables from the HVAC control panel.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200152.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200156.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect the cable routing clips and take out the bezel Assembly with HVAC control panel.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200153.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200157.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "By using star screw driver, remove the HVAC control panel mounting screws and remove the panel from the bezel assembly.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque : 1.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200160.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200161.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 32
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Inspect the HVAC Control Panel Assembly for any damage. Replace if found.",
+ "file": null,
+ "display_order": 33
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 207,
+ "sys_id": "THAR.AX-O-0007-Heating, Ventilation And Air Conditioning (HVAC)",
+ "subsys_id": "THAR.AX-O-0007-Heating, Ventilation And Air Conditioning (HVAC)-AC Pipe (Compressor To Condenser)",
+ "systems": "Heating, Ventilation And Air Conditioning (HVAC)",
+ "sub_systems": "AC Pipe (Compressor To Condenser)",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A200088.jpg",
+ "myid": 1320,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-AC Pipe (Compressor To Condenser)-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200088.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/50007.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/50009.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Do not release the refrigerant into the atmosphere. Use approved recovery/ recycling equipment to capture the refrigerant whenever the air conditioning System is discharged.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Always wear eye and hand protection (goggles and gloves) when working with any Refrigerant or air conditioning system.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Warning",
+ "content": "Close the high pressure and low pressure refrigerant lines with dust caps to avoid air entry and/or contamination.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Recover AC gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Front Grill Assembly.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1024,1368",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 12 mm Combination Spanner, Unscrew the AC pipe compressor side mounting nut.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 14.0+1.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200070.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew radiator LH seal mounting bolt and remove the seal.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200071.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Remove HVAC pipe condenser side mounting nut.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0+1.0 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both pipe ends mounting joints without any damage. Damage to the Oring may cause A/C refrigerant leakage which leads to A/c failure.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200069.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the HVAC pipe assembly from the vehicle.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200072.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Recharge the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. ",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the AC pipe for any damage. Replace if found.",
+ "file": null,
+ "display_order": 24
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 203,
+ "sys_id": "THAR.AX-O-0007-Heating, Ventilation And Air Conditioning (HVAC)",
+ "subsys_id": "THAR.AX-O-0007-Heating, Ventilation And Air Conditioning (HVAC)-Blower Motor",
+ "systems": "Heating, Ventilation And Air Conditioning (HVAC)",
+ "sub_systems": "Blower Motor",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A200043.jpg",
+ "myid": 1316,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Blower Motor-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200043.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31179.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/50003.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Disconnect the HVAC blower motor electrical connector.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200044.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using star screw driver, loosen and remove the blower motor mounting screw.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200045.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the blower motor from the HVAC unit assembly.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200207.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200045.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Rotate the blower motor and check for any noise due to bearing wear.For additional information refer to the Radiator LH & RH Seal R&R section. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew condenser mounting bolts from radiator end.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 5 \u00b11 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200185.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Remove the radiator bottom seal mounting bolts and detach it.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 7\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200075.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the ambient temperature sensor from the routing clip.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200074.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200196.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully remove the condenser from vehicle.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200076.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200077.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Refit the Radiator LH & RH seal. For additional information refer to the Radiator LH & RH Seal R&R section. ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Recharge the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. ",
+ "file": null,
+ "display_order": 25
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the condenser for any physical damage, leakages etc. Replace if found any.Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220004.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220005.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the floor console LH panel assembly scrivet and detach the panel from vehicle.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220006.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220007.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the RH vertical ascent mounting screw and detach it from vehicle.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1541.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1542.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the LH vertical ascent mounting screw and detach it from vehicle.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220010.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1543.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Partially detach HAVC control panel bezel and remove the mode cable from HVAC control panel end and routing clip.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290035.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200152.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200153.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the driver side IP panel assembly.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200142.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect the mode cable from HVAC unit end.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200158.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200159.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the cable from the vehicle.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200154.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 31
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Inspect the HVAC mode cable for any damage, Replace if required.
For additional information refer to AC Gas Recharging Procedure. ",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Inspect the heater core assembly for any damage. Replace if found.For additional information refer to AC Gas Recharging Procedure. ",
+ "file": null,
+ "display_order": 43
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the evaporator coil for any damage. Replace if found.
Open the left front door.
",
+ "file": null,
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Open the co-driver door.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200021.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Open the glow box and detach the stopper by pressing it.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200131.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disengage the glow box from the assembly.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200132.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Press and remove the HVAC particulate filter cover from HVAC unit.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200022.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the HVAC particulate filter.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200023.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200024.jpg",
+ "display_order": 14
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Install the HVAC particulate filter on HVAC unit.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200031.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Install the HVAC particulate filter cover.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200022.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Engage the glow box stopper and refit the glow box in its position.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "While installing the filter take sufficient care to prevent bent, damage etc.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200133.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Close the glow box.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200134.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Close the co-driver door.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Use only genuine filter element.
Never clean and reuse the HVAC particle filter element.
",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200030.jpg",
+ "display_order": 26
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 212,
+ "sys_id": "THAR.AX-O-0007-Heating, Ventilation And Air Conditioning (HVAC)",
+ "subsys_id": "THAR.AX-O-0007-Heating, Ventilation And Air Conditioning (HVAC)-HVAC Heater Cable",
+ "systems": "Heating, Ventilation And Air Conditioning (HVAC)",
+ "sub_systems": "HVAC Heater Cable",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A200149.jpg",
+ "myid": 1325,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-HVAC Heater Cable-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200149.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31250.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31249.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the floor console RH panel assembly scrivet and detach the panel from the vehicle.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220004.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220005.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the floor console LH panel assembly scrivet and detach the panel from vehicle.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220006.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220007.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the RH vertical ascent mounting screw and detach it from vehicle.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1538.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1539.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the LH vertical ascent mounting screw and detach it from vehicle.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220010.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1540.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Partially detach HAVC control panel bezel and remove the heater cable from HVAC control panel end and routing clip.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290035.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200156.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200157.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Open the glove box and remove the glove box by removing the glove box lock.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200131.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200132.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect the heater cable from the HVAC unit end.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200151.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the cable from the vehicle.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200155.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 31
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Inspect the HVAC heater cable for any damage, Replace if required.2 post lift/ 4 post lift. ",
+ "file": null,
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the HVAC drain pipe locking grommet fitment condition on BIW.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200027.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Ensure that pipe is straight downwards.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "Do not pull the water drain pipe excessively.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200028.jpg",
+ "display_order": 8
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 202,
+ "sys_id": "THAR.AX-O-0007-Heating, Ventilation And Air Conditioning (HVAC)",
+ "subsys_id": "THAR.AX-O-0007-Heating, Ventilation And Air Conditioning (HVAC)-HVAC Unit",
+ "systems": "Heating, Ventilation And Air Conditioning (HVAC)",
+ "sub_systems": "HVAC Unit",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A200097.jpg",
+ "myid": 1315,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-HVAC Unit-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200097.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31166.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31165.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Cross Car Beam (CCB) Assembly.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1020,1344",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Recover the AC gas. For additional information refer to AC gas recovery procedure. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm open end spanner, Remove the HVAC Pipe mounting nut from expansion valve end.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both liquid tube and discharge hose mounting joints without any damage.Damage to the O-ring may cause A/C refrigerant leakage which leads to A/c failure.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200061.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach heater inlet and outlet hose quick couplers.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Do not open the degassing tank cap when the coolant is hot. Failure to follow this instruction will lead to personal injury.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "Before removing the heater core hoses, open the degassing tank cap for releasing the coolant pressure. Coolant will leak, while removing the heater core hoses, as a result drain the coolant into a container.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200034.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200038.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm Socket Spanner, Unscrew the HVAC unit assembly mounting bolt and nuts.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 7 \u00b11 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 7 \u00b11 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 7 \u00b11 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200098.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200099.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200100.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200101.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm Socket Spanner, Remove the HVAC earth cable mounting nut.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200104.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the HVAC unit assembly from vehicle.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200102.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200103.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Refit the Cross Car Beam.",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1020,1344",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Recharge the Refrigerant.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Start the engine, check the coolant level. Refill if required.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Check the coolant leak when engine is started.",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Check the A/C system cooling and operation.",
+ "file": null,
+ "display_order": 38
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the HVAC assembly for any physical damages. Repair if found.For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Front Grill Assembly.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1024,1368",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the Air Cleaner Assembly.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1000,1003",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm open end spanner, Liquid pipe mounting nut from expansion valve end.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200061.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Remove Liquid pipe routing bracket mounting nut from the vehicle.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200062.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen and remove the suction hose routing bracket mounting nut.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200063.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200129.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect the pressure switch electrical connector.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200064.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew radiator LH seal mounting bolt and detach it.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1536.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew Liquid pipe mounting nut from condenser end.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0+1.0 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both end of liquid tube mounting joints without any damage. Damage to the O-ring may cause A/C refrigerant leakage which leads to A/c failure.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200067.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the liquid pipe from the vehicle.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200087.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Refit the Air Cleaner Assembly.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1000,1003",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Refit the Front Grill Assembly.",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1024,1368",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Recharge the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. ",
+ "file": null,
+ "display_order": 39
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the suction hose assembly for any physical damage, leakages etc. Replace if found any.Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the HVAC Control Panel.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1018,1329",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Open the glove box and remove the glove box by detaching the lock.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200131.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200132.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the Driver side IP panel assembly.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190016.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect the HVAC control panel C 720 connector.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3167.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect the intake actuator C 722 connector.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3168.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect the blower motor C 721 connector.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3169.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Disconnect the blower resistor C 723 connector.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3170.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Disconnect the thermo amplifier C 724 connector.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3171.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Disconnect the HVAC unit C 117 M connector.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3172.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Disconnect the blower switch C 720A connector.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3173.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen and disconnect the HVAC ground G 2 connector.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3174.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Remove the wiring harness separately.",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Notice",
+ "content": "Ensure proper engagement of all the connectors.For additional information refer to IP Centre Switch Bank Assembly \u2014 R &R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew HVAC control unit mounting screws.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 1.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220033.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the HVAC Control panel.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200083.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 10
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the HVAC Control Panel Assembly for any damage. Replace if found.",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 95,
+ "sys_id": "THAR.AX-O-0007-en-SM-Propeller Shaft",
+ "system_name": "Propeller Shaft",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1011,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 97,
+ "sys_id": "THAR.AX-O-0007-Propeller Shaft",
+ "subsys_id": "THAR.AX-O-0007-Propeller Shaft-Torsional Vibration Damper (TVD)",
+ "systems": "Propeller Shaft",
+ "sub_systems": "Torsional Vibration Damper (TVD)",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A130029.jpg",
+ "myid": 1217,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Torsional Vibration Damper (TVD)-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130029.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30895.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30896.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "By using screw driver remove the TVD screw.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130030.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 14 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 14 mm ring and socket spanners unscrew rear propeller shaft mounting bolts and nuts from transfer case end.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130031.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 55 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the TVD assembly from vehicle and hang the Rear propeller shaft aside.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130032.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W404.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W405.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a nose plier, pull-down the double torsion Spring downwards and detach from pedal box and then gently pullout spring. ",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the Torsional Vibration Damper (TVD) for any damage, if found replace the TVD assembly.* Inspect the propeller shaft for any bend, crack, twisting and stone penetration, if found replace the propeller shaft assembly.* Check the propeller shaft for any flyweights missing. Replace the propeller shaft if found.* Clean the propeller shaft if any foreign materials like dirt found.",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 95,
+ "sys_id": "THAR.AX-O-0007-Propeller Shaft",
+ "subsys_id": "THAR.AX-O-0007-Propeller Shaft-Propeller Shaft Imbalance - Check",
+ "systems": "Propeller Shaft",
+ "sub_systems": "Propeller Shaft Imbalance - Check",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A130002.jpg",
+ "myid": 1215,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Propeller Shaft Imbalance - Check-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Propeller Shaft Imbalance - Check",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "If the propellers shaft unbalance is suspected then it can be verified by the following procedure, removing & rendering the propeller shaft by 180\u00b0 may eliminate some vibrations.* Clean all the foreign material from propeller shaft and the universal joint.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Ensure that the propeller shaft is not worn, are properly installed and are correctly aligned with the propeller shaft.",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Check the companion flange mounting bolts.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Raise the vehicle and remove rear wheels & tyres.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install the wheel nuts to lock the brake drum.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Mark & number the shaft 6 inches from pinion end at four positions 90\u00b0 apart.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130002.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Run and accelerate the engine until vibration occurs. Note the intensity & the speed at which the vibration occurs.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install a screw clamp at position \u201c1\u201d.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130003.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Start the engine and recheck for vibrations. If there is little vibration or no change in vibrations then move the clamp to the other 3 positions.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "If there is no difference in vibration at the other position then the vibration is not due to the propeller shaft imbalance.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "If the vibration decreases, install a second clamp and repeat the test.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130004.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "If the clamps cause an additional imbalance, separate the clamp (\u00bc inch above & below the mark). Repeat the vibration test.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Increase the distance between the clamps until the vibration is at the lowest level.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130005.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130006.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "At this position bend the slack end of the clamp so that it does not loosen.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Install the wheel & tyres. Lower the vehicle.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "If the amount of the vibration remains unacceptable then repeat the exercise at the gearbox end.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Notice",
+ "content": "After completing above procedure, if vibration is reduced, which indicates there is some imbalance in the propeller shaft.2 post lift/ 4 post lift. ",
+ "file": null,
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the inboard and outboard joint RH side drive shaft boots, clamps for cut, nick, loose, bend, crush or abrasion. Replace if necessary.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W407.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Rotate Steering wheel from one end to other for better visualization of boots. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W408.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Inspect the RH side drive shaft condition for cracks or damage. Replace if necessary.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W409.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Inspect the inboard and outboard joint LH side drive shaft boots, clamps for cut, nick, loose, bend, crush or abrasion. Replace if necessary.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W410.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Rotate Steering wheel from one end to other for better visualization of boots. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W411.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Inspect the LH side drive shaft condition for cracks or damage. Replace if necessary.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W412.jpg",
+ "display_order": 15
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 177,
+ "sys_id": "THAR.AX-O-0007-en-SM-Steering ",
+ "system_name": "Steering ",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1017,
+ "active_status": true,
+ "Assets": [
+ {
+ "systemdisplayorder": 7,
+ "system_asset": "/files/Steering.mp4",
+ "active_status": true
+ }
+ ],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 184,
+ "sys_id": "THAR.AX-O-0007-Steering",
+ "subsys_id": "THAR.AX-O-0007-Steering-Clock Spring",
+ "systems": "Steering",
+ "sub_systems": "Clock Spring",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A190105.jpg",
+ "myid": 1297,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Clock Spring-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190105.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22298.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22299.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080024.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Steering Column Shrouds.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1017,1299",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the steering wheel.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1017,1296",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the clock spring electrical connectors.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190119.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190024.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Dis-engage the clock spring mountings (3 points) and lift out the clock spring assembly from the steering column. ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190127.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a flat end screw driver remove the steering angle sensor from the clock spring.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190025.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190026.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Warning",
+ "content": "If the contact coil is not aligned correctly,the steering wheel may not be able to rotate properly during turning. This kind of restricted turning ability may cause the vehicle to crash or damage the contact coil and prevent the air bags from deploying in a crash event.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Carry-out the clock spring setting procedure.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1017,1292",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Notice",
+ "content": "Failure to do clock spring setting may result in clock spring damage. ",
+ "file": null,
+ "display_order": 22
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the clock spring assembly of steering wheel for any malfunctioning or damages, replace if found any.",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 177,
+ "sys_id": "THAR.AX-O-0007-Steering",
+ "subsys_id": "THAR.AX-O-0007-Steering-Free Play Check",
+ "systems": "Steering",
+ "sub_systems": "Free Play Check",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A190098.jpg",
+ "myid": 1290,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Free Play Check-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": " For additional information refer to Steering straight ahead setting procedure. Free Play Value \u00b1 5\u00b0 If the free play is out of the specified value, check the free play in steering column shaft connection and steering linkage. Replace or repair if necessary. ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190098.jpg",
+ "display_order": 3
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 197,
+ "sys_id": "THAR.AX-O-0007-Steering",
+ "subsys_id": "THAR.AX-O-0007-Steering-Troubleshoot - Steering",
+ "systems": "Steering",
+ "sub_systems": "Troubleshoot - Steering",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1468,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Troubleshoot - Steering-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Trouble Shooting",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "The rack and pinion design is a simple design. However it is still susceptible to various problems in particular to leaks. If the bellows are ripped or are unable to keep the contaminant\u2019s away then it can cause damage to oil seal and subsequent leaks.Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050128.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner, loosen and detach the pressure hose flare nut from the power steering pump.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190083.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner, loosen and detach the pressure hose flare nut from the power steering gear.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Position a tray below the rack to collect the fluid ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190128.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the routing bracket mounting bolt.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190048.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the supply hose from the vehicle.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190114.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Fill the fluid and carry-out air bleeding procedure. For additional information refer to Power steering fluid filling procedure.",
+ "file": null,
+ "display_order": 24
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Inspect for any external damage or bent, if found replace.",
+ "file": null,
+ "display_order": 25
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 181,
+ "sys_id": "THAR.AX-O-0007-Steering",
+ "subsys_id": "THAR.AX-O-0007-Steering-Power Steering Fluid - Replace",
+ "systems": "Steering",
+ "sub_systems": "Power Steering Fluid - Replace",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B190001.jpg",
+ "myid": 1294,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Power Steering Fluid - Replace-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Power Steering Oil - MAHINDRA MAXIMILE POWER STEERING FLUID GENUINE POWER STEERING FLUID.*\u2014 0.85 Litres.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "In case of non-availability of Genuine fluid, SHELL MAKE SPIRAX S3 ATF MD3 can be used. NO OTHER BRANDS RECOMMENDED.",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B190001.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Power Steering Fluid Draining",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Rotate in anti-clockwise and remove the power steering fluid reservoir cap. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190074.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using star screw driver, remove the front stone guard screvits.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011105.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 10 mm & 13 mm socket spanner, loosen the front & rear mounting bolts and remove the front stone guard.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011106.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner remove the steering fluid line bracket mounting bolt.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque: 10\u00b1 2 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190048.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner,loosen the nut and disconnect pump to rack pressure hose. ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque: 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Position a tray below the rack to collect the fluid. ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190104.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Drain the complete fluid in a neat container or bottle. ",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ },
+ {
+ "procedure_name": "Power Steering Fluid Filling",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Refit the pump to rack pressure hose.Torque tighten the nut to specified value.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190104.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refit the fluid line mounting clamp with the help of mounting bolt. Torque tighten the bolt to specified value. ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190048.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Fill the recommended fluid to MAX mark on reservoir.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B190009.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carry-out Power steering circuit air bleeding procedure.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1017,1295",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Refit the reservoir cap.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190074.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit the front stone guard screvits & mounting bolts, torque tighten the bolts to specified value.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque: 4.0 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011105.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011106.jpg",
+ "display_order": 33
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 194,
+ "sys_id": "THAR.AX-O-0007-Steering",
+ "subsys_id": "THAR.AX-O-0007-Steering-Front Steering Knuckle",
+ "systems": "Steering",
+ "sub_systems": "Front Steering Knuckle",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A190001.jpg",
+ "myid": 1307,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Front Steering Knuckle-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190001.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/50002.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/50001.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Front wheel. For additional information refer into Front Wheel R &R- Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the respective side Front Wheel Hub. For additional information refer into Front Wheel Hub R &R- Section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner , loosen and remove the wheel speed sensor mounting bolt & routing bracket mounting bolt.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 8 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190008.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a cutting plier and 17 mm socket spanner, remove the tie rod end cotter pin and tie rod end nut and detach from knuckle.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 45\u00b19Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190009.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a cutting plier and 24 mm socket spanner, remove the lower ball joint cotter pin and Lower ball joint nut and detach from knuckle.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 130 \u2014 150 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190010.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 22 mm socket spanner, loosen and remove the knuckle Lower Half mounting bolts.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque :140 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190011.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a cutting plier and 24 mm socket spanner, remove the upper ball joint cotter pin and ball joint nut and detach from knuckle.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 90 \u2013 110 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190012.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the knuckle from the vehicle.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": "After installation of knuckle assembly, Carry out the wheel alignment.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": "After installation of knuckle assembly, Carry out the wheel alignment.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1015,1249",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190013.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190014.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Warning",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Notice",
+ "content": "Always use new split pin. ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Perform wheel alignment.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1015,1249",
+ "file": null,
+ "display_order": 31
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect for any external damage or bent, if found replace.",
+ "file": null,
+ "display_order": 32
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 191,
+ "sys_id": "THAR.AX-O-0007-Steering",
+ "subsys_id": "THAR.AX-O-0007-Steering-Power Steering Pump",
+ "systems": "Steering",
+ "sub_systems": "Power Steering Pump",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A190115.jpg",
+ "myid": 1304,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Power Steering Pump-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The steering pump is a constant flow, vane type incorporating a flow control valve (with an integrated relief valve) and it is belt driven by engine.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190115.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190101.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22374.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22375.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the power steering fluid. For additional information refer to Power steering fluid draining section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially detach the degassing tank. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050128.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the engine feed system cover. For additional information refer into the Engine Feed System Cover \u2014R &R; Section.\ufeff ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 14 mm rings spanner rotate the auto tensioner in counter clockwise Partially detach the power steering belt. ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190124.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner,loosen and detach the pressure hose flare nut from the power steering pump.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190083.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a hose clip plier, unclip the return hose to reservoir hose clamp from pump.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190082.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the power steering pump mounting bolts.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Notice",
+ "content": "While loosening the bolt hold the nut using 12 mm ring spanner. ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque :25\u00b1 3 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190084.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the power steering pump from the vehicle.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190085.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Notice",
+ "content": "While tightening the bolt hold the nut using 12 mm ring spanner.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Carry-out power steering fluid filling and bleeding procedure.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1017,1295",
+ "file": null,
+ "display_order": 27
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the pump for any physical damage. Replace the pump if found.The wheels should be in straight ahead position before disconnecting the steering rack assembly from the vehicle. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially detach the degassing tank.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050128.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a cutting plier remove the cotter pin from the LH & RH tie rod .",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190121.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using the 17 mm socket spanner, loosen and remove the LH & RH tie rod end ball joint nuts from the knuckle assembly.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 45 \u00b1 9 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190009.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft mounting nut from the rack and pinion assembly and detach the intermediate shaft.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 22\u00b14Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190044.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner, loosen and remove the flare nuts and detach the steering rack and pinion supply and return lines.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": "Plug the steering rack assembly inlet and outlet hose oil passage with dust cap to avoid any foreign particles entry. ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190047.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Drain the power steering fluid.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the supply line routing bracket mounting bolt.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190048.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a 19 mm socket spanner, loosen and remove the steering rack and pinion assembly mounting bolts.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Torque Value",
+ "content": "Torque : 85 \u00b1 13 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Notice",
+ "content": "Use open end torque wrench for tightening RH side mountingbolt. ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190049.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Detach the front differential breather hose routing tag.",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190123.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Remove the steering rack and pinion assembly from the vehicle. ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190050.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Notice",
+ "content": "Always use a new cotter pin. ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Warning",
+ "content": "Ensure I shaft connector is assembled as per given marking. At straight ahead condition bolt head should face top side for easy torquing. ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190135.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Fill the power steering fluid and do the air bleeding procedure. Tighten the combination switch mounting screw as per specification over tighten will lead to damage of the switch. ",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the combination switch for any damage.Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190042.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering column mounting nuts then remove the steering column from the vehicle.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190039.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the grommet mounting bolts then remove the grommet from vehicle .",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 2 Nm *:22\u00b12 NmTorque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050128.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the front differential breather hose routing clip.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190123.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner loosen and remove the steering return line routing bracket mounting bolts.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190090.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a hose clamp plier, unclip the hose clamp from power steering side.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190087.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner, loosen the flare nut and detach the return line from the rack and pinion side.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190075.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the steering return line hose gear end from the vehicle.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190112.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Fill the fluid and carry-out air bleeding procedure. For additional information refer to Power steering fluid filling procedure. ",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect for any external damage or bent, if found replace.",
+ "file": null,
+ "display_order": 24
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 178,
+ "sys_id": "THAR.AX-O-0007-Steering",
+ "subsys_id": "THAR.AX-O-0007-Steering-Steering Angle Check",
+ "systems": "Steering",
+ "sub_systems": "Steering Angle Check",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A190099.jpg",
+ "myid": 1291,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Steering Angle Check-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "If the steering angle is out of the specified value, check and adjust the toe. ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190099.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22147.jpg",
+ "display_order": 4
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 182,
+ "sys_id": "THAR.AX-O-0007-Steering",
+ "subsys_id": "THAR.AX-O-0007-Steering-Power Steering Circuit Air Bleeding Procedure",
+ "systems": "Steering",
+ "sub_systems": "Power Steering Circuit Air Bleeding Procedure",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A190074.jpg",
+ "myid": 1295,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Power Steering Circuit Air Bleeding Procedure-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Power Steering Circuit Air Bleeding",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Position the vehicle on a 2 post/ 4 post lift.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Do not operate the steering system without power steering fluid. Failure to follow this precaution will lead to the damage of the steering system components. Air enters the power steering hydraulic system, the system must be bleed to ensure free of air. Filling and bleeding the power steering system helps to ensure trouble-free operation as well as prevents the damage of the power steering system components. \u201cMAX\u201d mark.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "During the bleeding procedure, ensure that the power steering fluid in the power steering fluid reservoir does not fall below the \u201cMIN\u201d mark, as air could enter into the system. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B190009.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Start the engine.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Slowly turn the steering wheel to left lock position and hold for about 10 seconds. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "From left lock position turn the steering wheel slowly to Right lock position.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Continue steps 6\u20147 till there is no air bubbles visible in the power steering fluid reservoir and smooth operation of power steering is attained.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Warning",
+ "content": "If the air bleeding is not properly performed, the life span of the power steering pump may be shortened. ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Top up the fluid to MAX mark on reservoir.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Close the reservoir cap.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190074.jpg",
+ "display_order": 16
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 179,
+ "sys_id": "THAR.AX-O-0007-Steering",
+ "subsys_id": "THAR.AX-O-0007-Steering-Clock Spring Setting Procedure",
+ "systems": "Steering",
+ "sub_systems": "Clock Spring Setting Procedure",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B190005.jpg",
+ "myid": 1292,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Clock Spring Setting Procedure-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Clock Spring Setting Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "To re-centre the clock spring , from default position rotate the clock spring in clockwise rotation (Towards right hand side) until tight (RH lock position).",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B190005.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B190006.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "From RH lock position rotate the clock spring in opposite direction (anti-clockwise) approximately 3 turns and align the marks.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Clock Spring Setting Procedure.png",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B190008.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Warning",
+ "content": "Failure to follow the instructions can cause the clock spring failure. Clock spring if failed and not corrected can be a concern if the vehicle meets an accident which is above the threshold for airbag deployment. In such cases the airbag may not be deployed even though the signal is given. Even if airbag not deployed it will be giving a signal of airbag failure which will mean a return of customer with a complaint added on. ",
+ "file": null,
+ "display_order": 7
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 183,
+ "sys_id": "THAR.AX-O-0007-Steering",
+ "subsys_id": "THAR.AX-O-0007-Steering-Steering Wheel",
+ "systems": "Steering",
+ "sub_systems": "Steering Wheel",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A190149.jpg",
+ "myid": 1296,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Steering Wheel-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The steering wheel is the part of the steering system that is rotated by the driver; the rest of the steering system responds to driver inputs. The steering wheel houses the driver airbag and audio controls. It is connected to the collapsible steering column.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190149.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190020.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22287.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22288.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080024.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Torque : 47\u00b17Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190022.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect clock spring electrical connector.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190021.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the steering wheel from the vehicle.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Do not use excessive force to the steering wheel for removal. This may cause steering wheel bend. Gently tap if needed. While installing steering wheel ensure the splines are aligned properly and the steering wheel slides easily on the column shaft. ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190023.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Notice",
+ "content": "Ensure the front wheels are in straight ahead position. ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Warning",
+ "content": "Improper or incorrect removal and installation of the Restraint components will cause unintentional activation of the system which may lead to personal injury. ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "The service operations should be followed in the correct sequence. Failure to do so may cause the SRS to unexpectedly deploy during service leading to a serious accident. ",
+ "file": null,
+ "display_order": 22
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the steering wheel for any external damage or bent, if found replace.",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 186,
+ "sys_id": "THAR.AX-O-0007-Steering",
+ "subsys_id": "THAR.AX-O-0007-Steering-Steering Column",
+ "systems": "Steering",
+ "sub_systems": "Steering Column",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A190117.jpg",
+ "myid": 1299,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Steering Column-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The steering column is bolted to the bulk head. It is a tiltable and collapsible column. The steering column shaft is mounted on two needle bearings internally at the ends suspended by rubber mountings in the steering column assembly. An intermediate shaft connects the steering column to the steering gear. For reasons of safety, the steering column assembly incorporates a collapsible steel cage and an intermediate shaft with a deformation zone designed to crumple progressively in the event of a headon collision.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190117.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190035.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22315.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22316.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080024.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the combination switch.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1017,1298",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the ignition key barrel electrical connector.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190033.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a Small chisel or punch hit and unscrew the mounting screw of ignition switch barrel with support of hammer.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090003.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090004.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft bottom mounting bolts and detach the intermediate shaft bottom from the steering column.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190042.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering column mounting bolts and nuts then remove the steering column from the vehicle.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190039.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the mounting bolt and remove top intermediate shaft from column.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190108.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190040.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Notice",
+ "content": "Ensure to Assemble Upper & Lower I shaft connector according to the marking. ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190133.jpg",
+ "display_order": 27
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the steering column for any external damage or bent, if found replace.",
+ "file": null,
+ "display_order": 28
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 189,
+ "sys_id": "THAR.AX-O-0007-Steering",
+ "subsys_id": "THAR.AX-O-0007-Steering-Steering Lower Intermediate Shaft",
+ "systems": "Steering",
+ "sub_systems": "Steering Lower Intermediate Shaft",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A190041.jpg",
+ "myid": 1302,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Steering Lower Intermediate Shaft-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190041.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22351.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22352.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the engine feed system cover. For information refer to Engine Feed System Cover - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the front RH wheel. Torque : 22\u00b14Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "While attempting to remove the intermediate shaft, lock the steering wheel at center position. ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190044.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft lower mounting bolt.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190042.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft Center bracket mounting bolts.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 20\u00b12.0Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190043.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the Steering intermediate shaft from the vehicle.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190045.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Notice",
+ "content": "Ensure to install Upper & Lower I shaft connector according to the marking. ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Warning",
+ "content": "DO NOT HAMMER while disassembly / assembly. Ensure I shaft connector is assembled as per given marking. At straight ahead condition bolt head should face top side for easy torquing. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190042.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering column mounting nuts then remove the steering column from the vehicle. ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190039.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the top intermediate shaft mounting bolts then remove the top intermediate shaft from the steering column.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190108.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190109.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Notice",
+ "content": "Ensure to install Upper & Lower I shaft connector according to the marking. ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190133.jpg",
+ "display_order": 25
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect for any external damage or bent, if found replace.",
+ "file": null,
+ "display_order": 26
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 195,
+ "sys_id": "THAR.AX-O-0007-Steering",
+ "subsys_id": "THAR.AX-O-0007-Steering-Steering Rack Linkage & Boots",
+ "systems": "Steering",
+ "sub_systems": "Steering Rack Linkage & Boots",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J10-MAT-0501",
+ "cover_image": "/files/W4A190046.jpg",
+ "myid": 1449,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 8,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 54,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 96,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 136,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 178,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 218,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 262,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 300,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 343,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 381,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 426,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Steering Rack Linkage & Boots-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "Description",
+ "content": "Position the vehicle on 2 post lift/ 4 post lift.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Steering Rack Linkage & Boots - Inspect.mp4",
+ "display_order": 2
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190046.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Steering Rack Linkage & Boots Inspection Procedure ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the steering rack assembly RH side boots, clamps for cut, nick or abrasion,replace if necessary",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190159.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Check the steering rack assembly LH side boots, clamps for cut, nick or abrasion, replace if necessary.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190160.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Check the steering rack assembly RH side linkage condition (Without removing boots) for play, damage, replace if necessary.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "Rotate Steering wheel from one end to other for better visualization of boots.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190161.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190163.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Check the steering rack assembly LH side linkage condition (Without removing boots) for play, damage, replace if necessary",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "Rotate Steering wheel from one end to other for better visualization of boots.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190158.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190162.jpg",
+ "display_order": 16
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 180,
+ "sys_id": "THAR.AX-O-0007-Steering",
+ "subsys_id": "THAR.AX-O-0007-Steering-Power Steering Fluid Level - Inspect",
+ "systems": "Steering",
+ "sub_systems": "Power Steering Fluid Level - Inspect",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J10-MAT-0500",
+ "cover_image": "/files/W4B190001.jpg",
+ "myid": 1293,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 7,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 53,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 95,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 135,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 177,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 217,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 261,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 299,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 342,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 380,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 425,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Power Steering Fluid Level - Inspect-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "Description",
+ "content": "Position the Vehicle on 2 post /4 post lift.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Power Steering Fluid Level - Inspect.mp4",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Power Steering Oil - MAHINDRA MAXIMILE POWER STEERING FLUID GENUINE POWER STEERING FLUID.Capacity \u2014 0.85 Litres.Check Power Steering fluid level , if found less than MIN mark, top up to MAX mark. Always maintain fluid level at MAX mark on reservoir. In case of non-availability of Genuine fluid, SHELL MAKE SPIRAX S3 ATF MD3 can be used. NO OTHER BRANDS RECOMMENDED. ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190067.jpg",
+ "display_order": 15
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 315,
+ "sys_id": "THAR.AX-O-0007-en-SM-Reverse Parking Assistance System",
+ "system_name": "Reverse Parking Assistance System",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1031,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 316,
+ "sys_id": "THAR.AX-O-0007-Reverse Parking Assistance System",
+ "subsys_id": "THAR.AX-O-0007-Reverse Parking Assistance System-RPAS System Technical Spec",
+ "systems": "Reverse Parking Assistance System",
+ "sub_systems": "RPAS System Technical Spec",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1429,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-RPAS System Technical Spec-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Technical Specification",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31452.jpg",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 315,
+ "sys_id": "THAR.AX-O-0007-Reverse Parking Assistance System",
+ "subsys_id": "THAR.AX-O-0007-Reverse Parking Assistance System-RPAS Sensors",
+ "systems": "Reverse Parking Assistance System",
+ "sub_systems": "RPAS Sensors",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A330001.jpg",
+ "myid": 1428,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-RPAS Sensors-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A330001.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31448.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Disconnect the RPAS sensor electrical connectors.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/RPAS Sensors.png",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Unlock the RPAS sensors from the cover.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/RPAS Sensors_2_01.png",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Detach the sensors from vehicle.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A330002.jpg",
+ "display_order": 8
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check sensor, wiring, connector for any damage.* Check for mud on sensor, clean gently if found.",
+ "file": null,
+ "display_order": 9
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 376,
+ "sys_id": "THAR.AX-O-0007-en-SM-Cooling System",
+ "system_name": "Cooling System",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1003,
+ "active_status": true,
+ "Assets": [
+ {
+ "systemdisplayorder": 18,
+ "system_asset": "/files/Cooling_System(G).mp4",
+ "active_status": true
+ }
+ ],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 394,
+ "sys_id": "THAR.AX-O-0007-Cooling System",
+ "subsys_id": "THAR.AX-O-0007-Cooling System-Thermostat Valve Test",
+ "systems": "Cooling System",
+ "sub_systems": "Thermostat Valve Test",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/S2B050146.jpg",
+ "myid": 1080,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Thermostat Valve Test-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the thermostat valve from the thermostat housing.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1003,1069",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Thermostat and thermometer bulb should be suspended in water. If they touch bottom or the sides then temperature in which thermostat / thermometer operate will not be correct and wrong diagnosis will take place. ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Insert the thermostat valve in to a container filled with water. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S2B050146.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Heat the container and measure the temperature of water by Using digital thermometer. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S2B050145.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Keep track of water temperature and respective valve opening/ travel. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Thermostat should start opening at 88 \u00b1 2 \u00b0 C (0.1 mm travel). Once temperature reaches 96 \u00b1 2\u00b0 C valve should be fully open , at this moment, valve travel will be approximately 8 mm. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "In case thermostat valve behavior does not confirm to above specifications, it should be replaced. ",
+ "file": null,
+ "display_order": 10
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 380,
+ "sys_id": "THAR.AX-O-0007-Cooling System",
+ "subsys_id": "THAR.AX-O-0007-Cooling System-Radiator Assembly (For AT Variants)",
+ "systems": "Cooling System",
+ "sub_systems": "Radiator Assembly (For AT Variants)",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B060154.jpg",
+ "myid": 1064,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Radiator Assembly (For AT Variants)-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Component Location Index",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060154.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25299.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25300.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the engine coolant. For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Intercooler assembly.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1000,1504",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the AT Oil Cooler Assembly. For additional information refer to AT Oil Cooler Assembly - R &R; section. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W40060018.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release radiator vent hose clip and disconnect hose radiator end. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060011.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release degassing tank Outlet and remove degassing tank. ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060142.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060145.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using Hose clamp plier, release radiator inlet and outlet hose spring band clamps and disconnect the hoses radiator end. ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110096.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect the AT oil inlet hose quick coupler from radiator bottom side. ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110112.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Disconnect the AT oil outlet hose quick coupler from radiator top side. ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4D060007.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4D060006.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew degassing tank mounting brackets mounting bolts LH & RH. ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 10 \u00b1 0.5Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4D060008.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Disconnect radiator fan electrical connector.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4D060009.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew condenser mounting bolts. ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Torque Value",
+ "content": "Torque : 5 \u00b11Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060144.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew radiator mounting bolts. ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Torque Value",
+ "content": "Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4D060010.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Carefully detach the condenser and hang the condenser. ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4D060012.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Remove the radiator with Fan assembly from the vehicle. ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4D060013.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4D060014.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Disconnect the shroud holder clips from radiator and fan then remove the clips (Top & Bottom).",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4D060015.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen sand remove fan mounting bolts and remove fan from Radiator ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.5\u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4D060016.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4D060017.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Detach the fan assembly from radiator bottom seating and remove the radiator fan assembly. ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Notice",
+ "content": "While Installing ensure the fan bottom seating are properly seated on radiator ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Carry-out coolant filling and de-aeration process.For additional information refer to Coolant filling and de-aeration section.",
+ "file": null,
+ "display_order": 46
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the radiator fins for damage, replace if found any. 2. Check the radiator for coolant leakage, replace if found any.3. Check the radiator for dust accumulation, clean with compressed air if dust accumulation is noticed.4. Check the radiator drain plug for any leakage.",
+ "file": null,
+ "display_order": 47
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 383,
+ "sys_id": "THAR.AX-O-0007-Cooling System",
+ "subsys_id": "THAR.AX-O-0007-Cooling System-Resistor Radiator Fan",
+ "systems": "Cooling System",
+ "sub_systems": "Resistor Radiator Fan",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B060172.jpg",
+ "myid": 1067,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Resistor Radiator Fan-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Component Location Index",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060172.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25320.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25321.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060135.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Disconnect the electrical connectors from resistor. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060173.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060174.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using screw driver, loosen the resistor mounting screw and remove the resistor. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install the reverse order of removal.",
+ "file": null,
+ "display_order": 9
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the resistor for any damages, if found then replace it. ",
+ "file": null,
+ "display_order": 10
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 386,
+ "sys_id": "THAR.AX-O-0007-Cooling System",
+ "subsys_id": "THAR.AX-O-0007-Cooling System-Turbo Coolant Inlet Pipe",
+ "systems": "Cooling System",
+ "sub_systems": "Turbo Coolant Inlet Pipe",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B060167.jpg",
+ "myid": 1480,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Turbo Coolant Inlet Pipe-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Component Location Index",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060167.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25334.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25335.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the engine coolant. For additional information refer to coolant draining procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Pipe Inlet Oil Turbocharger.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1001,1034",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060165.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew turbo coolant supply pipe mounting banjo bolt turbo end.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 18 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060166.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew turbo coolant supply pipe banjo bolt OCFM end. ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 18 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060168.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the turbo coolant outlet pipe. ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Carry-out coolant filling and de-aeration process. For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the coolant inlet pipe for any damage, Replace if found. ",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 390,
+ "sys_id": "THAR.AX-O-0007-Cooling System",
+ "subsys_id": "THAR.AX-O-0007-Cooling System-Schematic Layout Of Cooling System Operating Process",
+ "systems": "Cooling System",
+ "sub_systems": "Schematic Layout Of Cooling System Operating Process",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B060024.jpg",
+ "myid": 1075,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Schematic Layout Of Cooling System Operating Process-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060024.jpg",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 393,
+ "sys_id": "THAR.AX-O-0007-Cooling System",
+ "subsys_id": "THAR.AX-O-0007-Cooling System-Water Pump Leakage Test",
+ "systems": "Cooling System",
+ "sub_systems": "Water Pump Leakage Test",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1079,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Water Pump Leakage Test-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Typical sign of failed water pump is leakage through the seal and bearings. If the water pump is leaking replace the pump as soon as possible. Water pump failure can be confirmed by below steps:
For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the CATCON Assembly. For additional information refer to CATCON Assembly - R &R; section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010062.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner, Loosen hose clip and detach water outlet hose pipe end. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.5 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060179.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060180.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew water inlet pipe mounting bolts and remove pipe. ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 11 \u00b1 1 Nms ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carry-out coolant filling and de-aeration process. For additional information refer to Coolant filling and de-aeration section. ",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check coolant inlet pipe for any damage or cracks. If found replace the outlet pipe with a new one. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060135.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect fan resistor electrical connector. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050054.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050056.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060136.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew fan mounting bolts. ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060137.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060139.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect the shroud holder clips from radiator and fan then remove the clips (Top & Bottom). ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020255.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner, Loosen intercooler inlet hose clip and detach the hose intercooler end. ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.5 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050130.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Detach the fan assembly from radiator bottom seating and remove the radiator fan assembly. ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Notice",
+ "content": "While Installing ensure the fan bottom seating are properly seated on radiator.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install the reverse order of removal. ",
+ "file": null,
+ "display_order": 25
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check electric fan blades for any damages. ",
+ "file": null,
+ "display_order": 26
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 391,
+ "sys_id": "THAR.AX-O-0007-Cooling System",
+ "subsys_id": "THAR.AX-O-0007-Cooling System-Coolant Circuit- Thermostat Closed",
+ "systems": "Cooling System",
+ "sub_systems": "Coolant Circuit- Thermostat Closed",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B060025.jpg",
+ "myid": 1076,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Coolant Circuit- Thermostat Closed-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060025.jpg",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 376,
+ "sys_id": "THAR.AX-O-0007-Cooling System",
+ "subsys_id": "THAR.AX-O-0007-Cooling System-Coolant - Inspect",
+ "systems": "Cooling System",
+ "sub_systems": "Coolant - Inspect",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J10-MAT-0090",
+ "cover_image": "/files/W4B060001.jpg",
+ "myid": 1060,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 2,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 44,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 85,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 126,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 167,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 208,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 283,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 290,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 332,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 372,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 414,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Coolant - Inspect-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060001.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "Description",
+ "content": "2 post lift/ 4 post lift. Coolant \u2014 Mahindra 'MAXIMILE ULTRA COOL' Genuine Long Life Coolant (READY TO USE COOLANT NO NEED TO MIX WATER).
Capacity \u2014 ~5.0 Litres.
Coolant Level And Leak Inspection Procedure ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the degassing tank pressure cap for any damage or coolant leakage. Rectify the leakage if found. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060016.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Check the coolant level in the degassing tank, it should be between MAX and MIN marks. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "Check the coolant level when the engine is cold. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "If found below MIN mark then top it up with 'MAHINDRA 'MAXIMILE ULTRA COOL' (ready to use coolant. no need to mix water). ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060004.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060006.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060018.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Inspect the degassing tank to radiator vent hose & engine vent hose for any coolant leakages, also check the mounting spring band clamp for any damage. If found any damage or leak, rectify. ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060014.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Inspect the engine to T connection vent hose for any coolant leakages, also check the mounting spring band clamp for any damage. If found any damage or leak,rectify. ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060011.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060009.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Inspect the degassing tank outlet hose assembly at every joints such as degassing tank end, T-connector connections, Turbo outlet pipe & hoses, OCFM side for any coolant leakage, also check the mounting spring band clamp for any damage. If found any damage or leak, rectify. ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060007.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Inspect the radiator inlet hose at radiator and engine block for coolant leakage, rectify the leakage if found. Also inspect the mounting spring band clamp for any damage,replace the mounting spring band clamp if found damaged or loose. ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060008.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060017.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Inspect the radiator outlet hose at Radiator & Thermostat, thermostat housing for any coolant leakage, rectify if found any leakage. Also inspect the mounting clamp for any damage, replace if found damaged or loose. ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060013.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060019.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Inspect the heater inlet & outlet hoses (Both sides) for any coolant leakage, also check the mounting spring band clamp for any damage. If found any damage or leak, rectify. ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060015.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060016.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Inspect the Heater Inlet & outlet pipes at Cylinder head & OCFM for any damage. If found any damage or leak, rectify.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060020.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060022.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060021.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Inspect the Turbo Inlet & outlet pipes at Turbo & OCFM for any damage. If found any damage or leak, rectify. ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Caution",
+ "content": "Never remove the degassing tank cap when the engine is hot. 2.Specific. Don't use other Coolants / Water for top up. In case of emergency, Coolant meeting JIS K2234 Specification should be used (30% Concentration Diluted with Distilled water) and coolant change period has to be reduced as 30,000 KM.3.mix MAHINDRA MAXIMILE ULTRA COOL with water. ",
+ "file": null,
+ "display_order": 34
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 378,
+ "sys_id": "THAR.AX-O-0007-Cooling System",
+ "subsys_id": "THAR.AX-O-0007-Cooling System-Degassing Tank",
+ "systems": "Cooling System",
+ "sub_systems": "Degassing Tank",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B060001.jpg",
+ "myid": 1062,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Degassing Tank-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Degassing tank",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060001.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Degassing tank",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060115.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Degassing tank",
+ "content_type": "Description",
+ "content": "The degassing tank or coolant reservoir tank is made of plastic it can be visually identified like the washer tank.* Function of the degassing tank is to remove air bubbles or vapour from the cooling system and to store the coolant as a reservoir. Proper filling of the coolant inside the cooling system is must in order to pressurize the system. * The coolant level should be between the MAX and MIN marks on the reservoir tank after the cooling system has been cooled down.* The degassing tank cap rating is 1.4 \u00b1 0.15 bar and vacuum 0.04 to 0.1 bar.",
+ "file": null,
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4788.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4789.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the engine coolant. For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060004.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, release the radiator vent hose spring band clamp and disconnect the hose.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Never work with cooling system when the engine is hot. failing to this may cause personal injury.. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060011.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release the degassing tank outlet hose spring band clamp and detach hose degassing tank end. ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060023.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew degassing tank mounting bolts.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050129.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully remove the degassing tank.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Carry-out coolant filling and de-aeration process. For additional information refer to Coolant filling and de-aeration section. ",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "
Coolant \u2014 Mahindra 'MAXIMILE ULTRA COOL' Genuine Long Life Coolant (READY TO USE COOLANT. NO NEED TO MIX WATER). Top up Capacity \u2014 ~5.0 Litres. Engine Coolant Draining Procedure ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Switch OFF the Ignition and allow Engine to cool down. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Never remove the degassing cap when the engine is hot ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/coolant_replace.png",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using star screw driver, remove the front stone guard screvits. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011105.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver, remove the front stone guard screvits. ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011106.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 10 mm & 13 mm socket spanner, loosen the front & rear mounting bolts and remove the front stone guard. ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050160.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the radiator drain plug and allow the entire coolant to get drained. ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Place a tray beneath the drain plug to collect coolant drained. ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step 6",
+ "content_type": "Description",
+ "content": "Refit the drain plug.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step 6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050160.jpg",
+ "display_order": 18
+ }
+ ]
+ },
+ {
+ "procedure_name": "Filling",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060010.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Engine Coolant Filling & De-aeration Procedure ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Start filling the recommended coolant in degassing tank. ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "While filling, open the drain Plug & wait for the coolant to drop & close drain Plug. ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Check coolant level in degassing tank, add coolant to MAX level and close the degassing cap. ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": ", ",
+ "file": "/files/coolant 1.PNG",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Check all the hoses and clips for leakage and correct fitment. ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Start the engine and run at 3000 rpm for about 10 minutes. (For Thermostat Opening). ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Maintain Coolant level at MAX level always and ensure coolant never goes below MIN level. ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Switch OFF the Ignition and allow the engine to cool down, Check coolant level in degassing tank and add coolant to MAX level. ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step 5",
+ "content_type": "File",
+ "content": ", ",
+ "file": "/files/coolant2.PNG",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060003.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit the degassing cap.",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refit the front stone guard screvits & mounting bolts, torque tighten the bolts to specified value. ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque: 4.0 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": ", ",
+ "file": "/files/coolant_replace2.png",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": ", ",
+ "file": "/files/coolant_replace3.png",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Inspect the coolant circuit for any leakages. For additional information refer to Coolant level & leak inspection section. ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": "Never remove the degassing cap when the engine is hot. Never mix MAHINDRA MAXIMILE ULTRA COOL genuine coolant with water. Brand Specific. Don't use other Coolants / Water for top up. In case of emergency, Coolant meeting JIS K2234 Specification should be used (30% Concentration Diluted with Distilled water) and coolant change period has to be reduced as 30,000 KM Do not overfill the system; allow free space in the degassing tank for expansion of the fluid. For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 10
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check thermostat valve opening and closing temperatures, if found deviation from specified value, replace the thermostat. * Check travel of thermostat valve, if found deviation from specified value, replace the thermostat.",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 387,
+ "sys_id": "THAR.AX-O-0007-Cooling System",
+ "subsys_id": "THAR.AX-O-0007-Cooling System-Heater Outlet Pipe",
+ "systems": "Cooling System",
+ "sub_systems": "Heater Outlet Pipe",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B060121.jpg",
+ "myid": 1481,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Heater Outlet Pipe-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Component Location Index",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060121.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25340.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25341.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the engine coolant. For additional information refer to coolant draining procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the CATCON Assembly. For additional information refer to CATCON Assembly - R&R Section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010183.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release heater outlet hose clamp and detach hose. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060118.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew pipe routing bracket mounting bolt engine block end. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060120.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew pipe routing bracket mounting bolt cylinder head end. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060119.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm combination spanner, Unscrew heater pipe mounting bolt OCFM end and remove pipe. ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060122.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the turbo coolant outlet pipe. ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Carry-out coolant filling and de-aeration process. For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the coolant outlet pipe for any damage, Replace if found. ",
+ "file": null,
+ "display_order": 21
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 381,
+ "sys_id": "THAR.AX-O-0007-Cooling System",
+ "subsys_id": "THAR.AX-O-0007-Cooling System-Radiator Air Guides",
+ "systems": "Cooling System",
+ "sub_systems": "Radiator Air Guides",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B060171.jpg",
+ "myid": 1065,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Radiator Air Guides-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Component Location Index",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060171.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25309.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25310.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the front grill assembly.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1003,1065",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050050.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060131.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew the LH and RH radiator seal mounting bolts. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.5 \u00b10.5Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060132.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver, loosen and remove the LH and RH radiator seal mounting screw rivets. ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.5 \u00b10.5Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060133.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060134.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the both LH and RH radiator seal from the vehicle.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install the reverse order of removal. ",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Intercooler assembly.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1000,1504",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060004.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release radiator vent hose clip and disconnect hose radiator end. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060011.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release degassing tank Outlet and remove degassing tank. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060011.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060112.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew degassing tank mounting brackets mounting bolts LH & RH. ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 10 \u00b1 0.5Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060135.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect radiator fan electrical connector. ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060136.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen and remove fan mounting bolts and remove fan from engine compartment. ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.5\u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060137.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060139.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Disconnect the shroud holder clips from radiator and fan then remove the clips (Top & Bottom). ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060141.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050130.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Detach the fan assembly from radiator bottom seating and remove the radiator fan assembly. ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Notice",
+ "content": "While Installing ensure the fan bottom seating are properly seated on radiator. ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060142.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060145.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using Hose clamp plier, release radiator inlet and outlet hose spring band clamps and disconnect the hoses radiator end.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060143.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using hose plier, release vent hose spring band clamp and disconnect hose radiator end. ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060144.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew radiator mounting bolts. ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Torque Value",
+ "content": "Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060147.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060146.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew radiator LH & RH seal mounting bolts ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.5 Nm ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060149.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060151.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060152.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew condenser mounting bolts and partially detach the condenser from the radiator. ",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Torque Value",
+ "content": "Torque : 5 \u00b11Nm ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060153.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060155.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Remove the radiator from the vehicle. ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Carry-out coolant filling and de-aeration process. For additional information refer to Coolant filling and de-aeration section. ",
+ "file": null,
+ "display_order": 48
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the radiator fins for damage, replace if found any. Inspect and ensure the following nuts/bolts are with proper torque as recommended: ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170174.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Front shock absorber assembly on chassis (LH/RH).",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170176.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque value: 40 \u00b1 5Nm
Torque Wrench Type - Open end Torque Wrench
",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Front shock absorber mounting bolt on LCA (LH/RH).",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170186.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque value: 120 \u00b1 12 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Front stabilizer bar mounting bracket bolts.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170003.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque value: 50 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Front stabilizer bar link mounting bolts on LCA (LH/RH).",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170181.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque value: 90 \u00b110 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170180.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Front upper control arm pivot mounting bolts on chassis (LH/RH).",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170187.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque value: 97\u00b1 10 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170188.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Front Lower arm mounting bolts on chassis (LH/RH).",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170191.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque value: 250 \u00b1 20 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Notice",
+ "content": "Ensure to do the torquing in the nut side and holding the bolt while torquing. ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Knuckle bottom mounting bolts LHS & RHS.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170178.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque value: 140 \u00b1 10 Nm Torque Wrench Type - Open end Torque Wrench * Torque value : 70 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Rear stabilizer bar link rod mounting on chassis (LH/RH).",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170197.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque value : 90 \u00b110 NmWhile torquing axle side, hold the nut by open end spanner & do the torquing in the bolt side. ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Rear upper link mounting on chassis and axle (LH&RH).",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170201.jpg",
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Torque Value",
+ "content": "Torque value: 230 \u00b1 20 NmTorque value : 110\u00b111 Nm
Torque Wrench Type - Open end Torque Wrench
",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140022.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Rear shock absorber top mounting on chassis (LH&RH).",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170196.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Torque Value",
+ "content": "Torque value : 65\u00b110Nm ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170185.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Pan hard rod mountings on axle & chassis.",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170204.jpg",
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Torque Value",
+ "content": "Torque value: 230 \u00b1 20 Nm ",
+ "file": null,
+ "display_order": 56
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 351,
+ "sys_id": "THAR.AX-O-0007-en-SM-Exhaust & Emission Control",
+ "system_name": "Exhaust & Emission Control",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1001,
+ "active_status": true,
+ "Assets": [
+ {
+ "systemdisplayorder": 17,
+ "system_asset": "/files/Exhaust_system(G).mp4",
+ "active_status": true
+ }
+ ],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 351,
+ "sys_id": "THAR.AX-O-0007-Exhaust & Emission Control",
+ "subsys_id": "THAR.AX-O-0007-Exhaust & Emission Control-Exhaust Pipe Mounting & Damage",
+ "systems": "Exhaust & Emission Control",
+ "sub_systems": "Exhaust Pipe Mounting & Damage",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J10-MAT-0230",
+ "cover_image": "/files/W4B030001.jpg",
+ "myid": 1020,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 15,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 62,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 104,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 143,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 187,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 225,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 270,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 308,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 351,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 388,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 435,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Exhaust Pipe Mounting & Damage-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Preliminary Activities/Conditions",
+ "content_type": "Description",
+ "content": "Position the vehicle on a 2 post / 4 post lift.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Preliminary Activities/Conditions",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Exhaust Pipe Mounts & Damage or Leakage - Inspect.mp4",
+ "display_order": 2
+ },
+ {
+ "step_name": "Preliminary Activities/Conditions",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030001.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Exhaust pipe mountings and damage - Procedure:",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Position the vehicle on a 2 post / 4 post lift.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Check the insulators of the exhaust front pipe , intermediate pipe with muffler and tail pipe with muffler, replace if found elongated or damaged.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030004.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030005.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030006.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Check the joint between exhaust tail pipe with intermediate pipe, if found leakage then replace the gasket and torque tighten the nuts to specified value.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030009.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Check the joint between exhaust intermediate pipe with front pipe for any leakage, if found leakage then replace the gasket and torque tighten the nuts to specified value.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030007.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Check the joint between exhaust front pipe with Catalytic Converter for any leakage, if found leakage then replace the gasket and torque tighten the nuts to specified value.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030002.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Do not work when the exhaust system is hot. Torque : 18 \u00b1 2Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew turbo oil supply pipe banjo bolt OCFM end.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030012.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 18 \u00b1 2Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the turbo oil inlet pipe.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030159.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Check Engine Oil level & Top-up the engine oil.",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check oil inlet tube for any external damage, replace if found any.",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 352,
+ "sys_id": "THAR.AX-O-0007-Exhaust & Emission Control",
+ "subsys_id": "THAR.AX-O-0007-Exhaust & Emission Control-Lambda Sensor Upstream",
+ "systems": "Exhaust & Emission Control",
+ "sub_systems": "Lambda Sensor Upstream",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B030106.jpg",
+ "myid": 1470,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Lambda Sensor Upstream-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The Lambda Sensor or Heated Oxygen Sensor which is bolted into the top of the catalytic converter is called as upstream lambda sensor. The Lambda Sensor measures the residual oxygen level in the exhaust gases. A lambda value of 1 indicates engine is running at stoichiometric air fuel ratio. A minimum temperature of 300\u00b0 C is required for proper functioning of the Lambda sensor. The integrated heater ensures that the sensor functions even at extremely low exhaust gas temperatures.* The Lambda Sensor is used to correct the fuel injection quantity to maintain stoichiometric air fuel ratio for combustion.* Second lambda sensor is bolted to the bottom of catalytic converter. The downstream lambda Sensor is used for diagnosis of catalytic converter and to ensure good catalytic converter efficiency. The voltage output of the sensors depends upon the oxygen content in the exhaust gas.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030106.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030141.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30420.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30421.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the NVH cover",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010045.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Warning",
+ "content": "Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect the Lambda sensor electrical connector.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030139.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 22 mm open end spanner loosen the sensor and remove sensor from CATCON.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030140.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030142.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external damage on sensor , replace if found any.",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 355,
+ "sys_id": "THAR.AX-O-0007-Exhaust & Emission Control",
+ "subsys_id": "THAR.AX-O-0007-Exhaust & Emission Control-Turbocharger",
+ "systems": "Exhaust & Emission Control",
+ "sub_systems": "Turbocharger",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B030154.jpg",
+ "myid": 1473,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Turbocharger-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030154.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30464.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30465.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Catalytic Converter Assembly",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1001,1472",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Warning",
+ "content": "Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner remove turbo support bracket mounting bolts.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030144.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 25\u00b13 Nm",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner loosen clean hose clip and detach it from turbo end.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020244.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner loosen Intercooler inlet hose clip and detach it from turbo end.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030145.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.5\u00b10.6Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect turbo dump valve electrical connector.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030146.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, remove turbo oil inlet pipe banjo bolt.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030147.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 18 \u00b1 2Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner remove turbo coolant inlet, outlet pipe banjo bolts.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030150.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 18 \u00b1 2Nm ",
+ "file": "/files/W4B030148.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner remove turbo oil drain pipe mounting bolts.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030151.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque : 11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner remove turbo mounting nuts.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030152.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Notice",
+ "content": "Always use new metal gasket once removed. check for any leakages* While installing, Molykote to be applied on both sides of stud on exhaust manifold- turbocharger.* Torquing to be done immediately after application of molykote sealant.* Nuts to be re torque after initial tightening in the same sequence.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Disconnect turbo electrical interconnector.",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030153.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove Turbocharger Assembly from vehicle.",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030022.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Disconnect turbo pigtail electrical connector and remove pigtail.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030021.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030120.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Check Engine Oil level & Top-up the engine oil.",
+ "file": null,
+ "display_order": 39
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the Compressor/Turbine wheel for damage.",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3C020057.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3C020058.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Inspect the Compressor/Turbine wheel for rubbing.",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3C020059.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3C020060.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Inspect the Rotor for free rotation.",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3C020061.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3C020062.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Inspect the rotor play by pressing the shaft outward & rotate, It should be rotate freely.",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3C020063.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3C020064.jpg",
+ "display_order": 51
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 356,
+ "sys_id": "THAR.AX-O-0007-Exhaust & Emission Control",
+ "subsys_id": "THAR.AX-O-0007-Exhaust & Emission Control-Pipe Oil Drain Turbocharger",
+ "systems": "Exhaust & Emission Control",
+ "sub_systems": "Pipe Oil Drain Turbocharger",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B030156.jpg",
+ "myid": 1033,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Pipe Oil Drain Turbocharger-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030156.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30488.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30489.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove turbo bottom heat shield.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Warning",
+ "content": "Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew turbo oil drain pipe mounting bolts cylinder head end.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030011.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew turbo oil drain pipe mounting bolts turbo end.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030151.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the turbo oil drain pipe.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030157.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Check Engine Oil level & Top-up the engine oil.",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check oil return tube for any external damage, replace if found any.",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 354,
+ "sys_id": "THAR.AX-O-0007-Exhaust & Emission Control",
+ "subsys_id": "THAR.AX-O-0007-Exhaust & Emission Control-Catalytic Converter",
+ "systems": "Exhaust & Emission Control",
+ "sub_systems": "Catalytic Converter",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B030101a93e20.jpg",
+ "myid": 1472,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Catalytic Converter-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The Closed coupled catalytic converter is mounted between the turbo charger and the exhaust front pipe assembly. The three way catalytic converter allows the three pollutants (CO, HC, NOx) to be converted simultaneously in a single chamber. It converts harmful carbon monoxide and hydrocarbons into water vapor & carbon dioxide and reduces NOx into nitrogen & carbon dioxide. In three way catalytic converter, Substrate is coated over with oxidation catalysts Platinum & Palladium and reduction catalyst Rhodium.High amount of substrate is loaded in the top portion & less amount in the bottom portion. Using 12 mm combination spanner remove turbo top heat shield mounting bolts and detach shield. Disconnect Upstream and Downstream lambda sensor electrical connectors Using 22 mm open end spanner remove Upstream and Downstream lambda Sensors Using 13 mm socket spanner unscrew exhaust front pipe mounting bolts CATCON end Carefully remove the fan assembly Using 13 mm socket spanner remove CATCON mounting nuts from turbocharger Using 12 mm socket spanner, Unscrew Upstream O2 sensor electrical connector holding bracket mounting bolt and remove the bracket Using 12 mm socket spanner, Unscrew Upstream O2 sensor electrical connector holding bracket mounting bolt and remove the bracket Using 12 mm socket spanner remove CATCON bracket mounting bolts and remove the brackets Refit the CATCON mounting brackets on CATCON and hand tighten the bolts. Ensure to only hand tighten the bracket bolts in this stage for proper position of Cat con on vehicle and after that torque tighten. Place and position the CATCON inside the engine compartment. Always replace the metal gasket once removed. Install the CATCON mounting nuts on turbocharger. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "Ensure to apply Molykote on stud tapping threads while Installation. Torquing to be done immediately after application of molykote sealant. Tighten the CATCON bracket mounting bolts on cylinder block side to the specific torque value. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030125.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Tighten the CATCON bracket mounting bolts on CATCON to the specific torque value. Torque : 25\u00b13 Nm ",
+ "file": "/files/W4B030020.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit exhaust front pipe and install the mounting bolts CATCON end and torque tighten. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refit the Upstream and Downstream lambda sensors on the CATCON and torque tighten. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030135.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Reconnect Upstream and Downstream lambda sensor electrical connectors. Refit turbo top heat shield and torque tighten the mounting bolts. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 58
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external cracks on catalytic converter assembly, replace if found any. Check for the obstruction of the air flow, replace if found any. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030138.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 13
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external damage on sensor , replace if found any.",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 334,
+ "sys_id": "THAR.AX-O-0007-en-SM-Ignition System",
+ "system_name": "Ignition System",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1035,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 337,
+ "sys_id": "THAR.AX-O-0007-Ignition System",
+ "subsys_id": "THAR.AX-O-0007-Ignition System-Troubleshoot - Ignition System",
+ "systems": "Ignition System",
+ "sub_systems": "Troubleshoot - Ignition System",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1506,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Troubleshoot - Ignition System-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Troubleshoot",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4739.pdf",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 336,
+ "sys_id": "THAR.AX-O-0007-Ignition System",
+ "subsys_id": "THAR.AX-O-0007-Ignition System-Ignition System Technical Spec",
+ "systems": "Ignition System",
+ "sub_systems": "Ignition System Technical Spec",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1484,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Ignition System Technical Spec-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Technical Specification",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11860.jpg",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 335,
+ "sys_id": "THAR.AX-O-0007-Ignition System",
+ "subsys_id": "THAR.AX-O-0007-Ignition System-Ignition Coil",
+ "systems": "Ignition System",
+ "sub_systems": "Ignition Coil",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B010204.jpg",
+ "myid": 1483,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Ignition Coil-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Ignition Coil gives high voltage current to the spark plug and is basically a step up transformer. Ignition timing is decided by the EMS ECU.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010204.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010207.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11846.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11847.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the battery negative terminal.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080024.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Before starting of the procedure, always switch off the ignition.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Do not smoke or carry lighted tobacco/open flame while working near any fuel related components.Torque Value: 10 - 12 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1043.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Connect Ignition coil electrical connectors.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1044.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Refit the engine encapsulation cover..",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1045.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Connect the battery negative cable mounting nut.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080024.jpg",
+ "display_order": 28
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 334,
+ "sys_id": "THAR.AX-O-0007-Ignition System",
+ "subsys_id": "THAR.AX-O-0007-Ignition System-Spark Plugs - Replace",
+ "systems": "Ignition System",
+ "sub_systems": "Spark Plugs - Replace",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J10-MAT-0210",
+ "cover_image": "/files/W4B010205.jpg",
+ "myid": 1482,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 37,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 66,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 112,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 150,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 194,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 237,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 251,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 321,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 360,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 398,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 446,
+ "kilometers_applicable": 0
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Spark Plugs - Replace-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Spark Plugs - Replace.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "It is a device for delivering electric current from the ignition system to the combustion chamber in the spark-ignition engine to ignite the charge by an electric spark. The timing of the spark ensure that the combustion pressure within limits and also the emissions. The spark plug has a metal threaded shell, electrically isolated from the central electrode by a porcelain insulator. The central electrode, is connected by a heavily insulated wire to the output terminal of an ignition coil. The spark plug's metal shell is screwed into the engine's cylinder head and thus electrically grounded. The central electrode protrudes through the porcelain insulator into the combustion chamber, forming spark gap between the inner end of the central electrode and the inner end of the threaded shell and designated the side, earth, or ground electrode.",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010205.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W200.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Preliminary Activities/Conditions",
+ "content_type": "Description",
+ "content": "MST 0308CBG0001ST - Spark Plug Installer Tool , loosen and remove spark plugs from cylinder head.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W148.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W149.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W150.jpg",
+ "display_order": 21
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Refit the new spark plugs and torque tighten them to the specified value.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W151.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 20 - 25 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W152.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Tighten the spark plug to specified torque value. Over tightening may damage the spark plug.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Spark plug gap is a gap between the centre and side electrodes of a spark plug. Before installing new spark plug, ensure that the specified gap is maintained between the electrodes. For Thar, Spark Plug gap should be maintained as 0.7 - 0.8 mm and Incorrect spark plug gaps can cause the following problemsRough, irregular engine Idle.Engine hesitation or stumbles while acceleration.Engine to miss or run erratically especially during idle.Poor engine performance.Engine knocking or pinging.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refit the Ignition coil mounting bolts and torque tighten to specified value.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W153.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 10 - 12 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W154.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Connect Ignition coil electrical connectors.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W155.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Refit the engine encapsulation cover.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W156.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Connect the battery negative cable mounting nut.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W157.jpg",
+ "display_order": 37
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 1,
+ "sys_id": "THAR.AX-O-0007-en-SM-Engine",
+ "system_name": "Engine",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1004,
+ "active_status": true,
+ "Assets": [
+ {
+ "systemdisplayorder": 4,
+ "system_asset": "/files/Powertrain_.mp4",
+ "active_status": true
+ },
+ {
+ "systemdisplayorder": 3,
+ "system_asset": "/files/Lubrication_System(G).mp4",
+ "active_status": true
+ }
+ ],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 3,
+ "sys_id": "THAR.AX-O-0007-Engine",
+ "subsys_id": "THAR.AX-O-0007-Engine-Engine Oil Filter - Replace",
+ "systems": "Engine",
+ "sub_systems": "Engine Oil Filter - Replace",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J10-MAT-0030",
+ "cover_image": "/files/W4B010011.jpg",
+ "myid": 1085,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 29,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 43,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 84,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 125,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 166,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 207,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 248,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 289,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 330,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 371,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 412,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Engine Oil Filter - Replace-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Engine Oil Filter - Replace.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010011.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11320.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Preliminary Activities/Conditions",
+ "content_type": "Description",
+ "content": "Position the vehicle on ground level/ 2 post lift/ 4 post lift and turn engine OFF.Torque :25 - 30 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Don\u2019t apply improper torque which leads to damage in threads.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Recommend to use only the Mahindra genuine oil filter for better engine protection and lubricant life.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Check the engine oil level.",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1004,1083",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Start the engine and check for Oil leakage/ seepage at:For additional information refer to Engine Case Cover - R&R Section. ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010971.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove MST 0307ABH0001ST - Flywheel Locking Tool - Eagle mounting bolts and detach it.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010617.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Refit engine front lifting hook and torque tighten the mounting bolts to the specified value.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010615.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010616.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 18 mm socket spanner, unscrew engine mounting bracket nut (Both LH & RH) from engine bed.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 110 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010618.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Provide engine support beam to support engine.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Warning",
+ "content": "Lift the engine with care, don\u2019t over lift since chances of damaging parts are more.Torque : 20\u00b12 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010622.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Position damper pulley and install damper pulley mounting bolt on crankshaft.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011169.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011166.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1531.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Insert the TDC locking pin (MST 0312ABH0001ST \u2014 Crankshaft Locking Tool - TDC Pin ) and lock the crankshaft.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Notice",
+ "content": "Ensure the crankshaft locking tool is seated properly into the slot on crankshaft and ensure the TDC locking pin insert upto Red mark in the pin as shown. * Check and ensure the 1st cylinder piston position to TDC.* Ensure that correct TDC locking tool is used.* TDC locking hole is near crankcase left side below intake manifold (Near Engine LH Mounting bracket).* If not able to position the MST in proper position into crankshaft, Slightly rotate damper pulley and align the crankshaft to insert MST:- 0312ABH0001ST Crankshaft Locking Tool - TDC Pin on crankshaft.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010622.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 24 mm socket spanner, loosen and remove damper pulley mounting bolt and detach damper pulley.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010258.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010259.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Check Crankshaft Sprocket woodruff key slot in 12\u2019o Clock Position, Intake and Exhaust camshaft cam phaser locking pin in 12\u2019o clock position.",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1532.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Align the MST \u2014 0310ABG0001ST Camshaft locking tool on the front side of engine in the camshaft slot as shown and fix the camshaft locking tool on cylinder head using appropriate bolts.",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Caution",
+ "content": "Ensure that correct Camshaft locking tool is used.* Ensure the Cam locking tool is seated properly on Cam shaft.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010257.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "If the tool is not properly seat on the cam shaft slot then the engine is not in proper timing and follow the below steps for Engine timing adjustment.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010613.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010614.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew chain tensioner mounting bolts and remove the tensioner.",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Torque Value",
+ "content": "Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010607.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using 8 mm Allen socket spanner, Unscrew chain tensioner LH fixed guide mounting bolt and remove the guide.",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010606.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using 8 mm Allen socket spanner, Unscrew chain tensioner RH guide mounting bolts and remove the guide.",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010608.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew chain tensioner top guide mounting bolt and remove the guide.",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Torque Value",
+ "content": "Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010609.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Remove the timing chain from sprocket.",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010256.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010258.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010259.jpg",
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Align the MST \u2014 0310ABG0001ST Camshaft locking tool on the front side of engine in the camshaft slot as shown and fix the camshaft locking tool on cylinder head using appropriate bolts. ",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Caution",
+ "content": "If not able to position the MST in proper position into camshaft, Slightly rotate Intake/Exhuast cam shaft and align the tool. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010607.jpg",
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": "Refit the chain tensioner guide and install the mounting Allen bolt.",
+ "file": null,
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010612.jpg",
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Compress the chain tensioner and lock it using lock pin.",
+ "file": null,
+ "display_order": 72
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010613.jpg",
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Refit the chain tensioner.",
+ "file": null,
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Torque Value",
+ "content": "Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010608.jpg",
+ "display_order": 76
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Refit the timing chain top guide and install the mounting bolts.",
+ "file": null,
+ "display_order": 77
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Torque Value",
+ "content": "Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010612.jpg",
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Remove the chain tensioner locking pin.",
+ "file": null,
+ "display_order": 80
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010624.jpg",
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Description",
+ "content": "Remove the CAM shafts locking MST.",
+ "file": null,
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1534.jpg",
+ "display_order": 83
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "Description",
+ "content": "Remove the TDC Pin from crankshaft.",
+ "file": null,
+ "display_order": 84
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1535.jpg",
+ "display_order": 85
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "Description",
+ "content": "Apply the Loctite 574 on TDC lock plug and tighten the plug on engine block to specified torque.",
+ "file": null,
+ "display_order": 86
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "Torque Value",
+ "content": "Torque : 20\u00b12 Nm ",
+ "file": null,
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010975.jpg",
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "Description",
+ "content": "Refit engine mounting LH bracket, torque tighten the mounting bolts to the specified value.",
+ "file": null,
+ "display_order": 89
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "Torque Value",
+ "content": "Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 90
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010618.jpg",
+ "display_order": 91
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "Description",
+ "content": "Remove engine support beam.",
+ "file": null,
+ "display_order": 92
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010615.jpg",
+ "display_order": 93
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010616.jpg",
+ "display_order": 94
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "Description",
+ "content": "Install engine bed mounting nuts Both RH & LH, torque tighten the mounting nut to the specified value.",
+ "file": null,
+ "display_order": 95
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "Torque Value",
+ "content": "Torque : 110 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010617.jpg",
+ "display_order": 97
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner , loosen and remove engine front lifting hook from head.",
+ "file": null,
+ "display_order": 98
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "Torque Value",
+ "content": "Torque : 35\u00b13 Nm ",
+ "file": null,
+ "display_order": 99
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010971.jpg",
+ "display_order": 100
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "Description",
+ "content": "Refit Flywheel locking tool (MST\u20140307ABH0001ST) with suitable mounting bolts on crankcase.",
+ "file": null,
+ "display_order": 101
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "Description",
+ "content": "Refit the Engine Front cover. For additional information refer to Engine Front cover - R&R Section. ",
+ "file": null,
+ "display_order": 102
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 33,
+ "sys_id": "THAR.AX-O-0007-Engine",
+ "subsys_id": "THAR.AX-O-0007-Engine-OCFM Oil Cooler",
+ "systems": "Engine",
+ "sub_systems": "OCFM Oil Cooler",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B010137.jpg",
+ "myid": 1507,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-OCFM Oil Cooler-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010137.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30204.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11477.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the engine coolant. For additional information refer to coolant drain procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Air Cleaner Assembly. For additional information refer to OCFM-Degassing Tank Outlet Pipe - R &R. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove Steering Lower Intermediate Shaft. For additional information refer to Steering Lower Intermediate Shaft - R &R; section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1513.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using the MST 0306GAM0006ST - Stretch Fit Belt Removal Tool Remove the AC compressor Drive belt. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010592.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect the AC compressor electrical connector.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010593.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew AC compressor mounting bolts and keep aside the compressor.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 23 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010140.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew degassing tank coolant outlet pipe OCFM end.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010139.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010138.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using T45 socket spanner, Unscrew Oil cooler mounting bolts.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the oil cooler from the engine.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Notice",
+ "content": "Replace New O ring while refitting.For additional information refer into Flywheel R &R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010142.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a suitable tool remove the front end oil seal.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010996.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the seal from the engine.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "The crankshaft oil seals are one time use, should never be reused.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010143.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010838.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010144.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010145.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Follow the below procedure for front oil seal Installation.Position the front oil seal on the Front Cover.Place the front oil seal installer (MST\u20140311DBH0001ST) over the oil seal and tighten the torsional vibration damper pulley bolt.Tighten the torsional vibration damper pulley bolt till the front oil seal is pushed to the Front Cover.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Notice",
+ "content": "Apply thin layer of oil on the new oil seal lip.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Notice",
+ "content": "Visually inspect the oil seal for proper seating.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Check & Top-up the engine oil.",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check and clean the oil seal seating area thoroughly for any damage.",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 21,
+ "sys_id": "THAR.AX-O-0007-Engine",
+ "subsys_id": "THAR.AX-O-0007-Engine-Hydrostatically Locked Engine",
+ "systems": "Engine",
+ "sub_systems": "Hydrostatically Locked Engine",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1108,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Hydrostatically Locked Engine-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Hydrostatically Locked Engine",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Hydro lock or hydrostatic lock is an abnormal condition in internal combustion engine. This occurs when a volume of liquid (Coolant/water or fuel) greater than the volume of the cylinder at its minimum (end of the piston stroke) enters the cylinder. Since liquids are nearly incompressible the piston cannot complete its travel; either the engine stop rotating or a mechanical failure occurs.*
When an engine is suspected to be hydrostatically locked, regardless of what caused the problem, the following steps should be used.
",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Warning",
+ "content": "DO NOT use starter motor to rotate the engine, severe damage may occur.",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "
9. Install a new oil filter.
10.Fill engine with specified amount of approved oil.
11.Connect negative battery cable.
12.Install all Injectors.
13.Start engine and check for any leaks.
",
+ "file": null,
+ "display_order": 5
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 25,
+ "sys_id": "THAR.AX-O-0007-Engine",
+ "subsys_id": "THAR.AX-O-0007-Engine-Engine Specification & Wear Data",
+ "systems": "Engine",
+ "sub_systems": "Engine Specification & Wear Data",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1112,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Engine Specification & Wear Data-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11745.pdf",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 13,
+ "sys_id": "THAR.AX-O-0007-Engine",
+ "subsys_id": "THAR.AX-O-0007-Engine-Oil Sump",
+ "systems": "Engine",
+ "sub_systems": "Oil Sump",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B010599.jpg",
+ "myid": 1098,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Oil Sump-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010599.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010159.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The Oil Sump is the reservoir for the oil and also cover for the crank case. Oil sump is bolted to the ladder frame. The oil sump structural type to have better NVH.* A liquid sealant is used to provide an leak proof joint.",
+ "file": null,
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11570.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11571.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the engine oil. For additional information refer to engine oil draining procedure section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove electric disconnect stone guard. For additional information refer to Electric Disconnect Stone Guard \u2014 R &R; Section. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove Water Pump/ AC compressor belt. For additional information refer to Water Pump/ AC compressor belt - R &R; section. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010526.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, Unscrew water pump idler mounting bolt and remove dealer.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 45 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010623.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the transmission bottom mounting bolts.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010527.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Provide jack to support the front axle assembly.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010528.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 15 mm socket spanner, unscrew front axle mounting bolts and partially detach the axle.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010918.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Partially down the front axle assembly .",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010239.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the AC compressor bottom mounting bolts.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 23 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010529.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using a 14 mm ring and 15 mm socket spanner, Unscrew the front cross member mounting bolts and nuts.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque : 65 \u00b110 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010916.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Detach the front cross member from the vehicle.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Remove Stabilizer bar with link. For additional information refer to Stabilizer bar with link - R &R; section. ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010530.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using a 8 mm socket spanner, loosen and remove the oil sump bottom mounting bolts.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Torque Value",
+ "content": "Torque : 11 \u00b1 1.0 Nm ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010531.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the oil sump bottom mounting bolts.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Torque Value",
+ "content": "Torque : 22.5 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010532.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1518.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Detach engine oil sump from the vehicle .",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Torque Value",
+ "content": "Torque : 22.5 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010653.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010119.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11586.jpg",
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Notice",
+ "content": "Clean the sump and sump seating area on crankcase .
For additional information refer to Timing Chain - R &R; section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010537.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Align the MST \u2014 0310ABG0001ST Camshaft locking tool on the front side of engine in the camshaft slot as shown and fix the camshaft locking tool on cylinder head using appropriate bolts.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010538.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010645.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 22 mm socket spanner, Loosen and remove Inlet CAM phaser mounting bolt.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 30 \u00b1 2 Nm + 34\u00b0\u00b1 3\u00b0 ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11655.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "While Installation, Check Exhaust Cam phaser mounting bolt tightening torque first and then torque tightened the Intake Cam phaser mounting bolt.",
+ "file": null,
+ "display_order": 13
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the CAM Phaser for any physical damage. If found replace.",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 12,
+ "sys_id": "THAR.AX-O-0007-Engine",
+ "subsys_id": "THAR.AX-O-0007-Engine-Oil Pump",
+ "systems": "Engine",
+ "sub_systems": "Oil Pump",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B010598.jpg",
+ "myid": 1096,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Oil Pump-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010598.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010160.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "This is a Variable type oil pump uses to supply variable oil pressure to the system. It is chain driven and integral oil strainer.* The oil pump circulates the engine oil to lubricate the components such as bearings, piston and valve.* The lower chain drives oil pump to lubricate the engine. This oil pump are integrated with the strainer. The oil strainer is the first stage in the filtration of the lubricant. It filters the coarse particles present in the oil before it enters the oil pump.",
+ "file": null,
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4742.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4743.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Engine Oil Sump. For additional information refer to Engine Oil Sump \u2014 R &R; section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010472.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew oil strainer bracket mounting bolt.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010473.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010474.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew Oil strainer mounting bolts and remove strainer.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "Always replace a new metal gasket once it removed.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010521.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 8 mm Allen socket spanner, Loosen and remove oil pump chain tensioner shoulder bolt.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010522.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010523.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the tensioner and detach the chain from oil pump.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010524.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew oil pump mounting bolts.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010525.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1519.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Carefully remove engine oil pump.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": "Make sure that the retaining key on the rear side of the oil pump is fitted correctly to the retaining key hole on the surface of the cylinder block bed plate.* While Installation, Partial attach the Oil Pump tensioner first and insert the tensioner spring lock on position. Then torque tighten the shoulder bolt.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Refill the engine oil and check for oil leakage. ",
+ "file": null,
+ "display_order": 29
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the oil pump for any damage. Replace if found.* Inspect the oil pump and strainer for any blockage, clean if found.",
+ "file": null,
+ "display_order": 30
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 24,
+ "sys_id": "THAR.AX-O-0007-Engine",
+ "subsys_id": "THAR.AX-O-0007-Engine-Tightening Sequence",
+ "systems": "Engine",
+ "sub_systems": "Tightening Sequence",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B010112.jpg",
+ "myid": 1111,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Tightening Sequence-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Front Cover Mounting Bolts",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010112.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11755.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Ladder Frame & Oil Pump",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010113.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11757.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Oil Strainer",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010114.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11759.jpg",
+ "display_order": 6
+ }
+ ]
+ },
+ {
+ "procedure_name": "Flywheel Mounting Bolts \u2013 MT",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010116.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11761.jpg",
+ "display_order": 8
+ }
+ ]
+ },
+ {
+ "procedure_name": "CAM Cover",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010118.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11763.jpg",
+ "display_order": 10
+ }
+ ]
+ },
+ {
+ "procedure_name": "Timing Chain Layout",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010117.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11765.jpg",
+ "display_order": 12
+ }
+ ]
+ },
+ {
+ "procedure_name": "Belt System",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010193.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11767.jpg",
+ "display_order": 14
+ }
+ ]
+ },
+ {
+ "procedure_name": "Exhaust System Assembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010122.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11769.jpg",
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Fuel Rail Assembly & FIP",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010123.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11771.jpg",
+ "display_order": 18
+ }
+ ]
+ },
+ {
+ "procedure_name": "Oil Sump Mounting Bolts",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010119.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11773.jpg",
+ "display_order": 20
+ }
+ ]
+ },
+ {
+ "procedure_name": "Drive Belt Assembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010120.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11775.pdf",
+ "display_order": 22
+ }
+ ]
+ },
+ {
+ "procedure_name": "Oil Cooler and Filtering Module",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010121.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11777.jpg",
+ "display_order": 24
+ }
+ ]
+ },
+ {
+ "procedure_name": "Water Inlet Pipe, Pipe Heater Inlet & Outlet",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010202.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11779.jpg",
+ "display_order": 26
+ }
+ ]
+ },
+ {
+ "procedure_name": "Cylinder Head Mounting Bolts",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010126.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11781.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010125.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11783.jpg",
+ "display_order": 30
+ }
+ ]
+ },
+ {
+ "procedure_name": "Intake Manifold Mounting Bolts",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020037.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11785.jpg",
+ "display_order": 32
+ }
+ ]
+ },
+ {
+ "procedure_name": "ROSR (Rear Oil Seal Retainer)",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010124.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11787.jpg",
+ "display_order": 34
+ }
+ ]
+ },
+ {
+ "procedure_name": "Crankshaft Main Bearing Cap Mounting Bolts",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010127.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11789.jpg",
+ "display_order": 36
+ }
+ ]
+ },
+ {
+ "procedure_name": "Turbocharger Assembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010128.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11791.jpg",
+ "display_order": 38
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 11,
+ "sys_id": "THAR.AX-O-0007-Engine",
+ "subsys_id": "THAR.AX-O-0007-Engine-Cam Shafts",
+ "systems": "Engine",
+ "sub_systems": "Cam Shafts",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B010542.jpg",
+ "myid": 1095,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Cam Shafts-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010542.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11526.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11527.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove Vacuum pump. For additional information refer to vacuum pump - R &R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the FIP. For additional information refer to FIP - R &R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the timing chain. For additional information refer to Timing Chain - R &R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010537.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using the MST \u2014 0310ABG0001ST Camshaft locking tool lock the cam shafts.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010538.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 22 mm socket spanner, Loosen and remove exhaust CAM phaser mounting bolt.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 30 \u00b1 2 Nm + 34\u00b0\u00b1 3\u00b0 ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010539.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 22 mm socket spanner, Loosen and remove Inlet CAM phaser mounting bolt",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 30 \u00b1 2 Nm + 34\u00b0\u00b1 3\u00b0 ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010537.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the MST.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010540.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 8 mm socket spanner, Unscrew CAM shafts cap mounting bolts.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010541.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010543.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the camshaft from the cylinder head.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010655.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010125.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11537.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Caution",
+ "content": "While Installation, Apply a thin layer of engine oil to the mounting parts of the Cam shafts & on Cam shafts.* Sealant (Loctite 5188 - 2mm thickness) to be applied on rear (Vacuum Pump) bearing cap as per below pattern.* Extra sealant to be wiped off after assembly of rear bearing cap.* Exhaust Cam phaser mounting bolt should be torque tightened first and then torque tightened the Intake Cam phaser mounting bolt.",
+ "file": null,
+ "display_order": 27
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the inlet camshaft and the exhaust camshaft for any damage and replace it if necessary.* Inspect the camshaft bearing journals for scoring or excessive wear.* Inspect the camshaft lobes for scoring or excessive wear.* Inspect the threaded bolt holes in the front of the camshaft for damaged threads or debris.",
+ "file": null,
+ "display_order": 28
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 9,
+ "sys_id": "THAR.AX-O-0007-Engine",
+ "subsys_id": "THAR.AX-O-0007-Engine-Crankshaft Rear Oil Seal",
+ "systems": "Engine",
+ "sub_systems": "Crankshaft Rear Oil Seal",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B010180.jpg",
+ "myid": 1092,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Crankshaft Rear Oil Seal-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/VST-0055_Engine timing mSTALLION 2 L.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010180.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11510.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11511.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the flywheel. For additional information refer into Flywheel - R &R Section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010237.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010770.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a screw driver, remove the crankshaft rear end oil seal.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010883.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011107.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install the rear end oil seal by using MST 0302ABH0001ST - Engine Rear End Oil Seal Installer on the crankshaft.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "Always use new oil seal while installation.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Check & Top-up the engine oil.",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check and clean the oil seal seating area thoroughly for any damage.",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 14,
+ "sys_id": "THAR.AX-O-0007-Engine",
+ "subsys_id": "THAR.AX-O-0007-Engine-Water Pump",
+ "systems": "Engine",
+ "sub_systems": "Water Pump",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B010632.jpg",
+ "myid": 1099,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Water Pump-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010632.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11588.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11589.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the engine coolant. For additional information refer into engine coolant draining procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "After installation of water pump, carry out refilling of the coolant. For additional information refer into coolant refilling procedure. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the water pump pulley. For additional information refer into Water Pump Pulley \u2014 R &R Section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010923.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Detach the wiring routing clip from the water pump.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010630.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, Unscrew water pump mounting bolts.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010633.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully remove the water pump from the engine.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010631.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010633.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the O ring from the water pump.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010631.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Always replace the O ring new one once removal of water pump.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Refill the engine coolant and carry-out de-aeration procedure.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Check for coolant seepage on the engine. Rectify if any traces found.",
+ "file": null,
+ "display_order": 21
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the water pump for any damage or leakage or noise. Replace if found.Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010045.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the engine top encapsulation cover.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Drain the Engine Coolant. For additional information refer to Engine Coolant Draining procedure. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Recover AC gas. For additional information refer to AC gas recovery procedure. ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1505.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 17 mm open end spanner, Loosen power steering pump outlet pipe mounting nut and Drain power steering fluid.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove Clean Side Hose Assembly. **For additional information refer to Clean Side Hose Assembly - R &R Section.**",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B090004.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, loosen starter motor positive cable mounting nut and detach cable from starter motor end.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 12\u00b12 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B090002.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 8 mm socket spanner, Unscrew starter motor solenoid switch electrical connector.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B090005.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the starter motor mounting bolts and remove starter motor from vehicle.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 44 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1506.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner unscrew exhaust front pipe mounting bolts CATCON end.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove Radiator Air Guides. For additional information refer to Radiator Air Guides - R &R; section. ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1003,1065",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Remove Transmission with Transfer Case.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1008,1151",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "For AT Variant : Automatic Transmission with Transfer Case. ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1008,1151",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Untitledb1432c.png",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Disconnect the AT oil cooler hoses from thermal bye pass valve end.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Notice",
+ "content": "Ensure to close the bypass tubes with dummy caps to avoid dust entry. ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner unscrew thermal bypass valve bracket mounting bolt from engine oil sump. ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/15daf66d.png",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010494.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010208.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using a hose clamp plier, Release coolant vent hose clamps radiator end,engine end and detach the hose both the ends and from routing clips.",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/17693996.png",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release degassing tank coolant outlet hose clamp and detach hose OCFM end. ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/18ad729e.png",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release turbo coolant outlet hose clamp and detach hose turbo end. ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew degassing tank mounting bolts and detach tank with hoses. ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": ", ",
+ "file": "/files/19b89eac.png",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": ", ",
+ "file": "/files/20d066a2.png",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew front top cross member mounting bolts. ",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 4.0 Nm ",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010213.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Detach front top cross member and disconnect bonnet latch cable from routing and from lock.",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010071.jpg",
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010071.jpg",
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, unscrew degassing tank mounting bracket LHS & RHS mounting bolts.",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Torque Value",
+ "content": "Torque : 10 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1509.jpg",
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020285.jpg",
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Disconnect boost pressure sensor, and intercooler fan electrical connectors.",
+ "file": null,
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010214.jpg",
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner, Loosen turbo outlet hose clip and detach hose turbo end.",
+ "file": null,
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010215.jpg",
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner, Loosen intercooler outlet hose clip and detach hose throttle valve end.",
+ "file": null,
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010073.jpg",
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew intercooler mounting bolts and remove intercooler with hoses and fan.",
+ "file": null,
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Torque Value",
+ "content": "Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010216.jpg",
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner, Loosen radiator outlet hose clip and detach hose OCFM end.",
+ "file": null,
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 72
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010218.jpg",
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release radiator inlet hose clamp and detach hose cylinder block end. ",
+ "file": null,
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010074.jpg",
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Description",
+ "content": "Disconnect heater inlet and outlet hose quick coupler heater end.",
+ "file": null,
+ "display_order": 76
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Torque Value",
+ "content": "Press and disconnect the quick coupler carefully to avoid seal damages.",
+ "file": null,
+ "display_order": 77
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040050.jpg",
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "Description",
+ "content": "Disconnect fuel inlet pipe quick coupler FIP end and detach hose.",
+ "file": null,
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "Notice",
+ "content": "Press and disconnect the quick coupler carefully to avoid seal damages.",
+ "file": null,
+ "display_order": 80
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040065.jpg",
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "Description",
+ "content": "Disconnect purge valve vapour hose quick coupler purge valve end and detach hose.",
+ "file": null,
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040067.jpg",
+ "display_order": 83
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "Description",
+ "content": "Disconnect purge valve electrical connector.",
+ "file": null,
+ "display_order": 84
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010219.jpg",
+ "display_order": 85
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010220.jpg",
+ "display_order": 86
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "Description",
+ "content": "Disconnect vapour hose quick coupler and routing clip intake manifold end and detach hose.",
+ "file": null,
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "Notice",
+ "content": "Press and disconnect the quick coupler carefully to avoid seal damages.",
+ "file": null,
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010226.jpg",
+ "display_order": 89
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "Description",
+ "content": "Detach purge valve from mounting bracket and remove purge valve with vapour hose assembly.",
+ "file": null,
+ "display_order": 90
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010076.jpg",
+ "display_order": 91
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release vacuum hose clamp and detach hose vacuum pump end.",
+ "file": null,
+ "display_order": 92
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010224.jpg",
+ "display_order": 93
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "Description",
+ "content": "Open the alternator positive cable cover.",
+ "file": null,
+ "display_order": 94
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010225.jpg",
+ "display_order": 95
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew alternator positive cable mounting nut and detach cable alternator end.",
+ "file": null,
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "Torque Value",
+ "content": "Torque : 15 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 97
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1510.jpg",
+ "display_order": 98
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010130.jpg",
+ "display_order": 99
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "Description",
+ "content": "Disconnect engine WH inter connector, Holding clip and routing clip fire wall end.",
+ "file": null,
+ "display_order": 100
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010078.jpg",
+ "display_order": 101
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010132.jpg",
+ "display_order": 102
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "Description",
+ "content": "Disconnect engine WH connector ECU end and detach harness from routing clips.",
+ "file": null,
+ "display_order": 103
+ },
+ {
+ "step_name": "Step-40",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010079.jpg",
+ "display_order": 104
+ },
+ {
+ "step_name": "Step-40",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release power steering oil inlet hose clamp and detach hose pump end.",
+ "file": null,
+ "display_order": 105
+ },
+ {
+ "step_name": "Step-41",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010080.jpg",
+ "display_order": 106
+ },
+ {
+ "step_name": "Step-41",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew AC compressor suction and discharge hose mounting nuts.",
+ "file": null,
+ "display_order": 107
+ },
+ {
+ "step_name": "Step-41",
+ "content_type": "Torque Value",
+ "content": "Torque : 14.0+1.0 Nm ",
+ "file": null,
+ "display_order": 108
+ },
+ {
+ "step_name": "Step-42",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010081.jpg",
+ "display_order": 109
+ },
+ {
+ "step_name": "Step-42",
+ "content_type": "Description",
+ "content": "Support the engine using engine removal support floor crane.",
+ "file": null,
+ "display_order": 110
+ },
+ {
+ "step_name": "Step-42",
+ "content_type": "Warning",
+ "content": "Improper tie-up of the lifting rope chain will cause damage to the vehicle and the persons involved.",
+ "file": null,
+ "display_order": 111
+ },
+ {
+ "step_name": "Step-43",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010615.jpg",
+ "display_order": 112
+ },
+ {
+ "step_name": "Step-43",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010616.jpg",
+ "display_order": 113
+ },
+ {
+ "step_name": "Step-43",
+ "content_type": "Description",
+ "content": "Using 18 mm socket spanner, unscrew engine bed mounting nuts LHS & RHS. ",
+ "file": null,
+ "display_order": 114
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010081.jpg",
+ "display_order": 115
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "Description",
+ "content": "Carefully remove the engine from compartment.",
+ "file": null,
+ "display_order": 116
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "Warning",
+ "content": "Improper tie-up of the lifting rope chain will cause damage to the vehicle and the persons involved. ",
+ "file": null,
+ "display_order": 117
+ },
+ {
+ "step_name": "Step-45",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010083.jpg",
+ "display_order": 118
+ },
+ {
+ "step_name": "Step-45",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release heater inlet and outlet hose clamps and detach the hoses.",
+ "file": null,
+ "display_order": 119
+ },
+ {
+ "step_name": "Step-46",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010084.jpg",
+ "display_order": 120
+ },
+ {
+ "step_name": "Step-46",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew engine WH carrier mounting bolts.",
+ "file": null,
+ "display_order": 121
+ },
+ {
+ "step_name": "Step-47",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010227.jpg",
+ "display_order": 122
+ },
+ {
+ "step_name": "Step-47",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew ignition coil ground connector mounting nut.",
+ "file": null,
+ "display_order": 123
+ },
+ {
+ "step_name": "Step-48",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010085.jpg",
+ "display_order": 124
+ },
+ {
+ "step_name": "Step-48",
+ "content_type": "Description",
+ "content": "Disconnect AC compressor electrical connector",
+ "file": null,
+ "display_order": 125
+ },
+ {
+ "step_name": "Step-49",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010086.jpg",
+ "display_order": 126
+ },
+ {
+ "step_name": "Step-49",
+ "content_type": "Description",
+ "content": "Disconnect Variable oil pump solenoid electrical connector.",
+ "file": null,
+ "display_order": 127
+ },
+ {
+ "step_name": "Step-50",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010093.jpg",
+ "display_order": 128
+ },
+ {
+ "step_name": "Step-50",
+ "content_type": "Description",
+ "content": "Disconnect upstream Lambda sensor electrical connector and connector holder. ",
+ "file": null,
+ "display_order": 129
+ },
+ {
+ "step_name": "Step-51",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010090.jpg",
+ "display_order": 130
+ },
+ {
+ "step_name": "Step-51",
+ "content_type": "Description",
+ "content": "Disconnect Engine oil pressure sensor electrical connector and routing clip.",
+ "file": null,
+ "display_order": 131
+ },
+ {
+ "step_name": "Step-52",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010091.jpg",
+ "display_order": 132
+ },
+ {
+ "step_name": "Step-52",
+ "content_type": "Description",
+ "content": "Disconnect WGTelectrical connector.",
+ "file": null,
+ "display_order": 133
+ },
+ {
+ "step_name": "Step-53",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010194.jpg",
+ "display_order": 134
+ },
+ {
+ "step_name": "Step-53",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010234.jpg",
+ "display_order": 135
+ },
+ {
+ "step_name": "Step-53",
+ "content_type": "Description",
+ "content": "Disconnect Dump valve electrical connector and routing clip.",
+ "file": null,
+ "display_order": 136
+ },
+ {
+ "step_name": "Step-54",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010102.jpg",
+ "display_order": 137
+ },
+ {
+ "step_name": "Step-54",
+ "content_type": "Description",
+ "content": "Disconnect VVT inlet and exhaust cam phase solenoid connector & routing clip.",
+ "file": null,
+ "display_order": 138
+ },
+ {
+ "step_name": "Step-55",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010103.jpg",
+ "display_order": 139
+ },
+ {
+ "step_name": "Step-55",
+ "content_type": "Description",
+ "content": "Disconnect throttle valve electrical connector.",
+ "file": null,
+ "display_order": 140
+ },
+ {
+ "step_name": "Step-56",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010195.jpg",
+ "display_order": 141
+ },
+ {
+ "step_name": "Step-56",
+ "content_type": "Description",
+ "content": "Disconnect MAP sensor electrical connector.",
+ "file": null,
+ "display_order": 142
+ },
+ {
+ "step_name": "Step-57",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010094.jpg",
+ "display_order": 143
+ },
+ {
+ "step_name": "Step-57",
+ "content_type": "Description",
+ "content": "Disconnect Spark plug (4 nos) electrical connectors.",
+ "file": null,
+ "display_order": 144
+ },
+ {
+ "step_name": "Step-58",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010134.jpg",
+ "display_order": 145
+ },
+ {
+ "step_name": "Step-58",
+ "content_type": "Description",
+ "content": "Disconnect Exhaust CAM sensor electrical connector.",
+ "file": null,
+ "display_order": 146
+ },
+ {
+ "step_name": "Step-59",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010089.jpg",
+ "display_order": 147
+ },
+ {
+ "step_name": "Step-59",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010233.jpg",
+ "display_order": 148
+ },
+ {
+ "step_name": "Step-59",
+ "content_type": "Description",
+ "content": "Disconnect downstream lambda sensor electrical connector and routing clip.",
+ "file": null,
+ "display_order": 149
+ },
+ {
+ "step_name": "Step-60",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010095.jpg",
+ "display_order": 150
+ },
+ {
+ "step_name": "Step-60",
+ "content_type": "Description",
+ "content": "Disconnect Inlet CAM phase sensor electrical connector.",
+ "file": null,
+ "display_order": 151
+ },
+ {
+ "step_name": "Step-61",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1511.jpg",
+ "display_order": 152
+ },
+ {
+ "step_name": "Step-61",
+ "content_type": "Description",
+ "content": "Disconnect Coolant temperature sensor electrical connector.",
+ "file": null,
+ "display_order": 153
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010228.jpg",
+ "display_order": 154
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "Description",
+ "content": "Disconnect FIP electrical connector.",
+ "file": null,
+ "display_order": 155
+ },
+ {
+ "step_name": "Step-63",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010096.jpg",
+ "display_order": 156
+ },
+ {
+ "step_name": "Step-63",
+ "content_type": "Description",
+ "content": "Disconnect Common rail electrical connector.",
+ "file": null,
+ "display_order": 157
+ },
+ {
+ "step_name": "Step-64",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010099.jpg",
+ "display_order": 158
+ },
+ {
+ "step_name": "Step-64",
+ "content_type": "Description",
+ "content": "Disconnect Injector (4 nos) electrical connector.",
+ "file": null,
+ "display_order": 159
+ },
+ {
+ "step_name": "Step-65",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010100.jpg",
+ "display_order": 160
+ },
+ {
+ "step_name": "Step-65",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010105.jpg",
+ "display_order": 161
+ },
+ {
+ "step_name": "Step-65",
+ "content_type": "Description",
+ "content": "Disconnect Knock sensor electrical connector & routing clips(2Nos).",
+ "file": null,
+ "display_order": 162
+ },
+ {
+ "step_name": "Step-66",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010231.jpg",
+ "display_order": 163
+ },
+ {
+ "step_name": "Step-66",
+ "content_type": "Description",
+ "content": "Disconnect Alternator connector & routing clip.",
+ "file": null,
+ "display_order": 164
+ },
+ {
+ "step_name": "Step-67",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010104.jpg",
+ "display_order": 165
+ },
+ {
+ "step_name": "Step-67",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010106.jpg",
+ "display_order": 166
+ },
+ {
+ "step_name": "Step-67",
+ "content_type": "Description",
+ "content": "Detach the WH harness from engine assembly.",
+ "file": null,
+ "display_order": 167
+ },
+ {
+ "step_name": "Step-68",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010109.jpg",
+ "display_order": 168
+ },
+ {
+ "step_name": "Step-68",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew CATCON mounting bolts and remove CATCON from Turbo end.",
+ "file": null,
+ "display_order": 169
+ },
+ {
+ "step_name": "Step-69",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010108.jpg",
+ "display_order": 170
+ },
+ {
+ "step_name": "Step-69",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew CATCON brackets mounting bolts and remove CATCON from engine.",
+ "file": null,
+ "display_order": 171
+ },
+ {
+ "step_name": "Step-70",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010222.jpg",
+ "display_order": 172
+ },
+ {
+ "step_name": "Step-70",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010223.jpg",
+ "display_order": 173
+ },
+ {
+ "step_name": "Step-70",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1512.jpg",
+ "display_order": 174
+ },
+ {
+ "step_name": "Step-70",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010221.jpg",
+ "display_order": 175
+ },
+ {
+ "step_name": "Step-70",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010252.jpg",
+ "display_order": 176
+ },
+ {
+ "step_name": "Step-70",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010251.jpg",
+ "display_order": 177
+ },
+ {
+ "step_name": "Step-70",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner loosen and remove clutch cover assembly mounting bolts and remove it.",
+ "file": null,
+ "display_order": 178
+ },
+ {
+ "step_name": "Step-70",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 5.0 Nm (Step Torque : 5,15,25) ",
+ "file": null,
+ "display_order": 179
+ },
+ {
+ "step_name": "Step-70",
+ "content_type": "Notice",
+ "content": "Install the MST : 0307ABH0001ST \u2014 Flywheel locking tool and lock the flywheel rotation.* Insert MST \u2014 0801BUA0001ST \u2014 Master clutch plate assembly, before loosening the clutch cover bolts to prevent clutch plate falling down and getting damage.* While Installation, the projected part of clutch disc should come towards transmission side only, fails may result in clutch disc damage.",
+ "file": null,
+ "display_order": 180
+ },
+ {
+ "step_name": "Step-71",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010107.jpg",
+ "display_order": 181
+ },
+ {
+ "step_name": "Step-71",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010110.jpg",
+ "display_order": 182
+ },
+ {
+ "step_name": "Step-71",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew engine feed cover mounting bolts and remove feed cover.",
+ "file": null,
+ "display_order": 183
+ },
+ {
+ "step_name": "Step-72",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 184
+ },
+ {
+ "step_name": "Step-73",
+ "content_type": "Description",
+ "content": "Recharge the AC refrigerant system. For additional information refer to Recharge the AC refrigerant system - R&R; section.",
+ "file": null,
+ "display_order": 185
+ },
+ {
+ "step_name": "Step-74",
+ "content_type": "Description",
+ "content": "Refill Engine coolant. For additional information refer to coolant refilling Procedure.",
+ "file": null,
+ "display_order": 186
+ },
+ {
+ "step_name": "Step-75",
+ "content_type": "Description",
+ "content": "Check & Top-up the engine oil.",
+ "file": null,
+ "display_order": 187
+ },
+ {
+ "step_name": "Step-76",
+ "content_type": "Description",
+ "content": "Check for coolant seepage and any oil seepage on the engine and transmission. Rectify if any traces found.",
+ "file": null,
+ "display_order": 188
+ },
+ {
+ "step_name": "Step-77",
+ "content_type": "Description",
+ "content": "Check & Clear DTC if found any. For additional information refer to diagnostic manual.",
+ "file": null,
+ "display_order": 189
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the accessory drive belt for any cracks, damage etc, replace if found anyEngine Oil \u2014 \u2014MAHINDRA 'MAXIMILE ULTRA' Gen-NXT Technology Genuine Engine Fluid.Capacity\u2014 6.0 Liters. if found below minimum level, top up with recommended oil.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010003.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Insert the dip stick back and fix properly.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Start the engine and check for oil leakage/ seepage at:Oil sump & crankcase joint.Oil sump drain plug.Oil filter joint.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Always use MAHINDRA 'MAXIMILE ULTRA'Gen-NXT Technology GENUINE ENGINE Fluid. This is specially developed for your engine\u2019s efficiency.Cylinder to Cylinder Leakage Test ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the cylinder compression pressure as already explained. Leakage between cylinders will be result in drop of compression pressure by nearly 50 to 70% in the affected cylinders.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Cylinder to Water jacket Leakage Test ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the degassing pressure cap.ground level/ 2 post lift/ 4 post lift and turn engine OFF.Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W376.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the engine feed cover from engine compartment.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W377.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 24 mm socket spanner, rotate the crank pulley 360\u00b0 till belt completes one full rotation to check belt condition and confirm following belt appearances if any.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010286.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Random Cracking Across the Ribs ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Small yet visible cracks along the length of a rib or ribs.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Continuous exposure to high temperatures and the stress of bending around the pulleys leads to cracking.Chunk-Out ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Pieces or chunks of rubber material have come off the belt. When chunk-out has occurred, a belt can fail at any moment. Belt should be replaced immediately.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Chunk-out can happen when several cracks in one area move parallel to the cord line. Heat, age and stress are the primary contributors.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010288.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "Pilling ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Belt material wears off from the ribs and builds up in the belts grooves.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "There are a number of causes, including misalignment, new belt on worn pulleys, lack of tension or a combination of these factors.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W378.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Heading",
+ "content": "Gravel Penetration ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Small pinholes are visible on the backside of the belt. Bumps may be visible and fabric around the holes can be frayed.",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Granular gravel or pebble gravel is wedged between the belt groove(s) and pulley ridge(s).",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010290.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Heading",
+ "content": "Damaged Outermost Ribs ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Sidewalls of the belt may appear glazed or the edge-cord may become frayed and ribs removed. A noticeable noise may result.",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Pulley misalignment is a common cause of premature belt failure. Misalignment forces the belt to twist while running, causing premature wear.",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010291.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Heading",
+ "content": "Oil Contamination ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "The belt surface is flaky, sticky or swollen.",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Oil and grease are a rubber compound\u2019s worst enemies, weakening the compound\u2019s bonds and making the belt soft and spongy. Eventually, such a belt will slip, create heat and fail.",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W379.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Heading",
+ "content": "Abrasion ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "The backside of the belt appears very shiny or glazed. In advance stages, the fabric or even the cord becomes exposed and gets damaged.",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "When in motion, the belt makes contact with the foreign objects in its path such as a flange or bolt. This may be caused by improper belt tension or by belt flutter (vibrations) on longer span lengths between two pulleys.",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010293.jpg",
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Heading",
+ "content": "Rib Separation ",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "The belt rib shears off or begins to separate from the belt base.",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "The belt is not correctly positioned. One of the belt ribs is placed outside the pulley groove, causing a belt rib to run without a supporting or aligning pulley groove. ",
+ "file": null,
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010294.jpg",
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "Uneven Rib Wear ",
+ "file": null,
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Wear that is more severe on one rib than on the others or one rib that exhibits a different wear pattern than the others. A thumping or grinding noise may also be heard.",
+ "file": null,
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "A foreign object \u2013 such as a pebble \u2013 in the pulley will cause uneven wear and cut into the belt and break the tensile cords.",
+ "file": null,
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010295.jpg",
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Heading",
+ "content": "Broken Belt ",
+ "file": null,
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "The belt is broken.",
+ "file": null,
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "A large foreign object between the belt and pulley can cut into the belt and break the tensile cords. Tensile break may occur but go unnoticed when the belt is forced or pried on during installation. Other possible causes may be severe shock loads or a blocked pulley and/or accessory.",
+ "file": null,
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010296.jpg",
+ "display_order": 72
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "Belt Noise ",
+ "file": null,
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "Inspection: ",
+ "file": null,
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Run the engine and inspect for Chirping, squealing. tapping, ticking or grinding noise coming from the belt.",
+ "file": null,
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Caution",
+ "content": "It is recommended to remove & check the drive belts thoroughly if any abnormality noticed.",
+ "file": null,
+ "display_order": 76
+ }
+ ]
+ },
+ {
+ "procedure_name": "Checking",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W380.jpg",
+ "display_order": 77
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W381.jpg",
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Check belt tension as per procedure mentioned below: ",
+ "file": null,
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Turn ON belt tension gauge.* Select reading mode in hertz (Hz) and hold the probe approximately 5mm distance in front of the belt.",
+ "file": null,
+ "display_order": 80
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Do not touch the probe to the belt, this can damage the probe.* Belt tension needs to be checked at the green points shown in illustration.Between Crank pulley & water pump pulley.Between water pump pulley & AC Compressor Pulley.",
+ "file": null,
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Tap on the belt near the probe.* Note the reading, if the reading is within 195 \u2014 228 Hz, belt tension is OK.* If the reading is not within the above limit, check & replace the belt if required.",
+ "file": null,
+ "display_order": 82
+ }
+ ]
+ },
+ {
+ "procedure_name": "Auto Tensioner & Belt (Alternator/Power Steering) \u2013 Inspect",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W382.jpg",
+ "display_order": 83
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11351.jpg",
+ "display_order": 84
+ },
+ {
+ "step_name": "Preliminary Activities /Conditions",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W382.jpg",
+ "display_order": 85
+ },
+ {
+ "step_name": "Preliminary Activities /Conditions",
+ "content_type": "Description",
+ "content": "Position the vehicle on ground level/ 2 post lift/ 4 post lift and turn engine OFF.2. Open the bonnet and lock it in open position using bonnet stay rod.",
+ "file": null,
+ "display_order": 86
+ }
+ ]
+ },
+ {
+ "procedure_name": "Accessory Drive Belt Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W383.jpg",
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen and remove the engine feed cover mounting bolts.",
+ "file": null,
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 89
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W384.jpg",
+ "display_order": 90
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the engine feed cover from engine compartment.",
+ "file": null,
+ "display_order": 91
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W385.jpg",
+ "display_order": 92
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 24 mm socket spanner, rotate the crank pulley 360\u00e2\u0081\u00b0 till belt completes one full rotation to check belt condition and confirm following belt appearances if any.",
+ "file": null,
+ "display_order": 93
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010286.jpg",
+ "display_order": 94
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Random Cracking Across the Ribs ",
+ "file": null,
+ "display_order": 95
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Small yet visible cracks along the length of a rib or ribs.",
+ "file": null,
+ "display_order": 97
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 98
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Continuous exposure to high temperatures and the stress of bending around the pulleys leads to cracking.* Cracks begin at the rib top and grow to the cord line. As a rule, if cracks appear 1 or 2 cm apart, 80% of the life is gone and the belt should be replaced.",
+ "file": null,
+ "display_order": 99
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010287.jpg",
+ "display_order": 100
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Chunk-Out ",
+ "file": null,
+ "display_order": 101
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 102
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Pieces or chunks of rubber material have come off the belt. When chunk-out has occurred, a belt can fail at any moment. Belt should be replaced immediately.",
+ "file": null,
+ "display_order": 103
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 104
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Chunk-out can happen when several cracks in one area move parallel to the cord line. Heat, age and stress are the primary contributors.",
+ "file": null,
+ "display_order": 105
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010288.jpg",
+ "display_order": 106
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "Pilling ",
+ "file": null,
+ "display_order": 107
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 108
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Belt material wears off from the ribs and builds up in the belts grooves.",
+ "file": null,
+ "display_order": 109
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 110
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "There are a number of causes, including misalignment, new belt on worn pulleys, lack of tension or a combination of these factors.",
+ "file": null,
+ "display_order": 111
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W386.jpg",
+ "display_order": 112
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Heading",
+ "content": "Gravel Penetration ",
+ "file": null,
+ "display_order": 113
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 114
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Small pinholes are visible on the backside of the belt. Bumps may be visible and fabric around the holes can be frayed.",
+ "file": null,
+ "display_order": 115
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 116
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Granular gravel or pebble gravel is wedged between the belt groove(s) and pulley ridge(s).",
+ "file": null,
+ "display_order": 117
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010290.jpg",
+ "display_order": 118
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Heading",
+ "content": "Damaged Outermost Ribs ",
+ "file": null,
+ "display_order": 119
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 120
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Sidewalls of the belt may appear glazed or the edge-cord may become frayed and ribs removed. A noticeable noise may result.",
+ "file": null,
+ "display_order": 121
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 122
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Pulley misalignment is a common cause of premature belt failure. Misalignment forces the belt to twist while running, causing premature wear.",
+ "file": null,
+ "display_order": 123
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010291.jpg",
+ "display_order": 124
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Heading",
+ "content": "Oil Contamination ",
+ "file": null,
+ "display_order": 125
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 126
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "The belt surface is flaky, sticky or swollen.",
+ "file": null,
+ "display_order": 127
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 128
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Oil and grease are a rubber compound\u2019s worst enemies, weakening the compound\u2019s bonds and making the belt soft and spongy. Eventually, such a belt will slip, create heat and fail.",
+ "file": null,
+ "display_order": 129
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010292.jpg",
+ "display_order": 130
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Heading",
+ "content": "Abrasion ",
+ "file": null,
+ "display_order": 131
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 132
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "The backside of the belt appears very shiny or glazed. In advance stages, the fabric or even the cord becomes exposed and gets damaged.",
+ "file": null,
+ "display_order": 133
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 134
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "When in motion, the belt makes contact with the foreign objects in its path such as a flange or bolt. This may be caused by improper belt tension or by belt flutter (vibrations) on longer span lengths between two pulleys.",
+ "file": null,
+ "display_order": 135
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010293.jpg",
+ "display_order": 136
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Heading",
+ "content": "Rib Separation ",
+ "file": null,
+ "display_order": 137
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 138
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "The belt rib shears off or begins to separate from the belt base.",
+ "file": null,
+ "display_order": 139
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 140
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "The belt is not correctly positioned. One of the belt ribs is placed outside the pulley groove, causing a belt rib to run without a supporting or aligning pulley groove. ",
+ "file": null,
+ "display_order": 141
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010294.jpg",
+ "display_order": 142
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "Uneven Rib Wear ",
+ "file": null,
+ "display_order": 143
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 144
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Wear that is more severe on one rib than on the others or one rib that exhibits a different wear pattern than the others. A thumping or grinding noise may also be heard.",
+ "file": null,
+ "display_order": 145
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 146
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "A foreign object \u2013 such as a pebble \u2013 in the pulley will cause uneven wear and cut into the belt and break the tensile cords.",
+ "file": null,
+ "display_order": 147
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010295.jpg",
+ "display_order": 148
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Heading",
+ "content": "Broken Belt ",
+ "file": null,
+ "display_order": 149
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 150
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "The belt is broken.",
+ "file": null,
+ "display_order": 151
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 152
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "A large foreign object between the belt and pulley can cut into the belt and break the tensile cords. Tensile break may occur but go unnoticed when the belt is forced or pried on during installation. Other possible causes may be severe shock loads or a blocked pulley and/or accessory.",
+ "file": null,
+ "display_order": 153
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U2A010296.jpg",
+ "display_order": 154
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "Belt Noise ",
+ "file": null,
+ "display_order": 155
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "Inspection: ",
+ "file": null,
+ "display_order": 156
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Run the engine and inspect for Chirping, squealing. tapping, ticking or grinding noise coming from the belt.",
+ "file": null,
+ "display_order": 157
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Caution",
+ "content": "It is recommended to remove & check the drive belts thoroughly if any abnormality noticed.",
+ "file": null,
+ "display_order": 158
+ }
+ ]
+ },
+ {
+ "procedure_name": "Auto Tensioner - Inspect",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W387.jpg",
+ "display_order": 159
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the auto-tensioner carefully for symptoms such as cracked arms, excessive vibration during idle speeds, looseness, noise (clatter or rattling) and sticking or seized operation. These all can be signs that roller needs replacement.",
+ "file": null,
+ "display_order": 160
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W388.jpg",
+ "display_order": 161
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S2B010322.jpg",
+ "display_order": 162
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Heading",
+ "content": "Rust bleed and cracks ",
+ "file": null,
+ "display_order": 163
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 164
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Rust bleeding between arm and base or dripping from the tensioner. Also, check the tensioner for cracks or damage to arm, housing and bracket.",
+ "file": null,
+ "display_order": 165
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 166
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Rust bleeding or dripping is a sign of internal component wear. Most common crack damage occurs at tensioner \u201cStops\u201d and mounting bolts.",
+ "file": null,
+ "display_order": 167
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Heading",
+ "content": "Solution: ",
+ "file": null,
+ "display_order": 168
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Replace the auto-tensioner.",
+ "file": null,
+ "display_order": 169
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S2B010323.jpg",
+ "display_order": 170
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Heading",
+ "content": "Pulley bearing wear ",
+ "file": null,
+ "display_order": 171
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 172
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "If any abnormality noticed, remove the belt and manually rotate the pulley. If you notice, resistance or roughness, the problem is likely to be pulley bearing wear.",
+ "file": null,
+ "display_order": 173
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 174
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Defective bearing and/or pulley.",
+ "file": null,
+ "display_order": 175
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Heading",
+ "content": "Solution: ",
+ "file": null,
+ "display_order": 176
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Replace the complete tensioner. Do not attempt to replace a worn pulley in a used tensioner assembly but always replace the entire tensioner assembly, as part failure will inevitably follow quickly.",
+ "file": null,
+ "display_order": 177
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S2B010324.jpg",
+ "display_order": 178
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/S2B010325.jpg",
+ "display_order": 179
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "TENSIONER ASSEMBLY MISALIGNMENT ",
+ "file": null,
+ "display_order": 180
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 181
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Abnormal belt tracking on tensioner pulley.",
+ "file": null,
+ "display_order": 182
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 183
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Bent or misaligned mounting bracket,improper tensioner installation or corrosion/ contamination between tensioner base and mounting surface. A small amount of contamination results in a large amount of at tensioner pulley.",
+ "file": null,
+ "display_order": 184
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Tensioner Noise ",
+ "file": null,
+ "display_order": 185
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 186
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Squeaks and rattles coming from the tensioner.",
+ "file": null,
+ "display_order": 187
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 188
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Failure of bearings or pivot are will cause excessive noise.",
+ "file": null,
+ "display_order": 189
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Solution: ",
+ "file": null,
+ "display_order": 190
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Replace the tensioner assembly.",
+ "file": null,
+ "display_order": 191
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 23,
+ "sys_id": "THAR.AX-O-0007-Engine",
+ "subsys_id": "THAR.AX-O-0007-Engine-Sealant Application Pattern",
+ "systems": "Engine",
+ "sub_systems": "Sealant Application Pattern",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B010652.jpg",
+ "myid": 1110,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Sealant Application Pattern-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Front Cover",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010652.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Oil Sump",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010653.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Cover Rear Oil Seal Retainer",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010654.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Cylinder Head",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010250.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Cylinder Block Assembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010651.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Camshaft Rear (Vacuum Pump) Bearing Cap",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010655.jpg",
+ "display_order": 6
+ }
+ ]
+ },
+ {
+ "procedure_name": "Vacuum Pump Bearing Cap Sealant",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010663.jpg",
+ "display_order": 7
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 15,
+ "sys_id": "THAR.AX-O-0007-Engine",
+ "subsys_id": "THAR.AX-O-0007-Engine-Engine Speed Sensor",
+ "systems": "Engine",
+ "sub_systems": "Engine Speed Sensor",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B010580.jpg",
+ "myid": 1100,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Engine Speed Sensor-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010580.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010650.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The crankshaft speed sensor is an hall effect type sensor. It measures the speed of the trigger wheel mounted on the crankshaft.For additional information refer to Air Cleaner Assembly R &R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Steering Lower Intermediate Shaft. For additional information refer to Steering Lower Intermediate Shaft R &R section. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1520.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Place the MST 0306GAM0006ST \u2014 Drive Belts Removal Tool on damper pulley side as shown in the image. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1521.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1522.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 24 mm socket spanner, rotate the damper pulley to clockwise direction then remove the water pump drive belt and MST 0306GBH0001ST \u2013 Drive Belts Removal Tool separately.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010592.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect AC compressor electrical connector.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010593.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew AC compressor mounting bolts and keep aside the compressor.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 23 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010240.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect engine speed sensor electrical connector detach it from holding clip.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner unscrew engine speed sensor mounting bolt and remove sensor.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010648.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010649.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Notice",
+ "content": "Take sufficient care not to damage the sensor while removing.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": "Ensure proper torque value is applied to sensor mounting bolt. Else chances of sensor malfunction is high.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010241.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 28
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the sensor and connector for any physical damage. Replace if found.",
+ "file": null,
+ "display_order": 29
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 16,
+ "sys_id": "THAR.AX-O-0007-Engine",
+ "subsys_id": "THAR.AX-O-0007-Engine-Engine Control Unit (ECU)",
+ "systems": "Engine",
+ "sub_systems": "Engine Control Unit (ECU)",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B090007.jpg",
+ "myid": 1101,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Engine Control Unit (ECU)-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/ELECTRONIC CONTROL UNIT (ECU)_V3.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B090007.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010167.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "EMS (Engine Management System) ECU is an electronic control unit which is used to ensure optimal engine performance. It does this by analyzing values or signals from various sensors and other ECU\u2019s and adjusting the actuators accordingly.Torque : 6.0 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010243.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Open the lock and gently pull-out and disconnect EMS ECU electrical connector.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010264.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010263.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner remove EMS ECU mounting bolts.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 6 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "For New EMS ECU replacement carry out Necessary Procedures by using iSMART. For additional information refer Diagnosis Manual. ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Warning",
+ "content": "ECU electrical connector should be disconnected before carrying out any welding activities in the vehicle.",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external damage, if found replace.",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 17,
+ "sys_id": "THAR.AX-O-0007-Engine",
+ "subsys_id": "THAR.AX-O-0007-Engine-Cylinder Head Assembly Overhauling",
+ "systems": "Engine",
+ "sub_systems": "Cylinder Head Assembly Overhauling",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A010289.jpg",
+ "myid": 1104,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Cylinder Head Assembly Overhauling-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11657.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Engine Assembly.",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1004,1088",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the cylinder head assembly.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1004,1104",
+ "file": null,
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Disassembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Place the cylinder head on clean flat work table.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010934.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010919.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a suitable valve compressor, compress and hold the valve spring and then remove the valve spring lock studs.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010920.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the upper retainer and valve spring.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Incase of reusing the same valves spring, make necessary marking according to the respective cylinder.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010921.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the valve stem seal.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010922.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1526.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the valve.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "The valve should be identified, so that in case the valves are being reused they can be used. Failure to do so may increase the probability of compression leak through the valve after the engine is rebuilt.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Similarly remove the other valves.",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010307.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the valve spring lock for any internal and external damage.2. Check the valve spring height.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1527.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11666.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Engine Oil \u2014 MAHINDRA 'MAXIMILE ULTRA' Gen-NXT Technology Genuine Engine Fluid.
Capacity\u2014 6.0 Liters.
",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11307.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Preliminary Activities/Conditions",
+ "content_type": "Description",
+ "content": "ground level/ 2 post lift/ 4 post lift and turn engine OFF.a new copper washer and tighten the drain plug to specific torque.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 25\u201430 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Always replace the copper washer with a new one.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010007.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Fill fresh recommended oil to specified quantity.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010008.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Refit the engine oil filler cap.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1502.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Refit the engine encapsulation cover.",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ },
+ {
+ "procedure_name": "Engine Oil Level Inspection",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010001.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Preliminary Activities/Conditions",
+ "content_type": "Description",
+ "content": "Wait for about 10 minutes for oil in circulation to drain down.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010002.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Pull out the dip stick gauge and wipe it clean with a cloth/paper.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010003.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Insert the dip stick gauge into the dip stick guide fully till the end.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010002.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010004.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Pull out the dip stick slowly and check for the oil level mark between Maximum and Minimum level - if found below minimum level, top up with recommended oil.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010003.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Insert the dip stick back and fix properly.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Start the engine and check for oil leakage/ seepage at:Oil sump & crankcase joint.Oil sump drain plug.Oil filter joint.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Always use MAHINDRA 'MAXIMILE ULTRA'Gen-NXT Technology GENUINE ENGINE Fluid. This is specially developed for your engine\u2019s efficiency.Torque : 20 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 12
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the knock sensor for any physical damage. If found replace.",
+ "file": null,
+ "display_order": 13
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 28,
+ "sys_id": "THAR.AX-O-0007-Engine",
+ "subsys_id": "THAR.AX-O-0007-Engine-Oil Pressure Sensor",
+ "systems": "Engine",
+ "sub_systems": "Oil Pressure Sensor",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B010588.jpg",
+ "myid": 1497,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Oil Pressure Sensor-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010588.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010198.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Oil Pressure sensor operates the low oil pressure indicator in the cluster. This serves as a warning indicator to the driver, indicating a decrease in the oil pressure which might harm the engine if driver continues running the engine.* The Oil Pressure Sensor is A Piezo \u2014 Resistive type sensor. It Sends oil pressure values to EMS ECU.",
+ "file": null,
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11618.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11619.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010090.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Disconnect the oil pressure sensor electrical connector.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010200.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010199.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 24 mm socket spanner, Loosen and remove the oil pressure sensor from OCFM.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 20 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Check engine oil level, Top up engine oil and check for oil leakage.",
+ "file": null,
+ "display_order": 13
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check oil pressure sensor for any cracks, damage etc, replace if found any.",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 7,
+ "sys_id": "THAR.AX-O-0007-Engine",
+ "subsys_id": "THAR.AX-O-0007-Engine-Oil Cooler And Filtering Module(OCFM)",
+ "systems": "Engine",
+ "sub_systems": "Oil Cooler And Filtering Module(OCFM)",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B010503.jpg",
+ "myid": 1090,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Oil Cooler And Filtering Module(OCFM)-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010503.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11486.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11487.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the coolant. For additional information refer to coolant drain procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove CATCON Assembly. For additional information refer to CATCON Assembly - R &R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove Engine Feed Cover. For additional information refer to Engine Feed Cover - R &R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove Air Cleaner Assembly. For additional information refer to Air Cleaner Assembly- R &R section. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1514.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using the MST 0306GAM0006ST - Stretch Fit Belt Removal Tool Remove the Water Pump Drive belt.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010505.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner, Loosen radiator outlet hose clip and detach hose water inlet pipe end.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010506.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew degassing tank coolant filling pipe mounting bolt OCFM end.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010507.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew heater outlet pipe routing bracket mounting bolt engine block end.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010508.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew heater outlet pipe routing bracket mounting bolt cylinder head end.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010509.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 10 mm combination spanner, Unscrew heater outlet pipe mounting bolt and partially remove pipe.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque :11\u00b11 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010592.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Disconnect AC compressor electrical connector.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010511.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Disconnect oil pressure sensor electrical connector.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010240.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Disconnect crank speed sensor electrical connector.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010512.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Disconnect engine variable oil pump solenoid electrical connector.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010514.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew engine wiring routing bracket mounting bolt.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010515.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew Turbo wiring routing bracket mounting bolt.",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Torque Value",
+ "content": "Torque : 10\u00b11 Nm ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1515.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew turbo coolant inlet and oil inlet mounting banjo bolts OCFM end.",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Torque Value",
+ "content": "Torque : 18\u00b12 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010517.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release oil separator hose clamp clean hose end.",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020244.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner, Loosen clean hose clip and detach hose turbo end.",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010519.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew OCFM rear mounting bolts.",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Torque Value",
+ "content": "Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010520.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew OCFM mounting bolt and strut.",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Caution",
+ "content": "Replace New rubber gasket while refitting.",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010504.jpg",
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Remove OCFM from engine compartment.",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010253.jpg",
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew water pump pulley mounting bolts and remove pulley from water pump.",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Torque Value",
+ "content": "Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Notice",
+ "content": "Using a suitable tool hold the pulley then remove the water pump pulley.",
+ "file": null,
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010254.jpg",
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1516.jpg",
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, Unscrew water pump mounting bolts and remove the water pump from the OCFM.",
+ "file": null,
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Refill the engine oil and check for the oil leakage.",
+ "file": null,
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Refill the engine coolant and carry-out de-aeration procedure.",
+ "file": null,
+ "display_order": 66
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the OCFM for any external cracks, replace if found any.",
+ "file": null,
+ "display_order": 67
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 27,
+ "sys_id": "THAR.AX-O-0007-Engine",
+ "subsys_id": "THAR.AX-O-0007-Engine-Troubleshoot - Engine",
+ "systems": "Engine",
+ "sub_systems": "Troubleshoot - Engine",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1455,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Troubleshoot - Engine-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4753.pdf",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 5,
+ "sys_id": "THAR.AX-O-0007-Engine",
+ "subsys_id": "THAR.AX-O-0007-Engine-Auto Tensioner & Belts - Replace",
+ "systems": "Engine",
+ "sub_systems": "Auto Tensioner & Belts - Replace",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J10-MAT-0080",
+ "cover_image": "/files/W1504.jpg",
+ "myid": 1087,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 31,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 75,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 117,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 157,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 199,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 239,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 282,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 320,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 364,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 403,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 413,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Auto Tensioner & Belts - Replace-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Auto Tensioner & Belts - Replace.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1504.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010927.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "This vehicle is equipped with one autotensioner to maintain the accessory drive belt tension for Alternator and Power steering pump drive belt.ground level/ 2 post lift/ 4 post lift and turn engine OFF.Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W129.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the engine feed cover from engine compartment.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W130.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Place the MST 0306GAM0006ST Stretch Fit Belt Removal Tool on dampe pulley side as shown in the image.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W131.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W132.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 24 mm socket spanner, rotate the damper pulley to clockwise direction then remove the water pump drive belt and MST separately.",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W133.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Place the MST 0306GBH0001ST - Stretch Fit Belt Installation Tool on damper pulley as shown in the image. ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W134.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 24 mm socket spanner, rotate the damper pulley in anticlockwise direction.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W135.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "By rotating pulley, belt started getting into pulley groove and once belt installed properly on pulley, then remove the MST and spanner.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Ensure proper engagement of belt teeth in all the pulley grooves after Installation.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Check the Belt tension. Refer Belt Tension Checking Procedure session below.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W136.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Refit the engine fead cover on engine compartment, torque tighten the bolts to specified value.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 11\u00b1 1Nm ",
+ "file": null,
+ "display_order": 27
+ }
+ ]
+ },
+ {
+ "procedure_name": "Checking Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Check belt tension as per procedure mentioned below: ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W138.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W137.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Run the engine for few minutes.",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Turn ON belt tension gauge.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Do not touch the probe to the belt, this can damage the probe.Torque : 45 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W144.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Position the drive belt.",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1551.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 14 mm ring spanner, swing the auto-tensioner in counter-clockwise direction and install the belt.",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Refit AC Compressor /Water Pump Stretch Fit Belt.",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1017,1296",
+ "file": null,
+ "display_order": 56
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 31,
+ "sys_id": "THAR.AX-O-0007-Engine",
+ "subsys_id": "THAR.AX-O-0007-Engine-Intake CAM Phaser Assembly",
+ "systems": "Engine",
+ "sub_systems": "Intake CAM Phaser Assembly",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B010644.jpg",
+ "myid": 1500,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Intake CAM Phaser Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010644.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11643.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11644.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove Timing Chain. For additional information refer to Timing Chain - R &R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010537.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Align the MST \u2014 0310ABG0001ST Camshaft locking tool on the front side of engine in the camshaft slot as shown and fix the camshaft locking tool on cylinder head using appropriate bolts.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010539.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010643.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 22 mm socket spanner, Loosen and remove Inlet CAM phaser mounting bolt",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 30 \u00b1 2 Nm + 34\u00b0\u00b1 3\u00b0 ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11648.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "While Installation, Check Exhaust Cam phaser mounting bolt tightening torque first and then torque tightened the Intake Cam phaser mounting bolt.",
+ "file": null,
+ "display_order": 13
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the CAM Phaser for any physical damage. If found replace.",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 19,
+ "sys_id": "THAR.AX-O-0007-Engine",
+ "subsys_id": "THAR.AX-O-0007-Engine-Cylinder Compression Test",
+ "systems": "Engine",
+ "sub_systems": "Cylinder Compression Test",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B010657.jpg",
+ "myid": 1106,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Cylinder Compression Test-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Cylinder Compression Test",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "The cylinder compression test is performed to determine the compression pressure of individual cylinders. The test is performed in two stages.Dry Test.Wet Test.For additional information refer to the Spark Plug - R &R section. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Drain the engine coolant. For additional information refer to coolant draining procedure. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the HLA assembly. For additional information refer to the HLA Assemblies \u2014 R &R section. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020279.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020257.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner, Loosen Inter cooler outlet hose clip and detach intercooler end.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010556.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew dipstick guide mounting bolt.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010558.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew intake manifold mounting bolts and remove Intake manifold With Throttle Valve & Inter cooler outlet hose.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1517.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect fuel rail electrical connector.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010560.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Disconnect injector electrical connector.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010559.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew fuel rail mounting bolts.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040123.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove fuel rail with Injectors.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Caution",
+ "content": "Injectors Combustion Seals should be replaced with new ones when ever removing & refitting the Fuel Rail Assembly from the cylinder head. For more information refer to Fuel Rail Assembly \u2014 R &R; section in Fuel System. * If Injector/Injectors struck with Cylinder Head and not able to remove from head, Injector can be removed by using Injector removal tool. For more information refer to Injector \u2014 R &R; section in Fuel System. ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the Turbocharger. For additional information refer to Turbocharger R&R section. ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010553.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using hose clip plier release coolant vent hose clip and detach hose engine head end.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010554.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew heater inlet pipe routing bracket mounting bolt cylinder head end.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Torque Value",
+ "content": "Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010555.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew heater inlet pipe mounting bolt cylinder head end and detach pipe.",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Torque Value",
+ "content": "Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010562.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew heater outlet pipe routing bracket mounting bolt cylinder head end.",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010563.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Disconnect coolant temperature sensor electrical connector.",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010564.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using 19 mm deep socket spanner, unscrew Coolant temperature sensor.",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Torque Value",
+ "content": "Torque : 20 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010565.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Remove alternator top mounting bolt.",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010566.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Loosen alternator top mounting bolt/nut and rotate alternator.",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010567.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Remove CAM shafts front lower bearing cap. ",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010568.jpg",
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Using 15 mm socket spanner, Loosen and remove cylinder head mounting bolts.",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Torque Value",
+ "content": "Torque : 60 \u00b1 6 Nm + (2x95\u00b0) \u00b1 5\u00b0 ",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010569.jpg",
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010570.jpg",
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010572.jpg",
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Remove the cylinder head from engine.",
+ "file": null,
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010158.jpg",
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010825.jpg",
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010829.jpg",
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11566.jpg",
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Caution",
+ "content": "Always replace the cylinder head gasket with a new one when installing.* Remove the foreign materials and the gasket residual on the top surface of the cylinder block and cylinder head before installing the cylinder head gasket.* Apply fresh engine oil on the head gasket while Installation.* Head gasket with the mark of \u201cTC\u201dand gasket part number must be directed towards the cylinder head.* When installing the mounting bolts : from the center to the outside diagonally.* Do not reuse the mounting bolts for the cylinder head, Always replace the mounting bolts New ones while installing head assembly.* Tighten the cylinder head mounting bolts to the specified torque and specified sequence.",
+ "file": null,
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": "Refill the engine coolant. For additional information refer to Coolant refilling and Deaeration procedure. ",
+ "file": null,
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Check for coolant seepage and any oil seepage on the engine. Rectify if any traces found.",
+ "file": null,
+ "display_order": 70
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Clean the cylinder head assemblies thoroughly, replace it if any cracks or damages are found.* Check the Cylinder Head for external damages.* Check the cylinder head height and if not meeting the specified value, replace the cylinder head assembly.* Check the Cylinder Head bottom face for distortion.",
+ "file": null,
+ "display_order": 71
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 112,
+ "sys_id": "THAR.AX-O-0007-en-SM-Rear Axle",
+ "system_name": "Rear Axle",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1013,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 119,
+ "sys_id": "THAR.AX-O-0007-Rear Axle",
+ "subsys_id": "THAR.AX-O-0007-Rear Axle-Rear Axle Pinion Oil Seal",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Axle Pinion Oil Seal",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A140204.jpg",
+ "myid": 1237,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Rear Axle Pinion Oil Seal-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140204.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31126.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31127.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm Allen key, loosen and remove rear axle filler plug.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140026.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm Allen key, remove rear axle drain plug and drain the entire oil.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140027.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "Wait till the entire oil get drained.* Place a tray beneath the rear axle for collecting the oil while draining.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 13 mm and 16 mm ring and open end spanners unscrew rear propeller shaft mounting bolts and nuts rear axle end.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110007.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 65 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "By using Special tool MST 203\u2013Companion Flange Holding Tool, hold the companion flange and Using 32 mm deep socket spanner loosen and remove the companion flange mounting nut.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140192.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140193.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the companion flange using mallet.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140196.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "If companion flange shows wear in the area of seal contact, it should be replaced.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the dust cap.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140197.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the pinion oil seal by using screw driver.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140198.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Ensure not to damage the oil seal mating surface while remove the Oil seal.",
+ "file": null,
+ "display_order": 22
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect t the pinion oil seal for any damage. Replace if found.2. Inspect t the companion flange for any damage. Replace if found.",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using MST 0502AUA0004ST Rear Axle Pinion Oil Seal Installer, Place and Press New oil seal uniformly on banjo gear carrier housing.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140200.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Apply a light coat of oil to the lip of oil seal before installation.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140199.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140201.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Install the dust cap, companion flange on the banjo housing and Install the new mounting nut with washer.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/RearAxlePinioOilSeal.png",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Always use new flange mounting nut once it removed. ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140195.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140203.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Hold the companion flange Using MST203 Companion Flange Holding Tool and torque tighten the companion flange mounting nut.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140194.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "Tighten nut to incremental torque from 270 Nm onwards to 330 Nm until specified PTTR ( Pinion torque to rotate) is achieved.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Measure the Pinion Rotational Torque (PTTR), It should be within 2.5 - 3.5 Nm. ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140205.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Attach the propeller shaft to the rear axle with mounting nuts, torque tighten it to the specified value.",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110007.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 65 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit the drain plug and torque tighten to specified value.",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140028.jpg",
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Notice",
+ "content": "Clean the drain plug and differential housing with a clean cloth before refitting.",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 47 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refill specified quantity of recommended differential oil into differential assembly. ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140024.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Notice",
+ "content": "Never reuse drained oil.* Always use recommended oil only.* Never mix different types of oil and use.* Clean filler plug area properly using acloth before filling the oil.",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Check the oil level and ensure its up to the level. ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140029.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Notice",
+ "content": "Ensure that the oil level is up to lower most point of the filler plug.",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Refit the filler plug back and torque tighten to mounting plug specified value. ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140030.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Notice",
+ "content": "Clean the filler plug with a clean cloth before refitting.",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 29 \u00b1 5Nm ",
+ "file": null,
+ "display_order": 55
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 122,
+ "sys_id": "THAR.AX-O-0007-Rear Axle",
+ "subsys_id": "THAR.AX-O-0007-Rear Axle-Troubleshoot - Rear Axle",
+ "systems": "Rear Axle",
+ "sub_systems": "Troubleshoot - Rear Axle",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1464,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Troubleshoot - Rear Axle-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Trouble Shooting",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Certain rear axle and driveline trouble symptoms are also common to the engine, transmission, tyres and other parts of the vehicle. For this reason be sure that the cause of the trouble is in the rear axle before adjusting, repairing or replacing any of the axle parts.",
+ "file": null,
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Rear Axle Noise Diagnosis",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Basic characteristics in a rear axle are more difficult to diagnose and repair than mechanical failures. Slight axle noise heard only at certain speed or under particular conditions must be considered normal. Axle noise tend to peak or be more pronounced at particular speeds and the noise is in no way a sign of the trouble in the vehicle.
For additional information refer to Rear Axle Shaft RH - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1013,1235",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using circlip plier, remove the toner wheel circlip.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140050.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140061.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "By using hydraulic press, remove toner wheel along with Rear bearing carrier assembly.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Take sufficient care not to damage the toner ring while removing.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140052.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the bearing from Rear bearing carrier.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140062.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Replace the toner ring and bearing assembly once removed.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140065.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a suitable tool, Remove the oil seal from Rear bearing carrier.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140063.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Replace the outboard oil seal once removed.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140064.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Check differential oil level, top up the oil if required.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Carry out Parking Brake Adjustment. For additional information refer to Parking Brake Adjustment Section. ",
+ "file": null,
+ "display_order": 22
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the axle shaft outer oil seal & bearing for any damage, Replace if necessary.",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 115,
+ "sys_id": "THAR.AX-O-0007-Rear Axle",
+ "subsys_id": "THAR.AX-O-0007-Rear Axle-Rear Axle Shaft Assembly",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Axle Shaft Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A140033.jpg",
+ "myid": 1233,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Rear Axle Shaft Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/files_VST-0068_Rear axle shaft removal.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140033.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31088.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31089.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove rear brake drum LH and RH. For additional information refer to Rear brake drum LH and RH \u2014 R &R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Detach the hand brake cable from brake shoe.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140007.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the hand brake cable lock clip and detach the hand brake cable from back plate.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140010.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 11 mm open end spanner, Loosen brake bundy tube flare nut wheel cylinder end.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140049.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 17 mm socket spanner, loosen and remove axle shaft mounting nuts.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140034.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 35 \u2014 50 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using MST (0505AAA0001ST puller rear axle shaft banjo) remove rear axle shaft, dust shield with brake liner assembly from vehicle.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140045.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Notice",
+ "content": "To avoid the back plate falling down, using a plastic tag tie it with any other fixed member before the shaft is pulled out.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Clean sealant on the axle housing flange, Back Plate and apply new sealant on the housing.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140054.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Apply Locktite Sealant 5060 during Installation and Ensure that sealer bead is on the inside of screw holes as shown above.For additional information refer to Parking Brake Adjustment Section. ",
+ "file": null,
+ "display_order": 24
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Rear Axle Oil \u2014Mahindra 'MAXIMILE ELITE' New Generation Genuine Differential Fluid.
Capacity \u2013 2.0Litres.
",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140025.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31041.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Preliminary Activities/Conditions",
+ "content_type": "Description",
+ "content": "Position the vehicle on 2 post lift/ 4 post lift.",
+ "file": null,
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Oil Draining Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm allen key, loosen and remove rear axle filler plug.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140026.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm allen key, remove rear axle drain plug and drain the entire oil.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140027.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "Wait till the entire oil get drained.
Place a tray beneath the rear axle for collecting the oil while draining.
",
+ "file": null,
+ "display_order": 10
+ }
+ ]
+ },
+ {
+ "procedure_name": "Oil Filling Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Refit the drain plug and torque tighten to specified value.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140028.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Clean the drain plug and differential housing with a clean cloth before refitting.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque:47\u00b17Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refill specified quantity of recommended differential oil into differential assembly.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140024.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "Never reuse drained oil.
Always use recommended oil only.
Never mix different types of oil and use.
Clean filler plug area properly using a cloth before filling the oil.
",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Check the oil level and ensure its up to the level.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140029.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "Ensure that the oil level is up to lower most point of the filler plug. ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Refit the filler plug back and torque tighten to mounting plug specified value.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140030.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "Clean the filler plug with a clean cloth before refitting. ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque:29\u00b15Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Recommend to use only Mahindra 'MAXIMILE Elite' new generation genuine differential fluid.For additional information refer to Rear axle oil draining procedure. ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Rear Axle Carrier Assembly.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1013,1232",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1013,1238",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Mount the Rear Axle carrier assembly on a suitable stand.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140074.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "Liquid sealant is used to seal carrier section with banjo beam. Clean the sealant on the carrier facing.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 17 mm socket spanner, loosen and remove the bearing cap mounting bolts and then remove the bearing caps. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140075.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a Mallet, tap and detach the bearing caps. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140076.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Identification marks are punched on bearing cap; this is to ensure correct bearing cap is installed on correct side. Ensure correct bearing caps used While reassembly. ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Pry out differential case from carrier with help of (MST 0502AAA0001ST - Tommy Bars) as shown in the illustration. ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W413.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140222.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the shims from both the sides of differential case. ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140223.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Notice",
+ "content": "(MST 0502AUA0013ST - R Axle Diff Case Bearing Puller Adapter) and (MST 0502AUA0012ST - Axle Bearing Puller) on side bearing cone as steps shown below. ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140081.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140082.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140109.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140110.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140117.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140111.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the side bearing cone by tightening the screw rod using 24 mm ring spanner and remove the bearing cone from the differential case.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140112.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Notice",
+ "content": "Hold the top plate using 36 mm open end spanner while tightening. Follow Steps 15 to 18 to remove Side Gears & Pinion Mate Gears for Open Differential. ",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using MST 0502AUA0033ST - Front Axle Diff Case Pin Remover &Installer; and hammer remove the differential gear locking pin. ",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140122.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140123.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using hammer and punch, Remove the differential shaft from differential case as shown in illustration.",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140124.jpg",
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140125.jpg",
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "To remove side gears and pinion mate gears, rotate the side gears, this will allow the pinion mate gears to turn to opening of the case.",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140126.jpg",
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140127.jpg",
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Remove the pinion and side gears.",
+ "file": null,
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140128.jpg",
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Notice",
+ "content": "Check the differential gear condition, any damage replaces it.(MST 203\u2014 Companion Flange Holding Tool) and Using 32 mm deep socket spanner loosen and remove the companion flange mounting nut.",
+ "file": null,
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140092.jpg",
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140093.jpg",
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Using mallet tap and remove the companion flange, washer and dust cup.",
+ "file": null,
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140094.jpg",
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Notice",
+ "content": "If companion flange shows wear in the area of seal contact, it should be replaced.",
+ "file": null,
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140095.jpg",
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140135.jpg",
+ "display_order": 72
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Using a mallet, tap the pinion assembly and remove the pinion assembly from the differential housing. ",
+ "file": null,
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140096.jpg",
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Notice",
+ "content": "Fit a nut of pinion before tapping to avoid thread damage.* Hold the pinion with hand to avoid falling.* Gear teeth have sharp edges. Handle gears carefully to avoid injury.",
+ "file": null,
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140097.jpg",
+ "display_order": 76
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140098.jpg",
+ "display_order": 77
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Remove the collapsible Washer. ",
+ "file": null,
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140099.jpg",
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Notice",
+ "content": "Discard collapsible spacer. New one is required to be used during assembly",
+ "file": null,
+ "display_order": 80
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": "Assemble (MST 0502AUA0014ST - R Axle Pinion Inner Bearing Puller Adapter) and (MST 0502AUA0012ST - Axle Bearing Puller) as shown in the illustration. ",
+ "file": null,
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140130.jpg",
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140131.jpg",
+ "display_order": 83
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140224.jpg",
+ "display_order": 84
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Tighten the screw rod using 24 mm ring spanner to remove the pinion inner bearing.",
+ "file": null,
+ "display_order": 85
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140225.jpg",
+ "display_order": 86
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Notice",
+ "content": "Hold the top plate using 36 mm open end spanner while tightening.",
+ "file": null,
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Remove the pinion head bearing & remove the shims from the pinion.",
+ "file": null,
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140142.jpg",
+ "display_order": 89
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Notice",
+ "content": "Collect shims and keep them together.* Replace shims if found damaged.",
+ "file": null,
+ "display_order": 90
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140136.jpg",
+ "display_order": 91
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Remove the pinion oil seal by using screw driver.",
+ "file": null,
+ "display_order": 92
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140102.jpg",
+ "display_order": 93
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Notice",
+ "content": "Ensure not to damage the oil seal mating surface while remove the Oil seal.",
+ "file": null,
+ "display_order": 94
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Remove the oil slinger.",
+ "file": null,
+ "display_order": 95
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140103.jpg",
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Description",
+ "content": "Gently pull-out and remove the pinion outer bearing.",
+ "file": null,
+ "display_order": 97
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140104.jpg",
+ "display_order": 98
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "Description",
+ "content": "Using suitable punch and hammer remove the outer bearing cap.",
+ "file": null,
+ "display_order": 99
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140105.jpg",
+ "display_order": 100
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140106.jpg",
+ "display_order": 101
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "Description",
+ "content": "Using suitable punch and hammer remove the inner bearing cap.",
+ "file": null,
+ "display_order": 102
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140107.jpg",
+ "display_order": 103
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140108.jpg",
+ "display_order": 104
+ }
+ ]
+ },
+ {
+ "procedure_name": "Pinion Shim Selection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Ring gear and pinion is supplied as a set. They are matched with each other during manufacture. Matching numbers on both pinion and ring gear are etched for verification. Refer Fig. A or Fig. B for more details. If a new gear set is used, verify numbers on pinion and ring for matching before proceeding with assembly. Standard mounting distance from center line of ring gear to back face of pinion is 109.525 mm . This dimension is controlled by selecting shims, which are positioned between the inner pinion bearing and pinion shoulder. Best running position of gear set is achieved by proper shim selection. On the bottom face of pinion, a number is etched. It can be a plus (+) number, a minus (-) number or Zero (0). Required pinion shim selection is achieved with help of this number.* Pinion offset always in thou (1 thou = 0.0254 mm). *A shows ring and pinion etched with inch identification.*B shows ring and pinion etched with metric identification.",
+ "file": null,
+ "display_order": 105
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1A150033.jpg",
+ "display_order": 106
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1A150034.jpg",
+ "display_order": 107
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "If no offset on pinion face then assume it zero. ",
+ "file": null,
+ "display_order": 108
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U3A110009.jpg",
+ "display_order": 109
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Shims with different thicknesses are available for selection. Use tables below as a guide for selecting correct thickness of shims either for addition or for subtraction from old shim pack.*\u2013 Pinion Shim Selection (Formula = Old Pinion offset \u2013 New Pinion offset)(MST 0502AUA0016ST - Rear Axle Pinion Height Master Block) over the inner bearing cup seating area as shown.",
+ "file": null,
+ "display_order": 115
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140138.jpg",
+ "display_order": 116
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Position the (MST 0502AUA0015ST - Rear Axle Pinion Height Setting Gauge) on the differential housing as shown.",
+ "file": null,
+ "display_order": 117
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140139.jpg",
+ "display_order": 118
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using feeler gauge measure the distance between the MST\u2019s as shown and the value assumed as \u2018A\u2019 . For example consider the value obtained as 1.51 mm.",
+ "file": null,
+ "display_order": 119
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140140.jpg",
+ "display_order": 120
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140141.jpg",
+ "display_order": 121
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Clean the sealant on the gear carrier.",
+ "file": null,
+ "display_order": 122
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 123
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Refill the rear axle oil.For additional information refer to Rear Axle Oil Refilling procedure. ",
+ "file": null,
+ "display_order": 124
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Convert the Thou value to mm ( 55 x 0.0254 = 1.40 mm) , which is the final shim thickness required.",
+ "file": null,
+ "display_order": 125
+ }
+ ]
+ },
+ {
+ "procedure_name": "Assembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Select shim pack based on Pinion Shim Selection Procedure to position the pinion at correct mounting distance as per value etched on pinion stem for best running position. ",
+ "file": null,
+ "display_order": 126
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140136.jpg",
+ "display_order": 127
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Mount the pinion positioning shim pack on pinion.",
+ "file": null,
+ "display_order": 128
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Position the pinion inner bearing on pinion & press the bearing by using (MST 0502AUA0017ST - R Axle Pinion Inner Brg Press Dolly). ",
+ "file": null,
+ "display_order": 129
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140142.jpg",
+ "display_order": 130
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140143.jpg",
+ "display_order": 131
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140144.jpg",
+ "display_order": 132
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Insert a new collapsible spacer. ",
+ "file": null,
+ "display_order": 133
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140099.jpg",
+ "display_order": 134
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Collapsible spacer should rest in between pinion inner and outer bearing and it can be fitted in any direction.
Always use new collapsible spacer, never use old one.
",
+ "file": null,
+ "display_order": 135
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install the Inner bearing cup by using (MST 0502AUA0018ST - Pinion Inner bearing cup installer) and (MST 0707BBA0003ST - Universal mandrel) on banjo gear carrier housing.",
+ "file": null,
+ "display_order": 136
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140146.jpg",
+ "display_order": 137
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140147.jpg",
+ "display_order": 138
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140149.jpg",
+ "display_order": 139
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install the Outer bearing cup by using (MST 0502AUA0019ST - Pinion outer bearing cup installer) and (MST 0707BBA0003ST - Universal mandrel) on banjo gear carrier housing.",
+ "file": null,
+ "display_order": 140
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140150.jpg",
+ "display_order": 141
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140151.jpg",
+ "display_order": 142
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140153.jpg",
+ "display_order": 143
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install the pinion on the axle banjo housing and provide a support for pinion in the bottom.",
+ "file": null,
+ "display_order": 144
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140157.jpg",
+ "display_order": 145
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using (MST 0502AUA0017ST - R Axle Pinion Inner Brg Press Dolly) and hammer press the pinion outer bearing.",
+ "file": null,
+ "display_order": 146
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140156.jpg",
+ "display_order": 147
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Place oil slinger on pinion outer bearing cone.",
+ "file": null,
+ "display_order": 148
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140160.jpg",
+ "display_order": 149
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Place and Press oil seal on banjo gear carrier housing using (MST 0502AUA0004ST - Rear Axle Pinion Oil Seal Installer). ",
+ "file": null,
+ "display_order": 150
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140165.jpg",
+ "display_order": 151
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Caution",
+ "content": "Apply a light coat of oil to the lip of oil seal.",
+ "file": null,
+ "display_order": 152
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140166.jpg",
+ "display_order": 153
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Install the dust cap into the companion flange.",
+ "file": null,
+ "display_order": 154
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140226.jpg",
+ "display_order": 155
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Install the companion flange on the banjo housing.",
+ "file": null,
+ "display_order": 156
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140227.jpg",
+ "display_order": 157
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Install the washer.",
+ "file": null,
+ "display_order": 158
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140162.jpg",
+ "display_order": 159
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Install the companion flange mounting nut.",
+ "file": null,
+ "display_order": 160
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140163.jpg",
+ "display_order": 161
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Hold the companion flange using (MST203 - Companion Flange Holding Tool) and torque tighten the companion flange mounting nut.",
+ "file": null,
+ "display_order": 162
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140164.jpg",
+ "display_order": 163
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Caution",
+ "content": "Tighten nut to Initial torque as 270 Nm.* Measure the Pinion Rotational Torque (PTTR), It should be within 2.5 - 3.5 Nm.* If measured Pinion Rotational Torque (PTTR) not within 2.5 - 3.5 Nm, Then tighten nut to incremental torque from 270 Nm onwards to 330 Nm until specified PTTR ( Pinion torque to rotate) is achieved.",
+ "file": null,
+ "display_order": 164
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140167.jpg",
+ "display_order": 165
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Warning",
+ "content": "Excessive care must be taken during bearing preload torque adjustment. Do not over tighten, loosen and then retighten nut. Do not exceed specified bearing preload torque .",
+ "file": null,
+ "display_order": 166
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Measure and ensure the Final Pinion Rotational Torque (PTTR), It should be within 2.5 - 3.5 Nm. *SPEC : 2.5 to 3.5 Nm)Follow Steps 17 to 20 to Install Side Gears & Pinion Mate Gears for Open Differential. ",
+ "file": null,
+ "display_order": 170
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Assemble both side gears and thrust washers, hold them in place with one hand and then assemble the pinion mate gears with thrust washer to hold the side gears in place.",
+ "file": null,
+ "display_order": 171
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140168.jpg",
+ "display_order": 172
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Notice",
+ "content": "An easy way to assemble the side gears and pinion mate gears is to have all parts lubricated before assembly.",
+ "file": null,
+ "display_order": 173
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140169.jpg",
+ "display_order": 174
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Rotate the side gears until the holes of the spherical washers and pinion mate gears line up with the holes in the case by the help of engaging the splines of axle shaft to side gears. When both the cross bore hole matched and insert the differential shaft.",
+ "file": null,
+ "display_order": 175
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140170.jpg",
+ "display_order": 176
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Notice",
+ "content": "Use a drift to line holes of the gears up with case.",
+ "file": null,
+ "display_order": 177
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Assemble differential shaft and pull out drift. Be sure vertical lock pin hole is lined up with that of the case, and that pinion mate washers are in place and lined up with gear and case.",
+ "file": null,
+ "display_order": 178
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Align the differential shaft hole, insert the lock pin and fix using (0502AUA0033ST - Differential gear lock pin removal tool) and hammer.",
+ "file": null,
+ "display_order": 179
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140171.jpg",
+ "display_order": 180
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140172.jpg",
+ "display_order": 181
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Assemble ring gear to the differential case using mounting bolts. Tighten the bolts to specified torque value in recommended sequence.",
+ "file": null,
+ "display_order": 182
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140173.jpg",
+ "display_order": 183
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Torque Value",
+ "content": "Torque : 90 - 105 Nm ",
+ "file": null,
+ "display_order": 184
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140174.jpg",
+ "display_order": 185
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Notice",
+ "content": "Always use new ring gear bolts.
Ring gear mounting bolts have LH threads.
While Installation torque in anti-clocking direction.
",
+ "file": null,
+ "display_order": 186
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Assemble (MST 0502AUA0020ST - Rear Axle Dummy Bearing) on to differential case.",
+ "file": null,
+ "display_order": 187
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140175.jpg",
+ "display_order": 188
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Place differential case assembly into housing.",
+ "file": null,
+ "display_order": 189
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140176.jpg",
+ "display_order": 190
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": "Push the differential case assembly towards the pinion side and insert the shims pack on the LH side (Back to ring gear) and Insert the shims pack on the RH side (Teeth side).",
+ "file": null,
+ "display_order": 191
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140235.jpg",
+ "display_order": 192
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140228.jpg",
+ "display_order": 193
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140229.jpg",
+ "display_order": 194
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Remove the shims (6 Thou) from LH Side and add to RH Side for backlash tolerance.",
+ "file": null,
+ "display_order": 195
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140230.jpg",
+ "display_order": 196
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140231.jpg",
+ "display_order": 197
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Install dial gauge and locate tip of indicator on the surface of one of the ring gear teeth and measure the backlash at three equally spaced points (Each 120 degree rotation space), confirm the Backlash tolerance is (0.15 to 0.25 mm). ",
+ "file": null,
+ "display_order": 198
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140232.jpg",
+ "display_order": 199
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Notice",
+ "content": "Fix the Dial Gauge on Housing, Set the Dial Indicator 0 on Ring gear teeth as shown.
(MST 0502AUA0021ST - R Axle Diff Case Brgs Pressing tool). ",
+ "file": null,
+ "display_order": 205
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140182.jpg",
+ "display_order": 206
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140183.jpg",
+ "display_order": 207
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140181.jpg",
+ "display_order": 208
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Description",
+ "content": "Repeat the same procedure for installation of bearing on other side.",
+ "file": null,
+ "display_order": 209
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140185.jpg",
+ "display_order": 210
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140186.jpg",
+ "display_order": 211
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140189.jpg",
+ "display_order": 212
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "Description",
+ "content": "Install the Differential bearing caps on both the sides.",
+ "file": null,
+ "display_order": 213
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140184.jpg",
+ "display_order": 214
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140187.jpg",
+ "display_order": 215
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "Description",
+ "content": "Install differential case assembly into carrier with the help of mallet.",
+ "file": null,
+ "display_order": 216
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140188.jpg",
+ "display_order": 217
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "Caution",
+ "content": "Carelessness while installing differential case assembly may result in injury.",
+ "file": null,
+ "display_order": 218
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "Description",
+ "content": "Install the shims on both the sides of differential case.",
+ "file": null,
+ "display_order": 219
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140078.jpg",
+ "display_order": 220
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "Caution",
+ "content": "Backlash shims are not to be interchanged during assembly.* If Backlash shims are damaged, replace with new shims during assembly.",
+ "file": null,
+ "display_order": 221
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "Description",
+ "content": "Assemble bearing caps using mounting bolts. Ensure correct fitment of caps by matching letters on caps and carrier on either side. Tight the bearing cap bolts to specified value.",
+ "file": null,
+ "display_order": 222
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140075.jpg",
+ "display_order": 223
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "Torque Value",
+ "content": "Torque : 90 - 110 Nm ",
+ "file": null,
+ "display_order": 224
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "Description",
+ "content": "Install dial gauge and locate tip of indicator on the surface of one of the ring gear teeth and measure the ring gear and pinion backlash at three equally spaced points (Each 120 degree rotation space), confirm the Backlash tolerance is (0.15 to 0.25 mm). ",
+ "file": null,
+ "display_order": 225
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140237.jpg",
+ "display_order": 226
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "Notice",
+ "content": "Fix the Dial Gauge on Housing, Set the Dial Indicator 0 on Ring gear teeth as shown.
Locktite RTV Sealant 5060 to flat surface of banjo beam.",
+ "file": null,
+ "display_order": 234
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140067.jpg",
+ "display_order": 235
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "Ensure that sealer bead is on the inside of bolt holes.
Bead must be 3 to 6 mm high and 3 to 6 mm wide.
",
+ "file": null,
+ "display_order": 236
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Refit the Differential Carrier Assembly. ",
+ "file": null,
+ "display_order": 237
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1013,1238",
+ "file": null,
+ "display_order": 238
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Fill the differential fluid. ",
+ "file": null,
+ "display_order": 239
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1013,1238",
+ "file": null,
+ "display_order": 240
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 121,
+ "sys_id": "THAR.AX-O-0007-Rear Axle",
+ "subsys_id": "THAR.AX-O-0007-Rear Axle-Rear Axle System Technical Spec",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Axle System Technical Spec",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1239,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Rear Axle System Technical Spec-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Specifications Wear Data & Tightening Specifications",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/14500.pdf",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 114,
+ "sys_id": "THAR.AX-O-0007-Rear Axle",
+ "subsys_id": "THAR.AX-O-0007-Rear Axle-Rear Axle Carrier Assembly",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Axle Carrier Assembly",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A140044.jpg",
+ "myid": 1232,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Rear Axle Carrier Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140044.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31075.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31076.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the rear axle oil. For additional information refer to rear axle oil draining procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Rear Axle Shaft Assembly LH. For additional information refer to Rear Axle shaft Assembly LH \u2014 R &R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the Rear Axle Shaft Assembly RH. For additional information refer to Rear Axle shaft Assembly RH \u2014 R &R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, Unscrew rear propeller shaft mounting bolts and detach propeller rear end and properly hang the shaft.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110007.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 65 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew gear carrier to banjo housing mounting bolts.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140035.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 17 mm socket spanner, Unscrew rear stabilizer bar bracket mounting bolts and detach the bracket partially.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140037.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140039.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Ensure to add washer only for bottom mounting of stabilizer bar.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170115.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 70 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 5 mm allen key, hold the rear stabilizer bar link bottom mounting then using a 18 ring spanner, loosen and remove the top mounting nut from stabilizer bar.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140036.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140038.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the rear axle gear carrier from vehicle.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140040.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Clean the sealant on the gear carrier.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140068.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Caution",
+ "content": "Apply Locktite Sealant 5060 during Installation and Ensure that sealer bead is on the inside of screw holes and pattern as shown below.For additional information refer to Rear Axle Oil Refilling procedure. ",
+ "file": null,
+ "display_order": 30
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "For additional information refer to Parking Brake Adjustment Section. ",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect t the toner wheel for any damage, Replace if necessary.2. Inspect the Rear bearing carrier assembly for any damage, Replace if necessary.",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 113,
+ "sys_id": "THAR.AX-O-0007-Rear Axle",
+ "subsys_id": "THAR.AX-O-0007-Rear Axle-Rear Axle Assembly",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Axle Assembly",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A140025.jpg",
+ "myid": 1231,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Rear Axle Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140025.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31051.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31052.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove rear brake drum LH and RH.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1016,1274",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Detach the hand brake cable both the sides(LH&RH;)from brake shoes.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140007.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140008.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the hand brake cable lock clips from both the sides (LH & RH) and detach the hand brake cables from back plate.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140010.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140009.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the hand brake holding spring on the axle from LH & RH side.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140012.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140011.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the bundy tube rear hose to LH wheel. For additional information refer to Bundy Tube Rear Hose to LH Wheel - R &R; section. ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the bundy tube rear hose to RH wheel. For additional information refer to Bundy Tube Rear Hose to LH Wheel - R &R; section. ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the flexible hose LH & RH side locking from the axle.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140013.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140014.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 10mm socket spanner, Unscrew wheel speed sensor mounting bolts and detach the sensors.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140016.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque:9\u00b11Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140015.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Provide a jack to support the rear axle assembly.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170013.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the rear propeller shaft. For additional information refer to Rear Propeller Shaft-R &R; section. ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the stabilizer bar rear. For additional information refer to Stabilizer Bar Rear-R &Rsection.; ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Remove the Pan hard rod.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1015,1248",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using a 24 mm socket spanner, loosen and remove the upper link mounting bolt/nut.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170028.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Torque Value",
+ "content": "Torque : 230 \u00b1 20 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170029.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 21mm ring spanner.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a 24 mm socket spanner, loosen and remove the lower arm mounting bolt/nut.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170025.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 21mm ring spanner.",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Torque Value",
+ "content": "Torque:230\u00b120Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using a 17 mm socket spanners, loosen and remove the both rear shock absorbers bottom side mounting bolts and nuts.",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170014.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Torque Value",
+ "content": "Torque value: 110\u00b111Nm ,Wrench Type - Open end Torque Wrench ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 15mm ring spanner",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Remove the rear coil spring and pad securely from vehicle.",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170016.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Caution",
+ "content": "Pay attention while Installation.6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the steering column shrouds.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1017,1299",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the ignition switch electrical connection.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090002.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a Small sizzle and hammer, hit and remove the key barrel screws.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090003.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "Use new screw while installing key barrel.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the Ignition key with ICU from the vehicle.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090004.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the ICU mounting screws then remove the ICU from the key barrel.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090005.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Insert the key and turn the key into AC position.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090006.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Cut the micro switch routing tag and detach the connector holding clip from the ICU.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090007.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090008.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Caution",
+ "content": "Always use new mounting bolts while installing the Ignition Switch Assembly clamping unit.",
+ "file": null,
+ "display_order": 24
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect ignition key for crack or damage. Replace if found any.Starter Motor Specification ",
+ "file": "/files/11820.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Heading",
+ "content": "Starter Motor Specification ",
+ "file": null,
+ "display_order": 2
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 44,
+ "sys_id": "THAR.AX-O-0007-Starting System",
+ "subsys_id": "THAR.AX-O-0007-Starting System-Immobilizer",
+ "systems": "Starting System",
+ "sub_systems": "Immobilizer",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A090052.jpg",
+ "myid": 1125,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Immobilizer-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Component Location Index",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090052.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25397.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25398.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm combination spanner loosen battery negative cable mounting nut and disconnect the cable. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080023.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Combination switch.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1017,1298",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the ignition switch electrical connection. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090002.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove ICU mounting screws then remove ICU from the key barrel. ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A900053.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A900054.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Ensure the wheels are straight ahead. Also the steering rack should be in center.Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Glove Box Assembly.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1020,1341",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the IP grab handle cover.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220022.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": ", ",
+ "file": "/files/Screenshot 2023-04-20 162835.png",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting screws.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220024.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220025.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Partially detach the door edge beading and using a trim removal tool, remove the IP LH side cover.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220139.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220065.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220076.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque : 8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220066.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220077.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Take out the IP LH side top cover with Passenger air bag from the IP.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220134.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using a 10 mm ring spanner, loosen and remove the air bag mounting bolt from IP top cover.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210046.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Torque Value",
+ "content": "Torque :4.5\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Expand the PAB module holder both sides using screw driver and detach the PAB separately from IP top cover.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210047.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210048.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew LH side AC vent mounting screws.",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/IP Top Cover Assembly LH16925a6.png",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Remove the AC Vent.",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Screenshot 2023-04-20 163039.png",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Caution",
+ "content": "Carefully release the vent locking clips from the cover and detach the vent.",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/IP Top Cover Assembly LH3.png",
+ "display_order": 43
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external damages or damaged locking clips, Replace if necessary.Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220073.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew the cluster mounting screws.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220072.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 2 \u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Partially Detach Cluster and disconnect the electrical connector.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220071.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the Instrument Cluster.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220021.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the Floor Console Assembly.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1020,1340",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using trim removal tool, Remove IP side vertical trim LHS And RHS.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220070.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220069.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Partially detach the switch bang assembly and remove electric connector to take out from the vehicle.",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1000.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1001.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Detach the USB Docking station bezel and disconnect the electrical connectors.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220067.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Disconnect Driver switch bank electrical connector.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220125.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Remove the IP grab handle cover.",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220022.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts.",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W651.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Torque Value",
+ "content": "Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting bolts.",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220024.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle.",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220025.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Partially detach the door edge beading and using a trim removal tool , remove the IP side trim LH side.",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1002.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220065.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt.",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220076.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Torque Value",
+ "content": "Torque : 8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw.",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220066.jpg",
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector.",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220077.jpg",
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Remove IP Speaker Grill from LH and RH Sides.",
+ "file": null,
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220078.jpg",
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220080.jpg",
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": "Disconnect speaker electrical connectors from both the sides.",
+ "file": null,
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220081.jpg",
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220082.jpg",
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Using a trim removal tool Detach the infotainment trims.",
+ "file": null,
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220087.jpg",
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220083.jpg",
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew the infotainment mounting screws.",
+ "file": null,
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220084.jpg",
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220085.jpg",
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Partially detach infotainment and disconnect the electrical connectors.",
+ "file": null,
+ "display_order": 72
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220086.jpg",
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Remove the infotainment from Instrument panel.",
+ "file": null,
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290007.jpg",
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew instrument panel mounting bolts.",
+ "file": null,
+ "display_order": 76
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1003.jpg",
+ "display_order": 77
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1004.jpg",
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1005.jpg",
+ "display_order": 80
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1006.jpg",
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1007.jpg",
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1008.jpg",
+ "display_order": 83
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290094.jpg",
+ "display_order": 84
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290095.jpg",
+ "display_order": 85
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "Description",
+ "content": "Carefully remove the instrument panel from vehicle.",
+ "file": null,
+ "display_order": 86
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220096.jpg",
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 88
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "check for any external damages or damaged locking clips, Replace if necessary.",
+ "file": null,
+ "display_order": 89
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 233,
+ "sys_id": "THAR.AX-O-0007-Instrument Panel",
+ "subsys_id": "THAR.AX-O-0007-Instrument Panel-IP Top Cover Assembly RH",
+ "systems": "Instrument Panel",
+ "sub_systems": "IP Top Cover Assembly RH",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A220013.jpg",
+ "myid": 1346,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-IP Top Cover Assembly RH-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220013.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12291.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12292.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using trim removal tool remove the cluster bezel.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220016.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, remove the IP panel assembly driver side.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190016.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Partially detach the door edge beading and using a trim removal tool, remove the IP RH side cover.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220133.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220017.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew driver side IP cover mounting screw.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220018.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the driver side IP cover.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220019.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew AC vent mounting screws.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220014.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the RH side AC vent.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220015.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Carefully release the vent locking clips from the cover and detach the vent.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1009.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 22
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "check for any external damages or damaged locking clips, Replace if necessary.",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 230,
+ "sys_id": "THAR.AX-O-0007-Instrument Panel",
+ "subsys_id": "THAR.AX-O-0007-Instrument Panel-Instrument Panel",
+ "systems": "Instrument Panel",
+ "sub_systems": "Instrument Panel",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A220099.jpg",
+ "myid": 1343,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Instrument Panel-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220099.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12237.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12238.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Instrument Panel Assembly.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1020,1342",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew the Instrument Panel AC & defroster Duct mounting screws and remove the ducts.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220137.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220136.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220135.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP driver switch bank mounting screws.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220103.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 1.5 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the Driver Switch bank from Instrument Panel.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270121.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP centre air vent mounting screws.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220102.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the Centre Air Vents from Instrument Panel.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220101.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220100.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "check for any external damages or damaged locking clips, Replace if necessary.",
+ "file": null,
+ "display_order": 21
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 234,
+ "sys_id": "THAR.AX-O-0007-Instrument Panel",
+ "subsys_id": "THAR.AX-O-0007-Instrument Panel-IP AC Vent RH",
+ "systems": "Instrument Panel",
+ "sub_systems": "IP AC Vent RH",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A220126.jpg",
+ "myid": 1347,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-IP AC Vent RH-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220126.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12304.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12305.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using trim removal tool remove the cluster bezel.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220016.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, remove the IP panel assembly driver side.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190016.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Partially detach the door edge beading and using a trim removal tool, remove the IP RH side cover.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220133.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220017.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew driver side IP cover mounting screw.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220018.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the driver side IP cover.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220019.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew AC vent mounting screws.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220014.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the IP AC Vent RH.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220015.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Carefully release the vent locking clips from the cover and detach the vent. ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220127.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 22
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "check for any external damages or damaged locking clips, Replace if necessary.",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 227,
+ "sys_id": "THAR.AX-O-0007-Instrument Panel",
+ "subsys_id": "THAR.AX-O-0007-Instrument Panel-Floor Console",
+ "systems": "Instrument Panel",
+ "sub_systems": "Floor Console",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A220042.jpg",
+ "myid": 1340,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Floor Console-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220042.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12151.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "Heading",
+ "content": "Tools Required ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12152.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console RH screvits and detach the panel from vehicle",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280032.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220005.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console LH screvits and detach the panel from vehicle.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Floor_console.png",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220007.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Loosen and Remove Gear Knob and Transfer case shifter knobs",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220036.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220037.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the gear shifter cover with trim",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220044.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the rummier mat from the cup holder",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the 4WD selection knob by rotating it in anti-clock wise direction.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110306.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Pull and fold the gear shifter boot from gear shifter bezel.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110269.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Partially detach the bezel from the console.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110134.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Notice",
+ "content": "Excessive pull may leads to damage of the electrical connector",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Disconnect the AT gaiter electrical connector from the bezel.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110135.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Carefully remove the bezel trim from the TGS lever.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110134.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Caution",
+ "content": "Handle bezel assembly carefully to prevent it from damage or scratches.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using trim removal tool, carefully remove the floor console top trim with transfer case shifter boot",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110269.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew floor console LH and RH side mounting bolts",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220047.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Floor_console2.png",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew floor console LH and RH side mounting screws",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220050.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220049.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Remove the bottle holder rubber mat",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220043.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew floor console mounting bolts",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220046.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew floor console LH and RH side mounting bolts",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220051.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220052.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Lift the floor console and disconnect the floor console electrical connector",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220053.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Remove the floor console from vehicle.",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220055.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Remove the power window switch assembly from floor console.",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220054.jpg",
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220058.jpg",
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 56
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check floor console assembly for any damage, replace if found any.",
+ "file": null,
+ "display_order": 57
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 231,
+ "sys_id": "THAR.AX-O-0007-Instrument Panel",
+ "subsys_id": "THAR.AX-O-0007-Instrument Panel-Cross Car Beam Assembly",
+ "systems": "Instrument Panel",
+ "sub_systems": "Cross Car Beam Assembly",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A220122.jpg",
+ "myid": 1344,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Cross Car Beam Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220122.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12249.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12250.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Instrument Panel Assembly.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1020,1342",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew fuse box mounting bolts.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220104.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "Torque : 5.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect ignition key barrel electrical connector.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220105.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the bonnet cable from the lever.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220106.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen the steering intermediate shaft top bolt and remove bottom mounting bolts and detach the intermediate shaft bottom from the steering column.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190042.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew steering column mounting bolts and nuts.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220107.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220108.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "using mm socket spanner, loosen and remove the Ip RH & LH speaker from Cross Car Beam.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220109.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 3 \u00b1 1Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220109.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Disconnect the IP wiring routing clips and HVAC unit electrical connector.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220111.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the Scuttle Grill.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1024,1373",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew CCB front facing mounting bolts.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220114.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "<bTorque : 22\u00b13 Nm</nb>",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew CCB bottom mounting bolts.",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220116.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Torque Value",
+ "content": "Torque : 22\u00b13 Nm ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220115.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew CCB LHS & RHS mounting bolts/nuts.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220113.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Torque Value",
+ "content": "Torque : 22\u00b13 Nm ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220112.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew CCB LHS & RHS side bottom mounting bolts.",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220117.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Torque Value",
+ "content": "Torque : 22\u00b13 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220118.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew CCB to HVAC unit mounting screws.",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220119.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Torque Value",
+ "content": "Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Remove the Cross Car Beam from vehicle.",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220120.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 48
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "check for any external damages, cracks or bends on the cross car beam, Replace if necessary.",
+ "file": null,
+ "display_order": 49
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 228,
+ "sys_id": "THAR.AX-O-0007-Instrument Panel",
+ "subsys_id": "THAR.AX-O-0007-Instrument Panel-Glove Box",
+ "systems": "Instrument Panel",
+ "sub_systems": "Glove Box",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A220031.jpg",
+ "myid": 1341,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Glove Box-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220031.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12181.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12182.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Open the Glove Box",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200131.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Unlock glove box lock and remove the glove box assembly from IP.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200132.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver, remove the handle mounting screws.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220027.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the glove box handle from the glove box assembly.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220028.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220029.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 13
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the glove box for damage, replace if necessary.",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 235,
+ "sys_id": "THAR.AX-O-0007-Instrument Panel",
+ "subsys_id": "THAR.AX-O-0007-Instrument Panel-IP AC Vent LH",
+ "systems": "Instrument Panel",
+ "sub_systems": "IP AC Vent LH",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A220128.jpg",
+ "myid": 1348,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-IP AC Vent LH-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220128.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12317.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12318.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Glove Box Assembly.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1020,1341",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the IP grab handle cover.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220022.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1010.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting screws.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220024.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220025.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Partially detach the door edge beading and using a trim removal tool, remove the IP LH side cover.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220139.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220065.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220076.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque : 8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220066.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220077.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Take out the IP LH side top cover with Passenger air bag from the IP.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220134.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew LH side AC vent mounting screws.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1011.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Remove the IP AC Vent LH.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1012.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Caution",
+ "content": "Carefully release the vent locking clips from the cover and detach the vent.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220129.jpg",
+ "display_order": 37
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external damages or damaged locking clips, Replace if necessary.",
+ "file": null,
+ "display_order": 38
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 236,
+ "sys_id": "THAR.AX-O-0007-en-SM-Instrument Cluster",
+ "system_name": "Instrument Cluster",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1021,
+ "active_status": true,
+ "Assets": [
+ {
+ "systemdisplayorder": 10,
+ "system_asset": "/files/INSTRUMENT CLUSTER.mp4",
+ "active_status": true
+ }
+ ],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 236,
+ "sys_id": "THAR.AX-O-0007-Instrument Cluster",
+ "subsys_id": "THAR.AX-O-0007-Instrument Cluster-Instrument Cluster",
+ "systems": "Instrument Cluster",
+ "sub_systems": "Instrument Cluster",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A220023.jpg",
+ "myid": 1349,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Instrument Cluster-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220023.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4723.pdf",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Tachometer",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The tachometer indicates the real-time engine speed in thousands of RPM(revolutions per minute). Each division is 500 RPM. Operating the engine at very high RPM may lead to excessive engine wear and low fuel economy. Maintain steady engine speed below 2500 RPM and do not accelerate or decelerate abruptly.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220009.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Caution",
+ "content": "Do not over-accelerate the engine during idling, this can cause severe engine damage and would be treated as abuse of the engine which is not covered by warranty ",
+ "file": null,
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Speedometer",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The speedometer indicates the real time road surface speed of the vehicle in kilometers per hour.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W353.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Notice",
+ "content": "The vehicle speedometer is affected by size of the tyres used. If the size of the tyres are changed from those fitted at the factory, the speedometer might not display the correct road surface speed and distance travelled ",
+ "file": null,
+ "display_order": 8
+ }
+ ]
+ },
+ {
+ "procedure_name": "Features",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4724.pdf",
+ "display_order": 9
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4712.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4713.jpg",
+ "display_order": 11
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using trim removal tool, remove the cluster bezel mounting clips and remove the cluster bezel.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220016.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using trim removal tool, remove the IP side trim.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220017.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP cover mounting screw and detach the IP cover using trim removal too.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220018.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220019.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew instrument cluster mounting screw.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W123.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 2 \u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect cluster electrical connector and remove instrument cluster.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W124.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220021.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal ",
+ "file": null,
+ "display_order": 25
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any damage or crack, replace if found.",
+ "file": null,
+ "display_order": 26
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 153,
+ "sys_id": "THAR.AX-O-0007-en-SM-Brake",
+ "system_name": "Brake",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1016,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 165,
+ "sys_id": "THAR.AX-O-0007-Brake",
+ "subsys_id": "THAR.AX-O-0007-Brake-Tandem Master Cylinder (TMC) - R&R",
+ "systems": "Brake",
+ "sub_systems": "Tandem Master Cylinder (TMC) - R&R",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B130007.jpg",
+ "myid": 1280,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Tandem Master Cylinder (TMC) - R&R-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B130007.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4732.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4733.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Disconnect the TMC electrical connector then detach from the routing clips.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130184.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 13 mm open end spanner, loosen and remove the TMC to EHCU Primary & Secondary bundy tubes from TMC side flare nuts.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130001.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque :16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using hose clip plier, release brake fluid reservoir tank to clutch TMC hose clip then detach the hose.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130002.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 12 mm combination spanner, Unscrew TMC mounting nuts and remove the TMC assembly from the brake booster.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130003.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130187.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Check and top up the brake fluid, If required.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Carry-out the brake bleeding procedure. For additional information refer to Brake bleeding procedure. ",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for master cylinder external damage, if found replace.",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 166,
+ "sys_id": "THAR.AX-O-0007-Brake",
+ "subsys_id": "THAR.AX-O-0007-Brake-Front Brake Caliper Assembly - R&R",
+ "systems": "Brake",
+ "sub_systems": "Front Brake Caliper Assembly - R&R",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A130163.jpg",
+ "myid": 1281,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Front Brake Caliper Assembly - R&R-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130163.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22088.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22089.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the front brake pad assembly. For information refer to front brake pad assembly \u2014 R &R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, loosen and remove the brake hose banjo bolt then detach the brake hose.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130085.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque :24 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Replace the banjo bolt washers with new ones always while installation, else brake fluid leakage may happen. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 19 mm socket spanner, loosen and remove the caliper assembly mounting bolts.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130165.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 95 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the caliper assembly from the vehicle. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130169.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Check and top up the brake fluid, If required.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Carry-out the brake bleeding procedure. For additional information refer to Brake bleeding procedure. ",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the caliper for any physical damage. Replace if found any.",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 170,
+ "sys_id": "THAR.AX-O-0007-Brake",
+ "subsys_id": "THAR.AX-O-0007-Brake-ABS EHCU",
+ "systems": "Brake",
+ "sub_systems": "ABS EHCU",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B130010.jpg",
+ "myid": 1285,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-ABS EHCU-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B130010.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22120.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22121.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 13 mm open end spanners, loosen and remove the TMC to primary and secondary bundy tubes flare nuts on EHCU side.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130025.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque :16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 11 and 13 mm open end spanners,loosen and remove the EHCU to FL,FR,RL, RR output bundy tubes flare nuts on EHCU side.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130026.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Carefully detach the bundy pipe without any bend. if the bundy tube bends, Constant pressure will not be maintained. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the EHCU electrical connector.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130027.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew air cleaner housing mounting bolts to partially detach and keep aside.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B130011.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanners, Unscrew EHCU mounting bolts and remove the EHCU assembly with EHCU mounting bracket.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130029.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 23 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner , Unscrew EHCU mounting nuts from the bracket.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130030.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 8 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130196.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "After removing the bundy tubes from EHCU, seal each port of ECHU with dummy plugs to avoid dust entry *not give any impact to hydraulic unit and take at most care not to allow dust to enter the hydraulic unit.*not place hydraulic unit on its side or upside down. Handling it in inappropriate way will affect its original performance. *sufficient care while installation and ensure correct bundy is connected to the specified inlet port.Use colour code for identification.Torque :25 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the pedal box mounting nuts then remove the brake pedal box assembly.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130010.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque :25\u00b15.0 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4D180003.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the brake pedal assembly for any physical damage. Replace if found any.",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 171,
+ "sys_id": "THAR.AX-O-0007-Brake",
+ "subsys_id": "THAR.AX-O-0007-Brake-Front Wheel Speed Sensor",
+ "systems": "Brake",
+ "sub_systems": "Front Wheel Speed Sensor",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A130229.jpg",
+ "myid": 1286,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Front Wheel Speed Sensor-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130229.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22130.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22131.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Disconnect battery negative connector.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130321.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect the wheel speed senor electrical connector.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Front Wheel Speed Sensor.png",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Detach the wheel speed sensor cable from the routing clips.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130033.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen and remove the wheel speed sensor mounting bolt then remove the sensor. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130034.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque :9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130035.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the sensor for any physical damage. Replace if found any.Torque :25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the parking brake switch from parking brake lever assembly.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130147.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130148.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Carry-out parking brake adjustment. For additional information refer to Parking brake adjustment section. ",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the park brake lever for any physical damage. Replace if found any.",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 167,
+ "sys_id": "THAR.AX-O-0007-Brake",
+ "subsys_id": "THAR.AX-O-0007-Brake-Front Caliper Piston Assembly",
+ "systems": "Brake",
+ "sub_systems": "Front Caliper Piston Assembly",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A130266.jpg",
+ "myid": 1282,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Front Caliper Piston Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the front caliper assembly.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1016,1281",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Blow dry compressed air into the caliper gradually through the inlet port connected to banjo bolt, to gradually move the piston out of the caliper. ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130266.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the piston from the caliper housing.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130268.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the dust cover from the caliper housing.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130263.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the rubber seal from the groove in the caliper housing.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130262.jpg",
+ "display_order": 10
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Piston Outer surface should be free from nicks, score or rust and should feel smooth to touch. Do not use emery paper on piston surface, Replace if found any.Clean all the internal parts thoroughly with fresh brake fluid or alcohol. Do not use mineral oil like kerosene, petrol, diesel etc. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Carefully refit the rubber seal.",
+ "file": "/files/W4A130262.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refit the dust cover.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130263.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Insert the piston.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130268.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "If the piston does not move smoothly, remove it and examine the sealing ring for correct seating in its groove. Fit the other end of the piston boot on to the caliper housing. ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Refit the front caliper assembly. For additional information refer to Caliper assembly \u2014 R &R; section. ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1016,1281",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 155,
+ "sys_id": "THAR.AX-O-0007-Brake",
+ "subsys_id": "THAR.AX-O-0007-Brake-Brake Switch Adjustment",
+ "systems": "Brake",
+ "sub_systems": "Brake Switch Adjustment",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A130129.jpg",
+ "myid": 1270,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Brake Switch Adjustment-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Brake Switch Adjustment",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Open the driver door.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130129.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Press the lock and disconnect the electrical connector from the brake switch. ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130128.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Place the brake pedal in release position. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130235.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Turn the brake switch in anti-clock wise direction to get the brake switch free from adjuster lock.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130119.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Insert the brake switch (A) in adjuster (B) till the switch plunger get completely pressed against brake pedal (at this point switch body will rest on brake pedal).",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/P4J140272.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Ensure no play between adjuster and the mounting bracket . Replace the adjuster if play is observed. 2 post lift/ 4 post lift and turn engine OFF.Clutch/Brake Fluid - Mahindra Maximile DOT 4 Genuine Brake fluid.Capacity - 1.75 Liters (Including bleeding quantity).\u201cMAX\u201d mark on the brake fluid reservoir.",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100013.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Press and release brake pedal gently several times, so that brake fluid will get circulated throughout the circuit.",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100076.jpg",
+ "display_order": 48
+ }
+ ]
+ },
+ {
+ "procedure_name": "Brake Fluid Air Bleeding",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "For vehicles equipped with ABS/ESP, brake circuit air bleeding needs to be carried out in 3 steps as mentioned below:
i-SMART diagnostic tester and turn the ignition \u201cON\u201d .",
+ "file": null,
+ "display_order": 95
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Launch i-SMART Select ABS ECU and Navigate to Write Data. ",
+ "file": null,
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030233.jpg",
+ "display_order": 97
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Routine screen will appear. Click on \u201cROUTINE SELECTION\u201d drop down list and select \u201cREPAIR BLEEDING\u201d. ",
+ "file": null,
+ "display_order": 98
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030234.jpg",
+ "display_order": 99
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Click on \u201cSTART ROUTINE\u201d to initiate the tool bleeding.",
+ "file": null,
+ "display_order": 100
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030235.jpg",
+ "display_order": 101
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "Ensure the fluid level in brake fluid reservoir is at \u201cMAX\u201d mark.",
+ "file": null,
+ "display_order": 102
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030236.jpg",
+ "display_order": 103
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Connect a transparent tube into rear LH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Loosen and open the rear LH bleeding screw and then press \u201cOK\u201d button. \u201cYES\u201d button to proceed for \u201cBleeding phase I\u201d. \u201cBleeding phase I\u201d ends.\u201cOK\u201d button. \u201cYES\u201d button to proceed for \u201cBleeding phase II\u201d. \u201cBleeding phase II\u201d ends.\u201cOK\u201d button. ",
+ "file": null,
+ "display_order": 113
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030240.jpg",
+ "display_order": 114
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Notice",
+ "content": "Ensure other end of tube is submerged in liquid, else chances for air entry is high.",
+ "file": null,
+ "display_order": 115
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Click on \u201cYES\u201d button to proceed for \u201cBleeding phase III\u201d. \ufeff \u201cBleeding phase III\u201d ends.\u201cOK\u201d button. ",
+ "file": null,
+ "display_order": 119
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A030242.jpg",
+ "display_order": 120
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Notice",
+ "content": "Ensure other end of tube is submerged in liquid, else chances for air entry is high.",
+ "file": null,
+ "display_order": 121
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Click on \u201cYES\u201d button to proceed for \u201cBleeding phase IV\u201d. \u201cBleeding phase IV\u201d ends.For additional information refer to Manual bleeding section. ",
+ "file": null,
+ "display_order": 125
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Check brake/clutch pedal for sponginess. If found spongy, repeat the entire procedure of bleeding.
Brake and Clutch Fluid - Mahindra Maximile DOT 4 Genuine Brake fluid.
Brake and Clutch Fluid - 1.75 Liters (Including bleeding quantity).
Torque :25 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the pedal box mounting nuts then remove the brake pedal box assembly.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130010.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque :25\u00b15.0 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130330.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the brake pedal assembly for any physical damage. Replace if found any.",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 158,
+ "sys_id": "THAR.AX-O-0007-Brake",
+ "subsys_id": "THAR.AX-O-0007-Brake-Front Brake Pads/ Calipers - Inspect",
+ "systems": "Brake",
+ "sub_systems": "Front Brake Pads/ Calipers - Inspect",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.2,
+ "rts": null,
+ "mat": "J10-MAT-0430",
+ "cover_image": "/files/W4A130171.jpg",
+ "myid": 1273,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 39,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 51,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 93,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 133,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 175,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 215,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 259,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 297,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 340,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 378,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 423,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Front Brake Pads/ Calipers - Inspect-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Front Brake Pads & Calipers - Inspect.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130171.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22015.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "Description",
+ "content": "Position the vehicle on 2 post lift.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 21 mm wheel spanner, remove wheel mounting nuts and then remove the front wheel.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160003.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "For vehicles with Alloy wheels,measuring can be done without removing the wheels. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Insert the Brake pad gauge between caliper housing and edge of brake pad backing plate and contact Tip of tool housing (A) on rotor machined surface as shown.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1E170041.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Brake pad gauge should be in perpendicular to rotor surface while measuring.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130343.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Push the Rear barrel (E) of tool inward and rotate the barrel to rotate Probe tip (B) of the tool as shown.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130345.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Release the barrel (E) outward upto the probe tip (B) in contact with surface of brake pad back plate as shown.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130344.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Rotate Knurled ring (D) of rear measuring barrel in same direction to view quick reference color pattern (C) and find actual brake pad thickness (In mm).",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130346.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refer Brake Pad Thickness Vs Quick reference colors table mentioned below.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22022.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "If Measured pad thickness is 1 mm or less, it has to be replaced.
Wear Limits
11.35 mm. 10.35 mm.
Actual thickness of disc: 30 mm.
\ufeff 28 mm.
",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130143.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Refit the front wheel back with the help of mounting nuts and torque tighten it to specified torque value.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150003.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22026.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Follow the above procedure for front other side wheel brake pad and disc inspection. ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Caution",
+ "content": "Remove and inspect the brake pads if the vehicle is reported for the following concerns,
For additional information refer Primary Bundy Tube \u2014 R &R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the secondary bundy tube. For additional information refer Secondary Bundy Tuber \u2014 R &R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using hose clip plier detach the vacuum hose clip and remove hose from the brake booster.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B130024.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the brake booster electrical connector and detach from the routing clips.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130184.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using hose clip plier, release the brake fluid reservoir tank to clutch TMC hose hose clip then detach the hose.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130123.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using cutting plier, remove the R-clip then remove the clevis pin. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130023.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew brake booster mounting nuts and remove the brake booster with TMC.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130010.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130024.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Carry out brake switch adjustment setting.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1016,1270",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Check and top up the brake fluid, If required.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Carry-out the brake bleeding procedure. For additional information refer to Brake bleeding procedure. ",
+ "file": null,
+ "display_order": 22
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for the booster diaphragm if found check & replace the assembly.",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 172,
+ "sys_id": "THAR.AX-O-0007-Brake",
+ "subsys_id": "THAR.AX-O-0007-Brake-Rear Wheel Speed Sensor",
+ "systems": "Brake",
+ "sub_systems": "Rear Wheel Speed Sensor",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B130022.jpg",
+ "myid": 1287,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Rear Wheel Speed Sensor-en",
+ "Procedure_details": []
+ },
+ {
+ "subSystemdisplayorder": 159,
+ "sys_id": "THAR.AX-O-0007-Brake",
+ "subsys_id": "THAR.AX-O-0007-Brake-Rear Brake Drum And Lining - Inspect",
+ "systems": "Brake",
+ "sub_systems": "Rear Brake Drum And Lining - Inspect",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J10-MAT-0440",
+ "cover_image": "/files/W4A160003bbf7c9.jpg",
+ "myid": 1274,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 38,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 80,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 92,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 163,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 174,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 244,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 258,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 326,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 339,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 409,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 422,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Rear Brake Drum And Lining - Inspect-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Rear Brake Drum & Linings - Inspect.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22028.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "Description",
+ "content": "Position the vehicle on 2 post lift.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130338.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Brake Drum Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 21 mm wheel spanner, Loosen and remove the rear LH wheel.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160036.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Loosen and remove drum mounting screw.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130250.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the brake drum.",
+ "file": null,
+ "display_order": 9
+ }
+ ]
+ },
+ {
+ "procedure_name": "Brake Drum/Lining Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Clean the brakes by blowing compressed air.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Check the wheel cylinder for oil leakage. (It is recommended to check the oil seepage from wheel cylinder by lifting the dust boots.) ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130251.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Check the brake lining for wear/cracks.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Measure the brake lining thickness by using Vernier caliper.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130348.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "The minimum usable thickness of the rear brake liner is 4.6 mm. ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130252.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Replace when thickness falls Minimum thickness of lining below 1 mm.5th notch position. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130329.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Check both the rear wheels for free rotation, if the wheels are rotate then tighten the adjusting nut 14 mm till the rear wheels can no longer be rotated using hands.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130298.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130300.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Apply and release the parking brake 5 times.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130296.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Set the parking brake lever into the released position. The rear wheels must be able to turn freely. If not, loosen the adjusting nut gradually until the wheel can turn freely.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130296.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130298.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130300.jpg",
+ "display_order": 19
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 175,
+ "sys_id": "THAR.AX-O-0007-Brake",
+ "subsys_id": "THAR.AX-O-0007-Brake-Front brake Pad Replace",
+ "systems": "Brake",
+ "sub_systems": "Front brake Pad Replace",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A130267.jpg",
+ "myid": 1509,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Front brake Pad Replace-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Brake pads convert the kinetic energy of the car to thermal energy by friction. Two brake pads are contained in the brake caliper with their friction surfaces facing the brake disc which are pressed together against the rotating disc to slow/stop the vehicle. ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130267.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 21 mm wheel spanner remove mounting nuts and remove the front RH wheel. ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130249.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove front caliper lower mounting bolt using 12 mm socket spanner. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130167.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Lift the caliper upwards as shown in the illustration. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130168.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Pull the Brake Pad outwards upto pad contact with clip as shown in the illustration. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130362.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Twist the pad in anti clock wise direction, lift the pad upwards and remove the pad. ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130363.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Follow Step 4 & 5 for remove another pad. ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W127.jpg",
+ "display_order": 14
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Notice",
+ "content_type": "Notice",
+ "content": "While inserting the pads between the carrier and disc care should be taken that the friction material should be towards the disc. Rotate the disc and make sure it is free to rotate. If it is not free to rotate, inspect and rectify. Before inserting the pads ensure that caliper is returned fully to its position. (Push the caliper inside if necessary.) Never polish pad lining with sandpaper. If lining is polished with sandpaper, hard particles of sandpaper will be deposited in lining and may damage disc. When pad lining requires correction, replace it with a new one. While fitting the guide pin ensure that the straight portion of the pin matches with the ear of the calliper body. The Pads in the Pad kit should be replace on the respective caliper i.e. assemble RH marked pads on RH Caliper and LH marked pads on LH Caliper. If the pads are to be reused make sure they are assembled back in the same position as they were when removed i.e., inboard pad on to the piston side and outboard pad to the wheel side. This is possible only when at the time of removal these pads are marked for their positions and kept aside. Never lubricate the pad seating areas as it may lead to jamming. After assembly of pads, apply brake pedal 5 - 6 times in static condition in order to make the pads align properly. It is recommended to apply light braking during the road test and avoid heavy and continuous braking during the initial 200 kms of run or until the new pads are performing satisfactorily. Never lubricate the pad seating areas as this may lead to jamming. Always ensure that the anti rattle pad clips (small low abutment clip \u2013 sLAC) are replaced whenever the pads are replaced. Always ensure the grease (Wolfracote) between clip & carrier whenever the sLAC clips are removed/replaced. Ensure that the sLAC clips are placed properly and fitted in correct direction in the caliper bracket as shown in the illustration. Ensure that the sLAC clips are replaced/swapped diagonally as shown in the illustration. Ensure that no damage or no deformation of retraction loop in the sLAC clips before fitment. Don\u2019t overload or pull the retraction loop during pad assembling. Don\u2019t use deformed clips & don\u2019t damage the clips during pad insertion. ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Notice",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130272.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Notice",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130271.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Notice",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130270.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Ensure the proper fitment of all the small low abutment clip (sLAC) . ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130269.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Replace sLAC clips with a new one if found any damage or crack. ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refit the brake pad by pushing the pad inside the clips in angled approach as shown in the illustration. ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130372.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Rotate the pad in clockwise direction to vertical position and push the pad inside to caliper. ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130364.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Ensure pad touching the clip retraction. ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130365.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130276.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Move the caliper downwards and bring back to its original position. ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130295.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "For easy movement, pull the caliper outwards a bit and move it down. Chances for piston seal damage is high, so take adequate precaution while moving the caliper downwards. If the pads are changed with a new one, push both the pistons inside before moving the caliper downwards. ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Refit the caliper bottom mounting bolt and torque tighten to specified torque value. ",
+ "file": "/files/W4A130167.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Ensure the sliding pins are greased well, whenever removed or replaced. ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 31 \u2013 38 Nm",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit the front RH wheel back with the help of mounting nuts and torque tighten it to specified torque value. ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130249.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 140\u00b110 Nm",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Follow the same procedure for front LH brake pad and caliper inspection. ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "If any one pad is worn out (inboard /outboard) then replace both the pads. If pads on one wheel only are worn, even then replace the other wheels also. ",
+ "file": null,
+ "display_order": 39
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 176,
+ "sys_id": "THAR.AX-O-0007-Brake",
+ "subsys_id": "THAR.AX-O-0007-Brake-Brake Liner Replace",
+ "systems": "Brake",
+ "sub_systems": "Brake Liner Replace",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A160003.jpg",
+ "myid": 1510,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Brake Liner Replace-en",
+ "Procedure_details": []
+ },
+ {
+ "subSystemdisplayorder": 168,
+ "sys_id": "THAR.AX-O-0007-Brake",
+ "subsys_id": "THAR.AX-O-0007-Brake-Brake Back Plate",
+ "systems": "Brake",
+ "sub_systems": "Brake Back Plate",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B130008.jpg",
+ "myid": 1283,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Brake Back Plate-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B130008.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22101.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22102.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove Brake Shoes. For additional information refer to brake shoe \u2014 R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the hand brake cable lock clip and detach the hand brake cable from back plate.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140010.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 11 mm open end spanner, Loosen brake bundy tube flare nut wheel cylinder end.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140049.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew Wheel cylinder mounting bolts and remove the cylinder.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130359.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 17 mm socket spanner, loosen and remove axle shaft mounting nuts. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130360.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 90 \u2014 100 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using MST (0505AAA0001ST puller rear axle shaft banjo) remove rear axle shaft, dust shield with brake liner assembly from vehicle. ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130361.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Notice",
+ "content": "To avoid the back plate falling down,using a plastic tag tie it with any other fixed member before the shaft is pulled out. ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Clean sealant on the axle housing flange, Back Plate and apply new sealant on the housing.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140054.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Apply Locktite Sealant 5060 during Installation and Ensure that sealer bead is on the inside of screw holes as shown above. *must be 3 to 6 mm high and 3 to 6 mm wide.For additional information refer to Brake bleeding procedure . ",
+ "file": null,
+ "display_order": 25
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the brake back plate any external damage & also check the brake back plate usable thickness, if required replace.",
+ "file": null,
+ "display_order": 26
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 154,
+ "sys_id": "THAR.AX-O-0007-Brake",
+ "subsys_id": "THAR.AX-O-0007-Brake-Vacuum Leak Test",
+ "systems": "Brake",
+ "sub_systems": "Vacuum Leak Test",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1269,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Vacuum Leak Test-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21922.pdf",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 173,
+ "sys_id": "THAR.AX-O-0007-Brake",
+ "subsys_id": "THAR.AX-O-0007-Brake-Brakes System Technical Spec",
+ "systems": "Brake",
+ "sub_systems": "Brakes System Technical Spec",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1288,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Brakes System Technical Spec-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Technical Specifications",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/14508.pdf",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 153,
+ "sys_id": "THAR.AX-O-0007-Brake",
+ "subsys_id": "THAR.AX-O-0007-Brake-Troubleshooting Of Vacuum Booster Assembly",
+ "systems": "Brake",
+ "sub_systems": "Troubleshooting Of Vacuum Booster Assembly",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1268,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Troubleshooting Of Vacuum Booster Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21921.pdf",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 133,
+ "sys_id": "THAR.AX-O-0007-en-SM-Suspension",
+ "system_name": "Suspension",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1015,
+ "active_status": true,
+ "Assets": [
+ {
+ "systemdisplayorder": 6,
+ "system_asset": "/files/Suspension.mp4",
+ "active_status": true
+ }
+ ],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 137,
+ "sys_id": "THAR.AX-O-0007-Suspension",
+ "subsys_id": "THAR.AX-O-0007-Suspension-Front Lower Control Arm",
+ "systems": "Suspension",
+ "sub_systems": "Front Lower Control Arm",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170093.jpg",
+ "myid": 1252,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Front Lower Control Arm-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170093.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21744.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21745.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the front wheel assembly. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1015,1250",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Front stabilizer bar assembly. For additional information refer to Front Stabilizer Bar \u2014 R&R; section.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 24 mm socket spanner, loosen and remove the front lower control arm mounting nuts on chassis.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170124.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 24 mm ring spanner.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque value: 250 \u00b1 20 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 19 mm socket spanner, loosen and remove strut fork mounting bolt.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170125.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 120 \u00b1 12 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.Torque : 130 \u2014 150 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 22 mm socket spanner, loosen and remove knuckle bracket mounting bolts, remove the knuckle lower half. ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170128.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque value: 140 \u00b1 10 Nm \ufeff Torque Wrench Type - Open end Torque Wrench ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a hammer, tap strut fork and release it from lower arm. ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170218.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170129.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the lower control arm mounting bolts from the vehicle frame.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170130.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque value: 250 \u00b1 20 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the lower control arm from the vehicle.",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170091.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170131.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170120.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Perform wheel alignment.",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1015,1250",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Caution",
+ "content": "Pay attention while Installation.(MST:0401BAA0043ST) on the bush.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170251.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a hydraulic press or hammer, Install the Pan hard bush One end.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170285.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Panhard bush should be fitted in center of panhard and ensure to maintain equal distance on both side of panhard as shown.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170287.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Place the Pan hard other end on base block and place the bush installer (MST:0401BAA0043ST) on the bush.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170274.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a hydraulic press or hammer, Install the Pan hard bush other end.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170286.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Refit the Panhard rod.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1015,1254",
+ "file": null,
+ "display_order": 26
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 145,
+ "sys_id": "THAR.AX-O-0007-Suspension",
+ "subsys_id": "THAR.AX-O-0007-Suspension-Upper Arm Bushes Overhaul",
+ "systems": "Suspension",
+ "sub_systems": "Upper Arm Bushes Overhaul",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170219.jpg",
+ "myid": 1260,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Upper Arm Bushes Overhaul-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/VST-0071_Front Suspension Upper Arm Bushes Removal & Installation.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Front Upper Control Arm.",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1015,1251",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Place the base block (MST: 0401BAA0033ST) and place the collar support (MST: 0401BAA0037ST) . on the base block.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170219.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Place the upper arm one end on the base block. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170220.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Place the upper arm bush remover (MST: 0401BAA0040ST) on the bottom bush.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170221.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Place the Pin cage (MST: 0401BAA0041ST) & the support cage (MST: 0401BAA0013ST) as shown. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170222.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a hydraulic press remove the upper arm one side (bottom) bush. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170223.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Place the upper arm other end on the base block (MST: 0401BAA0033ST) and collar support (MST: 0401BAA0037ST) .",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170225.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Place the upper arm bush remover (MST: 0401BAA0040ST) on the bush. ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170226.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Place the upper arm dummy bush (MST: 0401BAA0042ST) on the upper side bush seating hole.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170227.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Place the upper arm pin cage (MST: 0401BAA0041ST) & the support cage (MST: 0401BAA0013ST) as shown. ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170228.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a hydraulic press remove the other side bush.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170229.jpg",
+ "display_order": 23
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Place the Upper arm on the base block (MST: 0401BAA0033ST) & collar support (MST: 0401BAA0037ST) and place the bush over the upper arm.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170230.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Place the bush installer (MST: 0401BAA0043ST) on the bush.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170231.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a hydraulic press, Install the upper arm one side bush.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170232.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Place the Upper arm other side on the base block (MST: 0401BAA0033ST) & collar support (MST: 0401BAA0037ST) and place the bush over the upper arm.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170233.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Place the bush installer (MST:0401BAA0043ST) .on the bush. ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170234.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a hydraulic press, Install the upper arm bush. ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170235.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refit the Front Upper Control Arm.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1015,1251",
+ "file": null,
+ "display_order": 37
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 140,
+ "sys_id": "THAR.AX-O-0007-Suspension",
+ "subsys_id": "THAR.AX-O-0007-Suspension-Rear Upper Link",
+ "systems": "Suspension",
+ "sub_systems": "Rear Upper Link",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170065.jpg",
+ "myid": 1255,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Rear Upper Link-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/VST-0073_Rear Suspension Rear upper Link Bushes Removal & Installation.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Rear Upper Link is used to compensates the longitudinal load to the vehicle.",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170065.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170031.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21782.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21783.jpg",
+ "display_order": 6
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 24 mm socket spanner, loosen the mounting bolt and nut in the chassis end then remove nut from the link. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170028.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 230 \u00b1 20 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 21 mm ring spanner.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.* Torque Wrench Type - Open end Torque Wrench for LH chassis & axle ends",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 24 mm socket spanner, loosen and remove the link mounting nut from the axle end.",
+ "file": "/files/W4A170029.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": ", ",
+ "file": "/files/W4A170029.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 230 \u00b1 20 Nm* Torque Wrench Type - Open end Torque Wrench for LH chassis & axle ends",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 21 mm ring spanner",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a appropriate jack support slightly lift the rear axle.",
+ "file": "/files/W4A170013.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": ", ",
+ "file": "/files/W4A170013.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 17 mm socket spanners, loosen and remove the both rear shock absorbers bottom side mounting bolts and nuts.",
+ "file": "/files/W4A170014.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": ", ",
+ "file": "/files/W4A170014.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque value : 110\u00b111 Nm \ufeff Torque Wrench Type - Open end Torque Wrench ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.* While loosening the nut, hold the bolt using 15 mm ring spanner.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Lower the jack support.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the respective side coil spring.",
+ "file": "/files/W4A170027.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": ", ",
+ "file": "/files/W4A170027.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Jack up the rear axle slightly.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the rear upper link chassis end mounting bolt then remove the front and rear upper link from the vehicle.",
+ "file": "/files/W4A170026.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": ", ",
+ "file": "/files/W4A170026.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": ", ",
+ "file": "/files/W4A170050.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": "Pay attention while Installation.* Bolt should be fitted in the direction of Arrow shown in illustration.",
+ "file": "/files/W4A170050.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170102.jpg",
+ "display_order": 31
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the upper link for any damage, crack or twisting. Replace if found any.2. Inspect the upper link bushes for any damage, crack or material deterioration. Replace the bushes if found any.",
+ "file": null,
+ "display_order": 32
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 148,
+ "sys_id": "THAR.AX-O-0007-Suspension",
+ "subsys_id": "THAR.AX-O-0007-Suspension-Rear Lower Link Bushes Overhaul",
+ "systems": "Suspension",
+ "sub_systems": "Rear Lower Link Bushes Overhaul",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170276.jpg",
+ "myid": 1263,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Rear Lower Link Bushes Overhaul-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/VST-0074_Rear Suspension Rear lower Link Bushes Removal & Installation.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Rear Lower Link.",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1015,1256",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Place the base block (MST:0401BAA0033ST) & place the Rear Lower and Upper Link Coller (MST : 0401BDD0001ST) .",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170276.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Place the Lower link one end on the base block. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170254.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) on the lower link one end bush.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170255.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a hydraulic press, remove the lower link one end bush. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170256.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Place the Lower link other end on the base block.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170257.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) on the lower link other end bush.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1037.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a hydraulic press, remove the lower link other end bush.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170277.jpg",
+ "display_order": 17
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Place the Lower link one end on then base block and place the bush over the lower link.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170278.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Place the Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170258.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "While Installation ensure to maintain Bush Void at 45\u00b0 angle as shown.* Ensure to Install the Bush with Void end should be fitted in Chassis end on vehicle.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170279.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170281.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1038.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Place the Lower link other end on the base block and place the bush over the lower link.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170259.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Place the Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170280.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170279.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Refit the Rear Lower Link.",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1015,1256",
+ "file": null,
+ "display_order": 32
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 151,
+ "sys_id": "THAR.AX-O-0007-Suspension",
+ "subsys_id": "THAR.AX-O-0007-Suspension-Suspension System Technical Spec",
+ "systems": "Suspension",
+ "sub_systems": "Suspension System Technical Spec",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1266,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Suspension System Technical Spec-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Front Suspension",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/14504.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Rear Suspension",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/14505.jpg",
+ "display_order": 2
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 138,
+ "sys_id": "THAR.AX-O-0007-Suspension",
+ "subsys_id": "THAR.AX-O-0007-Suspension-Front Strut Assembly",
+ "systems": "Suspension",
+ "sub_systems": "Front Strut Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170098.jpg",
+ "myid": 1253,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Front Strut Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170098.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21758.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21759.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the front wheel assembly.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1015,1250",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner , loosen and remove the brake hose routing bracket mounting nut. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170124.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 19 mm socket spanner , loosen and remove the strut fork mounting bolt at lower arm end and detach it.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170133.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 120 \u00b1 12 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using hammer, tap strut fork gradually and release strut fork from lower arm.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170218.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170134.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 17 mm ring spanner, loosen and remove the strut top mounting nuts from chassis.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170135.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque value: 40 \u00b1 5Nm
Torque Wrench Type - Open end Torque Wrench
",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Detach Wheel speed sensor routing clips from upper control arm. ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170138.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner and 18 mm open end spanner, unscrew upper arm bolt and nut and detach partially.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170136.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque value: 97\u00b1 10 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170137.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove front strut assembly from front suspension. ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170139.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": "LH and RH identification sticker available on part for orientation.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 17 mm socket spanner and 19 mm open end spanner, loosen the fork mounting bolt and nut and remove fork from strut assembly.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170145.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Perform wheel alignment.",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1015,1250",
+ "file": null,
+ "display_order": 32
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for the coil spring for any damage, crack etc.(MST:0401BAA0033ST) & place the Rear Lower and Upper Link Coller (MST : 0401BDD0001ST) .",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170276.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Place the upper link one end on the base block.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170260.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) over the upper link one end bush and Using a hydraulic press, remove the bush.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170262.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Place the upper link other end on the base block.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170261.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) on the upper link other end bush and Using a hydraulic press, remove the bush. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170263.jpg",
+ "display_order": 13
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Place the upper link one end on then base block and place the bush over the upper link.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170265.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Place the Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170267.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "While Installation ensure to maintain Bush Void at 45\u00b0 angle as shown.Torque : 230\u00b1 20 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt with the help of 21 mm deep socket. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 21 mm socket spanner, loosen and remove the pan hard rod mounting bolt from axle side.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170037.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 230\u00b1 20 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove pan hard rod separately.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170051.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "Yellow color all round marking added on Pan hard rod to identify chassis end.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170148.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170101.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "After installation of pan hard rod remove the jack support.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Pay attention while Installation.(MST:0401BAA0033ST) & place the Front Lower Arm Big End Bush Collar (MST : 0401BBB0001ST) on the base block.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170219.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Place the Lower arm big bush end over the fixture.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170236.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Place the LCA big bush remover (MST: 0401BAA0038ST) and Front Lower Arm Bushs Support tool (MST: 0401BBB0002ST) on the big end bush.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170237.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170238.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Place the Pin cage (MST:0401BAA0019ST) & the support cage (MST:0401BAA0013ST) as shown.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170239.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a hydraulic press, remove the lower arm big end bush.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170240.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Place the LCA small bush end on the base block (MST: 0401BAA0033ST) and LCA small bush collar support (MST : 0401BAA0036ST) .",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170219.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Place the Lower arm small bush end over the fixture.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170270.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Place the LCA small bush remover (MST: 0401BAA0039ST) & Front Lower Arm Bushs Support tool (MST : 0401BBB0002ST) over the lower arm bush.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170271.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Place the dummy bush (MST: 0401BAA0016ST) on the big end bush seating hole.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170272.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Place the Pin cage (MST: 0401BAA0019ST) & support cage (MST: 0401BAA0013ST) as shown.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170241.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using a hydraulic press, remove the LCA small bush. ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170242.jpg",
+ "display_order": 26
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Place the lower arm on the base block (MST: 0401BAA0033ST).",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170243.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Place the bigger end bush on the lower arm & place the bush installer (MST: 0401BAA0044ST)on the bush.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170244.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Lower arm big end bush has Void profile and While Installation ensure to maintain Bush Void at appropriate angle as shown. ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170258.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170284.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a hydraulic press, Install the lower arm big end bush.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170247.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Place the lower arm small end on the base block (MST: 0401BAA0033ST) ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170245.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Place the lower arm small end bush & the installer (MST: 0401BAA0045ST). ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170246.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a hydraulic press, Install the lower arm small end bush.",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170247.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refit the Front Lower Control Arm.",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1015,1252",
+ "file": null,
+ "display_order": 43
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 142,
+ "sys_id": "THAR.AX-O-0007-Suspension",
+ "subsys_id": "THAR.AX-O-0007-Suspension-Rear Coil Springs",
+ "systems": "Suspension",
+ "sub_systems": "Rear Coil Springs",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170012.jpg",
+ "myid": 1257,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Rear Coil Springs-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170012.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21801.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21802.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Support the rear axle using the appropriate hydraulic jack.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170013.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 17 mm socket spanners, loosen and remove the both rear shock absorbers bottom side mounting bolts and nuts.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170014.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque value : 110\u00b111 Nm* Torque Wrench Type - Open end Torque Wrench",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 15 mm ring spanner ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Lower the jack support.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170015.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the rear coil spring and pad securely from vehicle.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170016.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170018.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170017.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170149.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Pay attention while Installation.* Locking lug to be matched with hole on Rear Coil spring dome bracket of Chassis.* Yellow coloured PU sleeve should be on chassis side while assembling the coil spring ashown in illustration.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170113.jpg",
+ "display_order": 20
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Torque : 40 \u2014 45 Nm Torque Wrench Type - Open end Torque wrench ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the spring compressor tool.",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170158.jpg",
+ "display_order": 51
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 136,
+ "sys_id": "THAR.AX-O-0007-Suspension",
+ "subsys_id": "THAR.AX-O-0007-Suspension-Front Upper Control Arm",
+ "systems": "Suspension",
+ "sub_systems": "Front Upper Control Arm",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170055.jpg",
+ "myid": 1251,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Front Upper Control Arm-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170055.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21735.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21736.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove front wheel. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1015,1251",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a cutting plier, remove the cotter pin from the ball joint. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170121.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "Never reuse the split pin, always replace with a new one. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 24 mm socket spanner, loosen and remove the upper control arm ball joint nut. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170057.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "90 \u2013 110 Nm",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the wheel speed sensor routing clips from the upper control arm. ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170123.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 18 mm ring spanner, hold the mounting nut & using an 14 mm socket spanner loosen the bolt, remove the bolts & nuts. ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170058.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 97 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Detach and remove the upper control arm. ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/front upper control armef1736.PNG",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Perform wheel alignment. ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170119.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1015,1250",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": "Pay attention while Installation. Torque value : 65\u00b110Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the shock absorber from the vehicle.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170040.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170100.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Pay attention while Installation.* Bolt should be fitted in the direction of Arrow shown in illustration.* Ensure the arrow on Rear Shock absorber should be on rear side of vehicle.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170150.jpg",
+ "display_order": 21
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Wheel Alignment Sequence ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U3A130002.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "If above sequence is not followed, it will lead to incorrect wheel alignment even though individual adjustments are done correctly.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Heading",
+ "content": "Run Out Compensation ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Park the vehicle on 4 post wheel alignment equipment to do the run-out compensation.* Refer wheel alignment equipment manufacturer's guide lines while doing run-out compensation.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Heading",
+ "content": "Refer the procedure given below for SAP setting ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Keep the wheels on turntables of the wheel alignment machine.2. Rotate the steering wheel to LHS lock position.3. From LHS lock position, rotate steering wheel to RHS Lock position.4. Count the number of turns of steering wheel from LHS to RHS lock position.5. From RHS lock position, rotate steering wheel exactly half the number of turns towards LHS.6. Lock the steering wheel.7. If the steering straight ahead does not match the wheel straight ahead, then adjust the OBJ of the desired side.8. Ensure that the silent bushes in the front suspension are in satisfactory condition.9. Ensure that the front suspension fasteners are tightened to specified torque.10. Ensure that there is no play in steering linkages and suspension ball joints.11. Follow instruction manual of wheel aligning system manufacturer. ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Wheel Alignment - Check & Adjust ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Wheel alignment consists of adjusting the angles of the wheels so that they are parallel to each other and perpendicular to the ground, thus maximizing tyre life and ensures straight and true tracking along a straight and level road.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Specification for Wheel Alignment Front Suspension ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21715.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "Front Suspension Steering Angle Parameters ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21716.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Wheel alignment procedure to be done in vehicle unladen condition only.* Do wheel alignment only according to manufacturer's specifications.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170079.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Notice",
+ "content": "Front tyre should have uniform wear and inflated to recommended pressure.* Ensure that hub play is correct.* Ensure that the front suspension fasteners are tightened to specified torque.* Ensure that there is no play in steering linkages and suspension ball joints.",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ },
+ {
+ "procedure_name": "Camber Adjustment",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Camber is defined as the inward or outward tilt of the top of the wheel as viewed from the front.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170110.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "While adjusting camber angle vehicle should be unladen and nobody should sit inside.* The camber values should be within: 0\u00e2\u0081\u00b0 \u00b1 0.2\u00e2\u0081\u00b0* The difference between two wheels should be within: 0\u00e2\u0081\u00b0\u00b1 0.4\u00e2\u0081\u00b0.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 24 mm socket spanner, loosen the camber bolt locking nut.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170080.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "While loosening hold the bolt with the help of a 24 mm ring spanner.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "To adjust camber angle, rotate the camber bolt using 24 mm ring/socket , to clockwise or anti clockwise direction. Clockwise rotation will reduce the camber angle and anti-clockwise rotation will increase the camber angle. ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170080.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "After adjusting camber angle tighten the camber bolt locking nut and recheck the camber angle.",
+ "file": null,
+ "display_order": 29
+ }
+ ]
+ },
+ {
+ "procedure_name": "Caster Adjustment",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "The angle between the vertical line and king pin, which fixes the steering knuckle and front axle, (steering column which connects the top and bottom ball joints in the independent axle type) when viewed the tyres from the side is called caster angle. ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170111.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "While adjusting caster angle vehicle should be unladen.* The values should be within: 4.2\u00b0 \u00b10.4\u00b0.* The difference between two wheels should be within: 0\u00b0 \u00b1 0.4\u00b0.* Adjust caster bolt until red zone becomes green. (Only if wheel alignment is out of specs).",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 24 mm socket spanner, loosen the caster bolt locking nut.",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170081.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 24 mm ring spanner.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "To adjust castor angle, rotate the caster bolt to clockwise or anti clockwise direction using 24 mm socket spanner. Clockwise rotation will decrease the caster angle and anti-clockwise rotation will increase the caster angle.",
+ "file": null,
+ "display_order": 36
+ }
+ ]
+ },
+ {
+ "procedure_name": "Toe-in Adjustment",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Toe is the difference of measured distances between the front ends of the tyres (A) and the rear ends of the tyres (B) along the same axle when viewed the wheels from the top.",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170112.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Front Toe In to be adjusted individually on LH and RH side tie rod ends.* Front Total toe between two wheels should be within: 0.23\u00e2\u0081\u00b0 \u00b1 0.1\u00e2\u0081\u00b0.* The difference between two wheels should be within: 0\u00b0 \u00b1 0.4\u00b0.",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 19 mm open end spanner, hold tie rod end first and then loosen tie rod end lock nut with the help of 19 mm open end spanner.",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170078.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 14 mm open end spanner, Toe-in is adjusted by varying the length of tie rods. ",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170077.jpg",
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "While adjusting toe-in, adjust the length of both the tie rods by rotating them in the same direction such that their lengths remain equal at all times.",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Perform steering angle sensor (SAS) calibration if steering wheel is removed and adjusted during straight ahead position setting and procedure as below.",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "After adjusting the length of tie rods, recheck toe in and then hold tie rod end with 19 mm open end spanner and then tightening locknut with 19 mm open end spanner. ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170079.jpg",
+ "display_order": 47
+ }
+ ]
+ },
+ {
+ "procedure_name": "Steering Angle",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Ensure the Steering Wheel is at center and the front wheels are straight.2. Connect the i-SMART diagnostic tester and turn the ignition ON .3. Launch i-SMART Select ABS ECU and Navigate to Write Data .4. Select the WRITE DATA tab.",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170207.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Click on \u201cROUTINE SELECTION\u201d drop down list and select \u201cSteering Angle Sensor Calibration \u00e2\u20ac' .",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Click on \u201cROUTINE SELECTION\u201d drop down list and select \u201cSteering Angle Sensor Calibration \u00e2\u20ac' .",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Click on \u201cROUTINE SELECTION\u201d drop down list and select \u201cSteering Angle Sensor Calibration \u00e2\u20ac' .",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Click on \u201cROUTINE SELECTION\u201d drop down list and select \u201cSteering Angle Sensor Calibration \u00e2\u20ac' .",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Click on \u201cROUTINE SELECTION\u201d drop down list and select \u201cSteering Angle Sensor Calibration \u00e2\u20ac' .",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170208.jpg",
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Click on \u201cSTART ROUTINE\u201d to initiate the SAS Calibration.",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170209.jpg",
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "Ensure the Steering Wheel is at center and the front wheels are straight.",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "The following pop up window appears once the SAS Calibration completed. Press \u201cOK\u201d button to complete SAS Calibration through i-SMART.",
+ "file": null,
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170210.jpg",
+ "display_order": 60
+ }
+ ]
+ },
+ {
+ "procedure_name": "Wheel Turning Angle",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Refer wheel alignment equipment manufacturer's guide lines for wheel turning angle check.",
+ "file": null,
+ "display_order": 61
+ }
+ ]
+ },
+ {
+ "procedure_name": "Ride Height",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Ride height is to be measured from wheel arch center (Bottom Surface) to ground for both front and rear in unladen condition. Front ride height : Front wheel arch center (Bottom Surface) to ground. Rear ride height : Rear wheel arch center (Bottom Surface) to ground.",
+ "file": null,
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170105.jpg",
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Heading",
+ "content": "Ride Heights of different variants ",
+ "file": null,
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21732.jpg",
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "R16 SF 6S - Rim Size 16, Side Facing 6 Seater.*FF 4S - Rim Size 16, Front Facing 4 Seater.*FF 4S - Rim Size 18, Front Facing 4 Seater",
+ "file": null,
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "Ensure below before Checking Ride heightCorrect Wheel alignment values.Recommended Tyre pressure.Fuel tank filled 90%.Spare Wheel mounted* If ride height is not within limits, then check (Measure ride heights only when the vehicle is on plain ground.)Correct tyre pressure.Coil spring damage.Loosened suspension mounting bolts.Rubber bushes of UCA and LCA.",
+ "file": null,
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21733.jpg",
+ "display_order": 68
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 133,
+ "sys_id": "THAR.AX-O-0007-Suspension",
+ "subsys_id": "THAR.AX-O-0007-Suspension-Ball Joint Checking",
+ "systems": "Suspension",
+ "sub_systems": "Ball Joint Checking",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170171.jpg",
+ "myid": 1248,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Ball Joint Checking-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Ball joint checking",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Prior to inspect the ball joint, inspect the wheel bearings for any play.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check 1 (On Vehicle)
Check 2 (On Vehicle) ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step 1",
+ "content_type": "Description",
+ "content": "Remove the wheel.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step 2",
+ "content_type": "Description",
+ "content": "Take a pry bar and place it between the lower control arm and the steering knuckle, the two parts that are connected together by the ball joint and attempt to pry them apart. ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step 2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170159.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step 3",
+ "content_type": "Description",
+ "content": "Loose ball joints will have an excessive amount of play and movement when you pry on them, may even make knocking or clicking sounds. ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step 1",
+ "content_type": "Heading",
+ "content": "Check 3 (On Vehicle) \u2014 Visual Inspection ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step 1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170172.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step 1",
+ "content_type": "Description",
+ "content": "Inspect the ball joints for any signs of rust, damage to the dust boot, grease leakage, or other potential problems that may indicate a need for replacement. ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step 2",
+ "content_type": "Description",
+ "content": "Check the looseness of ball joints in Control arms.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step 1",
+ "content_type": "Heading",
+ "content": "Check 4 (Off Vehicle) ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step 1",
+ "content_type": "Description",
+ "content": "Remove the Ball joints from Vehicle. Refer Respective Ball Joints R&R; Section.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step 2",
+ "content_type": "Description",
+ "content": "Check the ball joint for free rotational torque by rotate the ball pin through the periphery of ball joint cup for checking the movement. ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step 2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170173.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step 2",
+ "content_type": "Caution",
+ "content": "Replace the ball joint only if movement is found jerky during rotation.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step 3",
+ "content_type": "Description",
+ "content": "Check the Axial lift by holding the ball Joint and lifting the ball pin in upward direction.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step 3",
+ "content_type": "Caution",
+ "content": "If the play was observed more than 0.5 mm replace the ball joint.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step 3",
+ "content_type": "Notice",
+ "content": "Lift the ball pin by one hand & hold the lower end of ball joint grounded by other hand.",
+ "file": null,
+ "display_order": 25
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 141,
+ "sys_id": "THAR.AX-O-0007-Suspension",
+ "subsys_id": "THAR.AX-O-0007-Suspension-Rear Lower Link",
+ "systems": "Suspension",
+ "sub_systems": "Rear Lower Link",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170066.jpg",
+ "myid": 1256,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Rear Lower Link-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Rear Lower Link is used to provide articulation for rear suspension in vertical direction. It also supports the lower end of the axle. ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/VST-0074_Rear Suspension Rear lower Link Bushes Removal & Installation.mp4",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170066.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170030.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21794.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21795.jpg",
+ "display_order": 6
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 24 mm socket spanner loosen and remove the rear lower link front and rear mounting nuts and bolts.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170025.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque value: 230 \u00b1 20 NmFor additional information refer to Front Door Trim R &R; section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380076.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, unscrew glass channel mounting nuts and detach the run channel beading from the channel and take out the channel from door.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque :5\u00b11 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380042.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the door latch electrical connector.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380039.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the mounting link from latch to exterior door handle.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380074.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach link from the handle lever.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380043.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 5 mm Allen key, Unscrew the latch to door mounting Allen screws.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 7 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380046.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380047.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the front door latch assembly separately.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "7 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 21
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380047.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the latch assembly for any damage, replace if found.* Inspect the linkages for any damage or bend.",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 285,
+ "sys_id": "THAR.AX-O-0007-Mechanisms",
+ "subsys_id": "THAR.AX-O-0007-Mechanisms-Hood Catcher Both",
+ "systems": "Mechanisms",
+ "sub_systems": "Hood Catcher Both",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A380103.jpg",
+ "myid": 1398,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Hood Catcher Both-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380103.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12870.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12871.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370025.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Open the bonnet and lock it using bonnet stay rod.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250019.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250119.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove both side front splash shield mounting screw rivets.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250020.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250120.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove both front splash shields from vehicle .",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250032.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the front stone guard front mounting bolts.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250064.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen and remove the rear stone guard rear mounting bolts.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250033.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the stone guard mounting screw rivets.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250034.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the stone guard from the vehicle.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270025.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270083.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Disconnect the fog lamp electrical connectors LH & RH sides.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290002.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Pull and remove the front bumper top panel trim clips and remove the panel.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270025.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290004.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew front bumper mounting nuts.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290005.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "using a 13 mm socket spanner, Unscrew front bumper bottom mounting bolts.",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290006.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew front bumper top side mounting bolts.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290007.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front bumper top centre mounting screw rivets.",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290008.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Remove the front bumper assembly from the vehicle.",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290010.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, Unscrew front bumper center bracket mounting bolts and remove the front bumper center mounting bracket.",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Torque Value",
+ "content": "Torque : 10.0\u00b11 Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250060.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the front grill mounting screw rivets.",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290011.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the bottom side front grill mounting screw rivets.",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250061.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the front grill mounting bolts.",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250062.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Remove the front grill assembly from the vehicle.",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380106.jpg",
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380105.jpg",
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew hood catcher mounting nuts both the sides.",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Torque Value",
+ "content": "Torque : 7 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380104.jpg",
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Remove the hood catchers from the vehicle.",
+ "file": null,
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 60
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the hood catcher for any damages. Replace if found any",
+ "file": null,
+ "display_order": 61
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 278,
+ "sys_id": "THAR.AX-O-0007-Mechanisms",
+ "subsys_id": "THAR.AX-O-0007-Mechanisms-Front Door Glass Window Regulator",
+ "systems": "Mechanisms",
+ "sub_systems": "Front Door Glass Window Regulator",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A380032.jpg",
+ "myid": 1391,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Front Door Glass Window Regulator-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380032.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/50027.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/50028.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Front Door Window Glass. For additional information refer to Front Door Window Glass R &R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380033.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect the front door window glass motor electrical connector.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380034.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the front door window glass mechanism to door mounting nuts.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 10.50 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380035.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380036.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the front door window glass mechanism separately.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 13
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the glass for any damage. Replace if found.For additional information refer to Tail Door Trim R &R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380063.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380064.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a star screw drive, unscrew tail door handle top mounting screw and remove the cover.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380083.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380065.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Carefully pull and detach the outer door handle from tail door.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380062.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a star screw driver, unscrew handle inside support mounting screw from the tail gate.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 1.3 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the rear door exterior handle for any damages. Replace if found any.",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 282,
+ "sys_id": "THAR.AX-O-0007-Mechanisms",
+ "subsys_id": "THAR.AX-O-0007-Mechanisms-Bonnet Cable",
+ "systems": "Mechanisms",
+ "sub_systems": "Bonnet Cable",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A380066.jpg",
+ "myid": 1395,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Bonnet Cable-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380066.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12839.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12840.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380075.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Pull out the bonnet latch cable and open the bonnet.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370025.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Lock it using bonnet stay rod.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380068.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect cable guide and link from latch.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380067.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach cable from routing clips.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380112.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380069.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380070.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Press the lock and pull lever to detach bonnet cable lever with cable and take out the cable from the vehicle.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the latch assembly for any damage, replace if found.",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 281,
+ "sys_id": "THAR.AX-O-0007-Mechanisms",
+ "subsys_id": "THAR.AX-O-0007-Mechanisms-Tail Door Latch",
+ "systems": "Mechanisms",
+ "sub_systems": "Tail Door Latch",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A380051.jpg",
+ "myid": 1394,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Tail Door Latch-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380051.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12828.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12829.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove Tail Door Trim. For additional information refer to Tail Door Trim R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "For Softtop Variants,
For additional information refer to Tail Door Inner Handle - R &R Section. Torque : 7 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380055.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380056.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully detach tail door latch.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the latch assembly for any damage, replace if found.",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 279,
+ "sys_id": "THAR.AX-O-0007-Mechanisms",
+ "subsys_id": "THAR.AX-O-0007-Mechanisms-Front Door Glass Window Regulator Motor",
+ "systems": "Mechanisms",
+ "sub_systems": "Front Door Glass Window Regulator Motor",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A380079.jpg",
+ "myid": 1392,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Front Door Glass Window Regulator Motor-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380079.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12809.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12810.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Front Door Window Glass Regulator LH. For additional information refer to Front Door Window Glass regulator LH R &R; section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380110.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380081.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a T20 torx socket spanner, unscrew the regulator motor mounting screws.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Torque Value",
+ "content": "Torque : 2.5 to 3 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 9
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the glass for any damage. Replace if found.
Inspect the regulator for any damages, Replace if found any.
",
+ "file": null,
+ "display_order": 10
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 283,
+ "sys_id": "THAR.AX-O-0007-Mechanisms",
+ "subsys_id": "THAR.AX-O-0007-Mechanisms-Bonnet Latch",
+ "systems": "Mechanisms",
+ "sub_systems": "Bonnet Latch",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A380071.jpg",
+ "myid": 1396,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.AX-O-0007-Bonnet Latch-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380071.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12851.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12852.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Intercooler Assembly.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.AX-O-0007,1000,1504",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380068.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect cable guide and link from latch.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380072.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, unscrew bonnet latch mounting nuts.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque : 10.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380073.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the bonnet latch from hood.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380109.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "While Installation, hand tighten the latch mounting nuts first and align the latch in appropriate position
Ensure smooth locking of latch in holding bracket , finally torque tighten the mounting nuts.
",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the bonnet latch for any damage, replace if found.",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ "StepCount": 10377,
+ "TotalCount": 12623
+ },
+ {
+ "Variant": {
+ "name": "THAR.LX-0008",
+ "variant": "THAR.LX",
+ "vehicle": "THAR",
+ "family_code": "J10",
+ "vehicle_segment": "Personal",
+ "fuel": "GSL",
+ "transmission": "MT",
+ "drive": "4WD",
+ "active_status": true,
+ "kms_mapping_active_status": true,
+ "Assets": [],
+ "Systems": [
+ {
+ "systemdisplayorder": 266,
+ "sys_id": "THAR.LX-0008-en-SM-Doors, Bonnet & Tail Gate",
+ "system_name": "Doors, Bonnet & Tail Gate",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1025,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 270,
+ "sys_id": "THAR.LX-0008-Doors, Bonnet & Tail Gate",
+ "subsys_id": "THAR.LX-0008-Doors, Bonnet & Tail Gate-Bonnet",
+ "systems": "Doors, Bonnet & Tail Gate",
+ "sub_systems": "Bonnet",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A260051.jpg",
+ "myid": 1383,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Bonnet-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260051.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16737.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/16738.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the wiper washer nozzles. For additional information refer to the Wiper Washer Nozzle Front - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the stay rod. For additional information refer to the Stay Rod - R&R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280052.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the wiper hose routing clips from the bonnet. Remove the bonnet rubber beading from the bonnet. Using 12 mm socket spanner, loosen and remove the bonnet catcher bracket mounting bolts (Both sides). Torque : 13.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260054.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260053.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using T40 socket spanner, loosen and remove the bonnet mounting bolts. Torque : 24\u00b14 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260061.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the bonnet from the vehicle. Install in the reverse order of removal. Inspect the bonnet hinges for any crack or damage. Replace if found. Remove Side window RH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Remove Side window LH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Unzip the tail gate window, detach the tail gate bar locking from rear RH & LH belt rails remove the tailgate window. Unhook the \u2018C\u2019 pillar cover from rear RH & LH belt rails and fold the cover at top of the soft top. Using a T30 socket spanner, loosen and remove the belt rear rail Mounting bolts and remove the belt rail from the vehicle. Follow the same procedure for LH side. Remove the seal from the body. Install in the reverse order of removal. Inspect the tail door half seal for any damage or wears. Replace if found any. For additional information refer to Front Door Trim RH- R&R Section. ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260122.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Detach the key handle lever from the key lock set. Detach lock holding bracket and remove key lock from the vehicle. Install in the reverse order of removal. For additional information refer to Front Door Trim RH- R&R Section. ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260129.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Detach the key handle lever from the key lock set. Detach lock holding bracket and remove key lock from the tail door. Install in the reverse order of removal. Remove Glove Box Assembly. Using Screw driver, remove Glove box Latch mounting screws and remove the latch from the glove box. Using Screw driver, Remove Lock from Latch by pressing lock locking clips. Install in the reverse order of removal. Using vehicle key open the fuel filler door. Using Screw driver, detach lock holding bracket and remove key lock from the fuel lid door. Install in the reverse order of removal. Inspect the key locks for any damage or wears. Replace if found any. Pull the door outer handle and slowly close the door with outer door handle pulled in condition. Check and feel for the condition of latch fouling with striker. If the latch fouling with the striker then loosen the striker mounting screws and align the striker so that there is no fouling. Tighten the striker mounting screws to specific torque Torque : 23.5 \u00b1 2.5 ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "Ensure that door closing should be smooth and latch is not foul on the striker Follow the same procedure for other doors. Lift and open the tail gate glass. Using a screw driver carefully lift and open the gas strut lock at both the ends. Carefully remove tail gate glass gas strut. Install in the reverse order of removal. Inspect the gas strut assembly for any damage, replace if found. For additional information refer to the Tail Door Trim- R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260030.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the tail door electrical connector and remove the wiring routing clips from the tail door. Using a screws driver, loosen and remove the mounting screws from the hinges. Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260018.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, loosen and remove the stopper mounting bolt from the Body. Torque : 23.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260119.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the hinge mounting bolts inside tail door. Torque : 50\u00b15 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260033.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Ensure to hold the tail door with spare wheel properly while remove, failing will lead door falling down which may lead to personal injuries. Using 12 mm socket spanner, loosen and remove the Hinge Mounting bolts from body. Torque :27\u00b14 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the tail door hinges for any physical damage, replace if found. Lower the window glass to prevent from damage. Disconnect door accessory electrical connector. Protect the electrical connectors to avoid water entry, which may leads to short circuit. Detach the wiring harness bunch from holding bracket \u2018A\u2019 Pillar end. Using 12 mm socket spanner, Unscrew door stopper mounting bolts BIW end. Using T40 Torx Socket, Unscrew door hinge pin at bottom of the hinge. Carefully lift and remove the door assembly from vehicle. Refit in the reverse order of removal. Key IN Reminder & Park Lamp Reminder will not function in case of driver door is removed. Roof lamp will not work with respect to door status Lock & Unlock functions will not work through Master Actuator in case of driver door is removed Hinge pin can break if overtightened during door reinstall \u2014 Max. Torque 10 Nm. Doors are heavy, Take at most care when removing the doors, Failing to this may cause personal injury After Door removal vehicle will be left with only IRVM (as ORVM\u2019s fitted on doors) In such scenario driving the vehicle on road is not permitted as per regulations. Do not drive your vehicle on public roads with the doors removed as you will lose the protection they can provide. This procedure is furnished for use during off-road operation only All occupants must wear seat belts during off-road operation with doors removed. Disconnect the Door wiring harness electrical connector and detach WH bunch from \u2018A\u2019 pillar lower. Using 12 mm socket spanner, Unscrew door stopper mounting bolt BIW side. Torque : 23.5 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260006.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew door hinge mounting bolts from body. Torque : 50 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260041.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the door assembly from vehicle. Support the door while removing the bolts. Using star screw driver , Unscrew door hinge mounting screw door end. Torque : 24\u00b1 4.0 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Before tightening the bolts align the door assembly correctly, else door operation won\u2019t be smooth.. Refit in the reverse order of removal. Do the door alignment, if required. Inspect the door hinge for any damage. Replace if required. Disconnect the demister electrical connectors. Using 4 mm Allen key, Unscrew glass hinge mounting screws. Torque : 2.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260077.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260076.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260118.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using the screw driver Unlock the strut to detach the strut and remove the glass. Ensure to hold the Rear Windshield glass while detach the struts, failing to hold leads to glass falling. Using 10 mm socket spanner, Unscrew strut bracket mounting bolts from glass. Torque : 5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Ensure not to over tigthen the strut bracket mounting bolts while Installation. Remove strut mounting grommet and cap nuts from the glass. Install in the reverse order of removal. Inspect the rear windshield glass for any damage or wears. Replace if found any. Remove the spare wheel carrier. For additional information refer to the Tail Door Trim - R&R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the tail door latch. For additional information refer to the Tail Door Inner Handle - R&R section. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the tail door outer handle . For additional information refer to the tail door Stopper section. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the tail door lock. For additional information refer to the Tail Door Lock section. ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the tail door weather strip from the tail door. Remove the tail door electrical connector and remove the wiring routing clips from the tail door. Using a Screws driver, loosen and remove the mounting screws from the hinges. Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260018.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, loosen and remove the Stopper Mounting bolt from the Body. Torque : 50\u00b15 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260119.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, loosen and remove the hinge mounting bolts inside tail door. Torque : 50\u00b15 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260016.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Remove the tail door from vehicle. Install in the reverse order of removal. Inspect the tail door for any physical damage, replace if found Remove the hard top assembly. Remove the seal from the body. Install in the reverse order of removal. Inspect the tail door half seal for any damage or wears. Replace if found any Remove the scuttle grill. Using T40 socket spanner, loosen and remove the bonnet mounting bolts. Torque : 24\u00b14 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260058.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the bonnet hinge mounting bolts from the body and detach hinge. Torque : 24\u00b14 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260055.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the hood hinge from the bonnet. Install in the reverse order of removal. Inspect the bonnet hinges for any crack or damage. Replace if found. Remove Front LH wheel Hub. For additional information refer to Front LH wheel Hub \u2014 R&R section. Remove Front Stabilizer Bar. For additional information refer to Front Stabilizer Bar \u2014 R&R section. Using 10 mm socket spanner, Unscrew front LH wheel speed sensor mounting bolt and remove the sensor. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the wheel speed sensor routing clips from the upper control arm. Using cutting plier, remove upper arm ball joint cotter pin. Never reuse the cotter pin, always replace with a new one. Using 24 mm socket spanner, unscrew upper arm ball joint mounting nut. Torque : 90 \u2013 110 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Using suitable lever, partially detach the knuckle and remove the drive shaft. Pull the drive shaft downwards and remove it. Install in the reverse order of removal. Move the joint up, down, left, right, and in axial direction. Check for any rough movement or significant looseness. Check the drive shaft boot for cracks or other damage, and for grease leakage. If damaged, disassemble the drive shaft to verify the damage, repair or replace if necessary. Check the splines for wear and tear. Drain the front differential oil. For additional information refer to Front differential oil draining and filling procedure. For additional information refer to Front LH wheel Hub \u2014 R &R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove Front Stabilizer Bar. For additional information refer to Front Stabilizer Bar \u2014 R &R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front RH wheel speed sensor mounting bolt and remove the sensor. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the wheel speed sensor from routing bracket. Using cutting plier, remove upper arm ball joint cotter pin. Never reuse the cotter pin, always replace with a new one. Using 24 mm socket spanner, unscrew upper ball joint mounting nut. Torque : 90 \u2013 110 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Remove E-Disconnect stone guard. For additional information refer to E-Disconnect stone guard \u2013 R &R; section. Disconnect E \u2013 Disconnect electric connector. Provide a jack to support front axle. Using 19 mm socket spanner, unscrew front axle mounting bolts and partially down the axle. Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150037.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using suitable lever partially detach the knuckle and remove the drive shaft. Pull the drive shaft downwards and remove it. Install in the reverse order of removal. Refill the front axle oil upto Max level. For additional information refer to Front differential oil draining and filling procedure.
2. Check the drive shaft boot for cracks or other damage, and for grease leakage.
3. If damaged, disassemble the drive shaft to verify the damage, repair or replace if necessary.
4. Check the splines for wear and tear.
",
+ "file": null,
+ "display_order": 35
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 108,
+ "sys_id": "THAR.LX-0008-Front Axle",
+ "subsys_id": "THAR.LX-0008-Front Axle-Front Axle Drive Shaft LH Needle Bearing",
+ "systems": "Front Axle",
+ "sub_systems": "Front Axle Drive Shaft LH Needle Bearing",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A150263.jpg",
+ "myid": 1226,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Front Axle Drive Shaft LH Needle Bearing-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150263.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12110.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12111.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove Front LH drive shaft. Using 10 mm socket spanner, Unscrew electric disconnect housing mounting bolts Replace the Inboard Oil Seal once removed. Remove E-Disconnect stone guard. For additional information refer to E-Disconnect stone guard \u2013 R &R; section. Disconnect E \u2013 Disconnect electric connector. Using 10 mm socket spanner, Unscrew electric disconnect housing mounting bolts and Carefully remove the E-Disconnect Housing with Fork . Torque : 17\u00b12 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150265.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using circlip plier remove the intermediate shaft circlip from housing. Tool should not damage the splines on the axle shaft this affects disconnect operation. Pull out the axle shaft from wheel end side of e-disconnect housing. Using MST 0502AUA0008ST Front Axle Tube Needle Bearing Puller, remove the Needle bearing from e-disconnect housing LH side. By using MST 0502AUA0007ST - F Axle Tube Needle Bearing Dolly, Install the LH Side needle bearing In the disconnect housing. Clean and Insert the axle shaft through wheel end side of the disconnect housing. Align the shifter sleeve on the intermediate shift through disconnect housing window and Install the circlip on the axle shaft with the help of circlip tool. Ensure there should not be excessive play between two shafts this affects the disconnect. Install the new cover gasket while locating in the dowel on the disconnect housing. Ensure to use New Gasket while Installation. Ensure the cleanliness of disconnect housing cover face and cover resting face. Do not bent the wrap the Gasket while installing. Gasket orientation is fixed by dowel on the disconnect housing hence it will fit in one direction only. Bent or warped cover gasket may lead to leak during running. Locate the disconnect cover on the dowel and install the bolts. Tighten the mounting bolts to specified torque value. Ensure to use New bolts while Installation. Apply locktite sealant on the bolts while installing, this avoid the leakthrough cover. Torque : 17\u00b12 Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Connect e-Disconnect electrical connector. For additional information refer to E-Disconnect stone guard \u2013 R&R section. ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, refit the Oil seal on the housing. Refit Front LH drive shaft. Inspect the Front axle Tube Needle Bearing for any damage, Replace if necessary Remove Front RH drive shaft. Position the Special tool support piece inside the axle housing and using MST 0502AUA0002ST Front Axle Shaft Inboard Oil Seal Puller, remove the Oil seal from the housing. Replace the Inboard Oil Seal once removed. Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, refit the Oil seal on the housing. Refit Front RH drive shaft. Inspect the axle shaft Inboard Oil Seal for any damage, Replace if necessary. Remove Front LH drive shaft. Remove Front LH drive shaft. Using MST 0502AUA0002ST Front Axle Shaft Inboard Oil Seal Puller, remove the Oil seal from the housing. Replace the Inboard Oil Seal once removed. Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, refit the Oil seal on the housing. Refit Front LH drive shaft. Inspect the axle shaft Inboard Oil Seal for any damage, Replace if necessary. Using 8 mm socket spanner, Unscrew front propeller shaft mounting bolts/nuts at front axle end. Torque : 19\u00b13 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Front LH drive shaft. For additional information refer to Front differential oil draining and filling procedure. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove Front RH Wheel Hub. Using 10 mm socket spanner, Unscrew front RH wheel speed sensor mounting bolt and remove the sensor. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Detach the wheel speed sensor from routing bracket. Using cutting plier, Remove upper arm ball joint cotter pin. Never reuse the cotter pin, always replace with a new one. Using 24 mm socket spanner, unscrew upper arm ball joint mounting nut and remove the ball joint. Torque tightening should be done without load and with the tyres on level ground. Torque : 90 \u2013 110 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove E-Disconnect stone guard. For additional information refer to E-Disconnect stone guard \u2013 R&R section. ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Disconnect E \u2013 Disconnect electric connector. Provide a jack to support front axle. Using 19 mm socket spanner, unscrew front axle mounting bolts and partially remove the axle downwards. Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Partially detach the knuckle an remove the drive shaft by using a suitable lever. Pull the drive shaft downwards and remove it. Remove the front axle assembly from Vehicle. Install in the reverse order of removal. For additional information refer to Front differential oil draining and filling procedure. ",
+ "file": null,
+ "display_order": 39
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the axle shaft for straightness, cracks, damage, wear or distortion, replace it if necessary. Check the axle case for yield, deformation or cracks, replace if necessary. Inspect front axle for any oil leakage, seepage. Drain the Front Differential Oil. For additional information refer to Front differential oil draining and filling procedure. Remove the Front Axle Assembly. Mount the Front Axle Assembly on a suitable stand. Using 15 mm socket spanner, Unscrew front axle RH bracket mounting bolts and remove the RH bracket. Using 13 mm socket spanner, Unscrew differential assembly cover bolts and remove the cover. Clean the sealant on cover & banjo housing. Liquid sealant is used to seal cover with banjo beam. Scrap the sealant and clean the cover and banjo surfaces. Using 10 mm socket spanner, Unscrew e-disconnect cover assembly mounting bolts and remove the cover with shifter fork & motor. Using 10 mm socket spanner, Unscrew e-disconnect motor mounting bolts and remove the e-disconnect motor. Hit the shift shaft on suitable block and remove the shift shaft, shaft fork & spring from the disconnect cover. Using MST 0502AUA0002ST - Front Axle Shaft Inboard Oil Seal Puller, remove housing LH Oil seal. Replace the Inboard Oil Seal once removed. Position the Special tool support piece inside the axle housing and using MST 0502AUA0002ST Front Axle Shaft Inboard Oil Seal Puller, remove the RH Oil seal from the housing. Using circlip plier remove the intermediate shaft circlip from housing. Tool should not damage the splines on the axle shaft this affects disconnect operation. Pull out the axle shaft from wheel end side of e-disconnect housing. Remove the shifter shaft thrust washers from e-disconnect housing. Remove the shifter sleeve from edisconnect housing. Using MST 0502AUA0008ST Front Axle Tube Needle Bearing Puller, Needle bearing from e-disconnect housing LH side. Remove LH Side differential shaft from the housing wheel end side. Using 16 mm socket spanner, Remove the Differential bearing caps mounting bolts. Remove the Differential bearing caps. Identification marks are punched on bearing cap; this is to ensure correct bearing cap is installed on correct side. Ensure correct bearing caps used While reassembly. Mount MST 0502AUA0030ST Front Axle Expander on carrier and Spread carrier by rotating nut on expander. Do not spread more than 0.5 mm. Using MST 0502AAA0001ST - Tommy Bars-X, Pry out differential case from carrier. Remove the expander from housing. Mount the MST 0502AUA0023ST \u2014 Front Axle Diff Case Bearing Puller Adapter and Using MST 0502AUA0012ST \u2014 Axle Bearing Puller on side bearing cone and remove the bearing from differential case assembly. Identify shims and side bearings on both sides, they are not to be interchanged during assembly. Similarly remove ring gear other side bearing cone by using MST 0502AUA0023ST \u2014 Front Axle Diff Case Bearing Puller Adapter and MST 0502AUA0012ST \u2014Axle Bearing Puller. Identify shims and side bearings on both sides, they are not to be interchanged during assembly. Using 17 mm socket spanner, Remove the ring gear mounting bolts and remove the ring gear. If require tap ring gear by mallet to remove the ring gear. By Using MST 0502AUA0033ST \u2014 Front Axle Diff Case Pin Remover & Installer and hammer, remove the roll pin retaining the cross shaft. Using suitable punch & hammer, remove the cross pin from case. To remove side gears and pinion mate gears, rotate the side gears, this will allow the pinion mate gears to turn to opening of the case. Remove pinion mate gears and spherical washers behind the gears. Lift out the side gears and thrust washers. Using MST 203 - Wrench Universal Joint Flange Holding tool hold the companion flange and remove the pinion nut and washer using 30 mm socket spanner from the differential housing. Using mallet tap and remove the companion flange along with dust cover. If not able to remove the companion flange tapping by mallet, use suitable 2 Jaw puller for removal. If companion flange shows wear in the area of seal contact, it should be replaced. Using a mallet, tap the pinion assembly and remove the pinion assembly from the differential housing. Make a centre punch and tap at top of the pinion assembly by using a mallet. Hold the pinion with hand to avoid falling. Gear teeth have sharp edges. Handle gears carefully to avoid injury Discard collapsible washer. Remove the Pinion Oil seal By using Screw driver/ Oil Seal Puller. Remove the slinger and outer bearing. Turn Carrier and Using MST 0502AUA0028ST Front Axle Pinion Inner Bearing Cone Remove Adapter and MST 0502AUA0032ST Front Axle Universal Handle, Remove the Inner Pinion bearing cone. Turn Carrier and Using MST 0502AUA0029ST \u2014 Front Axle Pinion outer Bearing Cone Remove Adapter and MST 0502AUA0032ST \u2014 Front Axle Universal Handle, Remove the outer Pinion bearing cone. Using the MST 0502AUA0022ST Front Axle Pinion Inner Bearing Puller Adapter and MST 0502AUA0012ST Axle Bearing Puller, Remove the Pinion Inner Bearing. Take out the pinion shims from the pinion. Using MST 0502AUA0006ST Front Axle Tube Cyl Roller Bearing Puller, Remove the Cylindrical roller bearing from disconnect housing. Inspect all bearings and races for pitting or uneven wear. The inner carrier bearing races should not spin on the carrier journals. The carrier races should fit snugly in the differential housing. Inspect the carrier race bores for grooves from spinning races. The side gear bores inside the carrier should not have any abnormal wear. Inspect all gear teeth for pitting, chips, breaks, and for signs of uneven wear and overheating. Inspect the axles for pitted, grooved or dull and rough bearing surfaces. Inspect gear teeth of side gears and pinion mate gears for wear and cracks. Inspect external teeth of side gears for wear & cracks. Inspect cross pin for excessive wear. Replace if necessary. If replacement of one gear is required, then both side gears, pinion mate gears and washers have to be replaced. Always replace gears as a complete set, do not mix new gears with old gears, as this may cause uneven wear and short gear life. Ring gear and pinion is supplied as a set. They are matched with each other during service. Matching numbers on both pinion and ring gear are etched for verification. Refer illustration shown below for more clarity. If a new gear set is used, verify numbers on pinion and ring for matching before proceeding with assembly. Standard mounting distance from centre line of ring gear to back face of pinion is 103.5 \u00b1 0.1 mm. This dimension is controlled by selecting shims, which are positioned between the inner pinion bearing cone and pinion gear. Best running position of gear set is achieved by proper shim selection. This dimension for front live axle will be different. On the bottom face of pinion, a number is etched. It can be a plus (+) number, a minus (-) number or Zero (0). Required pinion shim selection is achieved with help of this number. If alphabet 'm' appears on pinion face shim, selection has to be done in mm (Metric). If alphabet 'm' does not appear on pinion face, shim selection has to be done in inches (English). Shims with different thicknesses are available for selection. Use tables shown below for selecting correct thickness of shims either for addition or for subtraction from old shim pack. Ring and pinion etched with inch identification. Refer Table A. Ring and pinion etched with metric identification. Refer Table B. Observe the marking on pinion. If \u2018m\u2019 is found etched on the face, refer table B. If not refer table A. Pinion Position shims selection can be done using MST\u2019s Pinion Height Master Block & Pinion Height Setting Gauge, in the absence of removed Ring/Pinion gear or Old shim not available. Ring and pinion etched with inch identification. Refer Table A. Ring and pinion etched with metric identification. Refer Table B. Position the MST 0502AUA0010ST - Front Axle Pinion Height Master Block on the pinion inner bearing setting area. Fix the dial gauge on MST 0502AUA0009ST Front Axle Pinion Height Setting Gauge and set dial gauge to zero reading on surface plate. Place the MST 0502AUA0009ST Front Axle Pinion Height Setting Gauge with Dial gauge on differential housing as shown. Rock the MST 0502AUA0009ST Front Axle Pinion Height Setting Gauge and load the Dial gauge on MST 0502AUA0010ST - Front Axle Pinion Height Master Block and measure the reading on Dial Gauge (X mm). Say X mm for example which is measured by using special tool - 0.79 mm (i.e X = 0.79 mm) Convert mm to thau, i.e (0.79*39) = 31 Thau Then see the Pinion off set i.e (+ 2) Thou (For example) Final shim size = 31 - 2 = 29 Thau Convert to mm = 29*0.0254 = 0.74 mm If Pinion offset is Positive (+), then subtract the pinion offset value. If Pinion offset is Negative (-), then add the pinion offset value. Using MST 0502AUA0026ST Front Axle Pinion Inner Bearing Cone Press Dolly and MST 0502AUA0032ST Front Axle Universal Handle, refit the pinion inner bearing cone into carrier housing. Using MST 0502AUA0027ST - Front Axle Pinion Outer Bearing Cone Press Dolly and MST 0502AUA0032ST - Front Axle Universal Handle, refit pinion outer bearing cone into carrier housing. Place shims selected as per Shim Selection procedure on pinion gear. Using MST 0502AUA0025ST Front Axle Pinion Inner Bearing Press Dolly, Install pinion inner bearing cone. Take care to avoid damaging the pinion teeth while installing the bearing. Place the Pinion outer Bearing cone and slinger into housing. Using MST - 0502AUA0031ST Front Axle Pinion Oil Seal Installer, Install the New pinion seal into housing. Ensure to replace New Oil seal while Install. Apply a light coat of oil to the lip of oil seal. Install a new collapsible spacer into pinion shaft. Collapsible spacer should rest on bearing inner race and pinion shoulder and it can be fitted in any one direction. Assemble the Pinion into differential housing. Install the end yoke, washer and new pinion mounting nut. Hold the end yoke using (MST203 - Companion Flange Holding Tool) and torque tighten the mounting nut. Tighten nut to Initial torque as 217 Nm. Measure the Pinion Rotational Torque (PTTR), It should be within 17 \u2013 34 Kgf\u2013cm (1.7 to 3.3 Nm) If measured Pinion Rotational Torque (PTTR) not within (1.7 to 3.3 Nm), Then tighten nut to incremental torque from 217 Nm onwards to 678 Nm until specified PTTR ( Pinion torque to rotate) is achieved Excessive care must be taken during bearing preload torque adjustment. Do not over tighten, loosen and then retighten nut. Do not exceed specified bearing preload torque Measure and ensure the Final Pinion Rotational Torque (PTTR), It should be within 17 \u2013 34 Kgf\u2013cm (1.7 - 3.3 Nm) PTTR SPEC : 17 \u2013 34 Kgf\u2013 cm (1.7 to 3.3Nm) If preload torque is exceeded, a new collapsible spacer must be installed and torquing sequence as above to be repeated If only oil seal needs to be changed, measure rotating torque of pinion with the help torque measuring tool. In this case use new collapsible spacer and keep same rotational torque of pinion as before. Apply grease to new side gear thrust washers and hubs of side gears. Assemble both side gears. Apply grease to new pinion spherical washers, and pinion mate gears. Assemble pinion mate gears. Assemble both side gears and thrust washers, hold them in place with one hand and then assemble the pinion mate gears with thrust washer to hold the side gears in place An easy way to assemble the side gears and pinion mate gears is to have all parts lubricated before assembly Always replace gears as a complete set. Do not mix new gears with old gears, as this may cause uneven wear and shorter gear life Rotate the side gears until the holes of the spherical washers and pinion mate gears line up with the holes in the case by the help of engaging the splines of axle shaft to side gears. When both the cross bore hole matched and insert the differential shaft Use MST 0502AUA0033ST Front Axle Differential Case Pin Remover and Installer to line holes of the gears up with case Assemble differential shaft and pull out MST. Be sure vertical lock pin hole is lined up with that of the case, and that pinion mate washers are in place and lined up with gear and case. Align the differential shaft hole, insert the lock pin and fix using (0502AUA0033ST - Differential gear lock pin removal tool)and hammer. Always replace with new Lock pin while Installation. When roll pin bottoms out, stake (peen) metal of case over pin in two places, 180 degrees apart. Assemble MST 0502AUA0011ST Front Axle Dummy Bearings on to differential case as shown in the illustration. Assemble the differential case with Dummy Bearings on housing (Without Ring Gear). Mount the magnetic dial indicator with magnetic base, locate its tip on that surface of case. Force differential assembly to the extreme in the direction towards indicator, With force still applied set indicator to 0.00. Force differential assembly to the extreme end in opposite direction. Repeat above steps until the same reading is obtained, Record reading in the format given as 'A'. Remove dummy bearing and keep aside. Assemble ring gear to the differential case using mounting bolts. Tighten the bolts to specified torque value in recommended sequence. Torque : 95 - 122 Nm ",
+ "file": null,
+ "display_order": 215
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Notice",
+ "content": "Always use new ring gear bolts. Assemble MST 0502AUA0011ST Front Axle Dummy Bearings on differential case as shown in the illustration. Position differential assembly into housing and Mount the magnetic base dial indicator on housing and locate the tip of indicator on the surface of one of the ring gear screws. Force differential case assembly away from pinion gear. With force still applied set indicator to zero. Force differential case assembly and ring gear to mesh with pinion gear. Rock the ring gear to allow teeth to mesh, Repeat to obtain the reading and continue the procedure until the same reading is obtained. Record reading in the format given as' B'. Remove dial indicator and dummy differential bearings from differential housing. Calculate the Ring Gear Backlash & Differential Bearing Preload shims based on below calculation. Install the selected shim pack in between side bearing and carrier assembly. Using MST 0502AUA0024ST Front Axle Differential Case Bearing Dolly, Install side bearing cone on hub of differential assembly. It is always preferred to replace side bearings once pulled out. But one can confirm free rolling of bearings and reuse it, if they are defect free. Install the selected shim pack in between other side bearing and carrier assembly. Using MST 0502AUA0024ST Front Axle Differential Case Bearing Dolly, Install other side bearing cone on hub of differential assembly. It is always preferred to replace side bearings once pulled out. But one can confirm free rolling of bearings and reuse it, if they are defect free. Install spreader and dial indicator and expand the carrier. Never expand the differential housing over 0.5 mm to avoid distortion. Remove dial indicator from the differential housing. Install differential case assembly into carrier with the help of mallet. Ensure differential case shim is behind the bearing cap. Carelessness while installing differential case assembly may result in injury. Position the bearing caps and install the mounting bolts and torque tighten the bolts to specified torque. Torque : 47 - 68 Nm ",
+ "file": null,
+ "display_order": 250
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "Notice",
+ "content": "Ensure correct fitment of caps by matching letters on caps and carrier on either side. Remove the expander from differential housing. Check ring gear and pinion backlash at three equally spaced points with dial indicator. Backlash tolerance is 0.13 to 0.20 mm and should not vary more than 0.08 mm between the three points checked. Fix the Dial Gauge on Housing, Set the Dial Indicator 0 on Ring gear teeth as shown. Hold the pinion flange at the bottom side. Rotate the ring gear by using ring spanner & measure the backlash. High backlash is corrected by moving ring gear closer to pinion. Low backlash is corrected by moving ring gear away from pinion. These corrections are made by switching shims from one side of differential case to other. If backlash is as per specification, check ring gear and pinion tooth contact pattern. Interpretation of Contact Pattern The TOE of the gear is the portion of the tooth surface at the end towards the centre. The HEEL of the gear tooth is the portion of the tooth surface at the outer end. The TOP LAND of a gear tooth is the surface of the top of the tooth. Every gear has a characteristic pattern. Measure and ensure the Final Total Torque To Rotate (TTTR) at pinion nut, It should be within 28 - 51 Kgf-cm (2.8 - 5 Nm). TTTR SPEC : 28 - 51 Kgf-cm (2.8 - 5 Nm). Using MST 0502AUA0005ST Front Axle Tube Cyl Roller Bearing Dolly, Install the RH housing cylindrical roller bearing through the oil seal bore In the housing. Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, Install the RH side housing Oil seal. Clean the intermediate shaft and insert the shims in intermediate shaft. Push intermediate shaft in same way the direction used during removal. Install the synthetic bush in the bore of axle shaft with the help of light nylon mallet. Press force must not so high which may damage the bush during pressing. Insert the thrust washers in the sequence opposite to removal in the disconnect housing. Insert the axle shaft through wheel end side of the disconnect housing. Install the circlip on the axle shaft with the help of circlip pressing tool. Check end play with dial gauge at the axle shaft end. End play should be 0.025 to 0.1 mm. End play can be adjusted by adding/ deleting shims from the intermediate shaft. After adjusting end play, remove the circlip & axle shaft from the housing. Install the shifter sleeve on the intermediate shift through disconnect housing window while aligning with the splines on it. shift splines and shifter sleeve must be free from foreign particles and burr Insert the axle shaft through wheel end side of the disconnect housing. Install the circlip on the axle shaft with the help of circlip pressing tool. Ensure there should not be excessive play between two shafts this affects the disconnect. Insert the spring and shaft fork through the disconnect cover window while aligning the spring into bore in the cover and sitting in the slit of shift fork. Insert the shaft shift fork in the opposite way of removal ensuring that it passing through shift fork as well as spring. Orientation of the shift fork is important and it should be in same way while was removing. Ensure old spring is discarded and to use spring during installation. Ensure cleanliness of the disconnect housing cover, shift fork shaft , shift fork and spring. Press the shaft shift fork in the bore by hand. Install the new cover gasket while locating in the dowel on the disconnect housing. Ensure to use New Gasket while Installation. Ensure the cleanliness of disconnect housing cover face and cover resting face. Do not bent the wrap the Gasket while installing. Gasket orientation is fixed by dowel on the disconnect housing hence it will fit in one direction only. Bent or warped cover gasket may lead to leak during running. Locate the disconnect cover on the dowel and install the bolts. Tighten the mounting bolts to specified torque value. Torque : 17\u00b12 Nm. Ensure to use New bolts while Installation. Apply locktite sealant on the bolts while installing, this avoid the leak through cover. Install the electrical motor on the cover assembly and tighten the screw with specified torque. Torque : 12.5\u00b13.5 Nm. Ensure that the 'O' ring on the electrical motor is not cracked or damaged if so replace the 'O' ring as new one. By using MST 0502AUA0007ST - F Axle Tube Needle Bearing Dolly, Install the LH Side needle bearing In the disconnect housing. By using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, Install the housing LH side Oil seal. Apply the uniform sealant bid along the carrier cover face and avoiding the bolt holes as far as possible. Use Anabond A-676 or 3M sealant on the cover plate. Ensure the cleanliness of the carrier cover face before Installation. Install the carrier cover plate and locate it on the cover plate mounting studs on the carrier. Install cover plate bolts and tighten them to specified torque value. Torque : 38 - 45 Nm. Discard the old bolts and Use new bolts for cover plate mounting as the bolts are coming with sealant patch on it and during sealant patch wears off. Reusing cover bolts may leads to leakage from cover bolts sides. Refit the Front Axle Assembly. Refill the front axle oil upto Max level. For additional information refer to Front differential oil draining and filling procedure. Remove E-Disconnect motor. Using 10 mm socket spanner, Unscrew electric disconnect housing mounting bolts. Torque : 17\u00b12 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Carefully remove the E-Disconnect Housing with Fork . Refit in the reverse order of removal. While Installation Apply Locktite sealant on the E-Disconnect Housing bolts to avoid the leak through cover. Check the E-Disconnect motor, connector for any damage, Replace if necessary. For additional information refer to E-Disconnect stone guard \u2013 R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect E \u2013 Disconnect electric connector. Using 10 mm socket spanner, unscrew E \u2013 Disconnect motor mounting bolts. Torque : 12.5\u00b13.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the E-Disconnect motor Refit in the reverse order of removal. While Installation ensure to replace the New O Ring for E \u2013 Disconnect motor Check the E-Disconnect motor, connector for any damage, Replace if necessary.
Front Axle Oil \u2013 Mahindra 'MAXIMILE ELITE' New Generation Genuine Differential Fluid. , Capacity \u2013 1.25 Litres.Using 10 mm square bit spanner, loosen and remove front axle filler plug. Using 10 mm square bit spanner, loosen and remove front axle drain plug and drain the entire oil. Wait till the entire oil get drained. Place a tray beneath the front axle for collecting the oil while draining. Refit the drain plug and torque tighten to specified value. Clean the drain plug and differential housing with a clean cloth before refitting. Torque : 34 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refill specified quantity of recommended differential oil into differential assembly. Never reuse drained oil. Always use recommended oil only. Never mix different types of oil and use. Clean filler plug area properly using a cloth before filling the oil. Check the oil level and ensure its up to the level. Ensure that the oil level is up to lower most point of the filler plug. Refit the filler plug back and torque tighten to specified value. Clean the filler plug with a clean cloth before refitting. Torque : 34 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Recommend to use only Mahindra 'MAXIMILE Elite' new generation genuine differential fluid. In case of non availability of 'Maximile' brand, other brands meeting API GL5, SAE 80W-90 specification can be used as second preference and oil change period should be reduced as 20,000 km.
2. Visually inspect the front axle for any noticeable signs of mechanical damage.
3. If an obvious cause is found during the inspection, correct the same before proceeding to the next step.
4. If the cause is not found visually during the inspection, refer to the troubleshooting chart.
5. Check for oil level and condition.
",
+ "file": null,
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Mechanical",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "1. Check for any oil leakage in the differential assembly, gasket and axle shaft oil seal.
2. Check for any noise in the bearing, pinion gear, crown wheel and planet gears.
",
+ "file": null,
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "various symptoms, causes and there remedial actions of system",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/17548.pdf",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Noise when the vehicle is coasting",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/17549.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Intermittent Noise",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/17550.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Noise when the vehicle is turning",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/17551.jpg",
+ "display_order": 6
+ }
+ ]
+ },
+ {
+ "procedure_name": "Constant Noise",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/17552.jpg",
+ "display_order": 7
+ }
+ ]
+ },
+ {
+ "procedure_name": "Vibration",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/17553.jpg",
+ "display_order": 8
+ }
+ ]
+ },
+ {
+ "procedure_name": "Oil leakage from Differential carrier leakage",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/17554.jpg",
+ "display_order": 9
+ }
+ ]
+ },
+ {
+ "procedure_name": "Axle case oil leakage",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/17555.jpg",
+ "display_order": 10
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 66,
+ "sys_id": "THAR.LX-0008-en-SM-Manual Transmission",
+ "system_name": "Manual Transmission",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1008,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 76,
+ "sys_id": "THAR.LX-0008-Manual Transmission",
+ "subsys_id": "THAR.LX-0008-Manual Transmission-Clutch Housing And Input Shaft Oil Seal",
+ "systems": "Manual Transmission",
+ "sub_systems": "Clutch Housing And Input Shaft Oil Seal",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A110018.jpg",
+ "myid": 1156,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Clutch Housing And Input Shaft Oil Seal-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110018.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21536.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21537.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "Description",
+ "content": "Tools Required ",
+ "file": null,
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the Transmission fluid. For additional information refer to Transmission fluid Drain & Filling Section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Clutch Concentric Slave Cylinder. For additional information refer Clutch Concentric Slave Cylinder - R &R; Section. Using a 14 mm socket spanner remove the clutch housing mounting bolts and then gently tap using plastic mallet & remove clutch housing. Using a screw driver/suitable oil seal remover, remove the input shaft oil seal from clutch housing. Check for any external cracks, if found replace. Check the oil seal for deformation, if found replace. Using a 10 mm socket spanner, loosen and remove the battery negative terminal. For additional information refer to Rear Propeller Shaft R&R Session. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130015.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 8 mm socket spanner, loosen and remove the front propeller shaft mounting C clamp bolts from the transfer case. Torque: 65 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110429.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110430.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the cross pin and detach the Shifter cable from the shifter control housing on transmission. Using a 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the Selector cable from the Shifter Control Housing ball pin. Detach the Selector cable & Shifter cable abutments from the cable brackets on transmission by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Using a 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the transfer case cable from the transfer case ball pins. Detach the transfer case cable abutment from the cable bracket on transmission by pressing locking clip and pull up the abutments. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Disconnect the GNS sensor & transfer case switch electrical connection. Disconnect the reverse switch electrical connection. Disconnect the transmission wiring routing clips. Disconnect the clutch bundy tube connection from clutch slave cylinder. Using a 14 mm socket spanner, loosen and remove the starter motor mounting bolts then keep aside the starter motor. Torque: 44 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110008.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the transmission housing mounting bolts. Torque: 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B110003.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Provide a jack to support the transmission. Using a 12 mm socket spanner, loosen and remove the transmission bed mounting bolts from transmission. Torque: 25\u00b15 Nm ",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B110005.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using 14mm, 15mm socket and ring spanners, unscrew transmission cross member mounting bolts, nuts and detach it. Torque: 65 \u00b110.0 Nm ",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B110004.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Lower the jack and remove the transmission along with the transfer case. Install in reverse order of removal. For additional information refer to clutch fluid Refilling and bleeding procedure. ",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Notice",
+ "content": "While refit Cables, Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Front housing is used to provide support for mounting transmission shafts with the help of bearings. It is mounted in between clutch housing and Intermediate plate. Remove the Clutch housing assembly. Using a 22 mm ring spanner, loosen and remove the neutral sensor. Remove the rear housing assembly. Using a snap ring removal tool/ flat end screw driver, remove the input shaft snap ring from the front housing. Using a snap ring removal tool/ flat end screw driver, remove the counter shaft snap ring from the front housing. Using open end spanner, detach the front housing from the intermediate plate. Remove the front housing assembly. Apply loctite 5188 on the front housing in intermediate plate side. Install the front housing assembly. Use 3 nos. of 17 mm dummy bolts (Appox. length of 40 mm) to tighten the front housing to ensure proper sealant application. Ensure to fix the dowels before tighten the front housing. Using a snap ring, removal tool/ screw driver install the counter shaft snap ring. Using a snap ring, install the input shaft snap ring. Refit the Clutch housing assembly. Refit the Rear housing assembly. Install the neutral sensor. Torque tighten the nut to specified value. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 38
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 66,
+ "sys_id": "THAR.LX-0008-Manual Transmission",
+ "subsys_id": "THAR.LX-0008-Manual Transmission-Gear Cable Setting Procedure",
+ "systems": "Manual Transmission",
+ "sub_systems": "Gear Cable Setting Procedure",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A110443.jpg",
+ "myid": 1147,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Gear Cable Setting Procedure-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Gear Cable Setting",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110443.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Move the shifter cable quick adjuster outer cover in forward direction and unlock the QA clip in transmission end. Position the shifter control housing in Neutral Position on transmission. Ensure the Selector cable is properly fitted on Shifter Control Housing ball pin on transmission. Ensure the selector cable & shifter cable butments are properly fitted on transmission cable brackets. Remove the gear shifter lever knob with spring and 4WD selection knob. Using trim removal tool, remove the Gear selection rod cover with trim. Ensure the selector cable & shifter cable abutments are properly fitted on shifter lever bracket Inside passenger cabin. Move the selector cable quick adjuster outer cover in forward direction and unlock the QA clip. Insert the Neutral lock Special tool to shifter housing hole and lock the tool C profile to shifter lever as shown for ensuring selector & shifter arm in neutral position. After Inserting the Neutral lock special tool, Shifter lever should not move in any direction. In this Condition press the selector cable QA clip as shown to lock it fully and release the quick adjuster outer cover. Ensure the proper locking by confirming/ hearing the click noise while install. Ensure the shifter cable end is properly fitted on the shifter lever ball pin inside passenger cabin. Ensure Transmission is in Neutral at transmission end. In this condition press the shifter cable QA clip towards arrow mark as shown to lock it fully and release the cable quick adjuster outer cover. Ensure the proper locking by confirming/ hearing the click noise while install. After adjustment remove the special tool from shifter lever. Refit the Gear selection rod cover with trim. Refit the gear shifter level knob with spring and 4WD selection knob. Inspect the shifter lever smooth shifting & gear engagement to all the gear range. Remove the Transfer Case. Using a screw driver, remove the rear end oil seal from the Rear housing. Position the rear end oil seal along with 0703BBA0002ST - Transmission Rear Housing Oil Seal Installer & install the oil seal using a mallet. Remove the Transmission with Transfer case. Pull the clutch bleeder lock and detach the bleeder from CSC. Using a 12 mm socket spanner, loosen and remove the CSC mounting bolts. Torque: 25 \u00b1 3.5 Nm ( Step UP Torque \u2013 5, 15 , 25) ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110016.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110017.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 15 mm socket spanner/ combination spanner, loosen and remove the transfer case mounting nuts then detach the transfer case from the transmission. Torque: 45 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Carry-out clutch bleeding procedure. For additional information refer to clutch fluid Refilling and bleeding procedure. Check the Transmission oil level and topup if needed. For additional information refer to transmission oil level inspection and refilling procedure. Remove the Shifter Control Housing. By Using 5 mm thin Punch & hammer, remove the Select lever guide locking pin and detach the guide. Take out the control housing boot from the shift lever assembly. By using 3 mm Allen key, remove the Plug to access shift lever ball assembly locking pin. By Using 5 mm thin Punch and hammer, remove the shift lever ball assembly locking pin by accessing through plug hole. Remove the Shift lever assembly from the housing and remove the shift lever ball assembly as shown in the Illustration. Remove the other side boot from the shift control housing. By using screw driver, remove the seal from the housing (One Side). By using screw driver, remove the seal from the housing (Other Side). By using M 8 flange headed bolt and 8 mm punch, remove the bush from the housing (One Side). Position the M8 flange headed bolt on bush as shown above & hit the bolt by using punch and mallet. By using M 8 flange headed bolt and 8 mm punch, remove the bush from the housing (Other Side). Position the M8 flange headed bolt on bush as shown above & hit the bolt by using punch and mallet. By using screw driver, remove the select lever circlip. By screw drive, hit the select lever shift pivot and remove the shaft. Detach select lever from the housing. By using 15 mm ring/open end spanner, remove the breather from the housing. By using 15 mm ring/open end spanner,refit the breather on the housing. Position the select lever on housing and insert the select lever shaft on lever. Refit the select lever circlip on select lever by using nose plier. Position the bush on housing (One side) and Install by using M8 flange headed bolt, 8 mm punch & mallet as shown illustration. After Installation, Ensure bush face parallel to housing bore face as shown. Install the Oil seal by gently press by using hand or suitable dolly. Position the bush on housing (Other side) and Install by using M8 flange headed bolt, 8 mm punch & mallet as shown illustration. After Installation, Ensure bush face parallel to housing bore face as shown. Install the Oil seal by gently press by using hand or suitable dolly (Other side). Refit the one side boot on shifter control housing. Insert the shift lever assembly on housing and insert the Shift lever ball assembly to the shift lever assembly (As direction shown). Align the Ball Assembly and shift lever shaft hole and Install the locking pin by using 5 mm punch and hammer. Install the Plug on housing. Insert the other side control housing boot to the shift lever. Insert the lever guide on shift lever. Install the select lever guide locking pin by using 5 mm punch and hammer. Refit the Shifter Control Housing. For additional information refer to Shifter Control Housing - R &R; Section. Remove the Floor Console. Using a MST 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the Selector cable & Shifter cable from the shift lever ball pins. Detach the Selector cable & Shifter cable abutments from the shifter bracket by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Using a 13 mm socket spanner, loosen and remove the gear shifter lever assembly mounting nuts. Remove the gear shifter lever assembly from the vehicle. Position the gear shifter lever assembly on the vehicle. Refit the gear shifter lever assembly mounting nuts and torque tighten the nuts to specified value. Torque: 21\u00b13 NM ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110365.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110368.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Refit the Selector cable & Shifter cable abutments on shift lever bracket. Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Refit the Selector cable & Shifter cable on shift lever. Carry out Gear Cable Setting. New Shifter Lever Assembly supplied with Gear shifter Neutral position tool, ensure to remove the tool from shifter housing after Gear cable setting. Support the transmission using jack. Using a 18 mm socket spanner, loosen and remove the transmission bed mount nuts. Using a 14 mm & 15 mm socket/ring spanner, loosen and remove the cross member mounting bolts & nuts then remove the transmission cross member. Torque: 65\u00b1 10 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110021.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110085.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the transmission bed mounting bolts then remove the transmission bed mount from the vehicle Torque: 25\u00b15 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Detach the Shifter cable abutment from the cable bracket on transmission by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Using a 12 mm socket spanner, loosen and remove the shifter cable bracket mounting bolts and remove the bracket. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110395.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the GNS electrical connection and detach the wiring routing clip. Using a 22 mm open end spanner, loosen & remove the Gear Neutral Sensor. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110382.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "install in reverse order of removal. While Install cable, Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Remove the Air Cleaner Assembly. Remove the Floor Console. Using a 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the Selector cable & Shifter cable from the shift lever ball pins. Detach the Selector cable & Shifter cable abutments from the shifter bracket by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Remove the cross pin and detach the Shifter cable from the shifter control housing on transmission. Using a 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the Selector cable from the Shifter Control Housing ball pins. Detach the Selector cable & Shifter cable abutments from the cable brackets on transmission by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Using a 10 mm socket spanner, loosen and remove the shifter & selector cable grommet mounting bolts. Detach the shifter and selector cable from routing clips & take out from the vehicle. Routing the shifter and selector cable to the vehicle and position the cables on routing clips. While routing the cable ensure to insert Selector cable in the left side of the Gear shifter lever and shifter cable in the right side. Select & Shift cable should not cross each other. Refit the shifter & selector cable grommet mounting bolts and torque tighten the bolts. Torque: 13\u00b1 2 Nm ",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Caution",
+ "content": "Ensure the cable grommet should get assemble from outside the cabin. Refit the selector cable & shifter cable abutments on transmission cable brackets. Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Attach the Shifter cable on shifter control housing on transmission and refit the cross pin on Shifter control housing. Attach the Selector cable on Shifter Control Housing ball pins by hand. Refit the selector cable & shifter cable abutments on shift lever bracket inside passenger cabin. Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Attach the Selector cable end on Shifter lever ball pin by hand. Refit the shifter cable end on Shifter lever ball pin by hand. Carry out Gear Cable Setting. Refit the Air Cleaner Assembly. Rear housing is used to protect rear parts of transmission components from external environment. It is used to hold the Shifter Control Housing assembly & detent block. Tools Required ",
+ "file": null,
+ "display_order": 6
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the transmission oil. Using a 12 mm socket spanner, remove the gear control housing mounting bolts and then gently detach and remove the gear control housing assembly. Yellow colored bolts are fitted with dowel inside, this bolts should be removed & refit first. Using a T30 torx spanner, remove the torx bolt from the shift block actuator. Using a 22 mm socket spanner, remove the reverse switch. Using a 12 mm socket spanner, remove the idler shaft front mounting bolt & using a 13 mm socket spanner remove the bottom idler shaft bolt. Using a 12 mm socket spanner, loosen and remove the selector bracket mounting bolts. Using a 12 mm socket spanner, loosen and remove the shifter bracket mounting bolts. Using a 14 mm socket spanner, remove the rear housing bolts from the front housing side. Ensure and take more care on not to breakage the front housing sealant while removing rear housing bolts from the front housing side. Using a 14 mm socket spanner/Open end spanner, remove the rear housing mounting bolts. Turn the shift block actuator & release from the spring support. By using screw driver, release the rear housing dowels and using open end spanner detach the rear housing. Release the dowels from the rear housing and ensure not to remove fully from the housing and it leads to touch the dowels on center housing projection as shown. Use the open end spanner on both the side simultaneously. Lift the rear housing assembly along with the shift block actuator. Remove the rear housing assembly and take out shift block actuator from housing. Using a screw driver/suitable oil seal remover, remove the rear end oil seal from the Rear housing. Using a 12 mm socket spanner, remove the H plate mounting bolts & the H plate assembly from the Rear housing. Using hydraulic press, remove both the detents by pressing from outside to inside. Check for any external oil leakage. Rectify if found. Using suitable tool and hydraulic press, fit the detent (press from outside to inside) Position the rear end oil seal along with 0703BBA0002ST - Transmission Rear Housing Oil Seal Installer & install the oil seal using a mallet. Check for the rear end oil seal correct seating. Refit the H plate mounting bolts & torque tighten the bolts to specified value. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110333.jpg",
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110322.jpg",
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Apply loctite 5188 on Intermediate plate and insert the rear housing assembly. Install the shift block actuator while installing the rear housing. Insert the rear housing mounting bolts,torque tighten the bolts specified value. Torque : 30\u00b15 Nm ",
+ "file": null,
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110121.jpg",
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110122.jpg",
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Insert the rear housing mounting bolts,torque tighten the bolts specified value. Torque : 30\u00b15 Nm ",
+ "file": null,
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110116.jpg",
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Refit the reverse light switch, torque tighten the switch to specified value. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 76
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110119.jpg",
+ "display_order": 77
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110120.jpg",
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Insert the front & the bottom idler shaft mounting bolts, torque tighten the bolts to specified value. Torque : Idler Shaft Bolts - 30\u00b15 Nm ",
+ "file": null,
+ "display_order": 80
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110417.jpg",
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Refit the shifter bracket with mounting bolts , torque tighten them to the specified value. Torque: 20.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 83
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110416.jpg",
+ "display_order": 84
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Refit the selector bracket with mounting bolts , torque tighten them to the specified value. Torque: 20.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 86
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110323.jpg",
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110114.jpg",
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Position the shift block actuator, apply Loctite 262 & insert the torx bolt and torque tighten the bolt to specified value. Torque : 10 - 15 Nm ",
+ "file": null,
+ "display_order": 90
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110324.jpg",
+ "display_order": 91
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110325.jpg",
+ "display_order": 92
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Apply 5188 loctite on the rear housing to fit gear control housing. Refit the gear control housing & the mounting bolts. torque tighten the bolts to specified value. Yellow colored bolts are fitted with dowel inside, this bolts should be refit first. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 98
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 81,
+ "sys_id": "THAR.LX-0008-Manual Transmission",
+ "subsys_id": "THAR.LX-0008-Manual Transmission-Transmission Overhaul",
+ "systems": "Manual Transmission",
+ "sub_systems": "Transmission Overhaul",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1161,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Transmission Overhaul-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/VST-0070_TRANSMISSION 6RM320 OVERHAUL (MT) \u2013 NEW THAR.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21570.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21571.pdf",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Dis-assembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the Transmission fluid. For additional information refer to Transmission fluid Drain & Filling Section. Using a 12 mm socket spanner, remove the gear control housing mounting bolts and then gently detach and remove the gear control housing assembly. Yellow colored bolts are fitted with dowel inside, this bolts should be removed & refit first. Using a T30 torx spanner, remove the torx bolt from the shift block actuator. Using a 22 mm socket spanner, remove the reverse switch. Using a 22 mm open end spanner,remove the neutral sensor. Using a 12 mm socket spanner,remove the idler shaft front mounting bolt & using a 13 mm socket spanner, remove the bottom idler shaft bolt. Using a 14 mm socket spanner, remove the rear housing bolts from the front housing side. Using a 14 mm socket spanner/Open end spanner, remove the rear housing mounting bolts. Turn the shift block actuator & release from the spring support. By using screw driver, release the rear housing dowels and using open end spanner, detach the rear housing. Release the dowels from the rear housing and ensure not to remove fully from the housing and it leads to touch the dowels on center housing projection as shown. Use the open end spanner on both the side simultaneously. Lift the rear housing assembly along with the shift block actuator. Remove the rear housing assembly and take out shift block actuator from housing. Using a screw driver/suitable oil seal remover, remove the rear end oil seal from the Rear housing. Using a 12 mm socket spanner remove the H plate mounting bolts & the H plate assembly from the Rear housing. Using hydraulic press, remove both the detents by pressing from outside to inside. Remove the idler gear, shaft & the plastic support assembly. Remove washer, idler gear & needle roller bearing from shaft. Remove main shift rod & the washers on both sides. Ensure Gear in neutral position Using a 14 mm socket spanner remove the counter shaft lock bolt in clock wise direction. The bolt is reverse threaded, hence rotate in clockwise for removing. Using a MST 0703AD2720H116 \u2013 Lock Nut Dolly, loosen the output shaft lock nut. Using a bearing puller (SKF TMMR 120F), remove the counter shaft rear DGBB (Double Grove Ball Bearing). Use Counter shaft dummy bolt for support bearing puller. Using a puller (SKF TMMR 350F), remove the reverse driven gear, washer & CRB (Cylinder Roller Bearing) from output shaft. Remove reverse synchro ring and remove the reverse driven gear needle bearing & remove the bush. Remove reverse synchro stud and reverse fork & rail shift assembly along with reverse synchro sleeve from output shaft. Using a puller (SKF TMMR 350F) remove the reverse synchro hub from output shaft. Using a puller (SKF TMMR 120F), remove the reverse drive gear, thrust washer & 5th drive gear from counter shaft. Remove the 5th drive gear NRB (Needle Roller Bearing) and 6th synchro ring. Using a suitable puller (SKF TMMR 350F) remove the 5th driven gear & bush from output shaft. Remove the 5th & 6th synchro studs and remove the 5th & 6 th synchro sleeve along with fork & rail shift. Using a puller (SKF TMMR 120F) remove 5th drive gear bush, 5th & 6th synchro hub, synchro ring & 6th drive gear from counter shaft. Remove the 6th drive gear NRB. Using 14 mm socket spanner, remove the clutch housing bolts. Gently tap using plastic mallet & remove clutch housing. Using a screw driver/suitable oil seal remover, remove the input shaft oil seal from clutch housing. Using a snap ring removal tool/ flat end screw driver, remove the input shaft snap ring from the front housing. Using a snap ring removal tool/ flat end screw driver, remove the counter shaft snap ring from the front housing. Using open end spanner, detach the front housing from the intermediate plate. Using a roll punch & hammer, remove the pin spring dowel from the 1st & 2nd shifter fork & rail assembly. Using a roll punch & hammer, remove the pin spring dowel from the 3rd & 4th shifter fork & remove fork rail assembly from intermediate plate. By using snap ring removal tool,expand the output shaft snap ring and release the output shaft from intermediate plate. Using a mallet tap and remove the intermediate plate. Remove the counter shaft assembly. Remove the output shaft assembly from the input shaft assembly. Remove the pilot bearing & Synchroring from input shaft. Using a circlip plier, remove the circlip from input shaft. By Using a puller (SKF TMBS 150E ) remove the DGBB from input shaft. Using a circlip plier, remove the circlip from counter shaft front end. By using a puller (SKF TMBS 150E) remove the DGBB from counter shaft front end. By using a puller (SKF TMMR 160F) remove the DGBB, 6th drive gear bush & thrust washer from counter shaft rear end. Using a puller (SKF TMBS 150E) remove the 1st driven gear, 2nd driven gear, 1st & 2nd synchro pack along with output shaft DGBB & 6th driven gear. Engage puller legs in the 2nd driven gear. Remove in the sequence of 6th driven gear, output shaft DGBB, 1st driven gear with bush, 1st driven gear NRB, 1st & 2nd synchro pack, 2nd driven gear. Remove the 2nd driven gear NRB. Using a circlip plier remove the circlip from the output shaft. Remove the 3rd & 4th synchro studs & sleeve. Using puller (SKF TMMR 350F) remove the 3rd & 4th synchro hub, synchro ring & the 3rd driven gear assembly. Remove the 3rd driven gear NRB. Shift Control Components ",
+ "file": null,
+ "display_order": 145
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check contact and sliding surfaces of shifter fork & rails for wear, scratches, projections and other damage. Gear Components ",
+ "file": null,
+ "display_order": 149
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Check shafts for cracks, wear and bend. Check gears for excessive wear, chips and cracks. Synchronizers ",
+ "file": null,
+ "display_order": 152
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Check spline portion of coupling sleeves, synchronizer hubs, and gears for wear, chips, and racks. Check ring for cracks and deformation. Check struts for wear and deformation. Bearings ",
+ "file": null,
+ "display_order": 155
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Make sure all bearings roll freely and are free from noise, cracks, pitting or wear. Shifter Control Housing is for gear selecting and shifting. It is connecting element between gear shift lever and shift rail through Shifter & Selector cables. Remove the Transmission with Transfer case. Using a 12 mm socket spanner, remove the gear control housing mounting bolts and then gently detach and remove the gear control housing assembly. Position the shifter lever in Natural Position on transmission. Yellow colored bolts are fitted with dowel inside, this bolts should be removed & refit first. While Installation, Apply sealant LOCTITE 5188 on the rear housing shifter control housing seating area . Install in reverse order of removal, before installation apply the sealant if required. Top up the transmission oil. Remove the gear shifter level knob with spring and 4WD selection knob. Using trim removal tool, remove the Gear selection rod cover with trim. Using a screw driver , loosen and remove the gear selection rod cover mounting screw and detach boot from trim. Install in reverse order of removal. Transmission Oil \u2013 MAHINDRA \u201cMAXIMILE SYNTEC F2\u201d New Generation Genuine Transmission Fluid. Capacity \u2013 2.25 Litres. Using a 8 mm square bit spanner, loosen and remove the filler plug. Using a 8 mm square bit spanner, loosen and remove the drain plug & allow the oil to drain out completely. Place a tray or drain oil collecting bin under the drain plug to collect the oil. Install the drain plug. Torque tighten the drain plug to specified value. Always replace the drain plug washer with a new one. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110343.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Fill recommended oil using an oil filling machine or by clean transparent pipe attached to the mechanical hand pump. Ensure that the oil level is up to lower most point of the filler plug. Refit the filler plug. Torque tighten the filler plug to specified value. Torque : 27.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Recommend to use only Mahindra MAXIMILE SYNTEC F2 new generation genuine transmission fluid. In case of genuine oil non-availability, manual transmission oil meeting API GL-4 SAE 80W-90 specification is suggested. This alternate oil or other brand may not provide equivalent performance of recommended genuine oil. Drain Interval should be reduced as 20,000 km. Never mix two different oils. Remove rear front facing Seat Back Rest Assembly. Open the seat cover strip back side of back rest assembly. Press the lock and remove the head rest. Unzip the seat cover LH & RH sides. Press the lock and remove the head rest guide inside seat cover. Detach the seat cover with foam from the frame and remove from back rest frame. Install in the reverse order of removal. Check for any damages. Replace if required. Check for any damages on seat trims. Replace if required. Remove Driver Seat Back Rest Assembly. Open the seat cover strip back side of back rest assy. Unzip the seat cover LH & RH sides. Pull and detach the lumber support handle. Press the lock and remove the head rest guide inside seat cover. Remove foam with cover from back rest frame. Excessive pull or improper removal may leads to damage the foam and seat cover. Install in the reverse order of removal. Check for any damages.Replace if required. Check for any damages on foam and cover. Replace if required. Remove the Driver Seat Back Rest foam with Cover. Using star screw driver, Unscrew lumber support Mechanism mounting screws and remove mechanism Disconnect lumber support cable link from back rest frame. Using star screw driver, Unscrew luggage hook mounting screw and remove it from the frame assy. Separate the driver seat back rest frame. Install in the reverse order of removal. Check the frame for any damages. Replace if required. Remove Driver Seat Back Rest Foam with Cover. Using Nose Plier, Remove the copper ring locks and remove cover from foam. Take extreme care to not to damage the foam and seat cover. Install in the reverse order of removal. Check the foam for any damages. Replace if required. Check for seat cover any damages. Replace if required. Remove Driver Seat Back Rest Assembly. Unlock the seat cover lock from the bottom side. Using Nose plier and Screw driver, Remove the seat cover locking rings. Using star screw driver, Unscrew seat side cover mounting screw and remove the cover. Detach the cover with foam. Install in the reverse order of removal. Check the Cushion and Frame Assembly for any damages. Replace if required. For additional information refer to the Rear Seat Recliner overs - R&R section. ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Detach the seat folding cable from the lock and remove the cable. Remove the cable from the bottom cushion routing bracket. Remove the cable from the seat. Install in the reverse order of removal. Check seat folding cable for any damages. Replace if found. For additional information refer to Driver Seat Assembly - R&R Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove seat recliner and height adjustment handle cover. By using star screw driver remove seat height adjustment handle mounting screws & remove the handle. By using star screw driver, remove LH & RH valance cover mounting screws and detach the covers. Detach back cushion cover lock from seat bottom. Using T50 torx socket spanner, Unscrew back rest mounting bolts. Torque: 47.5 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230111.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Detach the back rest from Seat assembly. Press the Lock and remove the head rest from the back rest assembly. Install in the reverse order of removal. Check for any damages. Replace if required. Check for any damages on seat trims. Replace if required. Remove the Rear Front Facing Bottom Cushion. Remove the copper locks from the rear front facing bottom cushion. Detach the both side the cable from the lock. Remove the both routing bracket cable tie from the seats. Remove the bottom cushion from the frame assembly and separate the Bottom Cushion Frame. Install in the reverse order of removal. Install in the reverse order of removal. Check for any damages on seat trims. For additional information refer to Roof Speaker - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Roof Tweeter LH & RH. For additional information refer to Roof Tweeter - R&R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a trim removal tool pull out center bow trim and disconnect roof lamp electrical connector. Disconnect the sound bar electrical connector. Using 10 mm socket spanner, Unscrew sound bar mounting bolts. Detach the Wiring Harness from routing and remove from the sound bar assembly. Install in the reverse order of removal. Inspect the Wiring Harness for any physical damage. Replace if found. Inspect the connector for any damage. For additional information refer to Driver Sun Visor - R&R Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Co-Driver Sun Visor. For additional information refer to Co-Driver Sun Visor - R&R Section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using Torx screw driver, Unscrew Centre bow trim mounting screw and detach the bow trim.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280010.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 5 \u00b1 0.5 Nm",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280011.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the MIC electrical.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W652.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the MIC from Centre bow trim.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280013.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280009.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the MIC unit for any damage.Inspect the electrical connectors for any damage.",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 303,
+ "sys_id": "THAR.LX-0008-Infotainment Assembly",
+ "subsys_id": "THAR.LX-0008-Infotainment Assembly-Infotainment Assembly",
+ "systems": "Infotainment Assembly",
+ "sub_systems": "Infotainment Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A290006.jpg",
+ "myid": 1416,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Infotainment Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290006.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12676.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12677.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using trim removal tool remove the infotainment center bezel. Using trim removal tool remove infotainment top side cover. Using star screw driver, Unscrew infotainment mounting screws. Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1015.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect Infotainment electrical connectors. Remove the Infotainment unit. Install in the reverse order of removal. Inspect the infotainment unit for any damage. Inspect the electrical connectors for any damage. Using star screw driver remove front LH wheel arch mounting screw rivets. Using T25 socket spanner remove the antenna mounting screw. Torque Value: 3 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280048.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the antenna electrical connector through wheel arch. Remove the antenna assembly separately. Inspect the antenna assembly and connector for any physical damage. Replace if found. Using star screw driver unscrew the panel assembly floor console RH screvits and detach the panel from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console LH screvits and detach the panel from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew vertical ascent RH mounting screw and detach the vertical ascent RH from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew vertical ascent LH mounting screw and detach the vertical ascent LH from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "partially detach the switch bang assembly and remove electric connector to take out from the vehicle. Carefully pull and remove the Audio Unit port Assembly. Disconnect the Audio Unit port electrical connectors and 12 volt electric connector. Using star screw driver unscrew the ,Audio Unit port mounting screws. Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the USB and DOC station assembly from the trim. Install in the reverse order of removal. Inspect the USB and DOC station assembly unit for any damage. Inspect the electrical connectors for any damage. Remove the Infotainment Assembly. Using star screw driver, Unscrew cluster bezel mounting screw and remove the bezel. Cut the GNSS antenna wire routing tag. Install in the reverse order of removal. Inspect the GPS Antenna for any damage. Inspect the electrical connector for any damage. Using star screw driver unscrew the panel assembly floor console RH screvits and detach the panel from vehicle. Using star screw driver unscrew the panel assembly floor console LH screvits and detach the panel from vehicle. Using star screw driver unscrew vertical ascent RH mounting screw and detach the vertical ascent RH from vehicle. Using star screw driver unscrew vertical ascent LH mounting screw and detach the vertical ascent LH from vehicle. partially detach the switch bang assembly and remove electric connector to take out from the vehicle. Carefully pull and remove the Audio Unit port Assembly. Disconnect the Audio Unit port electrical connectors and 12 volt electric connector. Using a small screw driver pull out the power port and remove the power port. Install in the reverse order of removal. Inspect the 12V power point for any physical damage. Replace if found.
2. Open the bonnet and lock it in open position using bonnet stay rod.
Brake and Clutch Fluid: Mahindra Maximile DOT 4 Genuine Brake fluid.Brake and Clutch Fluid: 1.75 Liters (Including bleeding quantity)
2. Check the reservoir for leakage and check the level of fluid, if found less top up till MAX mark.
3. Always maintain fluid level at MAX mark on reservoir.
",
+ "file": null,
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Check for leakage in Clutch system at",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B100001.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the hose joint at reservoir and clutch master cylinder (CMC) inlet hose connection for any leak and proper fitment. Check clutch master cylinder bundy tube connection for any leak and proper fitment. Check clutch bundy tube connection to concentric slave cylinder and bleeding nipple for any leak. Use recommended fluid & do not mix different brand fluids. In case fluid reservoir replaced, brake and clutch system needs bleeding. Use the same brand fluid for top up; do not top up brake fluid from used and unsealed brake fluid container. The Brake fluid reservoir cap/ container should not be opened with dirty hands. Avoid direct water spray on reservoir while washing engine compartment. Always use Mahindra 'Maximile DOT 4' genuine Brake fluid. If Maximile DOT 4 brake fluid is not available and in emergency conditions, use Brake Fluid Meeting SAE J1703 FMVSS NO.116 DOT 4 OR IS 8654 TYPE-2 Specification. Change it at 30,000 km or 2 years whichever is earlier. Unless the cause of a clutch problem is extremely obvious, accurate problem diagnosis will require a road test to confirm whether the problem exists or not. During the road test, drive the vehicle at normal operating speeds, shift the gears and observe the clutch action. If chatter, grab, slip or improper release is experienced, check clutch free pedal play, clutch fluid leakages, also do clutch bleeding, if the problem still persists, then remove & inspect the suspected parts. However if problem is noise or hard shift then the problem may not be in clutch only but also with the transmission or the drive-line. If the clutch slip is suspected then drive the vehicle in 1st or 2nd gear at the top speed (corresponding to the gear). Keeping the accelerator fully pressed; slowly apply the brake with your left feet. If the engine stalls then the clutch is not slipping. To find out the actual root cause of the problem, the failed parts needs to be examined. Fluid contamination is the most frequent cause of clutch malfunction. Oil, water on the clutch contact surface will cause faulty operation viz. slip, grab, and judder. During inspection check if any parts in the clutch are coated with oil or water splash from road. Oil contamination indicates a leak at either engine rear oil seal or transmission input shaft. The oil leaks from either of these areas will normally coat the housing interior or clutch cover or flywheel. Heat buildup due to slippage between the clutch plate and the flywheel or the pressure plate can result into the leaked oil literally getting baked. Visually this will result in a glazed residue varying from amber to black. Roads splash contamination will mean that the dirt water is entering the clutch housing either due to loosen bolt or torn rubber boot. The clutch housing has to be aligned with the engine so that the input shaft is aligned with the crankshaft. Absence of this alignment results in clutch noise, incomplete release of the clutch plate. It can normally be judged by uneven wear of the finger and pilot bearing. In severe case it can also damage the spline of the input shaft and clutch hubs well as the clutch splines. The clutch component i.e. the clutch plate, flywheel and the pressure plate have to be aligned with the crankshaft and the transmission input shaft. Misalignment caused by run outs/ warpage will cause clutch to grab judder as well as improper release (also manifesting as hard gearshift). Normally the clutch housing misalignment is a result of: Incorrect seating on the engine/transmission. Missing alignment dowel holes. Loose or missing mounting bolt. Mounting surfaces that are damaged/ not parallel. A noisy gearshift operation especially in 1st and 2nd gear can be due to clutch not getting disengaged completely. To check, turn the engine OFF, shift the gear lever to 1st or 2nd gear and then jack up the rear axle till both the wheels gets lifted enough from the ground. Now press the clutch pedal completely and start the engine, the wheels should not be spinning after that slowly release the pedal till it has moved about 10 mm, the wheel should still not be spinning. If some spinning is noticed then it indicates improper lift of the pressure plate. Do clutch bleeding and, then check for the pressure plate lift. To check the clutch housing misalignment bell housing run out will also need to be checked. For additional information refer to Transmission Assembly With Transfer Case \u2013 R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0008,1008,1151",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Put the dust cap/cotton cloth in CSC nozzle port during clutch or transmission service. Pull the locking clip outwards using a small flat end screw driver and disconnect concentric slave cylinder upper part of bleeder. using a 12mm socket spanner remove concentric slave cylinder mounting bolts . Torque : 25\u00b13.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100055.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove concentric slave cylinder assembly. Install in the reverse order of removal. For additional information refer to Clutch Fluid Air Bleeding Procedure. ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Link",
+ "content": "THAR.LX-0008,1007,1133",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100101.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect clutch slave cylinder for any leakages. Check the clutch slave cylinder Axial movement (Up & down) & bearing rotational movement (Right & left) for any abnormality. Inspect clutch slave cylinder boot condition for any damages. Inspect clutch slave cylinder mountings for any damages. Assemble the extension shaft and flat head to the push rod (Push end) of the Push & pull gauge. Switch OFF the Push & Pull gauge and adjust the gauge dial to zero. Now switch ON the gauge. Ensure engine is in running condition at idle speed. The push & pull gauge should be in line with the clutch pedal travel direction. Measurement taken by hitting the pedal to the bottom stopper would be wrong. Do not push the gauge by holding the top end. It would give us a wrong reading due to the extra force applied. Position the push & pull gauge at the centre of the clutch pedal pad with gauge\u2019s flat surface touching the pedal pad surface in parallel. Push the gauge by holding the gauge at the sides (as shown the figure) till the pedal moves down, stop before the pedal hits the bottom stopper. Note the peak values on the push & pull gauge during the clutch pedal travel. Repeat the procedure for another 2 times and record the peak values. The average of the three values would be the pedal effort in Kgf. New clutch assembly 9 -12 Kgf (88-118N). The maximum allowable clutch pedal effort is 17 Kgf (167N) Max. Cleck the fluid level in clutch fluid reservoir. Fluid Level Low \u2013 Check the Fluid Leakage in Lines, Bleeder or CSC. Fix the leaks or replace the part/s. Then perform clutch bleeding and check the pedal condition. Fluid Level is Ok \u2013 Go to Step 2. Check the Clutch Pedal to Clutch Master Cylinder Link for damage. Not Ok \u2013 Replace the Clutch master Cylinder and perform Bleeding. OK - Go to Step 3. Check Clutch master cylinder operation for internal leak. Checking procedure \u2013 Disconnect the CMC outlet Hose CMC side, then hold the output with figure. Press the clutch pedal and feel the fluid get compress and experience the pressure., Not Ok \u2013 Replace CMC., CMC output pressure as per specification \u2013 Go to Step 4. Check the Clutch Disc or Pressure plate condition., Clutch Disc & Cover Inspection Procedure. , Clutch pressure plate Spring damage or clutch disc burn \u2013 Replace the Set and check the clutch pedal condition. The pilot bearing is mounted in the crankshaft and supports and locates the input shaft of the transmission. Use of a rolling bearing in place of the conventional bush, reduces the rolling resistance. However it should be noted that because of the bearing, it gives less leeway during assembly procedure. For additional information refer to Clutch Pressure Plate & Disc - R&R section. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B100017.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100099.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "using a MST 543 - Extractor flywheel bearing, remove the Flywheel Pilot Bearing. Refit the Flywheel Pilot Bearing by using MST 0312CBH0001ST - Flywheel Pilot Bearing Installer. For additional information refer to Clutch Pressure Plate & Disc - R&R section. ",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the pilot bearing for any damage, crack. Replace if found any. For additional information refer to Clutch Pressure Plate & Disc - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100084.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Lock the flywheel using MST 0307ABH0001ST \u2013 Flywheel Locking Tool. Using 19 mm socket spanner, remove flywheel mounting bolts and detach the flywheel. Torque : 50 \u00b1 3 Nm + 45\u00b0\u00b11\u00b0 ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100080.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the flywheel assembly. Install in the reverse order of removal. Always replace flywheel mounting bolts with new one before installation. Tighten the flywheel as per sequence and torque tighten the bolts to specified value. Torque : 50 \u00b1 3 Nm + 45\u00b0\u00b11\u00b0 ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carry-out clutch circuit air bleeding. For additional information refer to Clutch Fluid Air Bleeding Procedure. ",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check Flywheel face-out and run-out. Check Flywheel Surface Thermal Cracks Condition. Check the flywheel ring gear for worn-out or damage. The clutch cover is a diaphragm type with single-piece construction. In the engaged position (when the clutch pedal is not pressed), the diaphragm spring of the clutch cover assembly holds the clutch pressure plate against the clutch disc, thus clutch disc is held strongly in between flywheel & clutch pressure plate. This enables the engine torque to be transmitted to the input shaft of the gearbox, without any slip / loss For additional information refer to the transmission assembly with transfer case \u2013 R&R section. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0008,1008,1151",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100084.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Lock the flywheel using MST 0307ABH0001ST \u2013Flywheel Locking Tool. Using a 12 mm socket spanner, loosen and remove clutch cover assembly mounting bolts. Insert MST 0801BUA0001ST \u2013 Clutch Disc Aligner Tool, before loosening the clutch cover bolts to prevent clutch plate falling down and getting damage. Torque : 25 \u00b1 5Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B100026.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100056.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the clutch cover assembly along with the clutch disc. Detach the clutch disc from clutch cove assembly. Install in the reverse order of removal. While Installation, the projected part of clutch plate should come towards transmission side only, false installation can lead to clutch plate damage. While Installation, Using MST 0801BUA0001ST \u2013 Clutch Disc Aligner Tool, align the clutch cover assembly and clutch disc and fix the clutch cover assembly with the help of mounting bolts. Carry-out clutch circuit air bleeding. Check for abnormal wear in finger, pressure plate. Check pressure plate face-out and run-out. Check thickness of clutch plate, replace if found below MIN value. Clutch pedal return spring helps in returning the clutch pedal as soon as the load on pedal is released. Remove the clutch pedal box assembly. Using a 14 mm socket and ring spanner loosen and remove the Clutch Pedal Pivot Shaft nut and bolt. Remove the pedal pivot bolt and remove the pedal shank from the clutch pedal box. Using a nose plier, pull-down the double torsion Spring downwards and detach from pedal box and then gently pullout spring. Install in the reverse order of removal. Check return spring for proper stiffness. Check the Clutch Pedal Shank & Return Spring for any damage, crack. Replace if found any. 2 post lift /4 post lift.
2. Open the bonnet and lock it in open position using bonnet stay rod.
Clutch/Brake Fluid- Mahindra 'Maximile DOT 4' Genuine Brake fluid.Clutch/Brake FluidCapacity- 1.75 Liters (Including bleeding quantity).Entire bleeding operation should be done with engine ON condition. In case of fluid reservoir or brake fluid replacement, bleeding of brake circuit is required. Always use recommended fluid and do not mix different brand fluids. Always use fresh and clean fluid from a sealed container. Do not reuse the drained fluid. Fluid level in the reservoir must be at MAX level at the start of bleeding and should be checked after bleeding each brake circuit and top up as required. Using a flat end screw driver pull the bleeder lock and pull-out the clutch bundy tube upward from bleeder to drain the clutch fluid. Keep a tray beneath, pull-out the clutch bundy tube and collect the drained fluid in the tray. Press the clutch pedal gently for draining the entire fluid. Collect the fluid drained in a tray. Avoid spilling on floor. Drain the complete brake fluid. Connect the bundy tube back and press locking clip to lock the bundy tube. Ensure the bundy tube connected back and locking clip locked the bundy tube in its position. Fill recommended brake fluid up to MAX mark on brake fluid reservoir. Press and release the clutch pedal gently to full stroke a few times for the fluid to enter completely in the circuit. Remove bleeder plug cap from clutch operating slave cylinder pipe. Attach a vinyl tube to bleeder plug and insert the other end into container. Ensure that the other end of the tube is fully immersed in the bottle having clean clutch /brake fluid. If the bleeding operation is done without connecting a tube and in the open air then the chance of air trapped in the system is high. Ensure that the other end of the tube is fully immersed in the bottle having clean brake fluid. Press and release the clutch pedal 3-4 times slowly to the full stroke and hold the pedal in depressed condition. Using 11 mm open end spanner, rotate the bleeder screw by 90 degree in anticlockwise rotation and allow all the air bubbles to escape into the container. Bleeding plug to be in opened condition during bleeding process only. Remaining time it should be in closed position. Fluid starts flowing through the transparent tube into the container. Tighten the bleeder screw as soon as there is no air bubbles visible in the transparent tube. Repeat this operation until there are no more air bubbles in hydraulic line. Ensure sufficient fluid level in reservoir throughout the bleeding procedure. Remove the transparent tube. Then attach bleeder plug cap. Check fluid level in reservoir, maintain brake fluid at MAX level mark. Close the reservoir cap back and tight properly. Check and ensure proper working of clutch. Ensure to check any leakage in the bundy tube connector & bleeding plug cap, if leak found ensure to fit properly the bundy tube connector & bleeding plug cap. If pedal sponginess is present do the entire bleeding procedure again. Check clutch pedal for sponginess. If found spongy, repeat the entire procedure of bleeding. Check and ensure there is no leakage from pipes and joints. Do not spill brake fluid on the vehicle, it may damage the paint, if the brake fluid does contact the paint, wash it off immediately with water. Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. The fluid reservoir cap should not be opened with dirty hands. Avoid direct water spray on reservoir while washing engine compartment. If Maximile DOT 4 brake fluid is not available and in emergency conditions, use Brake Fluid Meeting SAE J1703 FMVSS NO.116 DOT 4 OR IS 8654 TYPE-2 Specification. Change it at 30,000 km or 2 years whichever is earlier. During the bleeding operation ensure the container and pipe used is of transparent for better visual. At all times during the bleeding process, it has to be ensured that the fluid level in the reservoir does not drop below minimum. The clutch master cylinder push rod is connected to clutch pedal. The clutch master cylinder converts driver's foot effort to hydraulic pressure and transmits the pressure to the slave cylinder through clutch bundy tube. Remove the transmission assembly with transfer case . Detach clutch master cylinder(CMC) fluid inlet hose CMC end. Pull the lock clip upwards and detach clutch high pressure pipe CMC end. Carefully remove the clutch master cylinder. Install in the reverse order of removal. For additional information refer to Clutch Fluid Air Bleeding Procedure. ",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the clutch high pressure tube for any damage. Replace if found. Inspect the Clutch Master Cylinder for any damage, crack. 1. Clutch sensor related error is registered in EMS ECU or
2. The gap between magnetic holder and the sensor body is more than 2 mm.
",
+ "file": null,
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the clutch pedal box assembly. For additional information refer to Clutch Pedal box Assembly - R&R section. ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A100073.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Loosen the sensor lock nut with the help of 13 mm open end spanner. Insert a 2 mm spacer in the gap between magnetic holder and sensor body. Using a 12 mm open end spanner, adjust the magnetic holder till it touches the surface of spacer, thus maintain 2 \u00b10.5 mm gap between sensor body and magnetic holder. Tighten the sensor lock nut. For additional information refer to Clutch Pedal box Assembly - R&R section. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "After completing the clutch sensor setting, connect i-SMART and navigate to THAR \u2013 THAR_BS6. Select \u201cEMS\u201d in the ECU List. Click on \u201cLIVE DATA\u201d and select \u201cDriveability\u201d. Release the clutch pedal fully, the value of clutch status should be \u201c64\u201d. Press the clutch pedal to 10%, the value of clutch status should be \u201c65\u201d. Press the clutch pedal fully, the value of clutch status should be \u201c81\u201d. If the clutch status value is not changing according to different clutch pedal position, re-adjust the clutch sensor. Using a star screw driver, loosen and remove the front splash shield mounting screw rivets from both the sides of vehicle. Remove the front splash shield both the sides from vehicle. Using a 10 mm socket spanner, loosen and remove the front stone guard front mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen and remove the rear stone guard rear mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the stone guard mounting screw rivets. Remove the stone guard from the vehicle. Disconnect the fog lamp electrical connectors LH & RH sides. Pull and remove the front bumper winch cover clips and remove the panel. Using 10 mm socket spanner, Unscrew front bumper mounting nuts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290004.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": "Using 13 mm socket spanner, Unscrew front bumper bottom mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": "Using 10 mm socket spanner, Unscrew front bumper top side mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front bumper top centre mounting screw rivets.. Remove the front bumper assembly from the vehicle. Install in the reverse order of removal. Inspect the front bumper assembly for any crack or damage. Replace if found. 2 post lift/ 4 post lift. 2. Turn the ignition OFF.",
+ "file": null,
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "DTC \u2014 Check Procedure using i-Smart diagnostic tester",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Connect the i-SMART diagnostic tester and turn the ignition ON. Select Dearborn Electronics India Pvt Ltd. \u2014 Garuda and then click START. Select THAR from the list of vehicles displayed as in following window then select the HAR_ BS6. Click on the GENERATE button on the bottom right side of the Express View screen to generate DTC report. This will generate and store a report. Once completed, i-SMART will prompt to open Excel file. If any DTC is active, Refer Diagnostic manual for more information. Connect the miniSMART Bluetooth VCI on DLC and turn the ignition ON. Pair the Bluetooth of android tablet / smartphone with miniSMART VCI. Launch the miniSMART App and select the THAR from the vehicle list. Connect the miniSMART Android and select each \u201cECU\u201d from the list of controllers. From the list, select DTC Fetch. The ECU will be analysed and the registered DTCs will be displayed, then take screen shots of all registered DTCs and their Freeze Frame data by clicking over the DTC / FF icon, for records. If any DTC is active, Refer Diagnostic manual for more information. Repeat the above steps 4 to 7 for other ECU\u2019s present in the vehicle. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove HVAC Control Panel (Manual). Carefully pull the Telltale Bank from inside. Disconnect the Telltale Bank electrical connectors and 12 volt electric connector and remove the Assy from IP. Using star screw driver remove Telltale bank mounting screws. Torque : 1.5 \u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the telltale bank. Install in the reverse order of removal. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the telltale bank for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect engine WH connector ECU end and detach harness from routing clips. Disconnect AC compressor electrical connector. Using 12 mm socket spanner, Unscrew ignition coil ground connector mounting nut. Disconnect Variable oil pump solenoid electrical connector. Disconnect upstream Lambda sensor electrical connector and connector holder. Disconnect Engine oil pressure sensor electrical connector and routing clip. Disconnect WGTelectrical connector. Disconnect Dump valve electrical connector and routing clip. Disconnect VVT IN (Intake Phaser) electrical connector. Disconnect VVT Out (Outlet Phaser) electrical connector. Disconnect Throttle Valve Actuator & Position Sensor electrical connectors. Disconnect Spark plug (4 nos) electrical connectors. Disconnect downstream lambda sensor electrical connector and routing clip. Disconnect Exhaust CAM sensor electrical connector. Disconnect Intake CAM phase sensor electrical connector. Disconnect Crankshaft Sensor electrical connectors. Disconnect Coolant temperature sensor electrical connector. Disconnect FIP electrical connector. Disconnect Common rail electrical connector. Disconnect Injector (4 nos) electrical connector. Disconnect Knock sensor electrical connector & routing clips. Disconnect Alternator connector & routing clip. Using 8 mm socket spanner, Unscrew starter motor solenoid switch electrical connector. Torque : 2.5\u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Disconnect reverse switch electrical connector. Disconnect GNS electrical connector. Disconnect transfercase switch electrical connector. Detach Engine WH on intake manifold side. Using 10 mm socket spanner, Unscrew engine WH carrier mounting bolts. Disconnect engine WH inter connector, Holding clip and routing clip fire wall end. Detach the WH harness from engine assembly. Detach engine wiring harness from engine compartment. Install in the reverse order of removal. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Torque tighten the earth mounting nuts to specified values. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. For additional information refer to Front LH Scuff Plate - R&R section. ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Detach the LH B pillar partially.",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3133.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Disconnect the Pre tensioner electrical connectors LH side.",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3134.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Disconnect the LH seat electrical connector and routing clips.",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3135.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Disconnect the Airbag ECU electrical connector.",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3136.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3137.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew earth cable mounting nut and disconnect the cable.",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3138.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Disconnect the parking brake switch electrical connector.",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3139.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Remove the Front RH Scuff Plate. For additional information refer to Front RH Scuff Plate - R&R section. ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Detach the RHS B pillar partially.",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3140.jpg",
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": "Disconnect the Pre tensioner electrical connectors RH side.",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3141.jpg",
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Disconnect the floor console inside wiring Harness routing clips.",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3142.jpg",
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Disconnect the RH seat electrical connector and routing clips.",
+ "file": null,
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3143.jpg",
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Remove the wiring harness from vehicle.",
+ "file": null,
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3144.jpg",
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Notice",
+ "content": "Ensure proper engagement of all the connectorsEnsure proper engagement of all the wiring harness mounting clipsEnsure proper routing of wiring harnessTorque tighten the earth mounting nuts to specified valuesConnect diagnostic tool connector and clear any DTC\u2019s if registered.",
+ "file": null,
+ "display_order": 64
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the wiring harness for any external damage, If any replace it.",
+ "file": null,
+ "display_order": 65
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 328,
+ "sys_id": "THAR.LX-0008-Electrical Components And Electrical Wiring Harness",
+ "subsys_id": "THAR.LX-0008-Electrical Components And Electrical Wiring Harness-Roof Wiring Harness",
+ "systems": "Electrical Components And Electrical Wiring Harness",
+ "sub_systems": "Roof Wiring Harness",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A370010.jpg",
+ "myid": 1441,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Roof Wiring Harness-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370010.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31622.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31621.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6Nm",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove A Pillar Upper Trim LH.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.LX-0008,1023,1361",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect speaker electrical pigtail inter-connector.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3159.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3160.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach MIC wire from routing.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3161.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach roof wiring harness from routing clips.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280051.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect IP to roof WH inter-connector and holding clip with routing clips.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3162.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove IP TOP Cover with PAB Assembly LH.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Detach WH routing clip and from vehicle.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370039.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Notice",
+ "content": "Ensure proper engagement of all the connectors.Ensure proper engagement of all the wiring harness mounting clips.Ensure proper routing of wiring harness.Connect diagnostic tool connector and clear any DTC\u2019s if registered.",
+ "file": null,
+ "display_order": 22
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the wiring harness for any external damage, If any replace it.",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 329,
+ "sys_id": "THAR.LX-0008-Electrical Components And Electrical Wiring Harness",
+ "subsys_id": "THAR.LX-0008-Electrical Components And Electrical Wiring Harness-Tail Door Wiring Harness",
+ "systems": "Electrical Components And Electrical Wiring Harness",
+ "sub_systems": "Tail Door Wiring Harness",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A370013.jpg",
+ "myid": 1442,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Tail Door Wiring Harness-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370013.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31632.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31631.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6Nm",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Rear RH Tail Lamp Assembly. For additional information refer to Front RH Tail Lamp Assembly - R&R section. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect floor to tail door interconnector and holding clips.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3163.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3164.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the tail door WH grommet.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370036.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect BIW pigtail inter-connector and connector holding clip.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3165.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the tail door Trim. For additional information refer to Tail Door Trim - R&R Section. ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect door latch electrical connector.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3166.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the Tail Door Wiring Harness from vehicle.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370035.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Notice",
+ "content": "Ensure proper engagement of all the connectors.Ensure proper engagement of all the wiring harness mounting clips.Ensure proper routing of wiring harness.Connect diagnostic tool connector and clear any DTC\u2019s if registered.",
+ "file": null,
+ "display_order": 21
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the wiring harness for any external damage, If any replace it.",
+ "file": null,
+ "display_order": 22
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 331,
+ "sys_id": "THAR.LX-0008-Electrical Components And Electrical Wiring Harness",
+ "subsys_id": "THAR.LX-0008-Electrical Components And Electrical Wiring Harness-MBFM",
+ "systems": "Electrical Components And Electrical Wiring Harness",
+ "sub_systems": "MBFM",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A370056.jpg",
+ "myid": 1445,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-MBFM-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370056.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31657.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31656.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect the MBFM electrical connectors. Detach the IP wiring harness holding clip from MBFM bracket. Using 10 mm socket spanner, Unscrew MBFM bracket mounting bolts from BIW and remove MBFM with bracket from the vehicle. Torque : 6.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew MBFM mounting bolts from the bracket and detach the MBFM. Torque : 6.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370057.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the MBFM and bracket for any external damage, If any replace it. Service Reminder Indicator Reset Procedure ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Service Reminder Indicator - Reset.mp4",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "In the instrument cluster, the service reminder alert will start popping up in the cluster screen at 200 kms before the actual kilometers at which the service is due. This will continue at every ignition cycle. It is necessary to reset the service reminder once the service is rendered to the vehicle. If not reset, the service alert will continue to pop up at every ignition cycle, till it is reset by using recommended procedures. Press the OK button on Driver side switch bank and simultaneously turn the ignition ON. Release the OK button within 5 seconds after ignition on. Check and ensure that the service reminder alert is OFF in the cluster. The above procedure would reset the Service Reminder Alert till the next scheduled maintenance. Service reminder alert is provided with the intent of reminding the customer about a pending service visit hence, perform this SOP only after the vehicle has actually undergone servicing. For additional information refer to splash shield Front RH -R&R section. ",
+ "file": null,
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Disconnect RH fog lamp electrical connector routing clips.",
+ "file": null,
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C009_C 67.jpg",
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Disconnect RH head lamp electrical connector.",
+ "file": null,
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3118.jpg",
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Description",
+ "content": "Disconnect RH head lamp levelling motor(HLLD) electrical connector.",
+ "file": null,
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C033_C 99.jpg",
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "Description",
+ "content": "Disconnect RH side marker lamp electrical connector with a routing clip.",
+ "file": null,
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C037_C 202.jpg",
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "Description",
+ "content": "Disconnect Front RH indicator and DRL connector and detach grow mat to take out connector.",
+ "file": null,
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C050_C 590.jpg",
+ "display_order": 72
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner unscrew earth cable mounting nut from RH fender and detach cable.",
+ "file": null,
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C058_G 11.jpg",
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6 Nm",
+ "file": null,
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "Description",
+ "content": "Detach WH routing clips from fender.",
+ "file": null,
+ "display_order": 76
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370030.jpg",
+ "display_order": 77
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370029.jpg",
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "Description",
+ "content": "Disconnect engine compartment to IP electrical connectors.",
+ "file": null,
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C040_C 404 F.jpg",
+ "display_order": 80
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C041_C 405 F.jpg",
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C042_C 406 M.jpg",
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C043_C 407 F.jpg",
+ "display_order": 83
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "Description",
+ "content": "Disconnect accelerator pedal electrical connector.",
+ "file": null,
+ "display_order": 84
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C025_C 86.jpg",
+ "display_order": 85
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "Description",
+ "content": "Disconnect brake switch electrical connector with a routing clip.",
+ "file": null,
+ "display_order": 86
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C024_C 85.jpg",
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "Description",
+ "content": "Disconnect clutch sensor electrical connector.",
+ "file": null,
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C026_C 87.jpg",
+ "display_order": 89
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "Description",
+ "content": "Detach WH routing clips and take out wiring.",
+ "file": null,
+ "display_order": 90
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370031.jpg",
+ "display_order": 91
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "Description",
+ "content": "Detach WH from inside to outside.",
+ "file": null,
+ "display_order": 92
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370032.jpg",
+ "display_order": 93
+ },
+ {
+ "step_name": "Step-40",
+ "content_type": "Description",
+ "content": "Remove the scuttle Grill.",
+ "file": null,
+ "display_order": 94
+ },
+ {
+ "step_name": "Step-40",
+ "content_type": "Link",
+ "content": "THAR.LX-0008,1024,1373",
+ "file": null,
+ "display_order": 95
+ },
+ {
+ "step_name": "Step-41",
+ "content_type": "Description",
+ "content": "Disconnect Wiper motor electrical connector and a routing clip.",
+ "file": null,
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-41",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C004_C 54.jpg",
+ "display_order": 97
+ },
+ {
+ "step_name": "Step-42",
+ "content_type": "Description",
+ "content": "Disconnect IP to Engine compartment wiring harness inter-connectors.",
+ "file": null,
+ "display_order": 98
+ },
+ {
+ "step_name": "Step-42",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370017.jpg",
+ "display_order": 99
+ },
+ {
+ "step_name": "Step-43",
+ "content_type": "Description",
+ "content": "Disconnect engine compartment to chassis WH inter-connector.",
+ "file": null,
+ "display_order": 100
+ },
+ {
+ "step_name": "Step-43",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A02C044_C 424 M.jpg",
+ "display_order": 101
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "Description",
+ "content": "Disconnect washer tank electrical connector.",
+ "file": null,
+ "display_order": 102
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A320038.jpg",
+ "display_order": 103
+ },
+ {
+ "step_name": "Step-45",
+ "content_type": "Description",
+ "content": "Detach Engine compartment Wiring Harness from engine compartment.",
+ "file": null,
+ "display_order": 104
+ },
+ {
+ "step_name": "Step-45",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W662.jpg",
+ "display_order": 105
+ },
+ {
+ "step_name": "Step-46",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 106
+ },
+ {
+ "step_name": "Step-46",
+ "content_type": "Notice",
+ "content": "Ensure proper engagement of all the connectors.Ensure proper engagement of all the wiring harness mounting clips.Ensure proper routing of wiring harness.Torque tighten the earth mounting nuts to specified values.Connect diagnostic tool connector and clear any DTC\u2019s if registered.",
+ "file": null,
+ "display_order": 107
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the wiring harness for any external damage, If any replace it.",
+ "file": null,
+ "display_order": 108
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 327,
+ "sys_id": "THAR.LX-0008-Electrical Components And Electrical Wiring Harness",
+ "subsys_id": "THAR.LX-0008-Electrical Components And Electrical Wiring Harness-Chassis Wiring Harness",
+ "systems": "Electrical Components And Electrical Wiring Harness",
+ "sub_systems": "Chassis Wiring Harness",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W665.jpg",
+ "myid": 1440,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Chassis Wiring Harness-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W665.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31593.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31592.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable.",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6Nm",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the e-disconnect stone guard.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the Front RH wheel speed sensor C 361 connector.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A16C005_C 361.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach wiring harness routing clips on front cross member.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W666.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370009.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W667.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect the e-disconnect motor C 231 connector.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3145.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect the front LH wheel speed sensor C 360 connector.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Chassis Wiring Harness.PNG",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Detach wiring harness routing clips on chassis.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370011.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Disconnect engine compartment WH to Chassis WH inter-connector.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3146.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Detach routing clips on chassis LH side.",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W668.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Disconnect the chassis to FDM C 485 F inter-connector.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3147.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Disconnect the rear LH wheel speed sensor C 362 connector.",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3148.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Detach routing clips on chassis rear LH side .",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370014.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Disconnect the chassis to bumper C 434 F inter-connector.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3149.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Disconnect the DEF pigtail C 707 F inter-connector.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3150.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Detach rear chassis routing clips.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370040.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Disconnect the rear RH Wheel Speed Sensor C363 connector.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3151.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Detach routing clips on chassis rear RH side.",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3152.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Remove the Rear LH Tail Lamp Assembly. ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner unscrew LH tail lamp earth cable mounting nut and detach it.",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3153.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6 Nm",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Detach routing clip and grow mate.",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W669.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370015.jpg",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Remove the Rear RH Tail Lamp Assembly. ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner unscrew RH tail lamp earth cable mounting nut and detach it.",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3154.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Disconnect the tail lamp RH C 153 connector.",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3155.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": "Disconnect the tail lamp LH C 154 connector.",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3156.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Disconnect the chassis to tail gate-2 C 708 F inter- connector.",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3157.jpg",
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Disconnect the chassis to tailgate-3 C 709 F inter-connector.",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3158.jpg",
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Remove the chassis wiring harness from vehicle.",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Notice",
+ "content": "Ensure proper engagement of all the connectors.Ensure proper engagement of all the wiring harness mounting clips.Ensure proper routing of wiring harness.Torque tighten the earth mounting nuts to specified values.Connect diagnostic tool connector and clear any DTC\u2019s if registered.",
+ "file": null,
+ "display_order": 60
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the wiring harness for any external damage, If any replace it.",
+ "file": null,
+ "display_order": 61
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 330,
+ "sys_id": "THAR.LX-0008-Electrical Components And Electrical Wiring Harness",
+ "subsys_id": "THAR.LX-0008-Electrical Components And Electrical Wiring Harness-HVAC WIRING HARNESS (Manual)",
+ "systems": "Electrical Components And Electrical Wiring Harness",
+ "sub_systems": "HVAC WIRING HARNESS (Manual)",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/202db8cc.png",
+ "myid": 1444,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-HVAC WIRING HARNESS (Manual)-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/202db8cc.png",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Capture97451a.PNG",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Capture1.PNG",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Untitledb3511e.png",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the cable.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6Nm",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the HVAC Control Panel. For additional information refer to HVAC Control Panel \u2013 R&R Section.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.LX-0008,1018,1329",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/hvac_wiring_harness.JPG",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/3(2).png",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Open the glove box and remove the glove box by detaching the lock.",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4a92c2e.png",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the Driver side IP panel\nassembly.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/5a7885c.png",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect the HVAC control panel C\n720 connector.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/6.png",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect the intake actuator C 722\nconnector.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/758c66b.png",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect the blower motor C 721\nconnector.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/872b194.png",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Disconnect the blower resistor C 723\nconnector.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/9128e66.png",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Disconnect the thermo amplifier C 724\nconnector.",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/10ddee6e.png",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Disconnect the HVAC unit C 117 M\nconnector.",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11374674.png",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Disconnect the blower switch C 720A\nconnector.",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/121ae122.png",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen\nand disconnect the HVAC ground G 2\nconnector.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.0\u00b10.6 Nm",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Remove the wiring harness separately.",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Notice",
+ "content": "\u2022 Ensure proper engagement of all the connectors.\u2022 Ensure proper engagement of all the wiring harness mounting clips.\u2022 Ensure proper routing of wiring harness.\u2022 Torque tighten the earth mounting nuts to specified values.Connect diagnostic tool connector and clear any DTC\u2019s if registered.",
+ "file": null,
+ "display_order": 33
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the wiring harness for any external damage, If any replace it.",
+ "file": null,
+ "display_order": 34
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 333,
+ "sys_id": "THAR.LX-0008-Electrical Components And Electrical Wiring Harness",
+ "subsys_id": "THAR.LX-0008-Electrical Components And Electrical Wiring Harness-Ambient Temperature Sensor",
+ "systems": "Electrical Components And Electrical Wiring Harness",
+ "sub_systems": "Ambient Temperature Sensor",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A370061.jpg",
+ "myid": 1447,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Ambient Temperature Sensor-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370061.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31673.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the sensor from the routing slot. Take out the sensor and disconnect the electrical connector. Install in the reverse order of removal. Inspect the ambient temperature sensor for any external damage, If any replace it. Remove the hard top assembly. Remove the X-mas tree clips by trim remover from over the roof rail outer frame. Then pull the seal by manually, due to this seal has fixed with two-way pasting tape. Clean the surface by digresses cloth. Peel the sticker label sheet from the new Seal, then paste on the roof rail outer frame followed by press the X-mas tree clips. The Seal must be replaced along with X-mas tree clips, when the seal loses its softness or if found any damages, don't reused the X-mas tree clips. This seal is for preventing the water leakage and wind noise only. Seal coming with Two-way pasting tape. Install in the reverse order of removal. Using a star screw driver, Unscrew hard top quarter glass frame mounting screws from the rear window. Pull - out the glass beading from Quarter Glass. Carefully push from inside to outside and remove the rear window from the vehicle. Install in the reverse order of removal. While Installation always replace with New frame mounting screws Inspect the hard top quarter glass for any damage/crack etc. Replace if found any Inspect the hard top quarter glass mounting fasteners for any damage. Replace the fasteners if required Remove the B pillar lower trim.
Remove the centre roof bow trim. Open the top cover and Using a 14 mm socket spanner, loosen and remove the seat belt upper mounting bolt. 38 \u00b16 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210071.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the upper trim from vehicle. Install in the reverse order of removal. Inspect the B-pillar upper trim for any damage/crack/cut etc. Replace if found any. Inspect the B-pillar upper trim fasteners for any damage. Replace the fasteners if found any damage.. Remove the Hardtop Assembly. Remove the Seal from the vehicle. Inspect the Front Lateral trim for any damage/crack/cut etc. Replace if found any. Inspect the Front Lateral trim mounting legs for crack/bend etc. Remove Side window RH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Unzip the tail gate window, detach the tail gate bar locking from rear RH & LH belt rails remove the tailgate window. Unhook the \u2018C\u2019 pillar cover from rear RH & LH belt rails and fold the cover at top of the soft top. Using a T30 socket spanner, loosen and remove the belt rear rail Mounting bolts and remove the belt rail from the vehicle. Follow the same procedure for LH side. Using a T30 socket spanner, loosen and remove the belt center rail Mounting bolts and remove the belt rail from the vehicle Follow the same procedure for LH side. Using T30 socket spanner, loosen and remove the belt vertical rail mounting bolts and remove the belt rail from the vehicle. Follow the same procedure for LH side. Remove the belt corner rail from the vehicle. Follow the same procedure for LH side. Using T30 socket spanner, loosen and remove the belt door rail mounting bolts and remove the belt rail from the vehicle. Follow the same procedure for LH side. Install in the reverse order of removal. Inspect the Seal/rail for any damage/crack/cut etc. Replace if found any. Using a trim removal tool pull out center bow trim and disconnect roof lamp electrical connector Remove the centre bow trim from the vehicle. Remove the roof lamp from bow trim. Install in the reverse order of removal. Inspect the trim for any damage/crack/cut etc. Replace it if found. Remove the B Pillar Upper Trim. Using a 10 mm socket spanner unscrew Grab handle mounting bolts. 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner unscrew front lateral trim mounting bolt. 2 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the Front lateral trim. Install in the reverse order of removal. Inspect the Front Lateral trim for any damage/crack/cut etc. Replace if found any. Inspect the Front Lateral trim mounting legs for crack/bend etc. For additional information refer Driver Sun Visor \u2013 R&R. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove co-driver sun visor. For additional information refer Co-Driver Sun Visor \u2013 R&R. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a T40 Torx Socket spanner unscrew centre bow trim mounting screws. 5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a trim removal tool carefully detach the trim and remove electrical connector. Detach the MIC carefully from the trim.. install in the reverse order of removal. Inspect the trim for any damage/crack/cut etc. Replace it if found . Remove Front Roof Bow Trim. Remove Front Lateral Trim. For additional information refer to Front Lateral Trim \u2013 R &R; section. Using a 10 mm socket spanner unscrew A pillar trim mounting bolt. Torque : 2 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the A pillar upper trim from vehicle. Install in the reverse order of removal. Inspect the A-pillar upper trim for any damage/crack/cut etc. Replace if found any. Inspect the A-pillar upper trim mounting legs for crack/bend etc. When the engine is stopped and the ignition switched off, the battery feeds accessories which are directly connected to battery, such as alarms, clock, radio code and certain computers that operate continuously. Dark currents are considered normal if they do not exceed a few tens of milli amperes. If the value is more than that, one or more permanent electrical component is drawing too much current. They can be isolated by withdrawing the fuses one by one until the faulty circuit is identified. A multi-meter is the best tool for these measurements. A current clamp cannot accurately measure currents of less than 1 A. The measurement must be taken at the battery itself. Before carrying out leakage current test, Turn all accessories OFF. Switch OFF the ignition and remove the key. Close all doors and windows. Wait for minimum 3 Minutes and then do the checking procedure. In multi-meter, current selection should be in milliampere. Set the current measuring range of the ammeter to 10 A. Disconnect the negative terminal from the battery. Connect the positive terminal of multimeter (Red probe) with the negative terminal removed from the battery and connect the negative terminal of multimeter (black probe) with negative pole of the battery. Read the value in multi-meter. If the current measured is more than permissible value (For MT Variants \u2013 7 mA (Max) & for AT Variants \u2013 12 mA (Max)) ,check for any: Loose connection in ground points. Check for any active loads ( like roof lamp,etc;). Hydrometer is a float-type device used to determine the State-of-Charge by measuring the specific gravity of the electrolyte in each cell. It is an accurate way of determining a battery's state of charge and weak or dead cells. Wear suitable eye protectors (goggles). With the help of a flat end screw driver, remove the vent caps or covers from the battery. Squeeze the hydrometer bulb and insert the pickup tube into the cell close to the battery positive terminal. Slowly release the bulb to draw in only enough electrolyte to cause the float to rise. Do not remove the tube from the battery Read the specific gravity indicated on the float. Be sure the float is drifting free, and does not contact with sides of the barrel. Read the hydrometer at eye level. Disregard the slight curvature of liquid on the float. The specific gravity for fully charged battery is as follows:
1. AMARON -1.270 \u00b1 0.010 at 27\u00b0C
",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step 6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080030.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step 6",
+ "content_type": "Description",
+ "content": "Specific gravity readings
Specific gravity varies with the temperature. If the electrolyte temperature is substantially above 27\u00b0 C add seven points (0.007) to the observed specific gravity reading for every 10\u00b0 C by which the actual temperature is above 27\u00b0 C. Deduct seven points per 10\u00b0 C where the observed reading is below 27\u00b0 C to obtain the temperature corrected reading at 27\u00b0 C. Inspect battery electrolyte specific gravity whenever required. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the cable. Using 10 mm socket spanner, loosen and remove the engine feed cover mounting bolts. Using 14 mm socket spanner, rotate the auto tensioner in anti-clockwise direction and detach the accessory belt. Disconnect the alternator electrical connector. Remove alternator positive cable cover. Using 12 mm socket spanner, loosen and remove the alternator positive cable nut. Using 12 mm socket and ring spanner, Remove the alternator top mounting bolt and nut. Using 12 mm socket spanner, loosen and remove the alternator bottom mounting bolt and nut. Carefully remove the alternator from engine compartment. Install in reverse order of removal. level ground. 2. Open the bonnet and lock it in open position using bonnet stay rod.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Battery Health - Checkup.mp4",
+ "display_order": 2
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25352.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080001.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Testing",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "When you start a new test, the last test results in memory are overwritten. Remember to record or print the results if you need to retain them. Connect the MDX - 650P battery tester to battery terminals connecting probes on the battery posts respectively. Press the Enter button and confirm the BATTERY LOCATION by selecting the \u201cIN VEHICLE\u201d in the tester using navigation button Up or Down . Press the Enter button and confirm the POST TYPE by selecting the \u201cTOP POST\u201d in the tester using navigation button Up or Down . Press the Enter button and confirm the APPLICATION by selecting the \u201cAUTOMOTIVE\u201d in the tester using navigation button Up or Down . Press the Enter button and confirm the BATTERY TYPE by selecting the \u201cREGULAR FLOODED\u201d in the tester using navigation button Up or Down . Press the Enter button and confirm the BATTERY STANDARD by selecting the \u201cJIS\u201d in the tester using navigation button Up or Down . Press the Enter button and get the recommended JIS Number value by pressing button Up or Down . Press the Enter button and perform the TESTING. Once the TESTING done, the initial battery result will be display. Press the PRINT button to get the hard copy print out. Disconnect the battery tester probes from battery terminals. Follow the below table for Battery Testing test results condition and remedial action Check the electrolyte level. Add distilled water to all the cells which require water. Ensure the electrolyte level between MIN and MAX marks. Refit the vent plugs properly. Topping up should be done with distilled water only. Never use normal water or mineral water to top battery electrolyte. Vent holes should be clear Clean the terminals. Tighten terminals to specified torques. Check battery electrolyte level whenever required. Specific Gravity v/s With% Charge v/s With OCV Do battery electrolyte level inspection when required. Open Circuit Voltage Test Turn ON the head lamp high beam for 30 seconds to remove any surface charge. Digital voltmeter checks the battery\u2019s open circuit voltage. Analogue meters do not show accurate readings and should be avoided. Turn OFF the head lamp, disconnect the battery and connect the digital voltmeter across the battery terminals. Note the readings in the voltmeter. A fully charged battery will have an open-circuit voltage based on below table value. Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. Using 10 mm socket spanner, loosen battery positive cable mounting nut and disconnect the cable. Using 13 mm socket spanner, loosen and remove the battery holding clamp mounting nuts. Remove the battery from the vehicle. Install in reverse order of removal.
The driver airbag module connects to the steering column wiring harness via a rotary coupler called as clock spring. Within the driver airbag module there is a squib which, when given the correct current by the airbag ECU, inflates the airbag by initiating a chemical reaction. In deployment, the airbag inflates within a fraction of a second and then deflate at a controlled rate as the driver body regions; typically head and chest interact with airbag. Vents in the airbag control its deflation.
",
+ "file": "",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": "Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Steering Column Shrouds. For additional information refer to Steering Column Shrouds - R&R section. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Turn the steering wheel to 90\u00b0 counter clockwise direction from the steering wheel straight position and using a screw driver press the RHS DAB lock then release the lock. DAB locks are made up of plastic, ensure to press the locks softly by screwdriver. Turn the steering wheel to 90\u00b0 clockwise direction from the steering wheel straight position and using a screw driver press the LHS DAB lock then release the lock. DAB locks are made up of plastic, ensure to press the locks softly by screwdriver. Gently pull-out the DAB module from the steering wheel. Using a small flat end screw driver release the lock of the DAB electrical connector, then disconnect the DAB and horn electrical connectors. While refit ensure wires are routed out of the snapping zones to avoid damage. Remove the DAB module separately. Install in the reverse order of removal. Inspect the DAB module for any physical damage. Replace if found any Inspect the DAB connector for any damage.
Within the passenger airbag module is a squib which, when given the correct current by the airbag ECU, inflates the airbag by initiating a chemical reaction. In deployment, the airbag inflates within a fraction of a second and then deflates at a controlled rate as the passenger body regions; typically head and chest interact with airbag. Vents in the airbag control its deflation.
",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210035.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210045.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/32012.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/32013.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080024.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Glove Box Assembly. Remove the IP grab handle cover. Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts. Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220023.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting screws. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220024.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle. Partially detach the door edge beading and using a trim removal tool, remove the IP LH side cover. By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt. Torque : 8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220076.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220066.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector. Take out the IP LH side top cover with Passenger air bag from the IP. Using a 10 mm ring spanner, loosen and remove the air bag mounting bolt from IP top cover. Torque :4.5\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210046.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Expand the PAB module holder both sides using screw driver and detach the PAB separately from IP top cover. Install in the reverse order of removal. Inspect the PAB module for any damage. Replace if found any. Inspect the PAB module connector for any damage. Inspect the PAB module trim for any damage. The Airbag ECU is installed on the floor panel under the floor console. It deploys the proper Airbag according to the signals from the impact sensors. This ECU communicates with other ECU\u2019s through CAN directly. Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Front console assembly. For additional information refer to Front Console Assembly R&R section. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver remove the Airbag ECU Cover screw from airbag ECU. Disconnect the SRS/ Airbag ECU electrical connectors. Using a 10 mm socket spanner, loosen the SRS/ Airbag ECU mounting nuts on the floor panel. Torque :8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210052.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the SRS/ Airbag ECU from the body. Install in the reverse order of removal. Inspect the airbag ECU for any damage, replace if found any. Inspect the airbag ECU connectors for any damage. The Airbag unit monitors the internal/external devices of the Airbag system including battery voltage, limits certain functions of the Airbag, and turns on the Airbag warning lamp on the instrument cluster according to the conditions. Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front splash shield lower mounting screws. Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts. Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield. Disconnect the front Crash sensor electrical connector. Using a 10 mm socket spanner, loosen and remove the front Crash sensor mounting bolt from the vehicle. Torque :8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210057.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the front crash sensor from the vehicle. Install in the reverse order of removal. Inspect the front crash sensor for any damage. Replace if found. Using vehicle key open the fuel filler door. Rotate fuel filler lid cap anti-clock wise direction and remove the cap. Using 10 mm socket spanner unscrew fuel filler neck mounting bolts. Torque : 5 \u00b1 1.0 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner loosen hose clamp and remove fuel filler hose pipe end and detach the hose. Torque : 6 \u00b1 1.0 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect fuel vent and fuel vapour line quick couplers. Disconnect fuel filler hose routing clip and remove the hose from vehicle. Refit in the reverse order of removal. Inspect fuel filler pipe assembly for any physical damage, replace if found any. Inspect fuel filler pipe assembly for any leakage. Rectify if found any. Fuel Delivery Module delivers the fuel to the low pressure line and to measure the fuel level in the tank. Fuel delivery module consists ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040092.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "1. Float assembly for fuel level status.
2. An electric motor with in build reservoir for pumping the fluid at a pressure of 4 bar from the tank to the fuel rail.
3. An fuel-pressure regulator valve for regulating the fuel pressure.
The entire fuel delivery module is immersed in fluid and the electric motor is lubricated by fuel itself.
",
+ "file": null,
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30525.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30526.jpg",
+ "display_order": 7
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove Fuel tank assembly. Disconnect the FDM electrical connector. Remove fuel tank protection cover screw nuts and detach cover from tank. Press the lock and disconnect the fuel supply line and return line pipe from the fuel delivery module and remove the hoses from the fuel tank. Using shaft and mallet carefully hammer on the FDM lock in counter clock wise direction and release it. Carefully remove FDM unit from fuel tank. Install in the reverse order of removal. Always replace the O ring with a new one once FDM removed. Ensure the FDM top flange extension should be matched with the arrow mark on the fuel tank shell as shown in the above illustration Using a suitable metal shaft and hammer, tap the FDM lock ring to get properly lock. Inspect fuel delivery module for any damage. Inspect the float assembly operation and for any damage. Fuel System Low Pressure Circuit Test Gauge ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040231.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Fuel System Low Pressure Circuit Test Gauge tool kit is used to diagnose Fuel System Low pressure circuit related concerns only. Without removing FDM Assembly or Fuel Tank assembly from vehicle, we can able to check the Fuel Delivery Module supply pressure. Any blockages/ choke or air entrapment in Fuel line low pressure circuit can be diagnosed by using this Kit. Above steps are for removal of Residual pressure in Gasoline vehicles. Detach the fuel line quick coupler from the fuel supply pipe inter connection end. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Detach the fuel line quick coupler from the FIP. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Engage the Female adapter of gauge with the fuel supply pipe interconnection (Filter to FIP) Qwik fix connector. Connect the male Qwik fix connector of gauge with the FIP inlet. Turn the Ignition ON, FDM starts operating. Note down the maximum pressure reading. Allowable pressure Range of New Thar Gasoline vehicles : 5.2 to 5.4 bar. Turn the Ignition OFF and remove the Fuel Gauge. Connect the fuel line to FIP Inlet pipe and fuel supply pipe interconnection. The fuel tank is a reservoir for the fuel and incorporates the Fuel delivery module inside Disconnect fuel vent hose quick coupler from gasoline tank. Using hose clamp plier release fuel filler hose spring band clamp and disconnect the hose fuel tank endr. Disconnect fuel vapour hose quick coupler from gasoline tank fuel filter side. Disconnect the fuel vapour quick couplers in the tank supply end. Disconnect the fuel tank supply pipe quick coupler. Disconnect the fuel tank return hose quick coupler. Disconnect fuel tank electrical connector. Provide Jack to support the fuel tank. Using 13 mm socket spanner unscrew fuel tank mounting bolts. Torque : 55 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the tank Assembly from vehicle. Install in the reverse order of removal. Check for fuel leakage in the fuel tank. Check for any external damage, if found please replace. Disconnect fuel rail pressure sensor electrical connector. Before working on the high pressure side fuel components (Fuel Injection Pump, High Pressure Pipe, Fuel Rail & Injectors) turn the engine off, disconnect fuel supply hose quick coupler at FIP end and wait for Ten minutes. The fuel system is a non \u2013 return fuel system and fuel pressure within the system is very high. Failure to follow above instruction will result in personal injury Eye protection and a mask must be worn at all times while working near any fuel related components. Failure to follow this instruction will result in personal injury Using 24 mm deep socket spanner, Loosen and remove fuel rail pressure sensor. Torque : 25 \u00b1 3.0 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040026.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal. Fuel Rail sensor should be remove & refit only 5 times, ensure to replace New Assembly beyond 5 times Inspect the rail sensor for any damage. Replace if found. Inspect the rail sensor for any damage. Replace if found. Disconnect FDM electrical connector routing clip and detach WH. Detach the fuel tank vapour pipe from routing and tank end. Drain the fuel from the tank. Remove fuel tank bracket mounting push clips and detach the bracket. Refill the fuel in the tank. Install in the reverse order of removal. Check for fuel leakage in the fuel tank Check for any external damage, if found please replace. Check for free movement of float assembly without any restriction. This high pressure fuel line connects High pressure pump with fuel rail and supplies compressed high pressure fluid to fuel rail. Using 17 mm open end spanner loosen the HP pipe mounting from FIP and common rail ends. Torque : 22.5 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040061.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before working on the high pressure side fuel components (Fuel Injection Pump, High Pressure Pipe, Fuel Rail & Injectors) turn the engine off, disconnect fuel supply hose quick coupler at FIP end and wait for Ten minutes The fuel system is a non \u2013 return fuel system and fuel pressure within the system is very high. Failure to follow above instruction will result in personal injury Eye protection and a mask must be worn at all times while working near any fuel related components. Failure to follow this instruction will result in personal injury Remove the HP pipe from vehicle. Refit in the reverse order of removal. Inspect the high pressure fuel pipe for any damage. Replace if found any. Inspect the high pressure fuel pipe for leakage, rectify if found. Remove the Fuel Delivery Module Assembly. Press the clip and unlock the sensor from the mount, move the level sensor in upward direction with moderate strength & remove the sensor assembly from the FDM. Detach the wiring from the level sensor housing. By Using suitable pin take out the wiring pins from sensor. Pressing the both sided snap-on tabs of the cable connector through the opening of the housing and cover carefully and simultaneously pull out the wire connectors from float unit. Prior to the Installation, both the wiring connector snap-on tabs have to be bent back to the right position as shown below (By using Knife or suitable tool). Plug the wiring connectors pins on the New sensor housing at appropriate place with moderate force. Ensure to Plug the wiring connectors pins on the New sensor housing at appropriate slots based on wiring colours as shown The firm snap-on of the wire connectors is to be examined by a moderate pulling examination. Attach the wiring from the level sensor housing. Lock the sensor on the mount & refit the sensor assembly on the FDM. Refit the Fuel Delivery Module Assembly. Check for free movement of float assembly without any restriction. Inspect the float assembly for proper working condition. Check for any damage in float assembly, If any damage found replace it. Fuel System Low Pressure Circuit Test Gauge ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040231.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Fuel System Low Pressure Circuit Test Gauge tool kit is used to diagnose Fuel System Low pressure circuit related concerns only. Without removing FDM Assembly or Fuel Tank assembly from vehicle, we can able to check the Fuel Delivery Module supply pressure. Any blockages/ choke or air entrapment in Fuel line low pressure circuit can be diagnosed by using this Kit. 2 post lift/ 4 post lift and turn engine OFF.",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Preliminary Activities/Conditions",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040001.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Press the lock and disconnect the filter inlet hose quick coupler from the filter. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Press the lock and disconnect the filter outlet hose quick coupler from the filter. Remove the fuel filter from mounting bracket lock and remove the filter from the vehicle. Refit the fuel filter in the vehicle on mounting bracket lock. Ensure arrow mark on the fuel filter assembly should be pointing towards vehicle front (Arrow mark indicating that the fuel flow direction towards engine). Always use recommended filter only. Reconnect the fuel filter fuel outlet line quick coupler. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Reconnect the fuel filter fuel inlet quick coupler. Check and ensure proper fitment of fuel lines, any leakage can lead to fire. Remove High Pressure Pipe (Pump to Rail). Before working on the high pressure side fuel components (Fuel Injection Pump, High Pressure Pipe, Fuel Rail & Injectors) turn the engine off, disconnect fuel supply hose quick coupler at FIP end and wait for Ten minutes. The fuel system is a non \u2013 return fuel system and fuel pressure within the system is very high. Failure to follow above instruction will result in personal injury. Eye protection and a mask must be worn at all times while working near any fuel related components. Failure to follow this instruction will result in personal injury. Using 10 mm socket spanner unscrew oil dipstick guide mounting bolt, nut and keep aside dipstick guide. Torque : 11 \u00b11.0 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect fuel rail electrical connector. Disconnect injector electrical connectors. Using 12 mm socket spanner loosen and remove the fuel rail mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully remove the Fuel Rail Assembly with injectors. Injectors Combustion Seals should be replaced with new ones when ever removing & refitting the Fuel Rail Assembly from the cylinder head. Remove the Combustion Seal by using plastic lever or plastic pliers or Nose plier. The Combustion Seal can be stretched until it breaks or can be removed off the component. When removing Combustion Seal, no metallic fixtures (pliers, fork, scissors, cutter, trimmer) are allowed to be used, which may damage injector sealing surface. Only plastic fixtures can be used Take care not to damage the surface of the injector Inspect the sealing surface and replace the complete injector in case there is a defect on sealing surface (such as a tool mark) properly Clean the Combustion Seal groove & injector tip by bathing it in an appropriate cleaning fluid, before assembling the Combustion Seal. Position the injector in vertical position (O-ring in the upper side) in the cleaning bath for 10 to 15 min, not above the middle of the Valve Body Cleaning fluid must not content acids and/or substances not recommended to get in contact with steel or PA and avoid oil, lubricant, grease Can use P3-Galvaclean20 (Henkel) cleaning fluid with a concentration of 20 to 80 g/l diluted in demineralized water pre heated at 50\u00b0C Cleaning fluid must not get in the connector and/or inside the injector and non metallic parts of the injector Does not use brush, emery paper or ultrasonic device on clean the injector Inspect the sealing surface and replace the complete injector in case there is a defect on sealing surface (such as a tool mark) The surfaces of the new Combustion Seal must be clean and free of grease. The geometry of the groove must not be damaged or modified. Place the Combustion Seal installation special tool on the injector tip. Insert and push the sealing ring by using pushing tool over the sealing ring tool until it snaps into the groove. The seal must be completely free of grease and oil Remove the Combustion Seal installation special tool from injector tip. Insert the injector to the sizing special tool and turn 180\u2070 so that the seal fits well in the groove. Remove Injector from the sizing tool by turning it in the reverse direction. Check that the Combustion Seal has not been damaged during assembly to the injector and ensure seal must fit properly in the relative groove. Inspect the Fuel rail for any damage. Replace if found. Check injectors, Injector clips for any external damage, If found replace. Inspect the Injectors connectors for any damage. Replace if found. Refit in the reverse order of removal. After Installation, Running the engine at idle for few minutes and Check for fuel leakage in fuel rail and injector assembly. If found rectify the same. Carry out Injector routine procedure - using i-SMART. For additional information refer to the diagnostic manual. During assembly in Fuel Rail, no hammers or impact tools should be used which could directly bear on or affect the High Pressure Fuel Injector Fuel Rail Assembly should be remove & refit only 5 times, ensure to replace New Assembly beyond 5 times The Purge valve is a solenoid valve in a plastic housing which is controlled by the EMS ECU. The Purge valve controls the hydrocarbon vapours flow into Intake manifold in accordance with the engine\u2019s operating status. Disconnect the vapour hose quick coupler purge valve end. Using hose clamp plier release vapour hose spring band clamp and disconnect the hose. Disconnect purge valve electrical connector. Detach purge valve from holding bracket on the intake manifold. Refit in the reverse order of removal. Inspect the hose for any physical damage, replace if found any. Inspect the hose for any leakage. Rectify if found any. The high pressure pump (Direct Type) receives drive from intake cam shaft. The rotation of camshaft lifts and releases the roller tappet up and down according to the cam profile. The upward motion of Roller tappet compresses the plunger of pump which pressurizes the fuel and thus high pressure fuel gets feed to fuel rail through the delivery port on the top Once the roller tappet comes down, plunger comes back to its normal position. This cycle is continued to provide high pressure fuel to fuel Rail Using 17 mm open end spanner loosen the HP pipe mounting from FIP and common rail ends Torque : 22.5 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040061.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before working on the high pressure side fuel components (Fuel Injection Pump, High Pressure Pipe, Fuel Rail & Injectors) turn the engine off, disconnect fuel supply hose quick coupler at FIP end and wait for Ten minutes. The fuel system is a non \u2013 return fuel system and fuel pressure within the system is very high. Failure to follow above instruction will result in personal injury Eye protection and a mask must be worn at all times while working near any fuel related components. Failure to follow this instruction will result in personal injury Remove the HP pipe from vehicle Press the lock and disconnect the fuel inlet pipe pump end All are quick fix connectors, press gently and remove it carefully; avoid seal damages Disconnect FIP electrical connector Disconnect FIP electrical connector Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect FIP electrical connector Replace the FIP O Ring with a new one when installing Remove roller tappet from the high pressure pump housing Refit in the reverse order of removal While Installation, Ensure that the projection in the roller tappet should be matched with slot in the cylinder head for correct orientation Inspect the FIP for any physical damage, replace if found any Inspect the Roller Tappet for any physical damage, replace if found any It is an electromechanical device, which is used to inject the fuel to the cylinder head. The quantity of fuel injected in the combustion chamber is controlled by an electronic control module. Remove the Fuel Rail Assembly. Before working on the high pressure side fuel components (Fuel Injection Pump, High Pressure Pipe, Fuel Rail & Injectors) turn the engine off, disconnect fuel supply hose quick coupler at FIP end and wait for Ten minutes. The fuel system is a non \u2013 return fuel system and fuel pressure within the system is very high. Failure to follow above instruction will result in personal injury. Eye protection and a mask must be worn at all times while working near any fuel related components. Failure to follow this instruction will result in personal injury. Pull & Remove the injector locking clips from the dedicated groove on the Injectors and detach the fuel injectors from the fuel rail. Injector Clip, O-ring & Backup ring should be replaced with new ones when ever removing & refitting the Fuel Injector from the Rail Assembly Injectors Combustion Seals should be replaced with new ones when ever removing & refitting the Fuel Rail Assembly from the cylinder head If Injector/Injectors struck with Cylinder Head and not able to remove from head, Injector can be removed by using Injector removal tool and follow the below steps Insert the Injector removal tool twisting shaft and lateral sliding it onto injector and making sure the extraction socket of twisting shaft below the extraction bump on injector. Assemble the torsion pin with twisting shaft, twist it clockwise and counter clockwise. Ensure not to apply a more torque (Not greater than 5 Nm) Extract the injector from the cylinder head pulling it out with the tool. if not able to remove injector from cylinder head, extract the torsion pin and insert the shot mass on to twisting shaft. Then insert torsion pin. Hit the torsion pin with the shot mass to extract the injector from the cylinder head. Extract the injector together with spring clip after injector separate from the cylinder head. An excessive impulsive application of the pull-out load by an extraction tool might damage the injector in an irreversible way which may not be apparent visually. In this case it is strongly recommended to replace the injector Remove the O-ring by using hand or plastic lever or plastic pliers. The O-ring can be stretched until it breaks or can be removed off the component. Remove the Backup ring by using hand or plastic pliers. When removing O-ring, Backup ring, no metallic fixtures (pliers, fork, scissors, cutter, trimmer) are allowed to be used, which may damage injector sealing surface. Only plastic fixtures can be used Take care not to damage the surface of the injector Inspect the sealing surface and replace the complete injector in case there is a defect on sealing surface (such as a tool mark) Install the New Backup ring by gently rolling it over the O-ring Adapter upper collar and position it into the proper position inside the groove. Check that the Backup ring fit properly in the relative groove Install the New O-ring by gently rolling it over the O-ring adapter upper collar and position it into the proper position inside the groove. The O-ring must be always at the fuel side, the back up ring must be below the O-ring respect to the fuel side * Inspect the Fuel rail for any damage. Replace if found. Check injectors, Injector clips for any external damage, If found replace. Inspect the Injectors connectors for any damage. Replace if found. Insert the injector locking clips in the dedicated groove on the Injectors and attach the fuel injectors on the fuel rail. Position the injector in front of the injector cup in such a way that the rib of the spring clip is aligned with the Ushape feature on the external of the injector cup Insert the injector into the fuel rail cup up to the complete engagement of the clip rib over the U-shape feature Inspect accurately the sealing surfaces of the fuel rail prior to reassemble the injectors. In case of defect (such as a tool mark) replace the fuel rail Refit the Fuel Rail Assembly. For additional information refer to Fuel Rail Assembly - R &R; section. After Installation, Running the engine at idle for few minutes and Check for fuelleakage in fuel rail and injector assembly. If found rectify the same. Carry out Injector routine procedure - using i-SMART. For additional information refer to the diagnostic manual. During assembly in Fuel Rail, no hammers or impact tools should be used which could directly bear on or affect the High Pressure Fuel Injector Fuel Rail Assembly, Injector should be remove & refit only 5 times, ensure to replace New Assembly beyond 5 times Canister (charcoal filter) traps the hydrocarbon vapours from the tank and supply this hydrocarbon vapours to intake manifold by Purge valve for rich air fuel mixture. Disconnect vapour line quick couplers canister end. Using 13 mm socket spanner unscrew canister mounting bolts. Torque : 10 \u00b1 2.0 Nm Detach fuel supply hose from canister and take out canister. Refit in the reverse order of removal. Inspect Canister for any physical damage, replace if found any. Inspect Canister for any leakage. Rectify if found any. For additional information refer to Wheel R&R Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the tyre from the rim. For additional information refer to Tyre - R&R Section.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a T10 Socket Spanner, loosen and remove the TPMS sensor mounting screw and detach the sensor.",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160076.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "The TPMS and Valve cannot be replaced separately.These can be replaceable as assembly.The valve must be positioned just left of the start position to avoid sensor damage. Do not touch the sensor with the tyre tool.Starting to mount the tyre from the valve location is a wrong fitment. The fixing tool/ stem may hit the sensor and damage it. Start from the opposite direction.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160064.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "By using suitable TPMS removal/Installer tool, remove the valve from the rim.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160079.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 12
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Ensure that the TPMS Sensor is not damaged while removing the tyre.Check the tyre inner surface for cuts and punctures.",
+ "file": null,
+ "display_order": 13
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 317,
+ "sys_id": "THAR.LX-0008-Tyre Pressure Monitoring System",
+ "subsys_id": "THAR.LX-0008-Tyre Pressure Monitoring System-TPMS Manual Learning",
+ "systems": "Tyre Pressure Monitoring System",
+ "sub_systems": "TPMS Manual Learning",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A090057.jpg",
+ "myid": 1430,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-TPMS Manual Learning-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "TPMS Manual Learning is the process by which the identities of 5 sensors installed inside the tyres are learnt & programmed in to the memory of receiver module. It should be mandatory to performe on any of the following conditions or operations done. Any of the old TPMS sensors are damaged & sensors are replaced. Any of the tyre among 5 tyres are replaced. if any of the tyres or set of tyres are shuffled or swapped in position. If tyres rotation operation is performed. If observed that the alert indications in TPMS screen are not correlating with respect to their actual position in vehicle. Once the manual learning is initiated the sensors inside the tires needs to triggered by leaking the air from each tire one at a time and should be completed within 90 secs post to each event for learning all 5 tires. Do not perform Manual learning process at the same time on two vehicles with in the radius of 20 meters. It is mandatory that manual learning of tyres should follow the sequence of \u2018front left tyre position, front right tyre, rear right tyre, rear left tyre and spare tyre\u2019. It is required to ensure the tires are having pressure > 32 psi & < 36 psi before initiating the manual learning process. It is mandatory that manual learning of tyres should follow the sequence of \u2018front left tyre position, front right tyre, rear right tyre, rear left tyre and spare tyre\u2019. It is required to ensure the tires are having pressure > 32 psi & < 36 psi before initiating the manual learning process. Post to manual learning all tire should be filled with recommended tyre pressure value. At any point of time during the learning process if learning takes more than 90 secs of time for each tire position then the system shall exit the learning mode and show the Learning not successful screen. At a time, only one tyre can be swapped with the spare wheel and then follow the learning procedure. Position the vehicle on a flat surface. Press the Scroll Up arrow button on Driver side switch bank and simultaneously turn the ignition ON. Wait for cluster\u2019s tachometer & speedometer self-check rotation and then release the arrow button. Identifying weather the learning is initiated. Infotainment will show popped out screen TPMS Learning screen. TPMS telltale in cluster shall keep blinking. Three vehicle siren chirps will be heard. If failed to enter in to manual learning mode. Try initiating the manual learning once again. Check if reverse gear is engaged, if engaged disengage it. Check MBFM, Infotainment & Cluster software versions. Check if variant coding is done in all three. Check if Scroll Up arrow button on Driver side switch bank button is working fine. TPMS learning procedure must be done in the below sequence: 1. Front left tyre 2. Front right tyre 3. Rear right tyre 4. Rear left tyre 5. Spare tyre Start leaking the air from front left tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If front left tyre is learned 1 siren chirp sound is heard and FL tyre shows learned in infotainment system. Start leaking the air from front right tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If front right tyre is learned 1 siren chirp sound is heard and FR tyre shows learned in infotainment system. Start leaking the air from rear right tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If rear right tyre is learned 1 siren chirp sound is heard and RR tyre shows learned in infotainment system. Start leaking the air from rear left tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If Rear left tyre is learned 1 siren chirp sound is heard and RL tyre shows learned in infotainment system. Start leaking the air from the spare wheel tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If spare tyre is also learned then 1 siren chirp sound is heard and ALL tyres show learned at respective tyre positions and \u2018All tyres Learned successfully\u2019 in the center of the screen. At any point of time during the learning process, if learning takes more than 90 seconds of time for each tyre position then the system shall exit the learning mode and show the \u201cLearning not successful\u201d screen.
TPMS learning need to be carried out whenever :
1. Tyre rotation happens.
2. 2 or more wheels are swapped.
3. TPMS sensor is replaced.
4. MBFM is replaced.
The TPMS should not be used as a tyre pressure gauge while adjusting vehicle tyre pressure.
",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Notice",
+ "content": "",
+ "file": null,
+ "display_order": 32
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 86,
+ "sys_id": "THAR.LX-0008-en-SM-Transfer Case ",
+ "system_name": "Transfer Case ",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1010,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 86,
+ "sys_id": "THAR.LX-0008-Transfer Case",
+ "subsys_id": "THAR.LX-0008-Transfer Case-Transfer Case Diagnosis",
+ "systems": "Transfer Case",
+ "sub_systems": "Transfer Case Diagnosis",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1206,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Transfer Case Diagnosis-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Target Shift 2H - 4H",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30902.pdf",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Target Shift 4H - 4L",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30903.pdf",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Target Shift 4L - 4H",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30904.pdf",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Target Shift 4H - 2H",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30905.pdf",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Transfer Case Switch Position",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120060.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30907.jpg",
+ "display_order": 8
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 93,
+ "sys_id": "THAR.LX-0008-Transfer Case",
+ "subsys_id": "THAR.LX-0008-Transfer Case-Transfer Case System Technical Spec",
+ "systems": "Transfer Case",
+ "sub_systems": "Transfer Case System Technical Spec",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1213,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Transfer Case System Technical Spec-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Technical Specification",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4029.pdf",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 94,
+ "sys_id": "THAR.LX-0008-Transfer Case",
+ "subsys_id": "THAR.LX-0008-Transfer Case-Troubleshoot - Transfer Case",
+ "systems": "Transfer Case",
+ "sub_systems": "Troubleshoot - Transfer Case",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1461,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Troubleshoot - Transfer Case-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Inspection and Verification",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "1. Verify the customer concern.
2. Visually inspect the transfer case for any noticeable signs of mechanical damage.
3. If an obvious cause is found during the inspection, correct the same before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom and refer to troubleshooting chart.
",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Heading",
+ "content": "Mechanical ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Check for any oil leakage in the transfer case. Check the yoke, flange and drive gear for any damage. Check for loose mounting bolts.
2. Visually inspect the transfer case for any noticeable signs of mechanical damage.
3. If an obvious cause is found during the inspection, correct the same before proceeding to the next step.
4. If the cause is not visually evident, verify the symptom and refer to troubleshooting chart.
",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4030.pdf",
+ "display_order": 5
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 90,
+ "sys_id": "THAR.LX-0008-Transfer Case",
+ "subsys_id": "THAR.LX-0008-Transfer Case-Transfer Case Shifter Assembly",
+ "systems": "Transfer Case",
+ "sub_systems": "Transfer Case Shifter Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A120001.jpg",
+ "myid": 1210,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Transfer Case Shifter Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120001.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30955.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30956.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the gear shifter level knob and 4WD selection knob by rotating them in anticlock wise direction. Using trim removal tool, remove the gear selection rod cover with trim. For AT Variants top trim removal follow (Steps 3 - 8) : , Remove the 4WD selection knob by rotating it in anti-clock wise direction.Pull and fold the gear shifter boot from gear shifter bezel . Partially detach the bezel from the console. Excessive pull may leads to damage of the electrical connector. Disconnect the AT gaiter electrical connector from the bezel. Carefully remove the bezel trim from the TGS lever. Handle bezel assembly carefully to prevent it from damage or scratches. Using trim removal tool, carefully remove the floor console top trim with transfer case shifter boot. Detach the transfer case cable abutment from the shifter bracket by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Using 13 mm socket spanner unscrew transfer case shifter lever assembly mounting nuts. Take out the shifter and tilt the lever assembly gear shifter lever side to remove the TC shifter cable 'R' clip. Detach the TC shifter cable from shifter assembly. Remove the transfer case shifter from the vehicle. Inspect the transfer case shifter for any damage. Replace if found any. Position the transfer case cable on shift lever bracket. Install the shifter cable locking R clip. Position the transfer case shifter lever assembly. Position the transfer case shifter lever at 2H position. Ensure that the transfer case link should be in 2H position on transfer case (Extreme Rear end position from front of the vehicle). Refit the transfer case cable abutments on shift lever bracket. Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Refit the shifter lever assembly mounting nuts. Tighten the mounting nuts to specified torque value. Torque Value :22.51\u00b14 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from '2H' to other range. If Shifting not smooth Carry-out Transfer Cable setting. For AT Variants top trim Installation follow (Steps 8 \u2013 12) : , Refit the floor console top trim with transfer case shifter boot.Connect the AT gaiter electrical connector with the bezel. Refit the bezel trim with shifter bezel. Handle bezel assembly carefully toprevent it from damage or scratches Unfold the gear shifter boot and refit the boot with gear shifter bezel. Refit the 4WD selection knob by rotating it in clock wise direction. Refit the Manual transmission gear selection rod cover with trim. Refit gear shifter level knob and 4WD selection knob by rotating them in clock wise direction. Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from 'N' to other range. Inspect that engine can be started with shift lever only 'N' or 'P', but not in other range (For AT variants). Inspect that indicating lamp can be turned on correctly in PRND positions (For AT variants). Using MST 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the transfer case shifter cable from the transfer case ball pins. Detach the transfer case cable abutment from the cable bracket on transmission by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Using 10 mm socket spanner unscrew shifter cable grommet mounting bolts on fire wall. Remove the gear shifter level knob and 4WD selection knob by rotating them in anticlock wise direction. Using trim removal tool, remove the gear selection rod cover with trim For AT Variants top trim removal follow (Steps 6 \u2013 11) : Remove the 4WD selection knob by rotating it in anti-clock wise direction.Pull and fold the gear shifter boot from gear shifter bezel. Partially detach the bezel from the console. Excessive pull may leads to damage of the electrical connector. Disconnect the AT gaiter electrical connector from the bezel. Carefully remove the bezel trim from the TGS lever. Handle bezel assembly carefully to prevent it from damage or scratches. Using trim removal tool, carefully remove the floor console top trim with transfer case shifter boot. Remove the floor console side trim mounting screw rivet and remove the trim both sides. Detach the transfer case cable abutment from the shifter bracket by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Detach the transfer case cable from the cable bracket routing clamp. Using nose plier, remove cable cross pin from the transfer case shifter and detach shifter cable. Keep the Transfercase shifter in 4L position while remove R Clip. Detach the cable from lever and take out from vehicle. Keep the Transfercase shifter in 2H position while remove the cable. Inspect the transfer case for any damage. Replace if found any. Position and route the cable inside the vehicle. Move shifter to 2H position and attach the cable with the shifter lever. Keep the Transfercase shifter in 2H position while refit the cable. Refit shifter cable R clip with the transfer case shifter cable. Keep the Transfercase shifter in 4L position while refit R Clip. Attach the transfer case cable abutment with the shifter bracket by pressing locking clip. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Attach the transfer case cable with the cable bracket routing clamp. Refit the floor console side trim and install the mounting screw rivet. Refit the gear selection rod cover with trim. Refit gear shifter level knob and 4WD selection knob by rotating them in clock wise direction. For AT Variants top trim Installation follow (Steps 9 \u2013 13) : , Refit the floor console top trim with transfer case shifter boot.Connect the AT gaiter electrical connector with the bezel. Refit the bezel trim with shifter bezel. Handle bezel assembly carefully to prevent it from damage or scratches. Unfold the gear shifter boot and refit the boot with gear shifter bezel. Refit the 4WD selection knob by rotating it in clock wise direction. Refit shifter cable grommet and install the mounting bolts on fire wall. Ensure the cable grommet should get assemble from outside of the cabin. Torque Value : 10 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Position the transfer case lever at 2H position on transfer case (Extreme Rear end position from front of the vehicle). Refit the transfer case cable abutments on transmission cable brackets. Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. For adjust cable length, move the cable quick adjuster outer cover in forward direction and unlock the QA clip. Adjust the cable length to fix the cable on link ball pin. After adjusting the length, position the quick adjuster body on link ball pin. Once quick adjuster body snap on ball pin, press the QA clip towards arrow mark shown to lock it fully and release the cable quick adjuster outer cover. Ensure the proper locking by confirming/ hearing the click noise while install. Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from '2H' to other range. Drain the Transfer case fluid. For additional information refer to Transfer case fluid Drain & Filling Section. Remove the Transfer case from the vehicle. Position the transfer case on the suitable Wooden/ Nylon blocks. Ensure the oil is drained prior to disassembly of the transfer case. Using a Special tool MST 203 Companion Flange Holding Tool, hold the transfer rear flange. Using a 30 mm socket spanner, loosen and remove rear flange center nut. Torque Value : 340 - 370 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120130.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a magnetic stick, take out flange washer and remove seal from transfer case rear flange. Ensure the use New washer & Seal while installation. Using a mallet, remove the transfer case rear flange. Use suitable 2 Jaw puller to remove the flange, In case of flange not able to remove by mallet. Using a 10 mm square bit spanner, remove the transfer case draining & filling oil plugs from the cover. Using a 15 mm socket spanner remove the assembly cover mounting bolts and remove the mounting bolts & identification tag. Separate the front assembly cover and the rear case assembly. To avoid damage of the metal surface, apply limited force to the bosses on the cover and the transfer case while breaking the sealant bond. Using a flat end screw driver, remove transfer case Rear output shaft oil seal from the cover. Remove the Spacer from the cover. Separate the return spring from the front assembly cover by pulling them outwards. Using flat screw driver& circlip plier, remove the ball bearing snap ring. Rotate the cover and by using MST 0707BBA0003ST - Universal Mandtral remove the ball bearing from the cover. By using suitable Internal puller, pull out the needle bearing from the cover. Care must be taken not to damage the metal surface while removing the needle bearing. Position the transfer case casing and remove the shift collar hub from the output shaft. Remove the 2W-4W lock up assembly and lock up fork together from output shaft and separate lock up fork from the 2W-4W lock up assembly. To dismantle 2W-4W lockup assembly, remove snap ring, lock up hub return spring from lock up collar. Using a circlip plier & flat screw driver, remove the snap ring from the output shaft and remove the spacer. Remove the drive chain with sprocket and drive sprocket from the output shaft. Separate the drive chain, driven sprocket and drive sprocket. Remove the magnet from the slot in the case. Remove the coupler from the case. Remove the output shaft and the gear rotor (Gearotor) pump from the case. Rotate and align the guide pin of the shaft to the slot on the pump body and Separate the gear rotor pump and strainer assembly from the output shaft. By using nose plier, remove the hose clip and remove the hose from pump and remove the strainer. Remove the rail shaft assembly from the case. Remove the reduction hub and the reduction fork from the case. Separate the reduction hub and the reduction fork. Remove the two shift fork facings from the shift fork assembly (if required). Using a Special tool MST 203 Companion Flange Holding Tool, hold the transfer case output shaft yoke. Using a 30 mm socket spanner, loosen and remove rear output shaft yoke center nut. Torque Value : 340 - 370 Nm ",
+ "file": null,
+ "display_order": 93
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120141.jpg",
+ "display_order": 94
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "Description",
+ "content": "Using a magnetic stick & flat screw drive , take out flange washer and remove seal from transfer case output shaft yoke. Ensure the use New washer & Seal while installation. Using a mallet, remove the transfer case rear flange. Use suitable 2 Jaw puller to remove the flange, In case of flange not able to remove by mallet. Remove the lower output shaft from the casing. Using a 15 mm socket spanner, remove the adapter assembly, input shaft and carrier assembly bolts. Take out the adapter assembly with input shaft and carrier assembly. Using an outer circlip plier, Expanding the long ends snap ring unlock the bearing lock circlip and remove the input shaft and carrier assembly. Remove snap ring and oil seal from adapter assembly. Remove the input shaft bearing retaining ring. Remove the input shaft bearing retaining ring. Remove the ASM Carrier from the input shaft. Remove the sun gear snap ring from ASM Carrier. Remove the thrust plate & sun gear from ASM Carrier. By using suitable Internal puller, remove the copper bush from the input shaft. By using suitable Internal puller, remove the needle bearing from the input shaft. By using 17 mm Open end spanner, remove the Breather (For MT variants located at Adapter plate & for AT variants at Adapter case assembly). By using 13 mm socket spanner, remove the hexagonal nut of the shift shaft. By using T25 torx spanner, remove the transfer case and shift cam torx screws. By using flat end screw driver & mallet, remove the clip ring and pull out shift shaft & lever. Remove shift lever from shift shaft. By using flat end screw driver, remove the \u2018o\u2019 ring from shift shaft. Remove 4L assist spring and roller, shifter cam. Remove plunger and spring from the transfer case. By using 24 mm ring spanner, remove 4WD indicator switch from the transfer case (If required). By using flat end screw driver, remove the oil seal from the assembly case. By using flat end screw driver, remove the retaining ring from the assembly case. By using MST 0707BBA0003ST \u2014 Universal Mandtral remove the ball bearing from the case. By using cutting plier, remove the dowel pin from transfer case. Do not remove the ring gear shown in the below figure from the case. Before cleaning, check the magnet for the presence of metal particles which indicate internal chipping of the transfer case. Using a cleaning solvent, clean the old oil and dirt deposits. Before cleaning, check the magnet for the presence of metal particles which indicate internal chipping of the transfer case. After cleaning dry the parts with low pressure (20 psi maximum) compressed air. Lubricate the ball bearings and needle bearing with ATF oil. Protect lubricated bearings from dust. Always replace the hose coupling, O-ring , oil seal and flange/Yoke Nut with new parts. Visually check all the parts for damage. Referring to normal gear tooth face, specifically inspect the uneven wear and chips of gear tooth. Replace or repair if necessary Insert dowel pins to the ring gear casing Dropping of heavy/large objects will damage the part and cause personal injury. Press the ball bearing to the front casing by using MST\u2019s (0707AUA0005ST - Trasfer case Case Covers Ball Bearing Pressing tool) & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Check the ball bearing for functionality prior to installation. Using a snap ring removal tool/screw driver install the retainer ring to the front casing. Install the new output oil seal into the case by using 0707BBA0001ST-Transfer Case Output Shafts Oil Seal Installer & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Check the oil seal prior to installation. In case of any external damages are observed, then replace the oil seal. Install new \u2018O\u2019 ring on the shift shaft and lubricate it. Refit the shift shaft in to the shift lever. Position spring and plunger in the hole of the transfer case. Partially Insert star splined end of the shift shaft into the transfer case. Position shift cam into transfer case with flat end of cam approximately parallel with front face of case (as shown in the picture). Install clip ring in groove near inside end of shift shaft. Install 4L assist spring in groove of shift cam and slot of transfer case. Refit the transfer case and shift cam torx screws by using screwdriver. Make sure that shift shaft is fully engaged so that second screw end enters groove in shaft. Refit the hex nut of the shift shaft, Torque tighten mounting nut to specified value. Install 4WD indicator switch to transfer case. Press the needle bearing into the input shaft by using MST 0707AUA0003ST - T Case Input Shaft Sleeve Pressing tool & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Press the new sleeve bearing into the input shaft by using MST 0707AUA0004ST - T Case Input Shaft NRB Pressing tool & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Refit the input shaft to the carrier assembly by matching the splines. Install the thrust plate, thrust washer onto the input shaft. Position and press the bearing onto the input shaft by using a MST 0707AUA0002ST - T Case Input Shaft Ball Brg Pressing tool. Install the retaining on the input shaft assembly by using circlip plier. Invert from adapter assembly. Install snap ring by making sure that snap ring is correctly install in the groove. Using a circlip plier expand the snap ring and insert the carrier assembly with input shaft to the adapter case. (Ensure that planet carrier assembly on the work bench is such that the retaining rings\u2019 mounting groove faces upward. Press spiral the pin into the front adapter. Using a suitable MST, refit an oil seal from the carrier assembly body by using a MST 0707BAJ0001ST \u2014 Transfer Case Input Shaft Oil Seal Installer - MT (or) 0707BAJ0001ST \u2014 Transfer Case Input Shaft Oil Seal Installer - AT & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Apply a 1.6 mm bead of sealant on the mounting face for the transfer case. Refit the adapter input shaft and carrier assembly to the case, and using a 16 mm socket spanner, tighten the mounting nuts to specified torque. Refit the breather nipple. Position the output shaft in the transfer case. Position the output shaft in transfer case, and install the end yoke assembly, seal, washer and the lock nut. Using a suitable MST yoke holder, socket spanner and torque wrench, tighten the front flange mounting lock nut to specified torque. Install the two forks facing on the reduction shift fork assembly. Install the reduction hub in to the fork. Refit the reduction hub and reduction shift fork into the planet carrier. Slide roller of fork in to the cam groove. Insert shift rail in reduction fork bore, to match with case bore. Align rotor slot of the pump and slot of the pump body in line. Align the slide the pump assembly on output shaft over pump pin. Align the guide pin of the shaft to the slot on the pump body and slide the pump assembly onto the output shaft over pump pin. Assemble the strainer and hose to the gear rotor pump. Install the output shaft and gear rotor pump assembly into the reduction hub housing by matching the splines. Couple strainer with case and insert the magnet into the transfer case slot. Refit the magnet into body. Position the drive sprocket to the rear output shaft end and driven sprocket to the front output shaft end. Install the drive chain onto the sprockets. Holding each sprocket with drive chain tight and parallel with transfer case, install the drive chain assembly to the output shaft. Holding each sprocket with the drive chain tight and parallel with the transfer case, install the drive chain assembly to the output shaft. Rotate the driven sprocket slightly to engage splines on the front output shaft. Install the spacer to the front output shaft. Install the snap ring into the groove of the front output shaft. Install the lockup hub and return spring to the lockup collar and insert the snap ring. Install new facings to the fork. Engage the lockup fork in the groove in 2WD-4WD lockup assembly and slide this group down over output shaft and rail shaft. Check the ball bearing prior to installation. In case of any external damages are observed, then replace the ball bearing. Install shift collar engaging splines on output shaft and in 2WD-4WD lockup assembly. Position the cover with the open end facing up on the table. Position the end of the needle bearing with the identification mark and up the press into the cover by using a suitable MST 0707AUA0006ST\u2014 T Case Rear Cover NRB Pressing tool & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Press the ball bearing into cover by using MST 0707AUA0005ST \u2014 T Case Covers Ball Brg Pressing tool & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Install snap ring over the ball bearing into cover by using screw driver or circlip plier. Install the return spring over rail shaft in the transfer case. Position the cover with the open end facing down on the table. Install the spacer over output shaft spline in the cover assembly. Press the new oil seal into the cover assembly by using MST 0707BBA0001ST \u2014 Transfer Case Output Shafts Oil Seal Installer & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Apply 1.6 mm bead of Loctite RTV598 to the transfer case mounting surface. Installation of cover, align the transfer case with cover. Do not use excessive force. Align the cover holes with the transfer case dowel pins. Align the cover bearing with output shaft. Align the cover blind hole with rail shaft and make sure that return spring is not cocked. Refit the front and rear housing cover mounting bolts along with identification tag and torque tighten the bolt to specified value. Install the two oil plugs to the cover, torque tighten the nut to specified value. Install the flange and washer and lock nut to the output shaft. Do not fully tighten the bolts at this stage. Holding the flange by flange holder torque tighten the nut to specified value. Refit the Transfer case on the vehicle. Refill the Transfer case fluid. For additional information refer to Transfer case fluid Drain & Filling Section. Position the transfer case shifter lever at 2H position. Ensure cable cross pin is properly fitted on transfer case shifter. Ensure the transfer case cable abutment is properly fitted on shifter bracket. Ensure the transfer case cable abutment is properly fitted on transmission cable bracket. Using a 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the transfer case cable from the transfer case ball pins. Ensure that the transfer case link should be in 2H position on transfer case (Extreme Rear end position from front of the vehicle). For adjust cable length, move the cable quick adjuster outer cover in forward direction and unlock the QA clip. Adjust the cable length to fix the cable on link ball pin. After adjusting the length, position the quick adjuster body on link ball pin. Once quick adjuster body snap on ball pin, press the QA clip towards arrow mark shown to lock it fully and release the cable quick adjuster outer cover. Ensure the proper locking by confirming/ hearing the click noise while install. Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from '2H' to other range. Transfer case Oil \u2013 MAHINDRA 'MAXIMILE POWER STEERING FLUID' Genuine Power Steering Fluid. Capacity \u2013 1.2 Litres. Using a 10 mm square bit spanner, remove the oil filling plug from the transfer case. Place a tray beneath the drain plug for collecting the oil while draining. Using a 10 mm square bit spanner, loosen and remove the drain plug. Collect the drained oil in a suitable container. Refit the drain plug. Torque tighten the drain plug to specified value. 34\u00b16 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Fill recommended transfer case fluid with the help of a mechanical pump through filler plug. Ensure that the oil level by insert the 8 mm allen key and check the oil level mark. Refit the filler plug and torque tighten the filler plug to specified torque value. 34\u00b16 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Recommend to use only MAHINDRA 'MAXIMILE POWER STEERING FLUID' Genuine Power Steering Fluid. In case of non-availability of Genuine fluid, SHELL MAKE 'SPIRAX S3 ATF MD3' can be used. In emergency conditions, fluid meeting DEXRON III specification can be used and oil change interval should be at every 40000 km. It is a structure of a pipe, which carries air into the combustion chamber in an engine The primary function of the intake manifold is to evenly distribute the air to each intake port in the cylinder head. Even distribution is important to optimize the efficiency and performance of the engine Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable. Disconnect the purge valve vapor hose quick coupler and disconnect the hose intake manifold end. Pull out the purge valve from holding bracket and hose routing to partially detach purge valve vapor hose. Using hose clamp plier, Release breather hose clamp, routing clip and detach hose intake manifold end. Disconnect MAP sensor electrical connector. Using T25 Torx socket spanner, Unscrew boost pressure & temperature sensor mounting bolt and remove it. Torque : 4 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew engine oil dipstick guide routing bracket mounting bolt. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew intake manifold support bracket mounting bolt manifold end. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 16 mm ring spanner, Loosen and remove NVH cover mounting stud on intake manifold. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew intake manifold mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Carefully remove the intake manifold from engine compartment. Replace the gaskets to the intake manifold whenever removed from the engine. Install in the reverse order of removal. Check the intake manifold for the external damage. If any damage found replace it. The intercooler typically an air-to-air heat exchanger. Intercooler cools the air compressed by the turbocharger by reducing its temperature and increasing the density of the air supplied to the engine and thus improving the volumetric efficiency by increasing intake air charge density through nearly isobaric (constant pressure) cooling. The cooled air density improves, helping in increasing the power output and improving the fuel consumption. The intercooler is fitted with separate Electric fan for further better cooling Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable Using 7 mm socket spanner, Loosen intercooler inlet and outlet hose clips and detach hoses intercooler end Torque : 6.5 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020278.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020279.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect boost pressure & temperature sensor electrical connector Using 10 mm socket spanner, remove boost pressure & temperature sensor mounting bolt and detach it Torque : 2.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect intercooler electric fan electric connector Using 10 mm socket spanner, Unscrew degassing tank mounting bolts to partially detach the tank Torque : 4.5\u00b10.5Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew intercooler fan mounting nuts Remove the Intercooler fan from intercooler assembly While installing the fan, Ensure to align the arrow mark on Top side as shown below Using 13 mm socket spanner, Unscrew Intercooler mounting bolts Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew Intercooler mounting bolts Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020227.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal Check for the intercooler for external damage. If found replace it Inspect intercooler hoses for any damage. Replace if found any Inspect intercooler rubber Isolators for any damage. Replace if found any Inspect the Intercooler Fan Assembly for any external damage, Replace the fan assembly if required The boost pressure & temperature sensor is used to monitor the intake air pressure & temperature at the intercooler outlet. The sensor is an NTC type sensor. EMS ECU uses signal from this sensor for Air-intake system control & flow rate modelling. Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable. Disconnect the boost pressure & temperature sensor electrical connector. Using 10 mm Socket Spanner, Unscrew boost pressure & temperature sensor mounting bolt. Torque : 2.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the boost pressure & temperature sensor. Install in the reverse order of removal. Check for any external cracks or damage, replace if found any. Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable. Disconnect HFM sensor electrical connector and routing clip. Using a 10 mm socket spanner, Unscrew HFM sensor mounting bolts and detach sensor from air clear assembly. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020252.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew air cleaner assembly mounting bolts from BIW. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully take out the air cleaner assembly and air intake dirty duct. Using 5 mm Allen key, loosen and remove the dirty side duct mounting bolts from the air cleaner assembly then separate the air cleaner assembly. Install in the reverse order of removal. Check the air cleaner housing for the external damage. If any damage found replace it. While installing the fan, Ensure to align the arrow mark on Top side as shown below The air cleaner element is Non woven +Pleated Media type (Dry Type). Filtration happens in two stages. Coarser particles are filtered in first stage by foam media and fine particles are filtered by Paper media in second stage. The dust and other fine particles which are sucked inside along with air gets trapped in the air cleaner while passing through the filter element. Don\u2019t tap or hit the filter element. The air filter element should be inspected and replaced from time to time, when driving under the following conditions: Unpaved road. Dusty air-polluted road. Long-term driving in rainy weather. Using 5 mm allen key, Unscrew air cleaner dirty duct mounting screws and lift the top housing. Gently take out the air cleaner element from the housing. Clean the inner side of the air cleaner housing using a lint free cloth. Refit the air filter element gently inside the air cleaner housing. During Installation ensure to keep foam side of the filter element in the bottom side Ensure dust should not fall inside the clean hose area while fitting. Always use recommended genuine air filter element. Do not tap or hit the new filter element. Position the air cleaner assembly top cover and refit the mounting screws. Torque : 10 Nm ",
+ "file": null,
+ "display_order": 25
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 340,
+ "sys_id": "THAR.LX-0008-Air Intake",
+ "subsys_id": "THAR.LX-0008-Air Intake-HFM Sensor Cleaning",
+ "systems": "Air Intake",
+ "sub_systems": "HFM Sensor Cleaning",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B020018.jpg",
+ "myid": 1502,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-HFM Sensor Cleaning-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The HFM sensor is used to find out the mass flow rate of air entering into fuel injection internal combustion engine The air mass information is necessary for the ECU to balance and deliver the correct fuel quantity to the engine. Possible Customer Complaints/ Symptoms ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Heading",
+ "content": "Root Cause ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Wrong indication of the air flow to the ECU from the HFM sensor. This is due to the deposition of oil & dust particles on sensor element Logic ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Under normal driving conditions, if required boost pressure is not generated by the turbocharger, the smoke limitation map limits the fueling to avoid smoke due to lack of air If oil/ other soot particles are deposited on the HFM sensor element, the HFM sensor will not read the actual airflow and may report a lesser value to the ECU, thereby limiting the fuelling.This brings down the vehicle performance below acceptable limits. In such cases, the HFM sensor performance can be restored by cleaning the sensor with Petrol thoroughly as per the procedure given below Take Petrol in a container such that HFM sensor unit can be immersed completely. Ensure that the electrical connector is not immersed in the petrol bath Allow the HFM sensor unit to immerse in Petrol for about 5-10 min. Petrol once used should not be re-used for cleaning the HFM sensor. Remove the sensor assembly from the Petrol bath and remove the Petrol completely from the sensor. Allow the sensor to get dry Blow pressurized air jet (Pressure between 3 to 5 bars) from a distance of 10 to 15 cm from one end of the sensor so as to remove any Petrol content present in the mesh. The HFM sensor is used to find out the mass flow rate of air entering into fuel injection internal combustion engine. The air mass information is necessary for the ECU to balance and deliver the correct fuel quantity to the engine. Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable. Disconnect the HFM sensor electrical connector. Using a 7 mm socket spanner, loosen the hose clip and detach hose from HFM sensor. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew the HFM sensor mounting bolts. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the HFM sensor from the air cleaner assembly.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020252.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020232.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Check for any external cracks, replace if found any. Check for the obstruction of the air flow, if found please replace. Intake manifold pressure & temperature sensor is mounted located at the plenum of the intake manifold. This sensor continuously monitors the variation in intake air pressure & temperature. EMS ECU uses this information for fuel correction & turbocharger pressure control Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable. Remove the engine top encapsulation cover Disconnect pressure & temperature sensor electrical connector. Using T25 Torex socket spanner, loosen and remove the pressure & temperature sensor mounting bolt. Torque : 4 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully remove the sensor from intake manifold. Install in the reverse order of removal. Check for any external cracks, replace if found any. Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable. Disconnect the throttle valve electrical connector. Using 7 mm socket spanner, loosen intercooler outlet hose clip and detach the hose throttle end. Torque : 6.5 \u00b1 0.6Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew throttle valve mounting bolts. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully remove throttle body from intake manifold. Install in the reverse order of removal. Check for any external cracks, replace if found any. The air cleaner element is Non woven +Pleated Media type (Dry Type). Filtration happens in two stages. Coarser particles are filtered in first stage by foam media and fine particles are filtered by Paper media in second stage. The dust and other fine particles which are sucked inside along with air gets trapped in the air cleaner while passing through the filter element. Don\u2019t tap or hit the filter element. The air filter element should be inspected and replaced from time to time, when driving under the following conditions: Unpaved road. Dusty air-polluted road. Long-term driving in rainy weather. Using a 5 mm allen key, Unscrew air cleaner top housing mounting allen screws and lift the top housing. Gently take out the air cleaner element from the housing. Clean the inner side of the air cleaner housing using a lint free cloth. Blow the compressed air from the top clean side of filter element. Blow the compress air from the top clean side of filter element (From Paper side) Do not blow the air from bottom dirty side (Foam side) While cleaning, ensure the air pressure should be less than 2 bar. Clean the inner side of the air cleaner housing using a lint free cloth. Gently insert the air cleaner element inside the air cleaner housing. During Installation ensure to keep foam side of the filter element in the bottom side Ensure dust should not fall inside the clean hose area while fitting. Always use recommended genuine air filter element. Do not tap or hit the new filter element. Refit the air cleaner top housing and install the mounting allen screws. Torque : 10 Nm ",
+ "file": null,
+ "display_order": 28
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 349,
+ "sys_id": "THAR.LX-0008-Air Intake",
+ "subsys_id": "THAR.LX-0008-Air Intake-Intake System Technical Specification",
+ "systems": "Air Intake",
+ "sub_systems": "Intake System Technical Specification",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1009,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Intake System Technical Specification-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Technical Specification",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30408.jpg",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 123,
+ "sys_id": "THAR.LX-0008-en-SM-Wheel & Tyre",
+ "system_name": "Wheel & Tyre",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1014,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 130,
+ "sys_id": "THAR.LX-0008-Wheel & Tyre",
+ "subsys_id": "THAR.LX-0008-Wheel & Tyre-Front Wheel",
+ "systems": "Wheel & Tyre",
+ "sub_systems": "Front Wheel",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A160002.jpg",
+ "myid": 1511,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Front Wheel-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160002.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/56070.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/56071.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 21 mm Wheel spanner/ deep socket spanner, loosen and remove the wheel mounting bolts. Torque :140\u00b110 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the mounting bolts and then remove the wheel. Install in the reverse order of removal. Check for any external damage in the tyre or the rim, if found replace. Check for any foreign material on tyre or rim, remove if found. Remove the spare wheel from the vehicle. Torque :50\u00b17.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the spare wheel carrier from the vehicle. Install in the reverse order of removal. Check for any external damage in the spare wheel carrier , if found replace. Using 21 mm socket spanner, loosen and remove the wheel nuts on the spare wheel carrier. Torque :70\u00b110 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the spare wheel from the vehicle. Install in the reverse order of removal. Check for any external damage in the tyre or the rim, if found replace. Check for any foreign material on tyre or rim, remove if found. Using 21 mm Wheel spanner/ deep socket spanner, loosen and remove the wheel mounting bolts. Torque :140\u00b110 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the mounting bolts and then remove the wheel. Install in the reverse order of removal. Check for any external damage in the tyre or the rim, if found replace. Check for any foreign material on tyre or rim, remove if found. For additional information refer to the IP Center Switch Bank Assembly - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270003.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a star driver, loosen and remove the center switch mounting screws. Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270005.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the center switch from IP center switch bank assembly. Install in the reverse order of removal. Check the mounting clips condition to avoid rattling and falling down. Check the switch condition. If required replace. Remove tail lamp cover from tail lamp. Using 10 mm socket spanner unscrew tail lamp mounting bolts. Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270044.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect tail lamp electrical connector. Remove and turn the backup lamp bulb socket in the direction of the arrow. Remove the reverse lamp bulb from holder. Install in the reverse order of removal. Check the bulb condition to avoid rattling and falling down. Check the bulb condition. If required replace. Using a star screw driver, Unscrew front splash shield lower mounting screws (Front side screws). Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nut. Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the front side of shield to access front turn indicator and DRL. Disconnect the front turn indicator and DRL electrical connectors. Using a 10 mm socket spanner loosen and remove the front turn indicator and DRL mounting bolts. Torque : 4\u00b11 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270112.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully remove front turn indicator and DRL. Refit in the reverse order of removal. Inspect the front turn indicator and DRL for any damage, replace if required. Using a star screw driver, Unscrew front splash shield lower mounting screws. Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts. Torque : 6.5 \u00b10.7Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield. Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270037.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the electrical connector. Using hand, Push the side marker lamp assembly from the cladding and remove. Remove the Side Marker Lamp from vehicle. Install in the reverse order of removal. Inspect the side marker lamp assembly for any physical damage/crack etc. Inspect the glass for fading. Inspect the condition of bulbs. Inspect the connectors for proper fitment. For additional information refer front grill assembly \u2013 R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270020.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Pull the lock disconnect head lamp electrical connectors. Using 10 mm socket spanner, loosen and remove the head lamp mounting bolts. Torque : 6 \u00b11Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270022.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the head lamp assembly separately. Install in the reverse order of removal. Inspect the head lamp for any damage, crack and glass fading. Inspect the bulbs. Remove tail lamp cover from tail lamp. Using 10 mm socket spanner unscrew tail lamp mounting bolts. Torque :4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270044.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect tail lamp electrical connector. Remove the bulb from holder by turning the bulb in counter clock wise direction. Gently pull out the bulb from holder. Install in the reverse order of removal. Check the bulb condition to avoid rattling and falling down. Check the bulb condition. If required replace. Using a star screw driver, Unscrew front splash shield lower mounting screws. Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts. Torque : 6.5 \u00b1 0.7 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield. Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270058.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect parking lamp electrical connector. Rotate and remove the bulb holder from vehicle. Remove bulb from holder by turning the bulb in counter clock wise direction. Detach the bulb from holder. Install in the reverse order of removal. Check the bulb condition to avoid rattling and falling down. Check the bulb condition. If required replace.
2. Check and ensure all four tyre pressures as per specification.
3. Head lamp levelling switch position is on zero (0). Vehicle needs to be parked 10 meters or 3 meters away from the aiming board. (L = 10 meters / 3 meters which is the distance from starting point of front tyre to the aiming board as shown in illustration below).
4. Select the aiming board according to the value of \u201cL\u201d. Head lamp Alignment by Visual Method.
",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12540.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270085.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Refer below illustration for \u201cL= 10 Meters\u201d. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270086.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refer illustration for \u201cL= 3 Meters\u201d. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270091.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Refer the illustration for the head lamp adjustment arrangement ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270087.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270088.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Refer the illustration for the head lamp aiming board dimensions of Head Lamps ",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ },
+ {
+ "procedure_name": "Low Beam Setting Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270089.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270090.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Refer below illustration for the head lamp aiming board dimensions of Head Lamps ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Low beam & high beam aiming settings are common. Hence if adjust low beam, high beam will also get aligned with low beam. Using 5 mm socket spanner, rotate the adjusting screw on motor to vary the Low beam cut-off pattern in vertical direction. Clockwise rotation \u2013 Downwards. Anti-clockwise rotation \u2013 Upwards. Using star screw driver, rotate the RH side lamp adjusting screw to vary the low beam cut-off pattern in horizontal direction. Clockwise rotation \u2013 Left Side Anti-clockwise rotation \u2013 Right Side. RH & LH Head lamps are common for New THAR vehicle. Using star screw driver, rotate the LH side lamp adjusting screw to vary the low beam cut-off pattern in horizontal direction. Clockwise rotation \u2013 Right side. Anti-clockwise rotation \u2013 Left side. Check the function of system, by operating the switch from '0' to '3' and observe the cutoff pattern movement in downward direction accordingly. At zero position of switch, the cut- off should come at \u201ch\u201d heights 833 mm (For L= 10,000 mm) & 924 mm (For L=3,000 mm) on screen. Low beam & high beam aiming settings are common. Hence if adjust low beam, high beam will also get aligned with low beam. RIGHT TURN INDICATOR ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "For inspection, push the lighting control stalk clockwise (to stop position B) to indicate a right turn. The instrument cluster arrow lamp pointing towards the right flashes along with the right side turn signal lamps with chime indicating your intention of turning towards right After you have completed your right turn, the stalk will automatically return to the neutral position. Both the right turn lamp and the right turn signal lamp switch OFF. LEFT TURN INDICATOR ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "For inspection, push the lighting control stalk anti-clockwise (to stop position A) to indicate a left turn. The instrument cluster arrow lamp pointing towards the left flashes along with the left side turn signal lamps with chime indicating your intention of turning towards left. LAMPS OFF ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "For inspection, rotate the outer rotary switch on the lighting control stalk aligning the \u2018Arrow\u2019 on the switch to \u2018O\u2019 on the stalk to switch OFF all lamps. LANE CHANGING ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "For inspection of signal a lane change, move the light control stalk clockwise or anti-clockwise to the limit point of free movement of the lever and release. The turn signals will flash three times and stop. PARKING LAMPS ON ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "For inspection, rotate the outer rotary switch on the lighting control stalk aligning the \u2018arrow\u2019 on the switch to the \u20181st d\u00e9tente\u2019 position on the stalk to switch ON the parking lamps. HEAD LAMP ON ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "For inspection, rotate the outer rotary switch on the lighting control stalk aligning the \u2018Arrowt\u2019 on the switch to the \u20182nd d\u00e9tente\u2019 position on the stalk to switch ON the head lamps. HEAD LAMP HIGH BEAM/LOW BEAM ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "For inspection, with the head lamp ON, push the lighting control stalk down (away) from steering wheel to switch ON the head lamp high beam. The head lamp high beam tell-tale lamp in the instrument cluster illuminates indicating high beam option selected. With the head lamp high beam ON, pull the lighting control stalk up towards the steering wheel to switch ON the head lamp low beam. HEAD LAMP FLASH ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "For inspection, pull the lighting control stalk (from the head lamp low beam position) towards the steering wheel to instantaneously flash the head lamp high beam. The head lamp flash works even when the head lamp is OFF. FOG LAMPS OFF ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "For inspection, align the inner rotary switch on the lighting control stalk to the fog lamp off \u2018dot\u2019 on the inner fixed stalk as shown to switch OFF the fog lamps. FRONT FOG LAMPS ON ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "To inspect the front fog lamps, switch ON the ignition and the parking lamps. Turn the inner rotary switch on the lighting control stalk to align to the fog lamp symbol on the inner fixed stalk as shown. The front fog lamp indicator in the instrument cluster indicates the operation status. HAZARD WARNING LAMP ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "For inspection, press the hazard switch ON, All the turn signal lamps flash. To turn OFF, press the switch again. CENTER ROOF LAMP ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "The Roof lamp switch has three operation modes to choose from;
WIPER CONTROL STALK ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "1. Wiper Off
For inspection, move the wipe stalk in neutral position (B). Wiper remains OFF.
2. Flick-Wipe (Mist)
For inspection, push the wipe control stalk to position A for a flick-wipe, hold to operate the wipe continuously (simultaneously lift the wiper stalk towards the steering wheel to operate the wash). The stalk automatically comes back to position B when released.
3. Intermittent (INT) Mode
For inspection, push down the stalk down to position C. In the INT mode, the wiper operates on preset intervals.
4. Low Speed Wiping
For inspection, push the wipe control stalk up to the position D to operate the wiper at a fixed low speed.
5. High Speed Wiping
For inspection, push the wiper control stalk up to position E to operate the wiper at a fixed high speed.
",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A320002.jpg",
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "FRONT WIPE/WASH ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "For inspection, pull/lift the wiper control stalk towards the steering wheel from any position to activate the front wipe/wash function. Washer fluid is sprayed on the front windshield and the wipers wipe the windshield 3 times after the washer spray is stopped and wipe once after 4 sec. Hold the stalk in position for continuous spray of washer fluid. HORN ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "For inspection, press the pad on the steering wheel to sound the horn. The horn functions even when the ignition has been switched OFF. STOP LAMP/HIGH MOUNTED STOP LAMP ",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "For inspection, Press the brake pedal and the Stop Lamp /high mounted stop lamp will illuminate. REVERSE LAMP ",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "For inspection, Engage the reverse gear and the reverse lamp will illuminate. Remove the switch bank driver side. Remove the aiming switch lock by using flat screw driver. Insert the screw driver one side to release lock & release other side. Detach the IP driver side switch bank from the vehicle. Install in the reverse order of removal. Inspect the aiming switch condition, if required replace. Using a star screw driver, Unscrew front splash shield lower mounting screws. Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts. Torque :6.5\u00b10.7 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield. Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270033.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect front indicator electrical connector. Rotate and remove the bulb holder from vehicle. Remove bulb from holder by turning the bulb in counter clock wise direction. Install in the reverse order of removal. Check the bulb holder condition to avoid rattling and falling down. Check the bulb condition. If required replace. Using star screw driver unscrew the panel assembly floor console RH screvits and detach the panel from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290031.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console LH screvits and detach the panel from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290034.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew vertical ascent RH mounting screw and detach the vertical ascent RH from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290033.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew vertical ascent LH mounting screw and detach the vertical ascent LH from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290035.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290036.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290036.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "partially detach the switch bank assembly and remove electric connector to take out from the vehicle. Install in the reverse order of removal. Inspect the center switch for any physical damage. Replace if found. Remove the Convertible Soft top Canopy. Remove the support centre Rexine rivets other side. Remove the Support Side Rexines rivets RH & LH. Using star screw driver, loosen and remove the Bow 1 Injection Mould mounting screws (locate 1 screw at bottom side of centre rexine support). Using star screw driver, loosen and remove the Latch mounting screws. Remove the Bow 1 Injection mould from front side bow and remove the Convertible Soft top Frame Complete assembly. Refit in the reverse order of removal. Inspect the Convertible Soft top Frame Complete assembly for any crack or damage. Replace if any. Remove Side window RH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Remove Side window LH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Unzip the tail gate window, detach the tail gate bar locking from rear RH & LH belt rails remove the tailgate window. Unhook the \u2018C\u2019 pillar cover from rear RH & LH belt rails and fold the cover at top of the soft top. Slide the Sun visors and Remove the Footman's loops from front header. While unlock the Footman loop hook from the front header metal bracket, ensure to press & move the softtop assembly slightly in forward direction and release the hook from the bracket. Slide back the convertible top from front header to rear and roll up properly. Properly Roll up the convertible soft top assembly in the rear side as shown in fig . Unlock two Quick release knuckle RH & LH from main pivot brackets . Lift the convertible soft top assembly upwards (both sides) , silding towards rear and take out assembly from the vehicle. Lift the convertible soft top assembly upwards (both sides), sliding towards front and position on the vehicle as shown. Align the convertible soft top assembly both sides & Lock the two Quick release knuckle to RH & LH main pivot brackets . Properly open rolled convertible soft top assembly from the rear side. Slide convertible top from rear end to front header and position on front header properly. Lock the Footman's loops to the front header and slide the Sun visors. Lock the Footman loop hook on the front header metal bracket & press the loop handle While locking ensure top plastic support project on top of the header metal bracket for proper locking as shown. Unfold and Hook the \u2018C\u2019 pillar cover to rear RH & LH belt rails . Attach the tail gate bar locking to rear RH & LH belt rails and zip tailgate window. Position and hook LH side window to the vertical and horizontal belt rail. Zip the window and refit the LH Side window Velcro . Position and hook RH side window to the vertical and horizontal belt rail. Zip the window and refit the RH Side window Velcro . Check the Convertible Soft Top Assembly for any damage, replace if required. Remove Front Roof caps using trim remover and Using a T30 socket spanner, loosen and remove the roof front top mounting bolts. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250214.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250215.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250216.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250217.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Rear Roof caps using trim remover and Using a T30 socket spanner, loosen and remove the roof rear top mounting bolts. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240016.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240018.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a trim remover pull out center bow trim and disconnect roof lamp electrical connector. Ensure to use trim remover while removing centre roof bow trim, and avoid the press clip damage. Replace the press clip for proper fixing, if it is damaged. Remove the centre bow trim from the vehicle. Using a T30 socket spanner, loosen and remove the roof top mounting bolts inside bow trim. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250102.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250103.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "By Using T30 Torx Socket Spanner remove the RH & LH roof side upper frame mounting bolts. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250104.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250104.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "By Using T30 Torx Socket Spanner remove the RH & LH roof side lower frame mounting bolts Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250206.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250207.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "By Using T30 Torx Socket Spanner remove the RH & LH rear lower bracket mounting bolts. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250208.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250209.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a T30 socket spanner, loosen and remove the roof top mounting bolts from roll cage. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250108.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Disconnect the HMSL electrical connector. Insert and split the panel with trim remover, in between Hard-Top and frame mounting plate. Lift and Carefully remove the hard top assembly from the vehicle with sufficient manpower and keep it in Trolly bench or flat working bay. Use the recommended safety equipment\u2019s; Safety goggles, Cotton gloves, Safety shoes etc. while lifting the Hard-Top. Remove the dust & strain marks by Steel wire brush. (as shown in illustration) Clean with degreaser cloth for silicon sealant application. Don't use ordinary solvent for HardTop cleaning. (it may result some undefined problems in Hard-Top). Inspect the Hard-Top windshield upper frame Seal and replace if needed when the seal loses its softness or if found any damages. , Follow the below steps for replacement of Hard-Top windshield upper frame Seal Remove the X-mas tree clips by trim remover from over the roof rail outer frame. Then pull the seal by manually, due to this seal has fixed with two-way pasting tape. Clean the surface by degreaser cloth. Peel the sticker label sheet from the new Seal, then paste on the roof rail outer frame followed by press the X-mas tree clips. The Seal must be replaced along with X-mas tree clips, when the seal loses its softness or if found any damages, don't reused the X-mas tree clips. This seal is for preventing the water leakage and wind noise only. Seal coming with Two-way pasting tape. Before Installation, Apply the silicon sealant on inner side edges of Hard-Top by manual Sealant gun. , A triangular V- shaped notch will provide the optimal bead shape. (Height 4 mm/ width 5 mm). After sealant application, immediately fix the Hard-Top assembly, with help of sufficient manpower. Silicon sealant must be applied for water leakage and wind noise prevention. Refit in the reverse order of removal. While Installation hand tighten all the Hard top mounting bolts first for proper positioning and finally torque tighten all the bolts. Don\u2019t over tighten the screws to avoid the thread slipping and other damages. While Installation properly position the Hard top dowels in the body for proper positioning & fitment. Inspect the hard top assembly for any damage. Replace if found. Remove the Spare Wheel Carrier. Remove the air extractor from the vehicle. Refit in the reverse order of removal. Inspect the air extractor for any crack or damage. Replace if any. Tools Required: ",
+ "file": null,
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250184.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 12 mm socket and 13 mm combination spanner, Unscrew front bracket mounting bolt and nut. Using 12 mm socket and 13 mm combination spanner, Unscrew front centre bracket mounting bolt and nut. Using 13 mm socket combination spanner, Unscrew rear bracket mounting bolt. Remove the front foot step assembly from vehicle. Front extreme portion of foot step is not to stand, Since front portion is aesthetic part to merge the design theme with cladding. Refit in the reverse order of removal. Check for any damages or crack in foot step assembly. Replace if found. Tools Required ",
+ "file": null,
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250007.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Pull out cover cap from the wiper arm. Using a 13mm socket spanner, loosen and remove the Wiper arm mounting nuts. Torque : 15 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250009.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the wiper arms from vehicle. Using a star screw driver, loosen and remove the Scuttle Grill mounting screws . Torque : 1.9\u00b10.5Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250010.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the Scuttle Grill mounting Scrivets . Remove the Scuttle Grill from the vehicle. Refit in the reverse order of removal. Inspect the Scuttle grill for any damage. Replace if found. Inspect the mounting push buttons, replace if required. Using a star screw driver, loosen and remove the front splash shield mounting screw rivets from both the sides of vehicle. Remove the front splash shield both the sides from vehicle . Using a 10 mm socket spanner, loosen and remove the front stone guard front mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250064.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen and remove the rear stone guard rear mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250033.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the stone guard mounting screw rivets. Remove the stone guard from the vehicle. Disconnect the fog lamp electrical connectors LH & RH sides. Pull and remove the front bumper top panel trim clips and remove the panel. Using a 10 mm socket spanner, Unscrew front bumper mounting nuts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290005.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "using a 13 mm socket spanner, Unscrew front bumper bottom mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Front Bumper Assembly1.png",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew front bumper top side mounting bolts. Using a star screw driver, Unscrew front bumper top centre mounting screw rivets. Remove the front bumper assembly from the vehicle. Using a 13 mm socket spanner, Unscrew front bumper center bracket mounting bolts and remove the front bumper center mounting bracket. Torque : 10.0\u00b11 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250060.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the front grill mounting screw rivets. Using a star screw driver, loosen and remove the bottom side front grill mounting screw rivets. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250061.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the front grill mounting bolts. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250062.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250063.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Remove the front grill assembly from the vehicle. Using star screw driver, Remove centre grill mounting screws and locking clips from front facia. Remove the centre grill from front facia. Refit in the reverse order of removal. Inspect the front bumper assembly for any crack or damage, Replace if found any. Check the front grill assembly for any external cracks, replace if found any. Remove the Soft top canopy. Using a 10 mm socket spanner, loosen and remove the rear side cover LH mounting bolts. Using a 10 mm socket spanner, loosen and remove the rear side cover RH mounting bolts. Carefully remove the rear side covers LH and RH sides. Using a 10 mm socket spanner, loosen and remove the rear side member RH mounting bolts. Carefully remove the rear side member RH from vehicle. Using a 10 mm socket spanner, loosen and remove the rear side member LH mounting bolts. Carefully remove the rear side member LH from vehicle. Using a 10 mm socket spanner, loosen and remove the rear centre panel assembly mounting bolts. Using a T40 torx socket spanner, loosen and remove the rear structure frame mounting torx bolts. Remove the rear structure frame from vehicle. Refit in the reverse order of removal. Check the rear structure frame for any external cracks and damages, replace if found any. Remove the convertible soft top assembly. Using a star screw driver, loosen and remove Canopy mounting screws from the front side bow assembly RH and LH. Remove the lock from the RH and LH Front side bow assembly. Using star screw driver, loosen and remove Canopy mounting screws from Front side bow assembly inner side. Remove the Canopy from the front side bow assembly. Detach or unlock the spring from the Bow 2 Pivot assembly & remove Canopy from Bow 2 Pivot assembly . Using star screw driver, loosen and remove the canopy mounting screws from bow 2 pivot assembly and detach canopy. Using star screw driver, loosen and remove the canopy mounting screws from bow 3 assembly and detach canopy. Remove the Center Support Rexine Rivets. Remove the Canopy from the Frame. Remove the Cable with Spring from the Canopy (RH &LH;). Refit in the reverse order of removal. While Installation, Insert the cable from bracket side to Spring side (Insert spring inside from top) Inspect the convertible soft top canopy for any crack or damage. Replace if any. For additional information refer to the Front Door Inner Trim - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250283.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect the electrical connector from the ORVM. Using 10 mm socket spanner, loosen and remove the mounting nuts from the ORVM. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250275.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250276.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the ORVM from the vehicle completely. Refit in the reverse order of removal. Inspect the ORVM for any crack or damage. Replace if any. Tools Required ",
+ "file": null,
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove front lateral trim. Remove Roof Speaker trim assembly. Open the top cover and Using a 14 mm socket spanner, loosen and remove the seat belt upper mounting bolt. Torque :38 \u00b16 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210081.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the seat belt lower mounting bolt. Torque :38 \u00b16 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250023.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the hand support belt. Remove the floor mate partially from the vehicle. Using a 13mm socket spanner, loosen and remove the roller gage bar rear mounting bolt. Torque : 25 \u00b1 4Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250026.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 13mm socket spanner, loosen and remove the roller gage bar front mounting bolt. Torque : 25 \u00b1 4Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250027.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 13mm socket spanner, Unscrew roller gage bar side mounting bolts. Torque : 25 \u00b1 4Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250028.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the roller gage bar from vehicle. Remove the roller bar cover and separate roller gage bar. Refit in the reverse order of removal. Check for any damages or crack in roller gage bar assembly. Replace if found. Using a 10 mm socket spanner, loosen and remove the rear mounting tube pipe structure mounting bolts. Remove the welcro from the rear tubes . Remove the side cover from window bracket LH and RH sides. Using a 10 mm socket spanner, loosen and remove the front mounting tube pipe structure mounting bolts. Remove the welcro from the front tubes . Using a star screw, loosen and remove the canopy front LH and RH screw rivets. Using a 10mm socket spanner, Unscrew canopy front end mounting bolts. Remove the Canopy from the vehicle. Refit in the reverse order of removal. Check the canopy assembly for any external cracks, replace if found any. Remove the HVAC Mode Actuator. Using star screw driver, Unscrew plate mode main link mounting screws and remove the link. Remove the lever sub assembly and lever foot from the plate mode main link. Install in the reverse order of removal. Inspect the plate mode main link for any damage. Replace if found. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Air Cleaner Assembly. Remove the Steering Lower Intermediate Shaft. Using 12 mm open end spanner, Remove suction and discharge hose mounting nut from compressor. Torque Value: 14.0+1.0 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200093.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the AC/water pump belt. For additional information refer to AC/Water Pump Belt - R&R. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect the AC compressor electrical connector. Using 12 mm socket spanner, Remove the compressor mounting nuts from the crank case. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200095852b7a.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the compressor from the vehicle. Install in the reverse order of removal. Refit the Steering Lower Intermediate Shaft. Refit the Air Cleaner Assembly. For additional information refer to AC/Water Pump Belt - R&R. ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Recharge the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both liquid tube and discharge hose mounting joints without any damage. Damage to the O-ring may cause A/C refrigerant leakage which leads to A/c failure. Inspect the compressor for any physical damage. Replace if found. Inspect the clutch pulley for any damage. Replace if found. Inspect the drive belt and Pulley for any physical damage. Replace if found. Using screw driver, remove the floor console RH panel assembly scrivet and detach the panel from the vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220004.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220005.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the floor console LH panel assembly scrivet and detach the panel from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220006.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220007.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the RH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1547.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1549.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the LH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220010.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1548.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Partially detach bezel HAVC control panel assembly and disconnect electrical connectors. Disconnect Heater, Mode selection control cables from the HVAC control panel. Disconnect the cable routing clips and take out the bezel Assembly with HVAC control panel. By using star screw driver, remove the HVAC control panel mounting screws and remove the panel from the bezel assembly. Torque : 1.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200160.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200161.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the HVAC Control Panel Assembly for any damage. Replace if found. Do not release the refrigerant into the atmosphere. Use approved recovery/ recycling equipment to capture the refrigerant whenever the air conditioning System is discharged. Always wear eye and hand protection (goggles and gloves) when working with any Refrigerant or air conditioning system. Close the high pressure and low pressure refrigerant lines with dust caps to avoid air entry and/or contamination. Recover AC gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. Remove Front Grill Assembly. Using 12 mm Combination Spanner, Unscrew the AC pipe compressor side mounting nut. Torque : 14.0+1.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200070.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew radiator LH seal mounting bolt and remove the seal. Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200071.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Remove HVAC pipe condenser side mounting nut. Torque : 6.0+1.0 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both pipe ends mounting joints without any damage. Damage to the Oring may cause A/C refrigerant leakage which leads to A/c failure. Remove the HVAC pipe assembly from the vehicle. Install in the reverse order of removal. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. ",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the AC pipe for any damage. Replace if found. Disconnect the HVAC blower motor electrical connector. Using star screw driver, loosen and remove the blower motor mounting screw. Remove the blower motor from the HVAC unit assembly. Install in the reverse order of removal. Rotate the blower motor and check for any noise due to bearing wear. Check the blower motor fan blade for damage. Replace the blower motor if necessary. Whenever over voltage/under voltage situation will occur over ignition Line. These voltages will get sense by MCU and based on these sense voltages panel functionality will disabled or in case of under/over Voltage system will not detect any switch command. It is a kind of Security over connector Pins except Power supplies Pins. If any shorting occur on connector pin either short to battery or short to ground there should be no damage to control panel or circuitry. Over Current/Short to Ground: Face Indicator on off with Frequency 1000 mSec Interval. Short to Battery/ Actuator Stuck: Face Indicator on off with Frequency 500 mSec Interval. Over Current/Short to Ground: Air Intake Indicator on off with Frequency 1000 mSec Interval. Short to Battery/ Actuator Stuck: Air Intake Indicator on off with Frequency 500 mSec Interval. Over Current/Short to Ground: Defrost Indicator on off with Frequency 1000 mSec Interval. Short to Battery/ Actuator Stuck: Defrost Indicator on off with Frequency 500 mSec Interval. AC Indicator Blink with 500 mSec Frequency. The purpose of the condenser is to dissipate the heat accumulated during gas evaporation and compression. Once it is cooled, the gas becomes a liquid and remains under high pressure. To improve thermal exchange, the fluid is exposed to air flow produced by the engine cooling fans and vehicle movement.This step allows for fluid expansion. Its location is in front of the radiator. From compressor high pressure high temperature refrigerant is introduced into the top of the condenser as the gas moves through the condenser it gets cooled. As the refrigerant cools, it condenses and exits the bottom of the condenser as a high pressure low temperature liquid. Recover the A/C gas. For additional information refer to AC gas recovery procedure. Do not release the refrigerant into the atmosphere. Use approved recovery/ recycling equipment to capture the refrigerant whenever the air conditioning System is discharged. Always wear eye and hand protection (goggles and gloves) when working with any Refrigerant or air conditioning system. Close the high pressure and low pressure refrigerant lines with dust caps to avoid air entry and/or contamination. For additional information refer to the Radiator LH & RH Seal R&R section. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Heading",
+ "content": "For AT Variants. ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the AT Oil Cooler Assembly. Using 10 mm socket spanner, Unscrew HVAC Suction and return pipe mounting nuts. Torque : 6.0+1.0 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both pipes mounting joints without any damage. Damage to the O-ring may cause A/C refrigerant leakage which leads to A/c failure. Using 10 mm socket spanner, Unscrew condenser mounting bolts from radiator end. Torque : 5 \u00b11 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200075.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Remove the radiator bottom seal mounting bolts and detach it. Torque : 7\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200196.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200074.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Detach the ambient temperature sensor from the routing clip. Carefully remove the condenser from vehicle. Install in the reverse order of removal. For additional information refer to the Radiator LH & RH Seal R&R section. ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Recharge the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. ",
+ "file": null,
+ "display_order": 30
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the condenser for any physical damage, leakages etc. Replace if found any. Inspect for any foreign materials on condenser. Clean if found. Check and ensure free flow of condenser. Using screw driver, remove the floor console RH panel assembly scrivet and detach the panel from the vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220004.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220005.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the floor console LH panel assembly scrivet and detach the panel from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220006.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220007.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the RH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1541.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1542.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the LH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220010.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1543.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Partially detach HAVC control panel bezel and remove the mode cable from HVAC control panel end and routing clip. Remove the driver side IP panel assembly. Disconnect the mode cable from HVAC unit end. Remove the cable from the vehicle. Install in the reverse order of removal. Inspect the HVAC mode cable for any damage, Replace if required. Inspect the Mode Cable locks for any damage, Replace if required. performed AC PERFORMANCE TEST - Check the grill temperature (Engine Idle condition): Close Door test (Grill temperature individually from 4 vents). Open Door test (Grill temperature individually from 4 vents). Grill Temperature closer to Ambient Temperature \u2013 Go to Step 2. Connect the diagnostic Tool and DTC registered in EMS ECU. Yes \u2013 fix the error, clear the DTC and check the AC Performance. NO \u2013 GO to Step 3. Using Diagnostic tool actuate the compressor Clutch. No \u2013 Clutch Not actuating \u2013 Check the clutch condition, circuit and rectify or replace. Yes \u2013 Clutch Actuating as per input Go to Step 4. Check the compressor Drive Belt Condition and tightness. Yes \u2013 Matching the Specification \u2013 Go to Step 5. No \u2013 Replace the Drive Belt. Check The compressor condition. Yes - Compressor Overheating and Noisy \u2013 Replace the Compressor. Compressor in good condition \u2013 Go to Step 6. Check the System Refrigerant Quantity by using reconnector Equipment. Yes \u2013 The Refrigerant quantity is less (Gas Leakage) \u2013 Perform pressure test and Vacuum test by maintaining the pressure. Fix the leakage if any and charge the Refrigerant to recommended quantity and top up 50 ml compressor Oil. Then Go to Step 7. Check the grill temperature (Engine Idle condition). Close Door test (Grill temperature individually from 4 vents). Open Door test (Grill temperature individually from 4 vents) match the Recommended temperature \u2013 Go to Step 8. Perform test Drive and check the Temperature and any reproduce of the insufficient cooling. NO \u2013 Hand back the vehicle to customer Yes \u2013 Replace the HVAC System. Remove the Glove Box Assembly. Disconnect the electrical connector from the temperature actuator. Using star screw driver, Unscrew temperature actuator mounting screws. Remove the temperature actuator. Install in the reverse order of removal. Inspect the actuator for mechanical damage. Check and clean the connector pins for sulphation and deposits. For additional information refer to Evaporator Assembly \u2013 R &R Section. ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0008,1018,1327",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Carefully remove the heater core assembly. Install in the reverse order of removal. For additional information refer to Evaporator Assembly \u2013 R &R Section. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Link",
+ "content": "THAR.LX-0008,1018,1327",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Recharge the AC Gas. For additional information refer to AC Gas Recharging Procedure. ",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Inspect the heater core assembly for any damage. Replace if found. Inspect the evaporator coil for free flow. If found any obstruction Repair/Clean or replace. Remove the IP lower panel from the vehicle. Disconnect the mode actuator electrical connector. Using star screw driver, Unscrew mode actuator mounting screws. Remove the mode actuator. Install in the reverse order of removal. Inspect the actuator for mechanical damage. Check and clean the connector pins for sulphation and deposits. Before going to performance test, ensure following points are taken care \u2013
2. AC gas \u2013 Use only R134a A/C gas and only from recommended suppliers.
3. Ensure correct amount of A/C gas is filled in the system.
4. Ensure cleanliness of the condenser surface at regular interval.
5. Ensure proper function of condenser fan.
6. For A/C System testing use only approved Tools & Equipment.
",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "This A/C performance test is only to check mechanical performance of the HVAC system and not the flow or circulation related complaints.",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31148.jpg",
+ "display_order": 4
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 200,
+ "sys_id": "THAR.LX-0008-Heating, Ventilation And Air Conditioning (HVAC)",
+ "subsys_id": "THAR.LX-0008-Heating, Ventilation And Air Conditioning (HVAC)-HVAC Particle Filter Replace",
+ "systems": "Heating, Ventilation And Air Conditioning (HVAC)",
+ "sub_systems": "HVAC Particle Filter Replace",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J10-MAT-0590",
+ "cover_image": "/files/W4A200025.jpg",
+ "myid": 1313,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 25,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 59,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 100,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 140,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 183,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 222,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 266,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 305,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 347,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 385,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 431,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-HVAC Particle Filter Replace-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/HVAC Particulate Filter - Replace.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200025.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Preliminary Activities/ Conditions",
+ "content_type": "Description",
+ "content": "Park the vehicle on level work bay. Open the left front door. Open the glow box and detach the stopper by pressing it. Disengage the glow box from the assembly. Press and remove the HVAC particulate filter cover from HVAC unit. Remove the HVAC particulate filter. Install the HVAC particulate filter on HVAC unit. Install the HVAC particulate filter cover. Engage the glow box stopper and refit the glow box in its position. While installing the filter take sufficient care to prevent bent, damage etc. Close the co-driver door. Use only genuine filter element. Never clean and reuse the HVAC particle filter element. Disconnect the blower motor and actuator electrical connectors and its routing clips. Using 10 mm socket spanner, Unscrew the blower case assembly mounting bolts. Using screw driver, Heater coil holding bracket mounting screws. Using a star screw driver, Unscrew expansion valve cover mounting screw. Disconnect the HVAC resistor electrical connector. Using a star screw driver, Unscrew the resistor mounting screw and remove the resistor. Using star screw driver, Unscrew evaporator cover mounting screws. Detach thermistor from evaporator and remove the evaporator with cover. Remove the evaporator from the cover and separate the evaporator. Detach the thermistor trim from HVAC assembly and Disconnect the thermistor electrical connector and holding clip. Remove the thermistor from the HVAC unit assembly. Install in the reverse order of removal. Refit the HVAC Unit Assembly. For additional information refer to AC Gas Recharging Procedure. ",
+ "file": null,
+ "display_order": 43
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the evaporator coil for any damage. Replace if found. Inspect the blower and evaporator unit for any damage. Inspect the evaporator coil for free flow. If found any obstruction repair/clean or replace. Inspect the evaporator coil for any foreign particles. Clean if found. Inspect the thermistor for any physical damage. If found replace. Inspect the thermistor for proper functioning. Using screw driver, remove the floor console RH panel assembly scrivet and detach the panel from the vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220004.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220005.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the floor console LH panel assembly scrivet and detach the panel from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220006.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220007.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the RH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1538.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1539.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the LH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220010.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1540.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Partially detach HAVC control panel bezel and remove the heater cable from HVAC control panel end and routing clip. Open the glove box and remove the glove box by removing the glove box lock. Disconnect the heater cable from the HVAC unit end. Remove the cable from the vehicle. Install in the reverse order of removal. Inspect the HVAC heater cable for any damage, Replace if required. Inspect the heater Cable locks for any damage, Replace if required. Remove the driver side IP panel assembly. Remove mode selector cable from HVAC assembly. Using star screw driver, Unscrew plate mode main link mounting screws and remove the link. Remove the lever sub assembly and lever foot from the plate mode main link. Install in the reverse order of removal. Inspect the plate mode main link for any damage. Replace if found. Position the vehicle on 2 post lift/ 4 post lift. Check the HVAC drain pipe locking grommet fitment condition on BIW. Ensure that pipe is straight downwards. Do not pull the water drain pipe excessively. Remove the Cross Car Beam (CCB) Assembly. For additional information refer to AC gas recovery procedure. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm open end spanner, Remove the HVAC Pipe mounting nut from expansion valve end. Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both liquid tube and discharge hose mounting joints without any damage.Damage to the O-ring may cause A/C refrigerant leakage which leads to A/c failure. Detach heater inlet and outlet hose quick couplers. Do not open the degassing tank cap when the coolant is hot. Failure to follow this instruction will lead to personal injury. Before removing the heater core hoses, open the degassing tank cap for releasing the coolant pressure. Coolant will leak, while removing the heater core hoses, as a result drain the coolant into a container. Using 10 mm Socket Spanner, Unscrew the HVAC unit assembly mounting bolt and nuts. Torque : 7 \u00b11 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 7 \u00b11 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 7 \u00b11 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200098.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200099.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200100.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200101.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm Socket Spanner, Remove the HVAC earth cable mounting nut. Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200104.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the HVAC unit assembly from vehicle. Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200102.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200103.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Refit the Cross Car Beam. Recharge the Refrigerant. For additional information refer to AC gas recovery procedure. Start the engine, check the coolant level. Refill if required. Check the coolant leak when engine is started. Check the A/C system cooling and operation. Inspect the HVAC assembly for any physical damages. Repair if found. Inspect the kinematics for proper functioning. Inspect the actuators / cables for proper operation. Inspect the filter element and clean/replace if required. Disconnect air fresh and recirculation actuator electrical connector. Using star screw driver, Unscrew the actuator mounting screws. Remove the air fresh and recycling actuator. Install in the reverse order of removal. Inspect the actuator for mechanical damage. Check and clean the connector pins for sulphation and deposits. Do not release the refrigerant into the atmosphere. Use approved recovery/ recycling equipment to capture the refrigerant whenever the air conditioning System is discharged. Always wear eye and hand protection (goggles and gloves) when working with any Refrigerant or air conditioning system. Close the high pressure and low pressure refrigerant lines with dust caps to avoid air entry and/or contamination. Recover the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. For additional information refer to Front Grill Assembly \u2013 R&R section. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.LX-0008,1024,1368",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the Air Cleaner Assembly. Using 10 mm open end spanner, Liquid pipe mounting nut from expansion valve end. Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200061.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Remove Liquid pipe routing bracket mounting nut from the vehicle. Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200062.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen and remove the suction hose routing bracket mounting nut. Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200063.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200129.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect the pressure switch electrical connector. Using 10 mm socket spanner, Unscrew radiator LH seal mounting bolt and detach it. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1536.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew Liquid pipe mounting nut from condenser end. Torque : 6.0+1.0 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both end of liquid tube mounting joints without any damage. Damage to the O-ring may cause A/C refrigerant leakage which leads to A/c failure. Remove the liquid pipe from the vehicle. Install in the reverse order of removal. Refit the Air Cleaner Assembly. Refit the Front Grill Assembly. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. ",
+ "file": null,
+ "display_order": 39
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the suction hose assembly for any physical damage, leakages etc. Replace if found any. Inspect for any foreign materials on condenser. Clean if found. Check and ensure free flow of condenser.
\u2022 Check and clean the connector pins for sulphation and deposits
",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 216,
+ "sys_id": "THAR.LX-0008-Heating, Ventilation And Air Conditioning (HVAC)",
+ "subsys_id": "THAR.LX-0008-Heating, Ventilation And Air Conditioning (HVAC)-HVAC Control Panel",
+ "systems": "Heating, Ventilation And Air Conditioning (HVAC)",
+ "sub_systems": "HVAC Control Panel",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A200079.jpg",
+ "myid": 1329,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-HVAC Control Panel-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200079.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/50019.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/50020.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the IP Centre Switch Bank Assembly. For additional information refer to IP Centre Switch Bank Assembly \u2013 R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew HVAC control unit mounting screws. Torque : 1.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220033.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the HVAC Control panel. Install in the reverse order of removal. Inspect the HVAC Control Panel Assembly for any damage. Replace if found. By using screw driver remove the TVD screw. Torque : 14 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 14 mm ring and socket spanners unscrew rear propeller shaft mounting bolts and nuts from transfer case end. Torque : 55 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the TVD assembly from vehicle and hang the Rear propeller shaft aside. Inspect the Torsional Vibration Damper (TVD) for any damage, if found replace the TVD assembly. Inspect the propeller shaft for any bend, crack, twisting and stone penetration, if found replace the propeller shaft assembly. Check the propeller shaft for any flyweights missing. Replace the propeller shaft if found. Clean the propeller shaft if any foreign materials like dirt found. Tyres that are out of round or wheels that are out of balance causes a low frequency vibration. Brake drums that are unbalanced cause a harsh low frequency vibration. Drive line vibrations can also result from loose or damaged engine mountings. Propeller shaft vibrations will keep on increasing as the vehicle speed increase. The propeller shaft does not cause a vibration that is present only in a narrow speed range. Position the vehicle on 2 post lift/ 4 post lift. Inspect the inboard and outboard joint RH side drive shaft boots, clamps for cut, nick, loose, bend, crush or abrasion. Replace if necessary. Rotate Steering wheel from one end to other for better visualization of boots. Inspect the RH side drive shaft condition for cracks or damage. Replace if necessary. Inspect the inboard and outboard joint LH side drive shaft boots, clamps for cut, nick, loose, bend, crush or abrasion. Replace if necessary. Rotate Steering wheel from one end to other for better visualization of boots. Inspect the LH side drive shaft condition for cracks or damage. Replace if necessary. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Remove the Steering Column Shrouds. Remove the steering wheel. Disconnect the clock spring electrical connectors. Dis-engage the clock spring mountings (3 points) and lift out the clock spring assembly from the steering column. Using a flat end screw driver remove the steering angle sensor from the clock spring. Install in the reverse order of removal. If the contact coil is not aligned correctly,the steering wheel may not be able to rotate properly during turning. This kind of restricted turning ability may cause the vehicle to crash or damage the contact coil and prevent the air bags from deploying in a crash event. Carry-out the clock spring setting procedure. Failure to do clock spring setting may result in clock spring damage.
2. Turn the steering wheel until the tyres starts to move and measure the free play on the circumference of the steering wheel.
Free Play Value \u00b1 5\u00b0 If the free play is out of the specified value, check the free play in steering column shaft connection and steering linkage. Replace or repair if necessary. The rack and pinion design is a simple design. However it is still susceptible to various problems in particular to leaks. If the bellows are ripped or are unable to keep the contaminant\u2019s away then it can cause damage to oil seal and subsequent leaks. One complaint, which can be present, is that the steering may be stiff and jerky when the unit is cold and as the vehicle is driven and it warms up the power assist gradually comes back. This normally indicates that grooves have worn into the bore of the pinion aluminum housing by control valve seals which may have hardened due to ageing. Wear in the centre housing causes the fluid to leak around the rack piston. Causing either steering wander or lack of straight- ahead stability. Another cause of steering wander and erratic control often accompanied by clumping, thunking noise is the deterioration of rack mounting bushings. Fluid leaks can be hard to locate. Sometimes you will see a low level in the pump reservoir but no evidence of escaping fluid. Squeeze the bellows and you will probably find that they are full of fluid. To confirm if that side of the rack is the root cause, then remove the both the bellows, clean the rack housing and then operate the system to observe the seepage directly. A rusty input shaft U joint or deteriorated flexible textile coupling could imitate rack problems
2. Check the accessory drive belt for any damage.
3. Check the Tie-rod ends for bend or damage.
4. Check the steering inner ball joints for any bend or external damage.
5. Check ball joint rubber boots for signs of cracking or deterioration.
6. Check inner and outer ball joints for excessive wear.
7. Inspect all the steering bushes for signs of wear and deterioration
8. Check the steering oil level in the reservoir. If the level is below \u201cMIN\u201d mark, top up steering fluid.
9. Check the steering gear assembly for any external damage or steering fluid leakage.
10. Check the power steering pressure lines for fluid leakage and deterioration.
11. Check the power steering pump and the reservoir for fluid leakage.
12. Check the steering gear rubber bellows for cuts, cracks, deterioration and oil traces. If the cause is not visually evident, verify the symptom and refer to the Troubleshooting Chart.
",
+ "file": null,
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Trouble shooting chart",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/14513.pdf",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Component Inspection and Remedy Action",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/14514.pdf",
+ "display_order": 4
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 192,
+ "sys_id": "THAR.LX-0008-Steering",
+ "subsys_id": "THAR.LX-0008-Steering-Power Steering Pressure Hose (Pump Gear)",
+ "systems": "Steering",
+ "sub_systems": "Power Steering Pressure Hose (Pump Gear)",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A190113.jpg",
+ "myid": 1305,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Power Steering Pressure Hose (Pump Gear)-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190113.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/3302.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/3303.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the front RH wheel. For additional information refer into Front Wheel - R&R Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "By using Star Screw driver, remove the scrivets and remove the front RH wheel arch apron. Using a 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially detach the degassing tank. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050128.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner, loosen and detach the pressure hose flare nut from the power steering pump. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190083.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner, loosen and detach the pressure hose flare nut from the power steering gear. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Position a tray below the rack to collect the fluid Using a 12 mm socket spanner, loosen and remove the routing bracket mounting bolt. Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190048.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the supply hose from the vehicle. Install in the reverse order of removal. For additional information refer to Power steering fluid filling procedure. ",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Inspect for any external damage or bent, if found replace. Power Steering Oil - MAHINDRA MAXIMILE POWER STEERING FLUID GENUINE POWER STEERING FLUID. Capacity \u2013 0.85 Litres. In case of non-availability of Genuine fluid, SHELL MAKE SPIRAX S3 ATF MD3 can be used. NO OTHER BRANDS RECOMMENDED. Rotate in anti-clockwise and remove the power steering fluid reservoir cap. Using star screw driver, remove the front stone guard screvits. Using a 10 mm & 13 mm socket spanner, loosen the front & rear mounting bolts and remove the front stone guard. Using a 10 mm socket spanner remove the steering fluid line bracket mounting bolt. Torque: 10\u00b1 2 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190048.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner,loosen the nut and disconnect pump to rack pressure hose. Torque: 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Position a tray below the rack to collect the fluid. Drain the complete fluid in a neat container or bottle. Refit the pump to rack pressure hose.Torque tighten the nut to specified value. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190104.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refit the fluid line mounting clamp with the help of mounting bolt. Torque tighten the bolt to specified value. Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190048.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Fill the recommended fluid to MAX mark on reservoir. Carry-out Power steering circuit air bleeding procedure. Refit the front stone guard screvits & mounting bolts, torque tighten the bolts to specified value. Torque: 4.0 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011105.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011106.jpg",
+ "display_order": 33
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 194,
+ "sys_id": "THAR.LX-0008-Steering",
+ "subsys_id": "THAR.LX-0008-Steering-Front Steering Knuckle",
+ "systems": "Steering",
+ "sub_systems": "Front Steering Knuckle",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A190001.jpg",
+ "myid": 1307,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Front Steering Knuckle-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190001.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/50002.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/50001.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Front wheel. For additional information refer to Front Wheel \u2013 R&R Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the respective side Front Wheel Hub. For additional information refer to Front Wheel Hub \u2013 R&R Section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner , loosen and remove the wheel speed sensor mounting bolt & routing bracket mounting bolt. Torque : 8 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190008.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a cutting plier and 17 mm socket spanner, remove the tie rod end cotter pin and tie rod end nut and detach from knuckle. Torque : 45\u00b19Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190009.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a cutting plier and 24 mm socket spanner, remove the lower ball joint cotter pin and Lower ball joint nut and detach from knuckle. Torque : 130 \u2013 150 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190010.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 22 mm socket spanner, loosen and remove the knuckle Lower Half mounting bolts. Torque :140 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190011.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a cutting plier and 24 mm socket spanner, remove the upper ball joint cotter pin and ball joint nut and detach from knuckle. Torque : 90 \u2014 110 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190012.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the knuckle from the vehicle. After installation of knuckle assembly, Carry out the wheel alignment. Install in the reverse order of removal. Torque tightening should be done without load and with the tyres on level ground. Always use new split pin. Inspect for any external damage or bent, if found replace. The steering pump is a constant flow, vane type incorporating a flow control valve (with an integrated relief valve) and it is belt driven by engine. For additional information refer to Power steering fluid draining section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially detach the degassing tank. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050128.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the engine feed system cover. For additional information refer into the Engine Feed System Cover \u2013R&R Section. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 14 mm rings spanner rotate the auto tensioner in counter clockwise Partially detach the power steering belt. Using a 17 mm open end spanner,loosen and detach the pressure hose flare nut from the power steering pump. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190083.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a hose clip plier, unclip the return hose to reservoir hose clamp from pump. Using a 12 mm socket spanner, loosen and remove the power steering pump mounting bolts. While loosening the bolt hold the nut using 12 mm ring spanner. Torque :25\u00b1 3 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190084.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the power steering pump from the vehicle. Install in the reverse order of removal. While tightening the bolt hold the nut using 12 mm ring spanner. Carry-out power steering fluid filling and bleeding procedure. Inspect the pump for any physical damage. Replace the pump if found. Inspect the pump for any fluid leakages. Inspect the pulley for any damage. For additional information refer into E-Disconnect Motor \u2013 R&R Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0008,1015,1254",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the engine feed system cover. For additional information refer to Engine Feed System Cover - R&R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the Front wheels (Both RH & LH). For additional information refer into Front Wheel - R&R Section. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "The wheels should be in straight ahead position before disconnecting the steering rack assembly from the vehicle. Using a 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially detach the degassing tank. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050128.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a cutting plier remove the cotter pin from the LH & RH tie rod . Using the 17 mm socket spanner, loosen and remove the LH & RH tie rod end ball joint nuts from the knuckle assembly. Torque : 45 \u00b1 9 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190009.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft mounting nut from the rack and pinion assembly and detach the intermediate shaft. Torque : 22\u00b14Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190044.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner, loosen and remove the flare nuts and detach the steering rack and pinion supply and return lines. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": "Plug the steering rack assembly inlet and outlet hose oil passage with dust cap to avoid any foreign particles entry. Drain the power steering fluid. Using a 12 mm socket spanner, loosen and remove the supply line routing bracket mounting bolt. Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190048.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a 19 mm socket spanner, loosen and remove the steering rack and pinion assembly mounting bolts. Torque : 85 \u00b1 13 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Notice",
+ "content": "Use open end torque wrench for tightening RH side mountingbolt. Detach the front differential breather hose routing tag. Remove the steering rack and pinion assembly from the vehicle. Install in the reverse order of removal. Always use a new cotter pin. Ensure I shaft connector is assembled as per given marking. At straight ahead condition bolt head should face top side for easy torquing. For additional information refer to Power Steering Fluid Filling Procedure section. ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Carry out the wheel alignment. Check the steering rack assembly for cracks, damages or leakages. Replace the steering rack assembly if required. Check the steering inner ball joint for any damage. Replace the steering rack assembly if required. Check the steering rack dust boot for any wear or deterioration. Replace if necessary. The combination switch is mounted on the steering column and houses the switches for head lamps, fog lamps and wipers. It comprises a central switch assembly and 2 stalks for controlling the lamps and wipers. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Disconnect the electrical connector from combination switch. Using a star screw driver, loosen and remove the mounting screw to remove combination switch. Gently remove the combination switch from the vehicle. Install in the reverse order of removal. Tighten the combination switch mounting screw as per specification over tighten will lead to damage of the switch.
2. Inspect the combination switch connectors for any damage or loose connection.
",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 188,
+ "sys_id": "THAR.LX-0008-Steering",
+ "subsys_id": "THAR.LX-0008-Steering-Steering Grommet",
+ "systems": "Steering",
+ "sub_systems": "Steering Grommet",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A190110.jpg",
+ "myid": 1301,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Steering Grommet-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190110.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Summary",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22339.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/22340.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Remove the steering wheel. Disconnect the ignition key barrel electrical connector. Disconnect the combination switch & clock spring electrical connectors. Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft bottom mounting bolts and detach the intermediate shaft bottom from the steering column. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190042.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering column mounting nuts then remove the steering column from the vehicle. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190039.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the grommet mounting bolts then remove the grommet from vehicle . Torque : 22 \u00b1 2 Nm Torque :22\u00b12 Nm Install in the reverse order of removal. Ensure to fit the Grommet Projection should face driver side. Ensure Shaft to Grommet clearance is 5 mm in top side. Ensure to install Upper & Lower I shaft connector according to the marking. For additional information refer into Front Wheel - R&R Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "By using Star Screw driver, remove the scrivets and remove the front RH wheel arch apron. Using a 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially detach the degassing tank. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050128.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the front differential breather hose routing clip. Using a 12 mm socket spanner loosen and remove the steering return line routing bracket mounting bolts. Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190090.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a hose clamp plier, unclip the hose clamp from power steering side. Using a 17 mm open end spanner, loosen the flare nut and detach the return line from the rack and pinion side. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190075.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the steering return line hose gear end from the vehicle. Install in the reverse order of removal. For additional information refer to Power steering fluid filling procedure. ",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect for any external damage or bent, if found replace.
2. Turn the steering wheel to the its both ends and measure the maximum steering angle.
",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Caution",
+ "content": "If the steering angle is out of the specified value, check and adjust the toe. Position the vehicle on a 2 post/ 4 post lift. Do not operate the steering system without power steering fluid. Failure to follow this precaution will lead to the damage of the steering system components. Whenever air enters the power steering hydraulic system, the system must be bleed to ensure free of air. Filling and bleeding the power steering system helps to ensure trouble-free operation as well as prevents the damage of the power steering system components. Inspect the fluid pressure hoses and clips for proper fitment. Rotate in anti-clockwise and remove the power steering fluid reservoir cap. Fill the power steering fluid reservoir to the \u201cMAX\u201d mark. During the bleeding procedure, ensure that the power steering fluid in the power steering fluid reservoir does not fall below the \u201cMIN\u201d mark, as air could enter into the system. Slowly turn the steering wheel to left lock position and hold for about 10 seconds. From left lock position turn the steering wheel slowly to Right lock position. Continue steps 6\u20137 till there is no air bubbles visible in the power steering fluid reservoir and smooth operation of power steering is attained. If the air bleeding is not properly performed, the life span of the power steering pump may be shortened. Top up the fluid to MAX mark on reservoir. To re-centre the clock spring , from default position rotate the clock spring in clockwise rotation (Towards right hand side) until tight (RH lock position). From RH lock position rotate the clock spring in opposite direction (anti-clockwise) approximately 3 turns and align the marks. Failure to follow the instructions can cause the clock spring failure. Clock spring if failed and not corrected can be a concern if the vehicle meets an accident which is above the threshold for airbag deployment. In such cases the airbag may not be deployed even though the signal is given. Even if airbag not deployed it will be giving a signal of airbag failure which will mean a return of customer with a complaint added on. The steering wheel is the part of the steering system that is rotated by the driver; the rest of the steering system responds to driver inputs. The steering wheel houses the driver airbag and audio controls. It is connected to the collapsible steering column. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Remove the driver air bag. Using a 17 mm socket spanner, loosen and remove the steering wheel mounting nut. Torque : 47\u00b17Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect clock spring electrical connector. Remove the steering wheel from the vehicle. Do not use excessive force to the steering wheel for removal. This may cause steering wheel bend. Gently tap if needed. While installing steering wheel ensure the splines are aligned properly and the steering wheel slides easily on the column shaft. Install in the reverse order of removal. Ensure the front wheels are in straight ahead position. Improper or incorrect removal and installation of the Restraint components will cause unintentional activation of the system which may lead to personal injury. The service operations should be followed in the correct sequence. Failure to do so may cause the SRS to unexpectedly deploy during service leading to a serious accident. The steering column is bolted to the bulk head. It is a tiltable and collapsible column. The steering column shaft is mounted on two needle bearings internally at the ends suspended by rubber mountings in the steering column assembly. An intermediate shaft connects the steering column to the steering gear. For reasons of safety, the steering column assembly incorporates a collapsible steel cage and an intermediate shaft with a deformation zone designed to crumple progressively in the event of a headon collision. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Remove the combination switch. Disconnect the ignition key barrel electrical connector. Using a Small chisel or punch hit and unscrew the mounting screw of ignition switch barrel with support of hammer. Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft bottom mounting bolts and detach the intermediate shaft bottom from the steering column. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190042.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering column mounting bolts and nuts then remove the steering column from the vehicle. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190039.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the mounting bolt and remove top intermediate shaft from column. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190108.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190040.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Ensure to Assemble Upper & Lower I shaft connector according to the marking. For information refer to Engine Feed System Cover - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the front RH wheel. For additional information refer into Front Wheel RH - R&R Section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "By using Star Screw driver, remove the scrivets and remove the front RH wheel arch apron. Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft bolt from the rack and pinion. Torque : 22\u00b14Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "While attempting to remove the intermediate shaft, lock the steering wheel at center position. Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft lower mounting bolt. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190042.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190043.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft Center bracket mounting bolts. Torque : 20\u00b12.0Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the Steering intermediate shaft from the vehicle. Install in the reverse order of removal. Ensure to install Upper & Lower I shaft connector according to the marking. DO NOT HAMMER while disassembly / assembly. Ensure I shaft connector is assembled as per given marking. At straight ahead condition bolt head should face top side for easy torquing. Position the vehicle on 2 post lift/ 4 post lift. Steering Rack Linkage & Boots Inspection Procedure ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the steering rack assembly RH side boots, clamps for cut, nick or abrasion,replace if necessary Check the steering rack assembly LH side boots, clamps for cut, nick or abrasion, replace if necessary. Check the steering rack assembly RH side linkage condition (Without removing boots) for play, damage, replace if necessary. Rotate Steering wheel from one end to other for better visualization of boots. Check the steering rack assembly LH side linkage condition (Without removing boots) for play, damage, replace if necessary Rotate Steering wheel from one end to other for better visualization of boots. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Remove the steering wheel. Disconnect the ignition key barrel electrical connector. Disconnect the combination switch & clock spring electrical connectors. Using a 12 mm socket spanner, loosen the steering intermediate shaft top bolt and remove bottom mounting bolts and detach the intermediate shaft bottom from the steering column. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190039.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering column mounting nuts then remove the steering column from the vehicle. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190108.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190109.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the top intermediate shaft mounting bolts then remove the top intermediate shaft from the steering column. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190133.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Ensure to install Upper & Lower I shaft connector according to the marking. Power Steering Oil - MAHINDRA MAXIMILE POWER STEERING FLUID GENUINE POWER STEERING FLUID. Capacity \u2013 0.85 Litres. Fluid reservoir outlet and return hose connection to reservoir. Check Power Steering fluid level , if found less than MIN mark, top up to MAX mark. Always maintain fluid level at MAX mark on reservoir. Power steering pump inlet and outlet connection. Power steering gear fluid inlet and outlet connection. Power steering rack feed tube connections. In case of non-availability of Genuine fluid, SHELL MAKE SPIRAX S3 ATF MD3 can be used. NO OTHER BRANDS RECOMMENDED. Disconnect the RPAS sensor electrical connectors. Unlock the RPAS sensors from the cover. Detach the sensors from vehicle. Check sensor, wiring, connector for any damage. Check for mud on sensor, clean gently if found. Remove the thermostat valve from the thermostat housing. Thermostat and thermometer bulb should be suspended in water. If they touch bottom or the sides then temperature in which thermostat / thermometer operate will not be correct and wrong diagnosis will take place. Insert the thermostat valve in to a container filled with water. Heat the container and measure the temperature of water by Using digital thermometer. Keep track of water temperature and respective valve opening/ travel. Thermostat should start opening at 88 \u00b1 2 \u00b0 C (0.1 mm travel). Once temperature reaches 96 \u00b1 2\u00b0 C valve should be fully open , at this moment, valve travel will be approximately 8 mm. In case thermostat valve behavior does not confirm to above specifications, it should be replaced. Disconnect the electrical connectors from resistor. Using screw driver, loosen the resistor mounting screw and remove the resistor. Install the reverse order of removal. Check the resistor for any damages, if found then replace it . For additional information refer to coolant draining procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Pipe Inlet Oil Turbocharger. Using 10 mm socket spanner, Unscrew turbo coolant supply pipe mounting banjo bolt turbo end. Using 10 mm socket spanner, Unscrew turbo coolant supply pipe banjo bolt OCFM end. Remove the turbo coolant outlet pipe. Install in the reverse order of removal. For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Link",
+ "content": "THAR.LX-0008,1001,1034",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the coolant inlet pipe for any damage, Replace if found. Typical sign of failed water pump is leakage through the seal and bearings. If the water pump is leaking replace the pump as soon as possible. Water pump failure can be confirmed by below steps: 1. Remove the drive belt. 2. Rotate the water pump pulley and check for free rotation. 3. Replace the water pump, if necessary. Drain the engine coolant. For additional information refer into coolant draining and refilling procedure. Remove the CATCON Assembly. For additional information refer to CATCON Assembly - R &R; section. Using 7 mm socket spanner, Loosen hose clip and detach water outlet hose pipe end. Torque : 6.5 \u00b1 0.6 Nm Using 10 mm socket spanner, Unscrew water inlet pipe mounting bolts and remove pipe. Install in the reverse order of removal. Carry-out coolant filling and de-aeration process. For additional information refer to Coolant filling and de-aeration section. Check coolant inlet pipe for any damage or cracks. If found replace the outlet pipe with a new one. Check coolant inlet pipe mounting for proper tightness and damages, replace the outlet pipe if required. Remove the Intercooler Fan. Using 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially remove the degassing tank (Without disconnecting the hoses). Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060135.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect fan resistor electrical connector. Using 10 mm socket spanner, Unscrew fan mounting bolts. Torque : 6.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060137.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060139.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect the shroud holder clips from radiator and fan then remove the clips (Top & Bottom). Using 7 mm socket spanner, Loosen intercooler inlet hose clip and detach the hose intercooler end. Torque : 6.5 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050130.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Detach the fan assembly from radiator bottom seating and remove the radiator fan assembly. While Installing ensure the fan bottom seating are properly seated on radiator. Install the reverse order of removal. Check electric fan blades for any damages. For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060004.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, release the radiator vent hose spring band clamp and disconnect the hose.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Never work with cooling system when the engine is hot. failing to this may cause personal injury..",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060011.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release the degassing tank outlet hose spring band clamp and detach hose degassing tank end. ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060023.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew degassing tank mounting bolts.",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.5\u00b1 0.5 Nm",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050129.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully remove the degassing tank.",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Carry-out coolant filling and de-aeration process. For additional information refer to Coolant filling and de-aeration section. ",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the degassing tank for any damages or blockages, replace if found replace the degassing tank.Inspect the hoses for any damages, cracks or kinks, if found replace the hose assembly.inspect the coolant hoses clamps for proper fitment, if found loose then replace the clips.",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 377,
+ "sys_id": "THAR.LX-0008-Cooling System",
+ "subsys_id": "THAR.LX-0008-Cooling System-Coolant - Replace",
+ "systems": "Cooling System",
+ "sub_systems": "Coolant - Replace",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J10-MAT-0100",
+ "cover_image": "/files/W4B060001.jpg",
+ "myid": 1061,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 33,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 77,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 119,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 159,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 201,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 241,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 250,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 323,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 365,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 405,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 449,
+ "kilometers_applicable": 0
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Coolant - Replace-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Coolant - Replace.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25272.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060001.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Preliminary Activities",
+ "content_type": "Description",
+ "content": " Position the Vehicle on 2 post lift/ 4 post lift. Open the bonnet and lock it using bonnet retaining lever. Place a tray under vehicle for collecting the coolant. Coolant \u2014 Mahindra 'MAXIMILE ULTRA COOL' Genuine Long Life Coolant (READY TO USE COOLANT. NO NEED TO MIX WATER). Top up Capacity \u2014 ~5.0 Litres. ",
+ "file": null,
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Draining",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": " Engine Coolant Draining Procedure ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " Switch OFF the Ignition and allow Engine to cool down. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": " Never remove the degassing cap when the engine is hot ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/coolant_replace.png",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": " Using star screw driver, remove the front stone guard screvits. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011105.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": " Using star screw driver, remove the front stone guard screvits. ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011106.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": " Using a 10 mm & 13 mm socket spanner, loosen the front & rear mounting bolts and remove the front stone guard. ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050160.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": " Remove the radiator drain plug and allow the entire coolant to get drained. ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": " Place a tray beneath the drain plug to collect coolant drained. ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step 6",
+ "content_type": "Description",
+ "content": "Refit the drain plug.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step 6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050160.jpg",
+ "display_order": 18
+ }
+ ]
+ },
+ {
+ "procedure_name": "Filling",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060010.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": " Engine Coolant Filling & De-aeration Procedure ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " Start filling the recommended coolant in degassing tank. ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": " While filling, open the drain Plug & wait for the coolant to drop & close drain Plug. ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": " Check coolant level in degassing tank, add coolant to MAX level and close the degassing cap. ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/coolant 1.PNG",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": " Check all the hoses and clips for leakage and correct fitment. ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": " Start the engine and run at 3000 rpm for about 10 minutes. (For Thermostat Opening). ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": " Maintain Coolant level at MAX level always and ensure coolant never goes below MIN level. ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": " Switch OFF the Ignition and allow the engine to cool down, Check coolant level in degassing tank and add coolant to MAX level. ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step 5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/coolant2.PNG",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060003.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit the degassing cap.",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": " Refit the front stone guard screvits & mounting bolts, torque tighten the bolts to specified value. Torque: 4.0 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": " Torque: 4.0 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/coolant_replace2.png",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/coolant_replace3.png",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": " Inspect the coolant circuit for any leakages. For additional information refer to Coolant level & leak inspection section. ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": " Never remove the degassing cap when the engine is hot. Never mix MAHINDRA MAXIMILE ULTRA COOL genuine coolant with water. Brand Specific. Don't use other Coolants / Water for top up. In case of emergency, Coolant meeting JIS K2234 Specification should be used (30% Concentration Diluted with Distilled water) and coolant change period has to be reduced as 30,000 KM Do not overfill the system; allow free space in the degassing tank for expansion of the fluid. ",
+ "file": null,
+ "display_order": 37
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 384,
+ "sys_id": "THAR.LX-0008-Cooling System",
+ "subsys_id": "THAR.LX-0008-Cooling System-Thermostat Assembly",
+ "systems": "Cooling System",
+ "sub_systems": "Thermostat Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B060161.jpg",
+ "myid": 1069,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Thermostat Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Component Location Index",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060161.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25330.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Coolant Inlet Pipe. Carefully remove thermostat from OCFM. Install in the reverse order of removal. Always replace the O ring with New one while removing the thermostat. For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Link",
+ "content": "THAR.LX-0008,1003,1068",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check thermostat valve opening and closing temperatures, if found deviation from specified value, replace the thermostat. Check travel of thermostat valve, if found deviation from specified value, replace the thermostat. For additional information refer to coolant draining procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the CATCON Assembly. For additional information refer to CATCON Assembly - R&R Section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010183.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release heater outlet hose clamp and detach hose. Using 10 mm socket spanner, Unscrew pipe routing bracket mounting bolt engine block end. Using 12 mm socket spanner, Unscrew pipe routing bracket mounting bolt cylinder head end. Torque : Torque : 25 \u00b1 3 Nm Using 10 mm combination spanner, Unscrew heater pipe mounting bolt OCFM end and remove pipe. Torque : Torque : 11 \u00b1 1 Nm Remove the turbo coolant outlet pipe. Install in the reverse order of removal. For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the coolant outlet pipe for any damage, Replace if found. Remove the front grill assembly.
Using 10 mm socket spanner, Unscrew the LH and RH radiator seal mounting bolts. Torque : 4.5 \u00b10.5Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060132.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver, loosen and remove the LH and RH radiator seal mounting screw rivets. Torque : 4.5 \u00b10.5Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060133.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060134.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the both LH and RH radiator seal from the vehicle. Install the reverse order of removal. Drain the engine coolant.
Remove the Intercooler assembly. Using hose clamp plier, Release radiator vent hose clip and disconnect hose radiator end. Using hose clamp plier, Release degassing tank Outlet and remove degassing tank. Using 10 mm socket spanner, Unscrew degassing tank mounting brackets mounting bolts LH & RH. Disconnect radiator fan electrical connector. Using 10 mm socket spanner, loosen and remove fan mounting bolts and remove fan from engine compartment. Torque : 6.5\u00b1 1.5 Nm Disconnect the shroud holder clips from radiator and fan then remove the clips (Top & Bottom). Detach the fan assembly from radiator bottom seating and remove the radiator fan assembly. While Installing ensure the fan bottom seating are properly seated on radiator. Using Hose clamp plier, release radiator inlet and outlet hose spring band clamps and disconnect the hoses radiator end. Using hose plier, release vent hose spring band clamp and disconnect hose radiator end. Using 13 mm socket spanner, Unscrew radiator mounting bolts. Torque : 12.5 \u00b1 1.5 Nm Using 10 mm socket spanner, Unscrew radiator LH & RH seal mounting bolts Using 10 mm socket spanner, Unscrew condenser mounting bolts and partially detach the condenser from the radiator. Remove the radiator from the vehicle. Install in the reverse order of removal. Carry-out coolant filling and de-aeration process.
Position the Vehicle on 4 post lift. Inspect and ensure the following nuts/bolts are with proper torque as recommended: Front shock absorber assembly on chassis (LH/RH). Torque value: 40 \u00b1 5Nm Torque Wrench Type - Open end Torque Wrench Front shock absorber mounting bolt on LCA (LH/RH). Torque value: 120 \u00b1 12 Nm Front stabilizer bar mounting bracket bolts. Torque value: 50 \u00b1 5 Nm Front stabilizer bar link mounting bolts on LCA (LH/RH). Torque value: 90 \u00b110 Nm Front upper control arm pivot mounting bolts on chassis (LH/RH). Torque value: 97\u00b1 10 Nm Front Lower arm mounting bolts on chassis (LH/RH). Torque value: 250 \u00b1 20 Nm Ensure to do the torquing in the nut side and holding the bolt while torquing. Knuckle bottom mounting bolts LHS & RHS. Torque value: 140 \u00b1 10 Nm Torque Wrench Type - Open end Torque Wrench Rear stabilizer bar mounting on Rear Axle (RH/LH). Torque value : 70 \u00b1 7 Nm Rear stabilizer bar link rod mounting on chassis (LH/RH). Torque value : 90 \u00b110 Nm Torque Wrench Type - Open end Torque Wrench Rear lower link mounting on chassis and axle (LH&RH;). Torque value: 230 \u00b1 20 Nm Torque Wrench Type - Open end Torque Wrench for LH chassis side While torquing axle side, hold the nut by open end spanner & do the torquing in the bolt side. Rear upper link mounting on chassis and axle (LH&RH;). Torque value: 230 \u00b1 20 Nm Torque Wrench Type - Open end Torque Wrench for LH chassis & axle side Rear shock absorber bottom mounting on Rear axle (LH&RH;). Torque value : 110\u00b111 Nm Torque Wrench Type - Open end Torque Wrench Rear shock absorber top mounting on chassis (LH&RH;). Torque value : 65\u00b110Nm Pan hard rod mountings on axle & chassis. Torque value: 230 \u00b1 20 Nm Position the vehicle on a 2 post / 4 post lift. Check the insulators of the exhaust front pipe , intermediate pipe with muffler and tail pipe with muffler, replace if found elongated or damaged. Check the joint between exhaust tail pipe with intermediate pipe, if found leakage then replace the gasket and torque tighten the nuts to specified value. Check the joint between exhaust intermediate pipe with front pipe for any leakage, if found leakage then replace the gasket and torque tighten the nuts to specified value. Check the joint between exhaust front pipe with Catalytic Converter for any leakage, if found leakage then replace the gasket and torque tighten the nuts to specified value.
result in personal injury.
\u2022 Check all the exhaust joints for leakage and correct fittings. If leakage is found,
check the exhaust pipe gasket. Replace if required.
",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 357,
+ "sys_id": "THAR.LX-0008-Exhaust & Emission Control",
+ "subsys_id": "THAR.LX-0008-Exhaust & Emission Control-Pipe Oil Inlet Turbocharger",
+ "systems": "Exhaust & Emission Control",
+ "sub_systems": "Pipe Oil Inlet Turbocharger",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B030158.jpg",
+ "myid": 1034,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Pipe Oil Inlet Turbocharger-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030158.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4783.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30495.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove turbo bottom heat shield. For additional information refer to turbo bottom heat shield - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Warning",
+ "content": "Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury. Using 10 mm socket spanner, Unscrew turbo oil supply pipe mounting banjo bolt turbo end. Torque : 18 \u00b1 2Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew turbo oil supply pipe banjo bolt OCFM end. Torque : 18 \u00b1 2Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the turbo oil inlet pipe. Install in the reverse order of removal. Check Engine Oil level & Top-up the engine oil.
Check oil inlet tube for any external damage, replace if found any. The Lambda Sensor or Heated Oxygen Sensor which is bolted into the top of the catalytic converter is called as upstream lambda sensor. The Lambda Sensor measures the residual oxygen level in the exhaust gases. A lambda value of 1 indicates engine is running at stoichiometric air fuel ratio. A minimum temperature of 300\u00b0 C is required for proper functioning of the Lambda sensor. The integrated heater ensures that the sensor functions even at extremely low exhaust gas temperatures. The Lambda Sensor is used to correct the fuel injection quantity to maintain stoichiometric air fuel ratio for combustion. Second lambda sensor is bolted to the bottom of catalytic converter. The downstream lambda Sensor is used for diagnosis of catalytic converter and to ensure good catalytic converter efficiency. The voltage output of the sensors depends upon the oxygen content in the exhaust gas. Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury Disconnect the Lambda sensor electrical connector. Using 22 mm open end spanner loosen the sensor and remove sensor from CATCON. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030142.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Check for any external damage on sensor , replace if found any. Remove the Catalytic Converter Assembly Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury. Using 12 mm socket spanner remove turbo support bracket mounting bolts. Using 7 mm socket spanner loosen clean hose clip and detach it from turbo end. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner loosen Intercooler inlet hose clip and detach it from turbo end. Torque : 6.5\u00b10.6Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect turbo dump valve electrical connector. Using 10 mm socket spanner, remove turbo oil inlet pipe banjo bolt. Torque : 18 \u00b1 2Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030150.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": "Using 10 mm socket spanner remove turbo coolant inlet, outlet pipe banjo bolts. Torque : 18 \u00b1 2Nm ",
+ "file": "",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner remove turbo oil drain pipe mounting bolts. Torque : 11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner remove turbo mounting nuts. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Notice",
+ "content": "Always use new metal gasket once removed. check for any leakages While installing, Molykote to be applied on both sides of stud on exhaust manifold- turbocharger. Torquing to be done immediately after application of molykote sealant. Nuts to be re torque after initial tightening in the same sequence. Disconnect turbo electrical interconnector. Remove Turbocharger Assembly from vehicle. Disconnect turbo pigtail electrical connector and remove pigtail. Install in the reverse order of removal. For additional information refer to engine oil refilling procedure. ",
+ "file": null,
+ "display_order": 40
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the Compressor/Turbine wheel for damage. Inspect the Compressor/Turbine wheel for rubbing. Inspect the Rotor for free rotation. Inspect the rotor play by pressing the shaft outward & rotate, It should be rotate freely. For additional information refer to turbo bottom heat shield - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Warning",
+ "content": "Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury. Using 10 mm socket spanner, Unscrew turbo oil drain pipe mounting bolts cylinder head end. Torque : 11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew turbo oil drain pipe mounting bolts turbo end. Torque : 11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the turbo oil drain pipe. Install in the reverse order of removal. Check Engine Oil level & Top-up the engine oil.
Check oil return tube for any external damage, replace if found any. The Closed coupled catalytic converter is mounted between the turbo charger and the exhaust front pipe assembly. The three way catalytic converter allows the three pollutants (CO, HC, NOx) to be converted simultaneously in a single chamber. It converts harmful carbon monoxide and hydrocarbons into water vapor & carbon dioxide and reduces NOx into nitrogen & carbon dioxide. In three way catalytic converter, Substrate is coated over with oxidation catalysts Platinum & Palladium and reduction catalyst Rhodium.High amount of substrate is loaded in the top portion & less amount in the bottom portion. Using 12 mm combination spanner remove turbo top heat shield mounting bolts and detach shield. Disconnect Upstream and Downstream lambda sensor electrical connectors Using 22 mm open end spanner remove Upstream and Downstream lambda Sensors Using 13 mm socket spanner unscrew exhaust front pipe mounting bolts CATCON end Carefully remove the fan assembly Using 13 mm socket spanner remove CATCON mounting nuts from turbocharger Using 12 mm socket spanner, Unscrew Upstream O2 sensor electrical connector holding bracket mounting bolt and remove the bracket Using 12 mm socket spanner, Unscrew Upstream O2 sensor electrical connector holding bracket mounting bolt and remove the bracket Using 12 mm socket spanner remove CATCON bracket mounting bolts and remove the brackets Refit the CATCON mounting brackets on CATCON and hand tighten the bolts. Ensure to only hand tighten the bracket bolts in this stage for proper position of Cat con on vehicle and after that torque tighten. Place and position the CATCON inside the engine compartment. Always replace the metal gasket once removed. Install the CATCON mounting nuts on turbocharger. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "Ensure to apply Molykote on stud tapping threads while Installation. Torquing to be done immediately after application of molykote sealant. Tighten the CATCON bracket mounting bolts on cylinder block side to the specific torque value. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030125.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030019.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": "Tighten the CATCON bracket mounting bolts on CATCON to the specific torque value. Torque : 25\u00b13 Nm ",
+ "file": "",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit exhaust front pipe and install the mounting bolts CATCON end and torque tighten. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refit the Upstream and Downstream lambda sensors on the CATCON and torque tighten. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030135.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Reconnect Upstream and Downstream lambda sensor electrical connectors. Refit turbo top heat shield and torque tighten the mounting bolts. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 58
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external cracks on catalytic converter assembly, replace if found any. Check for the obstruction of the air flow, replace if found any. The Lambda Sensor or Heated Oxygen Sensor which is bolted into the top of the catalytic converter is called as upstream lambda sensor. The Lambda Sensor measures the residual oxygen level in the exhaust gases. A lambda value of 1 indicates engine is running at stoichiometric air fuel ratio. A minimum temperature of 300\u00b0 C is required for proper functioning of the Lambda sensor. The integrated heater ensures that the sensor functions even at extremely low exhaust gas temperatures. The Lambda Sensor is used to correct the fuel injection quantity to maintain stoichiometric air fuel ratio for combustion. Second lambda sensor is bolted to the bottom of catalytic converter. The downstream lambda Sensor is used for diagnosis of catalytic converter and to ensure good catalytic converter efficiency. The voltage output of the sensors depends upon the oxygen content in the exhaust gas. Disconnect the downstream Lambda sensor electrical connector. Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury. Using 22 mm open end spanner loosen the sensor and remove sensor from CATCON. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030138.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Check for any external damage on sensor , replace if found any. Ignition Coil gives high voltage current to the spark plug and is basically a step up transformer. Ignition timing is decided by the EMS ECU. Using a 10 mm socket spanner, loosen and remove the battery negative terminal. Before starting of the procedure, always switch off the ignition. Do not smoke or carry lighted tobacco/open flame while working near any fuel related components. The fuel may ignite and cause personal injury. Always follow fuel handling precautions to avoid personal injury. Remove the engine top encapsulation cover. Disconnect the ignition coil electrical connectors. Using a 10 mm socket spanner, loosen and remove Ignition coil mounting bolts and remove the Ignition coils. Check for any external damage in ignition coil, if found replace. Refit the Ignition coil mounting bolts and torque tighten to specified value. Torque Value: 10 - 12 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1043.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Connect Ignition coil electrical connectors. Refit the engine encapsulation cover.. Connect the battery negative cable mounting nut. It is a device for delivering electric current from the ignition system to the combustion chamber in the spark-ignition engine to ignite the charge by an electric spark. The timing of the spark ensure that the combustion pressure within limits and also the emissions. The spark plug has a metal threaded shell, electrically isolated from the central electrode by a porcelain insulator. The central electrode, is connected by a heavily insulated wire to the output terminal of an ignition coil. The spark plug's metal shell is screwed into the engine's cylinder head and thus electrically grounded. The central electrode protrudes through the porcelain insulator into the combustion chamber, forming spark gap between the inner end of the central electrode and the inner end of the threaded shell and designated the side, earth, or ground electrode. Do not smoke or carry lighted tobacco/open flame while working near any fuel related components. The fuel may ignite and cause personal injury. Always follow fuel handling precautions to avoid personal injury. Special care should be taken for the heating portion of the spark plug while removal or installation and storing. Do not remove the spark plug when the engine is in hot condition. Failure to follow this will cause personal injury. Before starting of the procedure, always switch off the ignition. Using a 10 mm socket spanner, loosen and remove the battery negative terminal. Remove the engine top encapsulation cover. Disconnect the ignition coil electrical connectors. Using a 10 mm socket spanner, loosen and remove Ignition coil mounting bolts and remove the Ignition coils. Using a MST 0308CBG0001ST - Spark Plug Installer Tool , loosen and remove spark plugs from cylinder head. Refit the new spark plugs and torque tighten them to the specified value. Torque Value: 20 - 25 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W152.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Tighten the spark plug to specified torque value. Over tightening may damage the spark plug. Spark plug gap is a gap between the centre and side electrodes of a spark plug. Before installing new spark plug, ensure that the specified gap is maintained between the electrodes. For Thar, Spark Plug gap should be maintained as 0.7 - 0.8 mm and Incorrect spark plug gaps can cause the following problems Rough, irregular engine Idle. Engine hesitation or stumbles while acceleration. Engine to miss or run erratically especially during idle. Poor engine performance. Engine knocking or pinging. Refit the Ignition coil mounting bolts and torque tighten to specified value. Torque Value: 10 - 12 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W154.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Connect Ignition coil electrical connectors. Refit the engine encapsulation cover. Connect the battery negative cable mounting nut. ground level/ 2 post lift/ 4 post lift and turn engine OFF. 2. Open the bonnet and lock it in open position using bonnet stay rod.",
+ "file": null,
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010013.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 27 mm 12 point doublehexagonal socket spanner, Loosen the engine oil filter bowl. To access Oil filter cap mounting slightly move the Intercooler hose (without removing) and Carefully remove the damaging the hose. Remove the engine oil filter with bowl from engine assembly. Ensure gasket isn\u2019t in casting housing and element assembly should come along with filter cap. Carefully rotate the oil filter element in clockwise direction, pull upward and remove the filter element. Remove the filter element carefully, with no damage to the plastic snaps. Pay attention not to damage the oil bypass valve while removing the oil filter element. Smear a layer of fresh oil on new oil filter O-ring and Position the O-ring on filter cap. Replace the O-ring with new one when replacing the oil filter element. Ensure no damage to O-ring during assembly, with no sharp edges damaging O-ring or element. Ensure to fix the oil bypass valve in proper position on oil filter cap. Place the oil filter in the bowl projection, push the filter inside and rotate the filter in anti-clockwise direction to lock it. Install the fuel filter element carefully, with no damage to snaps Position the oil filter cap with filter on the oil cooler surface. Tighten the oil filter cap in clockwise direction and torque tighten cap to the specified value. Torque :25 - 30 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Don\u2019t apply improper torque which leads to damage in threads. Check the engine oil level. Start the engine and check for Oil leakage/ seepage at: Oil pan & crankcase joint. Oil pan drain plug. Oil filter joint. Recommend to use only the Mahindra genuine oil filter for better engine protection and lubricant life. Remove Air Cleaner Assembly. Remove Steering Lower Intermediate Shaft. Using MST remove AC compressor drive belt. Disconnect AC compressor electrical connector. Using 12 mm socket spanner, Unscrew AC compressor mounting bolts and keep aside the compressor. Disconnect oil pump solenoid electrical connector. Using 8 mm socket spanner, Unscrew oil pump solenoid mounting bolt and remove the solenoid. Install in the reverse order of removal. Inspect the oil pump Solenoid for any physical damage. If found replace. Drain the engine coolant. For additional information refer to coolant drain procedure. For additional information refer to Air Cleaner Assembly - R&R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove Steering Lower Intermediate Shaft. For additional information refer to Steering Lower Intermediate Shaft - R &R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1513.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using the MST 0306GAM0006ST - Stretch Fit Belt Removal Tool Remove the AC compressor Drive belt. Disconnect the AC compressor electrical connector. Using 12 mm socket spanner, Unscrew AC compressor mounting bolts and keep aside the compressor. Torque : 23 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010140.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew degassing tank coolant outlet pipe OCFM end. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010139.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010138.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using T45 socket spanner, Unscrew Oil cooler mounting bolts. Remove the oil cooler from the engine. Replace New O ring while refitting. Ensure to clean the Engine oil spillages. Install in reverse order of removal. Refill the engine oil and check for the oil leakage. Refill the engine coolant and carry-out de-aeration procedure. Check the oil cooler assembly for any external damage, Replace if required. Make sure for all the subassembly and components going into engine assembly should be clean and away from foreign material. Remove the Engine case cover.
Remove MST 0307ABH0001ST - Flywheel Locking Tool - Eagle mounting bolts and detach it. Refit engine front lifting hook and torque tighten the mounting bolts to the specified value. Using 18 mm socket spanner, unscrew engine mounting bracket nut (Both LH & RH) from engine bed. Torque : 110 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010618.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Provide engine support beam to support engine. Lift the engine with care, don\u2019t over lift since chances of damaging parts are more. Ensure none of the components are effected or damaged during lifting. Using a 14 mm combination spanner & socket spanner, unscrew LH Side engine mounting bracket mounting bolts and remove the bracket from engine compartment. Using a 6 mm square socket spanner, loosen and remove TDC locking pin plug. Torque : 20\u00b12 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010622.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Position damper pulley and install damper pulley mounting bolt on crankshaft. Insert the TDC locking pin (MST 0312ABH0001ST \u2013 Crankshaft Locking Tool - TDC Pin ) and lock the crankshaft. Ensure the crankshaft locking tool is seated properly into the slot on crankshaft and ensure the TDC locking pin insert upto Red mark in the pin as shown. Check and ensure the 1st cylinder piston position to TDC. Ensure that correct TDC locking tool is used. TDC locking hole is near crankcase left side below intake manifold (Near Engine LH Mounting bracket). If not able to position the MST in proper position into crankshaft, Slightly rotate damper pulley and align the crankshaft to insert MST:- 0312ABH0001ST Crankshaft Locking Tool - TDC Pin on crankshaft. Using 24 mm socket spanner, loosen and remove damper pulley mounting bolt and detach damper pulley. Check Crankshaft Sprocket woodruff key slot in 12\u2019o Clock Position, Intake and Exhaust camshaft cam phaser locking pin in 12\u2019o clock position. Align the MST \u2013 0310ABG0001ST Camshaft locking tool on the front side of engine in the camshaft slot as shown and fix the camshaft locking tool on cylinder head using appropriate bolts. Ensure that correct Camshaft locking tool is used. Ensure the Cam locking tool is seated properly on Cam shaft. If the tool is not properly seat on the cam shaft slot then the engine is not in proper timing and follow the below steps for Engine timing adjustment. Using 10 mm socket spanner, Unscrew chain tensioner mounting bolts and remove the tensioner. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010607.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using 8 mm Allen socket spanner, Unscrew chain tensioner LH fixed guide mounting bolt and remove the guide. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010606.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using 8 mm Allen socket spanner, Unscrew chain tensioner RH guide mounting bolts and remove the guide. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010608.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew chain tensioner top guide mounting bolt and remove the guide. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010609.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Remove the timing chain from sprocket. Align the MST \u2013 0310ABG0001ST Camshaft locking tool on the front side of engine in the camshaft slot as shown and fix the camshaft locking tool on cylinder head using appropriate bolts. If not able to position the MST in proper position into camshaft, Slightly rotate Intake/Exhuast cam shaft and align the tool. Ensure Crankshaft Sprocket woodruff key slot in 12\u2019o Clock Position, Intake and Exhaust camshaft cam phaser locking pin should be in 12\u2019o clock position. Ensure the Cam locking tool is seated properly on Cam shaft. Position and Refit the timing chain. Ensure Timing mark provided on the crankshaft sprocket match with highlighted chain link (Blue Link) on timing chain. 1st link (Blue Link) of timing chain started on timing mark provided on the crankshaft sprocket. Ensure Timing mark provided on the cam phaser (Intake and Exhaust) match with highlighted chain link (Blue Link) on timing chain. 29th link (Blue Link) of timing chain on timing mark provided on the Intake cam phaser sprocket (Anti-clock wise direction from Crank shaft first chain link). 40th link (Blue Link) of timing chain on timing mark provided on the Exhaust cam phaser sprocket (Anti-clock wise direction from Crank shaft first chain link). Refit the timing chain fixed guide and install the Allen bolts. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010607.jpg",
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": "Refit the chain tensioner guide and install the mounting Allen bolt. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010612.jpg",
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Compress the chain tensioner and lock it using lock pin. Refit the chain tensioner. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010608.jpg",
+ "display_order": 76
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Refit the timing chain top guide and install the mounting bolts. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010612.jpg",
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Remove the chain tensioner locking pin. Remove the CAM shafts locking MST. Remove the TDC Pin from crankshaft. Apply the Loctite 574 on TDC lock plug and tighten the plug on engine block to specified torque. Torque : 20\u00b12 Nm ",
+ "file": null,
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010975.jpg",
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "Description",
+ "content": "Refit engine mounting LH bracket, torque tighten the mounting bolts to the specified value. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 90
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010618.jpg",
+ "display_order": 91
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "Description",
+ "content": "Remove engine support beam. Install engine bed mounting nuts Both RH & LH, torque tighten the mounting nut to the specified value. Torque : 110 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010617.jpg",
+ "display_order": 97
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner , loosen and remove engine front lifting hook from head. Torque : 35\u00b13 Nm ",
+ "file": null,
+ "display_order": 99
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010971.jpg",
+ "display_order": 100
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "Description",
+ "content": "Refit Flywheel locking tool (MST\u20130307ABH0001ST) with suitable mounting bolts on crankcase. Refit the Engine Front cover. For additional information refer to Engine Front cover - R &R; Section. For additional information refer to the Crankshaft Pulley - R&R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010142.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a suitable tool remove the front end oil seal. Remove the seal from the engine. Install in reverse order of removal. The crankshaft oil seals are one time use, should never be reused. Follow the below procedure for front oil seal Installation. 1. Position the front oil seal on the Front Cover. 2. Place the front oil seal installer (MST\u20130311DBH0001ST) over the oil seal and tighten the torsional vibration damper pulley bolt. 3. Tighten the torsional vibration damper pulley bolt till the front oil seal is pushed to the Front Cover. Apply thin layer of oil on the new oil seal lip. Visually inspect the oil seal for proper seating. Check & Top-up the engine oil. Check and clean the oil seal seating area thoroughly for any damage. Hydro lock or hydrostatic lock is an abnormal condition in internal combustion engine. This occurs when a volume of liquid (Coolant/water or fuel) greater than the volume of the cylinder at its minimum (end of the piston stroke) enters the cylinder. Since liquids are nearly incompressible the piston cannot complete its travel; either the engine stop rotating or a mechanical failure occurs. When an engine is suspected to be hydrostatically locked, regardless of what caused the problem, the following steps should be used. DO NOT use starter motor to rotate the engine, severe damage may occur. Squirt approximately one teaspoon of oil into the cylinders, rotate engine to lubricate the cylinder walls to prevent damage on restart. Drain engine oil and remove oil filter. Install a new oil filter. Fill engine with specified amount of approved oil. Connect negative battery cable. Install all Injectors. Start engine and check for any leaks. The Oil Sump is the reservoir for the oil and also cover for the crank case. Oil sump is bolted to the ladder frame. The oil sump structural type to have better NVH. A liquid sealant is used to provide an leak proof joint. For additional information refer to engine oil draining procedure section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove electric disconnect stone guard. For additional information refer to Electric Disconnect Stone Guard \u2013 R&R Section. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove Water Pump/ AC compressor belt. For additional information refer to Water Pump/ AC compressor belt - R&R section. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010526.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, Unscrew water pump idler mounting bolt and remove dealer. Torque : 45 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010623.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the transmission bottom mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010527.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Provide jack to support the front axle assembly. Using 15 mm socket spanner, unscrew front axle mounting bolts and partially detach the axle. Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010918.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Partially down the front axle assembly . Using a 12 mm socket spanner, loosen and remove the AC compressor bottom mounting bolts. Torque : 23 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010529.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using a 14 mm ring and 15 mm socket spanner, Unscrew the front cross member mounting bolts and nuts. Torque : 65 \u00b110 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010916.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Detach the front cross member from the vehicle. Remove Stabilizer bar with link. For additional information refer to Stabilizer bar with link - R &R; section. Using a 8 mm socket spanner, loosen and remove the oil sump bottom mounting bolts. Torque : 11 \u00b1 1.0 Nm ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010531.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the oil sump bottom mounting bolts. Torque : 22.5 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010532.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1518.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Detach engine oil sump from the vehicle . Torque : 22.5 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010653.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010119.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11586.jpg",
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Clean the sump and sump seating area on crankcase . Gently apply sealant for engine oil sump. Apply sealant 5188 as per recommendation and position the sump on crankcase. Please refer Sealant pattern session for sealant apply pattern. Torque tighten the bolts as per sequence below while Installation. Refill the engine oil and check for oil leakage. Check the oil sump for any cracks, damage etc, replace if found any. Remove Timing Chain. For additional information refer to Timing Chain - R &R; section. Align the MST \u2013 0310ABG0001ST Camshaft locking tool on the front side of engine in the camshaft slot as shown and fix the camshaft locking tool on cylinder head using appropriate bolts. Using 22 mm socket spanner, Loosen and remove Inlet CAM phaser mounting bolt. Torque : 30 \u00b1 2 Nm + 34\u00b0\u00b1 3\u00b0 ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11655.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. While Installation, Check Exhaust Cam phaser mounting bolt tightening torque first and then torque tightened the Intake Cam phaser mounting bolt. Inspect the CAM Phaser for any physical damage. If found replace. This is a Variable type oil pump uses to supply variable oil pressure to the system. It is chain driven and integral oil strainer. The oil pump circulates the engine oil to lubricate the components such as bearings, piston and valve. The lower chain drives oil pump to lubricate the engine. This oil pump are integrated with the strainer. The oil strainer is the first stage in the filtration of the lubricant. It filters the coarse particles present in the oil before it enters the oil pump. For additional information refer to Engine Oil Sump \u2013 R&R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010472.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew oil strainer bracket mounting bolt. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010473.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010474.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew Oil strainer mounting bolts and remove strainer. Always replace a new metal gasket once it removed. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010521.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 8 mm Allen socket spanner, Loosen and remove oil pump chain tensioner shoulder bolt. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010522.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010523.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the tensioner and detach the chain from oil pump. Using 12 mm socket spanner, Unscrew oil pump mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010525.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1519.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Carefully remove engine oil pump. Install in reverse order of removal. Make sure that the retaining key on the rear side of the oil pump is fitted correctly to the retaining key hole on the surface of the cylinder block bed plate. While Installation, Partial attach the Oil Pump tensioner first and insert the tensioner spring lock on position. Then torque tighten the shoulder bolt. Refill the engine oil and check for oil leakage. Inspect the oil pump for any damage. Replace if found. Inspect the oil pump and strainer for any blockage, clean if found. Remove Vacuum pump. For additional information refer to vacuum pump - R &R; section. Remove the FIP. For additional information refer to FIP - R &R; section. Remove the timing chain. For additional information refer to Timing Chain - R &R; section. Using the MST \u2013 0310ABG0001ST Camshaft locking tool lock the cam shafts. Using 22 mm socket spanner, Loosen and remove exhaust CAM phaser mounting bolt. Torque : 30 \u00b1 2 Nm + 34\u00b0\u00b1 3\u00b0 ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010539.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 22 mm socket spanner, Loosen and remove Inlet CAM phaser mounting bolt Torque : 30 \u00b1 2 Nm + 34\u00b0\u00b1 3\u00b0 ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010537.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010540.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 8 mm socket spanner, Unscrew CAM shafts cap mounting bolts. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010541.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010543.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the camshaft from the cylinder head. Install in reverse order of removal. While Installation, Apply a thin layer of engine oil to the mounting parts of the Cam shafts & on Cam shafts. Sealant (Loctite 5188 - 2mm thickness) to be applied on rear (Vacuum Pump) bearing cap as per below pattern. Extra sealant to be wiped off after assembly of rear bearing cap. Exhaust Cam phaser mounting bolt should be torque tightened first and then torque tightened the Intake Cam phaser mounting bolt. Check the inlet camshaft and the exhaust camshaft for any damage and replace it if necessary. Inspect the camshaft bearing journals for scoring or excessive wear. Inspect the camshaft lobes for scoring or excessive wear. Inspect the threaded bolt holes in the front of the camshaft for damaged threads or debris. Remove the flywheel. For additional information refer into Flywheel - R &R; Section. Using a screw driver, remove the crankshaft rear end oil seal. Install the rear end oil seal by using MST 0302ABH0001ST - Engine Rear End Oil Seal Installer on the crankshaft. Always use new oil seal while installation. Install in reverse order of removal. Check & Top-up the engine oil. Check and clean the oil seal seating area thoroughly for any damage. For additional information refer into engine coolant draining procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "After installation of water pump, carry out refilling of the coolant. For additional information refer into coolant refilling procedure. For additional information refer into Water Pump Pulley \u2013 R&R Section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010923.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Detach the wiring routing clip from the water pump. Using a 13 mm socket spanner, Unscrew water pump mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010633.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully remove the water pump from the engine. Remove the O ring from the water pump. Install in reverse order of removal. Always replace the O ring new one once removal of water pump. Refill the engine coolant and carry-out de-aeration procedure. Check for coolant seepage on the engine. Rectify if any traces found. Inspect the water pump for any damage or leakage or noise. Replace if found. Inspect the impeller for any damage, Replace if found. For AT Variant:
Remove Automatic Transmission with Transfer Case.
",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Link",
+ "content": "THAR.LX-0008,1004,1088",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Untitledb1432c.png",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Disconnect the AT oil cooler hoses from thermal bye pass valve end.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Notice",
+ "content": "Ensure to close the bypass tubes with dummy caps to avoid dust entry.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner unscrew thermal bypass valve bracket mounting bolt from engine oil sump.",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/15daf66d.png",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010494.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010208.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using a hose clamp plier, Release coolant vent hose clamps radiator end,engine end and detach the hose both the ends and from routing clips.",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/17693996.png",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release degassing tank coolant outlet hose clamp and detach hose OCFM end.",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/18ad729e.png",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release turbo coolant outlet hose clamp and detach hose turbo end.",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew degassing tank mounting bolts and detach tank with hoses.",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/19b89eac.png",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.5\u00b1 0.5 Nm",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/20d066a2.png",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew front top cross member mounting bolts.",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 4.0 Nm",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010213.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Detach front top cross member and disconnect bonnet latch cable from routing and from lock.",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010071.jpg",
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010071.jpg",
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, unscrew degassing tank mounting bracket LHS & RHS mounting bolts.",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Torque Value",
+ "content": "Torque : 10 \u00b1 0.5 Nm",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1509.jpg",
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020285.jpg",
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Disconnect boost pressure sensor, and intercooler fan electrical connectors.",
+ "file": null,
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010214.jpg",
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner, Loosen turbo outlet hose clip and detach hose turbo end.",
+ "file": null,
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.5\u00b10.6 Nm",
+ "file": null,
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010215.jpg",
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner, Loosen intercooler outlet hose clip and detach hose throttle valve end.",
+ "file": null,
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.5\u00b10.6 Nm",
+ "file": null,
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010073.jpg",
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew intercooler mounting bolts and remove intercooler with hoses and fan.",
+ "file": null,
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Torque Value",
+ "content": "Torque : 12.5 \u00b1 1.5 Nm",
+ "file": null,
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010216.jpg",
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner, Loosen radiator outlet hose clip and detach hose OCFM end.",
+ "file": null,
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Torque Value",
+ "content": "Torque : 6.5\u00b10.6 Nm",
+ "file": null,
+ "display_order": 72
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010218.jpg",
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release radiator inlet hose clamp and detach hose cylinder block end. ",
+ "file": null,
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010074.jpg",
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Description",
+ "content": "Disconnect heater inlet and outlet hose quick coupler heater end.",
+ "file": null,
+ "display_order": 76
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "Torque Value",
+ "content": "Press and disconnect the quick coupler carefully to avoid seal damages.",
+ "file": null,
+ "display_order": 77
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040050.jpg",
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "Description",
+ "content": "Disconnect fuel inlet pipe quick coupler FIP end and detach hose.",
+ "file": null,
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "Notice",
+ "content": "Press and disconnect the quick coupler carefully to avoid seal damages.",
+ "file": null,
+ "display_order": 80
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040065.jpg",
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-31",
+ "content_type": "Description",
+ "content": "Disconnect purge valve vapour hose quick coupler purge valve end and detach hose.",
+ "file": null,
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040067.jpg",
+ "display_order": 83
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "Description",
+ "content": "Disconnect purge valve electrical connector.",
+ "file": null,
+ "display_order": 84
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010219.jpg",
+ "display_order": 85
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010220.jpg",
+ "display_order": 86
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "Description",
+ "content": "Disconnect vapour hose quick coupler and routing clip intake manifold end and detach hose.",
+ "file": null,
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "Notice",
+ "content": "Press and disconnect the quick coupler carefully to avoid seal damages.",
+ "file": null,
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010226.jpg",
+ "display_order": 89
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "Description",
+ "content": "Detach purge valve from mounting bracket and remove purge valve with vapour hose assembly.",
+ "file": null,
+ "display_order": 90
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010076.jpg",
+ "display_order": 91
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release vacuum hose clamp and detach hose vacuum pump end.",
+ "file": null,
+ "display_order": 92
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010224.jpg",
+ "display_order": 93
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "Description",
+ "content": "Open the alternator positive cable cover.",
+ "file": null,
+ "display_order": 94
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010225.jpg",
+ "display_order": 95
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew alternator positive cable mounting nut and detach cable alternator end.",
+ "file": null,
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-37",
+ "content_type": "Torque Value",
+ "content": "Torque : 15 \u00b1 1 Nm",
+ "file": null,
+ "display_order": 97
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1510.jpg",
+ "display_order": 98
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010130.jpg",
+ "display_order": 99
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "Description",
+ "content": "Disconnect engine WH inter connector, Holding clip and routing clip fire wall end.",
+ "file": null,
+ "display_order": 100
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010078.jpg",
+ "display_order": 101
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010132.jpg",
+ "display_order": 102
+ },
+ {
+ "step_name": "Step-39",
+ "content_type": "Description",
+ "content": "Disconnect engine WH connector ECU end and detach harness from routing clips.",
+ "file": null,
+ "display_order": 103
+ },
+ {
+ "step_name": "Step-40",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010079.jpg",
+ "display_order": 104
+ },
+ {
+ "step_name": "Step-40",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release power steering oil inlet hose clamp and detach hose pump end.",
+ "file": null,
+ "display_order": 105
+ },
+ {
+ "step_name": "Step-41",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010080.jpg",
+ "display_order": 106
+ },
+ {
+ "step_name": "Step-41",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew AC compressor suction and discharge hose mounting nuts.",
+ "file": null,
+ "display_order": 107
+ },
+ {
+ "step_name": "Step-41",
+ "content_type": "Torque Value",
+ "content": "Torque : 14.0+1.0 Nm",
+ "file": null,
+ "display_order": 108
+ },
+ {
+ "step_name": "Step-42",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010081.jpg",
+ "display_order": 109
+ },
+ {
+ "step_name": "Step-42",
+ "content_type": "Description",
+ "content": "Support the engine using engine removal support floor crane.",
+ "file": null,
+ "display_order": 110
+ },
+ {
+ "step_name": "Step-42",
+ "content_type": "Warning",
+ "content": "Improper tie-up of the lifting rope chain will cause damage to the vehicle and the persons involved.",
+ "file": null,
+ "display_order": 111
+ },
+ {
+ "step_name": "Step-43",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010615.jpg",
+ "display_order": 112
+ },
+ {
+ "step_name": "Step-43",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010616.jpg",
+ "display_order": 113
+ },
+ {
+ "step_name": "Step-43",
+ "content_type": "Description",
+ "content": "Using 18 mm socket spanner, unscrew engine bed mounting nuts LHS & RHS. ",
+ "file": null,
+ "display_order": 114
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010081.jpg",
+ "display_order": 115
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "Description",
+ "content": "Carefully remove the engine from compartment.",
+ "file": null,
+ "display_order": 116
+ },
+ {
+ "step_name": "Step-44",
+ "content_type": "Warning",
+ "content": "Improper tie-up of the lifting rope chain will cause damage to the vehicle and the persons involved. ",
+ "file": null,
+ "display_order": 117
+ },
+ {
+ "step_name": "Step-45",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010083.jpg",
+ "display_order": 118
+ },
+ {
+ "step_name": "Step-45",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release heater inlet and outlet hose clamps and detach the hoses.",
+ "file": null,
+ "display_order": 119
+ },
+ {
+ "step_name": "Step-46",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010084.jpg",
+ "display_order": 120
+ },
+ {
+ "step_name": "Step-46",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew engine WH carrier mounting bolts.",
+ "file": null,
+ "display_order": 121
+ },
+ {
+ "step_name": "Step-47",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010227.jpg",
+ "display_order": 122
+ },
+ {
+ "step_name": "Step-47",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew ignition coil ground connector mounting nut.",
+ "file": null,
+ "display_order": 123
+ },
+ {
+ "step_name": "Step-48",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010085.jpg",
+ "display_order": 124
+ },
+ {
+ "step_name": "Step-48",
+ "content_type": "Description",
+ "content": "Disconnect AC compressor electrical connector",
+ "file": null,
+ "display_order": 125
+ },
+ {
+ "step_name": "Step-49",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010086.jpg",
+ "display_order": 126
+ },
+ {
+ "step_name": "Step-49",
+ "content_type": "Description",
+ "content": "Disconnect Variable oil pump solenoid electrical connector.",
+ "file": null,
+ "display_order": 127
+ },
+ {
+ "step_name": "Step-50",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010093.jpg",
+ "display_order": 128
+ },
+ {
+ "step_name": "Step-50",
+ "content_type": "Description",
+ "content": "Disconnect upstream Lambda sensor electrical connector and connector holder. ",
+ "file": null,
+ "display_order": 129
+ },
+ {
+ "step_name": "Step-51",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010090.jpg",
+ "display_order": 130
+ },
+ {
+ "step_name": "Step-51",
+ "content_type": "Description",
+ "content": "Disconnect Engine oil pressure sensor electrical connector and routing clip.",
+ "file": null,
+ "display_order": 131
+ },
+ {
+ "step_name": "Step-52",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010091.jpg",
+ "display_order": 132
+ },
+ {
+ "step_name": "Step-52",
+ "content_type": "Description",
+ "content": "Disconnect WGTelectrical connector.",
+ "file": null,
+ "display_order": 133
+ },
+ {
+ "step_name": "Step-53",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010194.jpg",
+ "display_order": 134
+ },
+ {
+ "step_name": "Step-53",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010234.jpg",
+ "display_order": 135
+ },
+ {
+ "step_name": "Step-53",
+ "content_type": "Description",
+ "content": "Disconnect Dump valve electrical connector and routing clip.",
+ "file": null,
+ "display_order": 136
+ },
+ {
+ "step_name": "Step-54",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010102.jpg",
+ "display_order": 137
+ },
+ {
+ "step_name": "Step-54",
+ "content_type": "Description",
+ "content": "Disconnect VVT inlet and exhaust cam phase solenoid connector & routing clip.",
+ "file": null,
+ "display_order": 138
+ },
+ {
+ "step_name": "Step-55",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010103.jpg",
+ "display_order": 139
+ },
+ {
+ "step_name": "Step-55",
+ "content_type": "Description",
+ "content": "Disconnect throttle valve electrical connector.",
+ "file": null,
+ "display_order": 140
+ },
+ {
+ "step_name": "Step-56",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010195.jpg",
+ "display_order": 141
+ },
+ {
+ "step_name": "Step-56",
+ "content_type": "Description",
+ "content": "Disconnect MAP sensor electrical connector.",
+ "file": null,
+ "display_order": 142
+ },
+ {
+ "step_name": "Step-57",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010094.jpg",
+ "display_order": 143
+ },
+ {
+ "step_name": "Step-57",
+ "content_type": "Description",
+ "content": "Disconnect Spark plug (4 nos) electrical connectors.",
+ "file": null,
+ "display_order": 144
+ },
+ {
+ "step_name": "Step-58",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010134.jpg",
+ "display_order": 145
+ },
+ {
+ "step_name": "Step-58",
+ "content_type": "Description",
+ "content": "Disconnect Exhaust CAM sensor electrical connector.",
+ "file": null,
+ "display_order": 146
+ },
+ {
+ "step_name": "Step-59",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010089.jpg",
+ "display_order": 147
+ },
+ {
+ "step_name": "Step-59",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010233.jpg",
+ "display_order": 148
+ },
+ {
+ "step_name": "Step-59",
+ "content_type": "Description",
+ "content": "Disconnect downstream lambda sensor electrical connector and routing clip.",
+ "file": null,
+ "display_order": 149
+ },
+ {
+ "step_name": "Step-60",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010095.jpg",
+ "display_order": 150
+ },
+ {
+ "step_name": "Step-60",
+ "content_type": "Description",
+ "content": "Disconnect Inlet CAM phase sensor electrical connector.",
+ "file": null,
+ "display_order": 151
+ },
+ {
+ "step_name": "Step-61",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1511.jpg",
+ "display_order": 152
+ },
+ {
+ "step_name": "Step-61",
+ "content_type": "Description",
+ "content": "Disconnect Coolant temperature sensor electrical connector.",
+ "file": null,
+ "display_order": 153
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010228.jpg",
+ "display_order": 154
+ },
+ {
+ "step_name": "Step-62",
+ "content_type": "Description",
+ "content": "Disconnect FIP electrical connector.",
+ "file": null,
+ "display_order": 155
+ },
+ {
+ "step_name": "Step-63",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010096.jpg",
+ "display_order": 156
+ },
+ {
+ "step_name": "Step-63",
+ "content_type": "Description",
+ "content": "Disconnect Common rail electrical connector.",
+ "file": null,
+ "display_order": 157
+ },
+ {
+ "step_name": "Step-64",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010099.jpg",
+ "display_order": 158
+ },
+ {
+ "step_name": "Step-64",
+ "content_type": "Description",
+ "content": "Disconnect Injector (4 nos) electrical connector.",
+ "file": null,
+ "display_order": 159
+ },
+ {
+ "step_name": "Step-65",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010100.jpg",
+ "display_order": 160
+ },
+ {
+ "step_name": "Step-65",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010105.jpg",
+ "display_order": 161
+ },
+ {
+ "step_name": "Step-65",
+ "content_type": "Description",
+ "content": "Disconnect Knock sensor electrical connector & routing clips(2Nos).",
+ "file": null,
+ "display_order": 162
+ },
+ {
+ "step_name": "Step-66",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010231.jpg",
+ "display_order": 163
+ },
+ {
+ "step_name": "Step-66",
+ "content_type": "Description",
+ "content": "Disconnect Alternator connector & routing clip.",
+ "file": null,
+ "display_order": 164
+ },
+ {
+ "step_name": "Step-67",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010104.jpg",
+ "display_order": 165
+ },
+ {
+ "step_name": "Step-67",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010106.jpg",
+ "display_order": 166
+ },
+ {
+ "step_name": "Step-67",
+ "content_type": "Description",
+ "content": "Detach the WH harness from engine assembly.",
+ "file": null,
+ "display_order": 167
+ },
+ {
+ "step_name": "Step-68",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010109.jpg",
+ "display_order": 168
+ },
+ {
+ "step_name": "Step-68",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew CATCON mounting bolts and remove CATCON from Turbo end.",
+ "file": null,
+ "display_order": 169
+ },
+ {
+ "step_name": "Step-69",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010108.jpg",
+ "display_order": 170
+ },
+ {
+ "step_name": "Step-69",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew CATCON brackets mounting bolts and remove CATCON from engine.",
+ "file": null,
+ "display_order": 171
+ },
+ {
+ "step_name": "Step-70",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010222.jpg",
+ "display_order": 172
+ },
+ {
+ "step_name": "Step-70",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010223.jpg",
+ "display_order": 173
+ },
+ {
+ "step_name": "Step-70",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1512.jpg",
+ "display_order": 174
+ },
+ {
+ "step_name": "Step-70",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010221.jpg",
+ "display_order": 175
+ },
+ {
+ "step_name": "Step-70",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010252.jpg",
+ "display_order": 176
+ },
+ {
+ "step_name": "Step-70",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010251.jpg",
+ "display_order": 177
+ },
+ {
+ "step_name": "Step-70",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner loosen and remove clutch cover assembly mounting bolts and remove it.",
+ "file": null,
+ "display_order": 178
+ },
+ {
+ "step_name": "Step-70",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 5.0 Nm (Step Torque : 5,15,25)",
+ "file": null,
+ "display_order": 179
+ },
+ {
+ "step_name": "Step-70",
+ "content_type": "Notice",
+ "content": "Install the MST : 0307ABH0001ST \u2014 Flywheel locking tool and lock the flywheel rotation.Insert MST \u2014 0801BUA0001ST \u2014 Master clutch plate assembly, before loosening the clutch cover bolts to prevent clutch plate falling down and getting damage.While Installation, the projected part of clutch disc should come towards transmission side only, fails may result in clutch disc damage.",
+ "file": null,
+ "display_order": 180
+ },
+ {
+ "step_name": "Step-71",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010107.jpg",
+ "display_order": 181
+ },
+ {
+ "step_name": "Step-71",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010110.jpg",
+ "display_order": 182
+ },
+ {
+ "step_name": "Step-71",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew engine feed cover mounting bolts and remove feed cover.",
+ "file": null,
+ "display_order": 183
+ },
+ {
+ "step_name": "Step-72",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 184
+ },
+ {
+ "step_name": "Step-73",
+ "content_type": "Description",
+ "content": "Recharge the AC refrigerant system. For additional information refer to Recharge the AC refrigerant system - R&R section.",
+ "file": null,
+ "display_order": 185
+ },
+ {
+ "step_name": "Step-74",
+ "content_type": "Description",
+ "content": "Refill Engine coolant. For additional information refer to coolant refilling Procedure.",
+ "file": null,
+ "display_order": 186
+ },
+ {
+ "step_name": "Step-75",
+ "content_type": "Description",
+ "content": "Check & Top-up the engine oil.",
+ "file": null,
+ "display_order": 187
+ },
+ {
+ "step_name": "Step-76",
+ "content_type": "Description",
+ "content": "Check for coolant seepage and any oil seepage on the engine and transmission. Rectify if any traces found.",
+ "file": null,
+ "display_order": 188
+ },
+ {
+ "step_name": "Step-77",
+ "content_type": "Description",
+ "content": "Check & Clear DTC if found any. For additional information refer to diagnostic manual.",
+ "file": null,
+ "display_order": 189
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the accessory drive belt for any cracks, damage etc, replace if found anyCheck SMF face-out and run-out.Check SMF Surface thermal cracks condition.Check the flywheel ring gear for worn-out or damage, Refer SMF Inspection procedures for more details.",
+ "file": null,
+ "display_order": 190
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 1,
+ "sys_id": "THAR.LX-0008-Engine",
+ "subsys_id": "THAR.LX-0008-Engine-Engine Oil Level - Inspect",
+ "systems": "Engine",
+ "sub_systems": "Engine Oil Level - Inspect",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J10-MAT-0010",
+ "cover_image": "/files/W4B010001.jpg",
+ "myid": 1083,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 1,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 74,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 116,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 156,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 198,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 238,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 281,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 319,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 363,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 402,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 447,
+ "kilometers_applicable": 0
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Engine Oil Level - Inspect-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Engine Oil Level - Inspect.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010001.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Engine Oil \u2013 \u2013MAHINDRA 'MAXIMILE ULTRA' Gen-NXT Technology Genuine Engine Fluid. Capacity \u2013 6.0 Liters. Pull out the dip stick gauge and wipe it clean with a cloth/paper. Insert the dip stick gauge into the dip stick guide fully till the end. Pull out the dip stick slowly and check for the oil level mark between Maximum and Minimum level - if found below minimum level, top up with recommended oil. Insert the dip stick back and fix properly.
MAXIMILE ULTRA 'Gen-NXT Technology GENUINE ENGINE Fluid. This is specially developed for your engine\u2019s efficiency.MAXIMILE ULTRA '.The cylinder head gasket failure can be easy to determine. A large stream of white smoke blowing from the exhaust and an overheating engine are sure signs. However, more suitable cylinder head gasket failure signs may be more difficult to diagnose. The engine may experience mysterious coolant loss, or only lose coolant when the engine is driven under heavy load. You may even experience a rough running engine when you first start the vehicle. An initial inspection of cooling system components and a comprehensive test drive may be necessary to confirm the customer's complaint of coolant loss or overheating. Check for the presence of white steam/smoke coming from the exhaust. Steam coming out of the exhaust may smell slightly sweet as the steam gently dissipates into the surrounding air. Another sign that the head gasket may be leaking is the presence of oil in the cooling system. Check for oil residue in the coolant reservoir. It is important to confirm actual engine running temperature and accuracy of the temperature gauge. This can be verified by using a non-contact infrared heat detection gun. It is a non intrusive method used by most repair shops to verify temperature gauge accuracy and actual engine running temperature. Pressurizing the cooling system (to eliminate coolant leaks as being the source of coolant loss), checking for proper operation of the cooling fan, and checking radiator efficiency are important before jumping to the conclusion that the head gasket is defective. Cylinder to Cylinder Leakage Test ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the cylinder compression pressure as already explained. Leakage between cylinders will be result in drop of compression pressure by nearly 50 to 70% in the affected cylinders. Cylinder to Water jacket Leakage Test ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the degassing pressure cap. Warm up the engine and allow it to warm up until the engine thermostat opens. If large combustion pressure leak exist, bubbles will be visible in coolant. If bubbles are not visible, install a pressure tester and pressurize the cooling circuit. If a cylinder is leaking combustion pressure into the water jackets then the tester\u2019s needle will pulsate with every combustion stroke of the cylinder. ground level/ 2 post lift/ 4 post lift and turn engine OFF. 2. Open the bonnet and lock it in open position using bonnet stay rod.",
+ "file": null,
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W375.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the engine feed cover mounting bolts. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W376.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the engine feed cover from engine compartment. Using a 24 mm socket spanner, rotate the crank pulley 360\u2070 till belt completes one full rotation to check belt condition and confirm following belt appearances if any. Random Cracking Across the Ribs ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Small yet visible cracks along the length of a rib or ribs. Causes: ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Continuous exposure to high temperatures and the stress of bending around the pulleys leads to cracking. Cracks begin at the rib top and grow to the cord line. As a rule, if cracks appear 1 or 2 cm apart, 80% of the life is gone and the belt should be replaced. Chunk-Out ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Pieces or chunks of rubber material have come off the belt. When chunk-out has occurred, a belt can fail at any moment. Belt should be replaced immediately. Causes: ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Chunk-out can happen when several cracks in one area move parallel to the cord line. Heat, age and stress are the primary contributors. Pilling ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Belt material wears off from the ribs and builds up in the belts grooves. Causes: ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "There are a number of causes, including misalignment, new belt on worn pulleys, lack of tension or a combination of these factors. Gravel Penetration ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Small pinholes are visible on the backside of the belt. Bumps may be visible and fabric around the holes can be frayed. Causes: ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Granular gravel or pebble gravel is wedged between the belt groove(s) and pulley ridge(s). Damaged Outermost Ribs ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Sidewalls of the belt may appear glazed or the edge-cord may become frayed and ribs removed. A noticeable noise may result. Causes: ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Pulley misalignment is a common cause of premature belt failure. Misalignment forces the belt to twist while running, causing premature wear. Oil Contamination ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "The belt surface is flaky, sticky or swollen. Causes: ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Oil and grease are a rubber compound\u2019s worst enemies, weakening the compound\u2019s bonds and making the belt soft and spongy. Eventually, such a belt will slip, create heat and fail. Abrasion ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "The backside of the belt appears very shiny or glazed. In advance stages, the fabric or even the cord becomes exposed and gets damaged. Causes: ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "When in motion, the belt makes contact with the foreign objects in its path such as a flange or bolt. This may be caused by improper belt tension or by belt flutter (vibrations) on longer span lengths between two pulleys. Rib Separation ",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "The belt rib shears off or begins to separate from the belt base. Causes: ",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "The belt is not correctly positioned. One of the belt ribs is placed outside the pulley groove, causing a belt rib to run without a supporting or aligning pulley groove. Uneven Rib Wear ",
+ "file": null,
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Wear that is more severe on one rib than on the others or one rib that exhibits a different wear pattern than the others. A thumping or grinding noise may also be heard. Causes: ",
+ "file": null,
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "A foreign object \u2014 such as a pebble \u2014 in the pulley will cause uneven wear and cut into the belt and break the tensile cords. Broken Belt ",
+ "file": null,
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "A large foreign object between the belt and pulley can cut into the belt and break the tensile cords. Tensile break may occur but go unnoticed when the belt is forced or pried on during installation. Other possible causes may be severe shock loads or a blocked pulley and/or accessory. Belt Noise ",
+ "file": null,
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "Inspection: ",
+ "file": null,
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Run the engine and inspect for Chirping, squealing. tapping, ticking or grinding noise coming from the belt. It is recommended to remove & check the drive belts thoroughly if any abnormality noticed. Check belt tension as per procedure mentioned below: ",
+ "file": null,
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Turn ON belt tension gauge. Select reading mode in hertz (Hz) and hold the probe approximately 5mm distance in front of the belt. Do not touch the probe to the belt, this can damage the probe. Belt tension needs to be checked at the green points shown in illustration. Between Crank pulley & water pump pulley. Between water pump pulley & AC Compressor Pulley. Tap on the belt near the probe. Note the reading, if the reading is within 195 \u2013 228 Hz, belt tension is OK. If the reading is not within the above limit, check & replace the belt if required. Using 10 mm socket spanner, loosen and remove the engine feed cover mounting bolts. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 89
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W384.jpg",
+ "display_order": 90
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the engine feed cover from engine compartment. Using a 24 mm socket spanner, rotate the crank pulley 360\u2070 till belt completes one full rotation to check belt condition and confirm following belt appearances if any. Random Cracking Across the Ribs ",
+ "file": null,
+ "display_order": 95
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Small yet visible cracks along the length of a rib or ribs. Causes: ",
+ "file": null,
+ "display_order": 98
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Continuous exposure to high temperatures and the stress of bending around the pulleys leads to cracking. Cracks begin at the rib top and grow to the cord line. As a rule, if cracks appear 1 or 2 cm apart, 80% of the life is gone and the belt should be replaced. Chunk-Out ",
+ "file": null,
+ "display_order": 101
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 102
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Pieces or chunks of rubber material have come off the belt. When chunk-out has occurred, a belt can fail at any moment. Belt should be replaced immediately. Causes: ",
+ "file": null,
+ "display_order": 104
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Chunk-out can happen when several cracks in one area move parallel to the cord line. Heat, age and stress are the primary contributors. Pilling ",
+ "file": null,
+ "display_order": 107
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 108
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Belt material wears off from the ribs and builds up in the belts grooves. Causes: ",
+ "file": null,
+ "display_order": 110
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "There are a number of causes, including misalignment, new belt on worn pulleys, lack of tension or a combination of these factors. Gravel Penetration ",
+ "file": null,
+ "display_order": 113
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 114
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Small pinholes are visible on the backside of the belt. Bumps may be visible and fabric around the holes can be frayed. Causes: ",
+ "file": null,
+ "display_order": 116
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Granular gravel or pebble gravel is wedged between the belt groove(s) and pulley ridge(s). Damaged Outermost Ribs ",
+ "file": null,
+ "display_order": 119
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 120
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Sidewalls of the belt may appear glazed or the edge-cord may become frayed and ribs removed. A noticeable noise may result. Causes: ",
+ "file": null,
+ "display_order": 122
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Pulley misalignment is a common cause of premature belt failure. Misalignment forces the belt to twist while running, causing premature wear. Oil Contamination ",
+ "file": null,
+ "display_order": 125
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 126
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "The belt surface is flaky, sticky or swollen. Causes: ",
+ "file": null,
+ "display_order": 128
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Oil and grease are a rubber compound\u2019s worst enemies, weakening the compound\u2019s bonds and making the belt soft and spongy. Eventually, such a belt will slip, create heat and fail. Abrasion ",
+ "file": null,
+ "display_order": 131
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 132
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "The backside of the belt appears very shiny or glazed. In advance stages, the fabric or even the cord becomes exposed and gets damaged. Causes: ",
+ "file": null,
+ "display_order": 134
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "When in motion, the belt makes contact with the foreign objects in its path such as a flange or bolt. This may be caused by improper belt tension or by belt flutter (vibrations) on longer span lengths between two pulleys. Rib Separation ",
+ "file": null,
+ "display_order": 137
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 138
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "The belt rib shears off or begins to separate from the belt base. Causes: ",
+ "file": null,
+ "display_order": 140
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "The belt is not correctly positioned. One of the belt ribs is placed outside the pulley groove, causing a belt rib to run without a supporting or aligning pulley groove. Uneven Rib Wear ",
+ "file": null,
+ "display_order": 143
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 144
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Wear that is more severe on one rib than on the others or one rib that exhibits a different wear pattern than the others. A thumping or grinding noise may also be heard. Causes: ",
+ "file": null,
+ "display_order": 146
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "A foreign object \u2014 such as a pebble \u2014 in the pulley will cause uneven wear and cut into the belt and break the tensile cords. Broken Belt ",
+ "file": null,
+ "display_order": 149
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 150
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 151
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 152
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "A large foreign object between the belt and pulley can cut into the belt and break the tensile cords. Tensile break may occur but go unnoticed when the belt is forced or pried on during installation. Other possible causes may be severe shock loads or a blocked pulley and/or accessory. Belt Noise ",
+ "file": null,
+ "display_order": 155
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "Inspection: ",
+ "file": null,
+ "display_order": 156
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Run the engine and inspect for Chirping, squealing. tapping, ticking or grinding noise coming from the belt. It is recommended to remove & check the drive belts thoroughly if any abnormality noticed. Inspect the auto-tensioner carefully for symptoms such as cracked arms, excessive vibration during idle speeds, looseness, noise (clatter or rattling) and sticking or seized operation. These all can be signs that roller needs replacement. Rust bleed and cracks ",
+ "file": null,
+ "display_order": 163
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 164
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Rust bleeding between arm and base or dripping from the tensioner. Also, check the tensioner for cracks or damage to arm, housing and bracket. Causes: ",
+ "file": null,
+ "display_order": 166
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Rust bleeding or dripping is a sign of internal component wear. Most common crack damage occurs at tensioner \u201cStops\u201d and mounting bolts. Solution: ",
+ "file": null,
+ "display_order": 168
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Replace the auto-tensioner. Pulley bearing wear ",
+ "file": null,
+ "display_order": 171
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 172
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "If any abnormality noticed, remove the belt and manually rotate the pulley. If you notice, resistance or roughness, the problem is likely to be pulley bearing wear. Causes: ",
+ "file": null,
+ "display_order": 174
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Defective bearing and/or pulley. Solution: ",
+ "file": null,
+ "display_order": 176
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Replace the complete tensioner. Do not attempt to replace a worn pulley in a used tensioner assembly but always replace the entire tensioner assembly, as part failure will inevitably follow quickly. TENSIONER ASSEMBLY MISALIGNMENT ",
+ "file": null,
+ "display_order": 180
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 181
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Abnormal belt tracking on tensioner pulley. Causes: ",
+ "file": null,
+ "display_order": 183
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Bent or misaligned mounting bracket,improper tensioner installation or corrosion/ contamination between tensioner base and mounting surface. A small amount of contamination results in a large amount of at tensioner pulley. Tensioner Noise ",
+ "file": null,
+ "display_order": 185
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 186
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Squeaks and rattles coming from the tensioner. Causes: ",
+ "file": null,
+ "display_order": 188
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Failure of bearings or pivot are will cause excessive noise. Solution: ",
+ "file": null,
+ "display_order": 190
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Replace the tensioner assembly. The crankshaft speed sensor is an hall effect type sensor. It measures the speed of the trigger wheel mounted on the crankshaft. During engine cranking and running, the EMS ECU receives the output signal from crankshaft speed sensor. Remove Air Cleaner Assembly. For additional information refer to Air Cleaner Assembly - R &R; section. Remove Steering Lower Intermediate Shaft. For additional information refer to Steering Lower Intermediate Shaft - R &R; section. Place the MST 0306GAM0006ST \u2013 Drive Belts Removal Tool on damper pulley side as shown in the image. Using a 24 mm socket spanner, rotate the damper pulley to clockwise direction then remove the water pump drive belt and MST 0306GBH0001ST \u2014 Drive Belts Removal Tool separately. Disconnect AC compressor electrical connector. Using 12 mm socket spanner, Unscrew AC compressor mounting bolts and keep aside the compressor. Torque : 23 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010240.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect engine speed sensor electrical connector detach it from holding clip. Using 10 mm socket spanner unscrew engine speed sensor mounting bolt and remove sensor. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Notice",
+ "content": "Take sufficient care not to damage the sensor while removing. Ensure proper torque value is applied to sensor mounting bolt. Else chances of sensor malfunction is high. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Inspect the sensor and connector for any physical damage. Replace if found. EMS (Engine Management System) ECU is an electronic control unit which is used to ensure optimal engine performance. It does this by analyzing values or signals from various sensors and other ECU\u2019s and adjusting the actuators accordingly. EMS ECU is mounted on front left side apron in the engine compartment. ECU electrical connector should be disconnected before carrying out any welding activities in the vehicle. Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010243.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Open the lock and gently pull-out and disconnect EMS ECU electrical connector. Using 10 mm socket spanner remove EMS ECU mounting bolts. Torque : 6 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. For New EMS ECU replacement carry out Necessary Procedures by using iSMART. For additional information refer Diagnosis Manual. ECU electrical connector should be disconnected before carrying out any welding activities in the vehicle. Check for any external damage, if found replace. Remove the Engine Assembly. Remove the cylinder head assembly. Place the cylinder head on clean flat work table. Using a suitable valve compressor, compress and hold the valve spring and then remove the valve spring lock studs. Remove the upper retainer and valve spring. Incase of reusing the same valves spring, make necessary marking according to the respective cylinder. Remove the valve stem seal. The valve should be identified, so that in case the valves are being reused they can be used. Failure to do so may increase the probability of compression leak through the valve after the engine is rebuilt. Similarly remove the other valves.
2. Check the valve spring height.
",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1527.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11666.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "1. Check the valve guide bore diameter. 2. Check the valve guide for any damages.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010308.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11668.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "1. Check the valve for any damages.
2. Using a micrometer measures the diameter of the valve stems.
3. If the measurements are not to specification, install a new valve.
4. Check the valves for bend - especially if the engine has suffered water entry into combustion chamber.
",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010918.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "1. Clean the cylinder head assembly thoroughly, if any cracks or damages are found replace the cylinder head. 2. Check the Cylinder Head for external damages. 3. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. 4. Check the valve seat area for leakages.",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010925.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Check the Cylinder Head bottom face for distortion. Check the cylinder head flatness, if any misalignment or bend found replace the cylinder head assembly. Check the cylinder head for warpage. Check the length of the Cylinder Head bolts.
2. Measure at two different points on the journal to determine if there is any tapering.
3. Check the camshaft for any damage and replace it if necessary.
",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1528.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11677.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "1. Inspect the rocker arm for wear or damage. Replace as necessary.",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Caution",
+ "content": "Do not dis-assemble the HLLA, as it is not a serviceable component. Incase of a failure of a HLLA, replace the complete assembly. Carefully insert the valve from bottom. Apply oil on the valve stem before installation. Incase of reusing the same valves again, make sure the valves used is of respective cylinder. Using suitable tool refit new valve stem seal. Never use old valve stem seal, always use a new one. Always apply oil on the valve stem seal before installation. Insert the respective valve spring and top retainer. Using a suitable tool, compress the valve spring carefully insert the locking pins and lock it properly. Install the cylinder head assembly. Clean the cylinder head assembly thoroughly, if any cracks or damages are found replace the cylinder head. Replace the cylinder head gasket with a new one. Failure to follow this will lead to compression failure. The cylinder head mounting bolts cannot be reused. Always use new bolts during installation Refit the engine assembly. Engine Oil \u2013 MAHINDRA 'MAXIMILE ULTRA' Gen-NXT Technology Genuine Engine Fluid. Capacity \u2013 6.0 Liters. ground level/ 2 post lift/ 4 post lift and turn engine OFF. 3. Open the bonnet and lock it in open position using bonnet stay rod.",
+ "file": null,
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Draining",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1501.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the engine top encapsulation cover. Remove the engine oil filler cap. Using 22 mm ring/ socket spanner, Unscrew engine oil drain plug located under the oil sump. Allow the entire oil to get drained. Place a tray under the drain plug to collect the oil. Refit the drain plug with a new copper washer and tighten the drain plug to specific torque. Torque : 25\u201330 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Always replace the copper washer with a new one. Fill fresh recommended oil to specified quantity. Refit the engine oil filler cap. Refit the engine encapsulation cover. Pull out the dip stick gauge and wipe it clean with a cloth/paper. Insert the dip stick gauge into the dip stick guide fully till the end. Pull out the dip stick slowly and check for the oil level mark between Maximum and Minimum level - if found below minimum level, top up with recommended oil. Insert the dip stick back and fix properly. Start the engine and check for oil leakage/ seepage at: Oil sump & crankcase joint. Oil sump drain plug. Oil filter joint. Always use MAHINDRA 'MAXIMILE ULTRA'Gen-NXT Technology GENUINE ENGINE Fluid. This is specially developed for your engine\u2019s efficiency. In extreme cases of emergency and non-availability of above oil, we suggest to use 'Maximile Feo' engine oil, take the vehicle to nearest Mahindra Authorised Service centre and replace the oil with 'MAXIMILE ULTRA'. No other brand / grade oil recommended. The knock sensor converts mechanical oscillations of the cylinder block into electrical impulses which can then be processed by the EMS ECU. The Knock sensor consists of piezo-ceramic crystals that generate a voltage when subjected to a mechanical load. Disconnect the knock sensor electrical connector. Using 12 mm socket spanner, Unscrew Knock sensor mounting bolt and remove sensor. Torque : 20 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the knock sensor for any physical damage. If found replace. Oil Pressure sensor operates the low oil pressure indicator in the cluster. This serves as a warning indicator to the driver, indicating a decrease in the oil pressure which might harm the engine if driver continues running the engine. The Oil Pressure Sensor is A Piezo \u2013 Resistive type sensor. It Sends oil pressure values to EMS ECU. Disconnect the oil pressure sensor electrical connector. Using 24 mm socket spanner, Loosen and remove the oil pressure sensor from OCFM. Torque : 20 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Check engine oil level, Top up engine oil and check for oil leakage. Check oil pressure sensor for any cracks, damage etc, replace if found any. Remove Engine Feed Cover. For additional information refer to Engine Feed Cover - R &R; section. Remove Air Cleaner Assembly. For additional information refer to Air Cleaner Assembly - R &R; section. Using the MST 0306GAM0006ST - Stretch Fit Belt Removal Tool Remove the Water Pump Drive belt. Using 7 mm socket spanner, Loosen radiator outlet hose clip and detach hose water inlet pipe end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010506.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew degassing tank coolant filling pipe mounting bolt OCFM end. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010507.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew heater outlet pipe routing bracket mounting bolt engine block end. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010508.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew heater outlet pipe routing bracket mounting bolt cylinder head end. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010509.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 10 mm combination spanner, Unscrew heater outlet pipe mounting bolt and partially remove pipe. Torque :11\u00b11 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010592.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Disconnect AC compressor electrical connector. Disconnect oil pressure sensor electrical connector. Disconnect crank speed sensor electrical connector. Disconnect engine variable oil pump solenoid electrical connector. Using 12 mm socket spanner, Unscrew engine wiring routing bracket mounting bolt. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010515.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew Turbo wiring routing bracket mounting bolt. Torque : 10\u00b11 Nm ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1515.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew turbo coolant inlet and oil inlet mounting banjo bolts OCFM end. Torque : 18\u00b12 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010517.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release oil separator hose clamp clean hose end. Using 7 mm socket spanner, Loosen clean hose clip and detach hose turbo end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010519.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew OCFM rear mounting bolts. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010520.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew OCFM mounting bolt and strut. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Caution",
+ "content": "Replace New rubber gasket while refitting. Remove OCFM from engine compartment. Using a 10 mm socket spanner, Unscrew water pump pulley mounting bolts and remove pulley from water pump. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Notice",
+ "content": "Using a suitable tool hold the pulley then remove the water pump pulley. Using a 13 mm socket spanner, Unscrew water pump mounting bolts and remove the water pump from the OCFM. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Refill the engine oil and check for the oil leakage. Refill the engine coolant and carry-out de-aeration procedure. Check the OCFM for any external cracks, replace if found any. This vehicle is equipped with one autotensioner to maintain the accessory drive belt tension for Alternator and Power steering pump drive belt. It is mandatory to maintain belt tension through out the belt life in-order to have maximum efficiency and life. A tensioner is a device that applies a force to create or maintain recommended belt tension. ground level/ 2 post lift/ 4 post lift and turn engine OFF. 2. Open the bonnet and lock it in open position using bonnet stay rod.",
+ "file": null,
+ "display_order": 6
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W128.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen and remove the engine feed cover mounting bolts. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W129.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the engine feed cover from engine compartment. Place the MST 0306GAM0006ST Stretch Fit Belt Removal Tool on dampe pulley side as shown in the image. Using a 24 mm socket spanner, rotate the damper pulley to clockwise direction then remove the water pump drive belt and MST separately. Place the MST 0306GBH0001ST - Stretch Fit Belt Installation Tool on damper pulley as shown in the image. Using a 24 mm socket spanner, rotate the damper pulley in anticlockwise direction. By rotating pulley, belt started getting into pulley groove and once belt installed properly on pulley, then remove the MST and spanner. Ensure proper engagement of belt teeth in all the pulley grooves after Installation. Check the Belt tension. Refer Belt Tension Checking Procedure session below. Refit the engine fead cover on engine compartment, torque tighten the bolts to specified value. Torque : 11\u00b1 1Nm ",
+ "file": null,
+ "display_order": 27
+ }
+ ]
+ },
+ {
+ "procedure_name": "Checking Procedure",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W137.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W138.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Heading",
+ "content": "Check belt tension as per procedure mentioned below: ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Run the engine for few minutes. Turn ON belt tension gauge. Select reading mode in hertz (Hz) and hold the probe approximately 5mm distance in front of the belt. Do not touch the probe to the belt, this can damage the probe. Belt tension needs to be checked at the green points shown in illustration. Between Crank pulley & water pump pulley. Between water pump pulley & AC Compressor Pulley. Tap on the belt near the probe. Note the reading, if the reading is within 195 \u2013 228 Hz , belt tension is OK. ground level/ 2 post lift/ 4 post lift and turn engine OFF.
2. Open the bonnet and lock it in open position using bonnet stay rod.
",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11386.jpg",
+ "display_order": 36
+ }
+ ]
+ },
+ {
+ "procedure_name": "Accessory Drive Belt & Auto-tensioner Removal Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove AC Compressor /Water Pump Stretch Fit Belt. Using a 14 mm ring spanner, turn the hexagon knob in the belt tensioner counterclockwise direction to release the tension. Using 14 mm socket spanner, remove the alternator/power steering auto tensioner mounting bolt and remove the tensioner. Refit the new auto-tensioner assembly . Torque tighten the mounting bolt to specified value. Torque : 45 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W144.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1551.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 14 mm ring spanner, swing the auto-tensioner in counter-clockwise direction and install the belt. Refit AC Compressor /Water Pump Stretch Fit Belt. Remove Timing Chain. For additional information refer to Timing Chain - R &R; section. Align the MST \u2013 0310ABG0001ST Camshaft locking tool on the front side of engine in the camshaft slot as shown and fix the camshaft locking tool on cylinder head using appropriate bolts. Using 22 mm socket spanner, Loosen and remove Inlet CAM phaser mounting bolt Torque : 30 \u00b1 2 Nm + 34\u00b0\u00b1 3\u00b0 ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11648.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. While Installation, Check Exhaust Cam phaser mounting bolt tightening torque first and then torque tightened the Intake Cam phaser mounting bolt. Inspect the CAM Phaser for any physical damage. If found replace. Check engine oil level and add oil if necessary. Drive the vehicle until engine reaches normal operating temperature. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Remove all the spark plug. Fit the appropriate adaptor in one cylinder at a time and connect it with the compression gauge. Disconnect the cam phase sensors electrical connector. Note down the max value the gauge indicates. Repeat the procedure for all the other cylinders. Refer to the specification for the value. The variation between the cylinders should not be more than \u00b1 0.5 Bar. Spray 10 to 20 ml of engine oil inside the bore through the spark plug port with the help of an oil can. Fit the appropriate adaptor in one cylinder at a time and connect it with the compression gauge. Disconnect the cam phase sensors electrical connector. Note down the maximum value displaying in the gauge. Repeat the procedure for all the other cylinders.
Compare both the dry and the wet values with the specifications. The wet test values should always be higher than the dry test values. If the reading does not change during wet test this can hint towards compression leakage from cylinder head or through the valves. If the wet and
dry test values vary considerably between cylinders then the piston rings can be suspected.
",
+ "file": null,
+ "display_order": 30
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 8,
+ "sys_id": "THAR.LX-0008-Engine",
+ "subsys_id": "THAR.LX-0008-Engine-Cylinder Head",
+ "systems": "Engine",
+ "sub_systems": "Cylinder Head",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B010573.jpg",
+ "myid": 1091,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Cylinder Head-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/files_VST-0060_Cylinder Head Installation.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010573.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010571.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "A gasoline engine cylinder head performs several functions. They provide the top seal for the cylinders bore and the air fuel mixture in this location. They provide structure holding the Valves, ignition coil, camshaft, spark plugs and other components. The cylinder head is construct with cross flow cooling system. It has inclined ignition coil bore and integral intake and exhaust VVT. Remove the Spark Plug. For additional information refer to the Spark Plug - R &R; section. Drain the engine coolant. For additional information refer to coolant draining procedure. For additional information refer to the HLA Assemblies \u2013 R &R section. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020279.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020257.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner, Loosen Inter cooler outlet hose clip and detach intercooler end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010556.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew dipstick guide mounting bolt. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010558.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew intake manifold mounting bolts and remove Intake manifold With Throttle Valve & Inter cooler outlet hose. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1517.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect fuel rail electrical connector. Disconnect injector electrical connector. Using 12 mm socket spanner, Unscrew fuel rail mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040123.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove fuel rail with Injectors. Injectors Combustion Seals should be replaced with new ones when ever removing & refitting the Fuel Rail Assembly from the cylinder head. For more information refer to Fuel Rail Assembly \u2013 R &R; section in Fuel System. If Injector/Injectors struck with Cylinder Head and not able to remove from head, Injector can be removed by using Injector removal tool. For more information refer to Injector \u2013 R &R; section in Fuel System. Remove the Turbocharger. For additional information refer to the Turbocharger - R &R; section. Using hose clip plier release coolant vent hose clip and detach hose engine head end. Using 10 mm socket spanner, Unscrew heater inlet pipe routing bracket mounting bolt cylinder head end. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010555.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew heater inlet pipe mounting bolt cylinder head end and detach pipe. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew heater outlet pipe routing bracket mounting bolt cylinder head end. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010562.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010563.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Disconnect coolant temperature sensor electrical connector. Using 19 mm deep socket spanner, unscrew Coolant temperature sensor. Torque : 20 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010565.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Remove alternator top mounting bolt. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010566.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Loosen alternator top mounting bolt/nut and rotate alternator. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010567.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Remove CAM shafts front lower bearing cap. Using 15 mm socket spanner, Loosen and remove cylinder head mounting bolts. Torque : 60 \u00b1 6 Nm + (2x95\u00b0) \u00b1 5\u00b0 ",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010569.jpg",
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010570.jpg",
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010572.jpg",
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Remove the cylinder head from engine. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010158.jpg",
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010825.jpg",
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010829.jpg",
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11566.jpg",
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Always replace the cylinder head gasket with a new one when installing. Remove the foreign materials and the gasket residual on the top surface of the cylinder block and cylinder head before installing the cylinder head gasket. Apply fresh engine oil on the head gasket while Installation. Head gasket with the mark of \u201cTC\u201dand gasket part number must be directed towards the cylinder head. When installing the mounting bolts : from the center to the outside diagonally. Do not reuse the mounting bolts for the cylinder head, Always replace the mounting bolts New ones while installing head assembly. Tighten the cylinder head mounting bolts to the specified torque and specified sequence. Refill the engine coolant. For additional information refer to Coolant refilling and Deaeration procedure. Check for coolant seepage and any oil seepage on the engine. Rectify if any traces found. Clean the cylinder head assemblies thoroughly, replace it if any cracks or damages are found. Check the Cylinder Head for external damages. Check the cylinder head height and if not meeting the specified value, replace the cylinder head assembly. Check the Cylinder Head bottom face for distortion. Using a 10 mm combination spanner,loosen battery negative cable mounting nut and disconnect cable. 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the steering column shrouds. Disconnect the ignition switch electrical connection. Using a Small sizzle and hammer, hit and remove the key barrel screws. Use new screw while installing key barrel. Remove the Ignition key with ICU from the vehicle. Using a star screw driver, loosen and remove the ICU mounting screws then remove the ICU from the key barrel. Insert the key and turn the key into AC position. Cut the micro switch routing tag and detach the connector holding clip from the ICU. Install in reverse order of removal. Always use new mounting bolts while installing the Ignition Switch Assembly clamping unit. Inspect ignition key for crack or damage. Replace if found any. Inspect ICU for crack or damage. Replace if found any. This test can only be performed with starter motor removed from vehicle. Remove Starter Motor from vehicle. Disconnect wire from solenoid field coil terminal. Check for continuity between solenoid terminal and solenoid field coil terminal with a continuity tester. There should be continuity. If OK, go to Step 4. If not OK, replace faulty starter motor. Check for continuity between solenoid terminal and solenoid case. There should be continuity. If not OK, replace faulty starter motor. Remove the relay from fuse box. Once supply is given sound can be noticed which indicated control circuit is perfect.
If sound is not noticed, replace the relay.
",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using multi-meter, check continuity between pin number 30 & 87. (Power given to pin number 86 and earth given to pin number 85). If continuity is there, which indicates that the power circuit is perfect.
If Continuity is not there then replace the relay.
",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090048.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using multi-meter, check for continuity between pin numbers 30 and 87 (No power given to pin number 86 and no earth given to pin number 85). If continuity is there which indicates power circuit is NOT OK (Short internally).Replace the relay.
If continuity is not there, Relay is OK.
",
+ "file": null,
+ "display_order": 5
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 50,
+ "sys_id": "THAR.LX-0008-Starting System",
+ "subsys_id": "THAR.LX-0008-Starting System-Starting System Technical Spec",
+ "systems": "Starting System",
+ "sub_systems": "Starting System Technical Spec",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1131,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Starting System Technical Spec-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": "Starter Motor Specification ",
+ "file": "/files/11820.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Heading",
+ "content": "Starter Motor Specification ",
+ "file": null,
+ "display_order": 2
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 51,
+ "sys_id": "THAR.LX-0008-Starting System",
+ "subsys_id": "THAR.LX-0008-Starting System-Troubleshoot - Starting System",
+ "systems": "Starting System",
+ "sub_systems": "Troubleshoot - Starting System",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1457,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Troubleshoot - Starting System-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Troubleshoot",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4729.pdf",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Component Inspection Table",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4730.pdf",
+ "display_order": 2
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 47,
+ "sys_id": "THAR.LX-0008-Starting System",
+ "subsys_id": "THAR.LX-0008-Starting System-Cranking Voltage Test",
+ "systems": "Starting System",
+ "sub_systems": "Cranking Voltage Test",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1128,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Cranking Voltage Test-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Cranking Voltage Test",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "The cranking voltage test measures the voltage available for ignition while the starting motor cranks the engine. Turn off the ignition, connect a voltmeter across the battery and crank the engine. Note the voltage reading. If the starting motor cranks normally and the voltmeter reads 9 volts or higher, cranking voltage is normal. Slow cranking with the voltage above 9 volts indicates high resistance in the motor circuit or starting motor Low cranking speed and low voltage may indicate a discharger battery. If the battery is charger, look for trouble in the starter motor or engine The following operation will require a voltmeter accurate to 1/10 (0.10) volt. The battery should be fully-charged. Engage the parking brake. Position the gearshift selector lever in the neutral position and lock the clutch pedal in the fully depressed position. Verify that all lamps and accessories are turned off. In-order to avoid the engine from starting, remove the starter relay. Connect the positive lead of the voltmeter to the battery negative terminal post and then connect the negative lead of the voltmeter to the battery negative cableterminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery negative cable terminal clamp and the battery negative terminal post. Connect the positive lead of the voltmeter to the battery positive terminal post. Connect the negative lead of the voltmeter to the battery positive cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery positive cable terminal clamp and the battery positive terminal post. Connect the voltmeter to measure between the battery positive cable terminal clamp and the starter solenoid terminal stud.Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt. Clean and tighten the battery positive cable eyelet terminal connection at the starter solenoid terminal stud. Repeat the test. If the reading is still above 0.2 volt,replace the faulty battery positive cable. Connect the voltmeter to measure between the battery negative cable terminal clamp and ground on the transmission. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery negative cable eyelet terminal connection to the engine block. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery negative cable. The starting motor is a device that converts electric energy into mechanical energy to generate rotational power, and transfers the energy required for starting the engine initially with this power.
The starter motor is composed of three parts, which are:
The solenoid, which moves the starter pinion by means of a fork and at the same time closes the power circuit to feed the electric motor. The direct current electric motor, which cranks the engine. The fork and pinion assembly, which makes the connection between the starter motor and the ring gear on the flywheel.
",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090047.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Component Location Index",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B090003.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25391.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25392.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm combination spanner, loosen battery negative cable mounting nut and disconnect cable. Using a 13 mm socket spanner, loosen and remove the battery positive cable mounting nut on starter motor end. Using a 8 mm socket spanner, loosen and remove the starter motor solenoid switch mounting nut on starter motor end. Torque : 2.5\u00b1 0.25 Nm Using a 14 mm socket spanner, loosen and remove the starter motor mounting bolts and remove starter motor from vehicle. Install in the reverse order of removal.
2. Check the starter motor external crack or damage. Replace if found any.
3. Check the starter motor internal gear crack or damage. Replace if found any.
",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 112,
+ "sys_id": "THAR.LX-0008-en-SM-Rear Axle",
+ "system_name": "Rear Axle",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1013,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 119,
+ "sys_id": "THAR.LX-0008-Rear Axle",
+ "subsys_id": "THAR.LX-0008-Rear Axle-Rear Axle Pinion Oil Seal",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Axle Pinion Oil Seal",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A140204.jpg",
+ "myid": 1237,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Rear Axle Pinion Oil Seal-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140204.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31126.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31127.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 10 mm Allen key, loosen and remove rear axle filler plug. Using 10 mm Allen key, remove rear axle drain plug and drain the entire oil. Wait till the entire oil get drained. Place a tray beneath the rear axle for collecting the oil while draining. Using 13 mm and 16 mm ring and open end spanners unscrew rear propeller shaft mounting bolts and nuts rear axle end. Torque : 65 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "By using Special tool MST 203\u2013Companion Flange Holding Tool, hold the companion flange and Using 32 mm deep socket spanner loosen and remove the companion flange mounting nut. Remove the companion flange using mallet. If companion flange shows wear in the area of seal contact, it should be replaced. Remove the pinion oil seal by using screw driver. Ensure not to damage the oil seal mating surface while remove the Oil seal.
2. Inspect t the companion flange for any damage. Replace if found.
",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using MST 0502AUA0004ST Rear Axle Pinion Oil Seal Installer, Place and Press New oil seal uniformly on banjo gear carrier housing. Apply a light coat of oil to the lip of oil seal before installation. Install the dust cap, companion flange on the banjo housing and Install the new mounting nut with washer. Always use new flange mounting nut once it removed. Hold the companion flange Using MST203 Companion Flange Holding Tool and torque tighten the companion flange mounting nut. Tighten nut to incremental torque from 270 Nm onwards to 330 Nm until specified PTTR ( Pinion torque to rotate) is achieved. Measure the Pinion Rotational Torque (PTTR), It should be within 2.5 - 3.5 Nm. Attach the propeller shaft to the rear axle with mounting nuts, torque tighten it to the specified value. Torque : 65 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit the drain plug and torque tighten to specified value. Clean the drain plug and differential housing with a clean cloth before refitting. Torque : 47 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refill specified quantity of recommended differential oil into differential assembly. Never reuse drained oil. Always use recommended oil only. Never mix different types of oil and use. Clean filler plug area properly using acloth before filling the oil. Check the oil level and ensure its up to the level. Ensure that the oil level is up to lower most point of the filler plug. Refit the filler plug back and torque tighten to mounting plug specified value. Clean the filler plug with a clean cloth before refitting. Torque : 29 \u00b1 5Nm ",
+ "file": null,
+ "display_order": 55
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 122,
+ "sys_id": "THAR.LX-0008-Rear Axle",
+ "subsys_id": "THAR.LX-0008-Rear Axle-Troubleshoot - Rear Axle",
+ "systems": "Rear Axle",
+ "sub_systems": "Troubleshoot - Rear Axle",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1464,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Troubleshoot - Rear Axle-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Trouble Shooting",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Certain rear axle and driveline trouble symptoms are also common to the engine, transmission, tyres and other parts of the vehicle. For this reason be sure that the cause of the trouble is in the rear axle before adjusting, repairing or replacing any of the axle parts. Basic characteristics in a rear axle are more difficult to diagnose and repair than mechanical failures. Slight axle noise heard only at certain speed or under particular conditions must be considered normal. Axle noise tend to peak or be more pronounced at particular speeds and the noise is in no way a sign of the trouble in the vehicle. Where noise is present in objectionable form (Loud and/ or at all speeds) the first effort should be to isolate the noise. Isolation of noise in any one unit requires care and experience and an attempt to eliminate a slight noise may baffle even the most experienced mechanic/ technician. Occurs in direct transmission ratio (4th gear). Changes with throttle/ accelerator variations (drive and coast) (i.e. driving in neutral with the clutch released and engine running). Always occur at the same road speed and not engine speed. Occurs over a limited vehicle speed. (This can vary over a wide band should the axle be in extremely bad condition.).
2. A high spot sometimes occur on either the ring gear or the drive pinion; this shows up as a ticking or light knocking noise over a restricted range of throttle position. The frequency of the noise will indicate whether the high spot is on the pinion (drive shaft frequency) or on the ring gear. The severity of the noise indicates the size of the defect. A light \u201ctick\u201d is seldom detrimental and usually occurs in new axle and will normally disappears once the axle has been run in.
3. Louder noise usually indicates a more serious defect and a knock occurring in an axle which was previously free from this type of noise must always be investigated.
",
+ "file": null,
+ "display_order": 6
+ }
+ ]
+ },
+ {
+ "procedure_name": "Trouble Shoot",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/14501.pdf",
+ "display_order": 7
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 118,
+ "sys_id": "THAR.LX-0008-Rear Axle",
+ "subsys_id": "THAR.LX-0008-Rear Axle-Rear Axle Inboard Oil Seal",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Axle Inboard Oil Seal",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A140054.jpg",
+ "myid": 1236,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Rear Axle Inboard Oil Seal-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140054.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31116.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31117.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the rear axle shaft. For additional information refer to Rear Axle Shaft RH - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 0502CAA0012ST \u2014Puller Oil Seal Pinion /Flange Inbord-X ,remove the inboard oil seal. Refit in the reverse order of removal. Use a MST (0502BUA0001ST \u2014 Rear Axle Shaft Inboard Oil Seal Installer, during Installation. Check differential oil level, top up the oil if required. For additional information refer to Parking Brake Adjustment Section. ",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "1. Inspect t the axle inboard for any damage. Rectify if found.",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 117,
+ "sys_id": "THAR.LX-0008-Rear Axle",
+ "subsys_id": "THAR.LX-0008-Rear Axle-Rear Axle Shaft Oil Seal Outer & Wheel Bearing",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Axle Shaft Oil Seal Outer & Wheel Bearing",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A140066.jpg",
+ "myid": 1235,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Rear Axle Shaft Oil Seal Outer & Wheel Bearing-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140066.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31105.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31106.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the rear axle shaft RH. For additional information refer to Rear Axle Shaft RH - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using circlip plier, remove the toner wheel circlip. By using hydraulic press, remove toner wheel along with Rear bearing carrier assembly. Take sufficient care not to damage the toner ring while removing. Remove the bearing from Rear bearing carrier. Replace the toner ring and bearing assembly once removed. Using a suitable tool, Remove the oil seal from Rear bearing carrier. Replace the outboard oil seal once removed. Refit in the reverse order of removal. Check differential oil level, top up the oil if required. For additional information refer to Parking Brake Adjustment Section. ",
+ "file": null,
+ "display_order": 21
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "1. Inspect the axle shaft outer oil seal & bearing for any damage, Replace if necessary.",
+ "file": null,
+ "display_order": 22
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 115,
+ "sys_id": "THAR.LX-0008-Rear Axle",
+ "subsys_id": "THAR.LX-0008-Rear Axle-Rear Axle Shaft Assembly",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Axle Shaft Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A140033.jpg",
+ "myid": 1233,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Rear Axle Shaft Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/files_VST-0068_Rear axle shaft removal.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140033.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31088.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31089.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove rear brake drum LH and RH. For additional information refer to Rear brake drum LH and RH \u2013 R&R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Detach the hand brake cable from brake shoe. Remove the hand brake cable lock clip and detach the hand brake cable from back plate. Using 11 mm open end spanner, Loosen brake bundy tube flare nut wheel cylinder end. Torque : 16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 17 mm socket spanner, loosen and remove axle shaft mounting nuts. Torque : 35 \u2013 50 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using MST (0505AAA0001ST puller rear axle shaft banjo) remove rear axle shaft, dust shield with brake liner assembly from vehicle. To avoid the back plate falling down, using a plastic tag tie it with any other fixed member before the shaft is pulled out. Clean sealant on the axle housing flange, Back Plate and apply new sealant on the housing. Apply Locktite Sealant 5060 during Installation and Ensure that sealer bead is on the inside of screw holes as shown above. Bead must be 3 to 6mm high and 3 to 6mm wide. Refit in the reverse order of removal. Check differential oil level, top up the oil if required. For additional information refer to Parking Brake Adjustment Section. ",
+ "file": null,
+ "display_order": 24
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "1. Inspect the axle shaft for any damage, crack or bend.
2. Inspect the toner ring for any damage.
3. Inspect the rear wheel bearing for any damage.
4. Inspect the back plate for any damage.
",
+ "file": null,
+ "display_order": 25
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 112,
+ "sys_id": "THAR.LX-0008-Rear Axle",
+ "subsys_id": "THAR.LX-0008-Rear Axle-Rear Axle Oil - Replace",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Axle Oil - Replace",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J10-MAT-0340",
+ "cover_image": "/files/W4A140025.jpg",
+ "myid": 1230,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 23,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 46,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 111,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 152,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 193,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 233,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 276,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 292,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 359,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 396,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 442,
+ "kilometers_applicable": 0
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Rear Axle Oil - Replace-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Rear Axle Oil - Replace.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Rear Axle Oil \u2013Mahindra 'MAXIMILE ELITE' New Generation Genuine Differential Fluid. Capacity\u20132.0 Litres. using 10 mm allen key, loosen and remove rear axle filler plug. Using 10 mm allen key, remove rear axle drain plug and drain the entire oil. Wait till the entire oil get drained. Place a tray beneath the rear axle for collecting the oil while draining. Refit the drain plug and torque tighten to specified value. Clean the drain plug and differential housing with a clean cloth before refitting. Torque:47\u00b17Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refill specified quantity of recommended differential oil into differential assembly. Never reuse drained oil. Always use recommended oil only. Never mix different types of oil and use. Clean filler plug area properly using a cloth before filling the oil. Check the oil level and ensure its up to the level. Ensure that the oil level is up to lower most point of the filler plug. Refit the filler plug back and torque tighten to mounting plug specified value. Clean the filler plug with a clean cloth before refitting. Torque:29\u00b15Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Recommend to use only Mahindra 'MAXIMILE Elite' new generation genuine differential fluid. In case of non availability of 'Maximile' brand, other brands meeting API GL5, SAE 80W-90 specification can be used as second preference and oil change period should be reduced as 20,000 km. Drain the Rear axle oil. For additional information refer to Rear axle oil draining procedure. Remove the Rear Axle Carrier Assembly. Mount the Rear Axle carrier assembly on a suitable stand. Liquid sealant is used to seal carrier section with banjo beam. Clean the sealant on the carrier facing. Using a 17 mm socket spanner, loosen and remove the bearing cap mounting bolts and then remove the bearing caps. Using a Mallet, tap and detach the bearing caps. Identification marks are punched on bearing cap; this is to ensure correct bearing cap is installed on correct side. Ensure correct bearing caps used While reassembly. Pry out differential case from carrier with help of (MST 0502AAA0001ST - Tommy Bars) as shown in the illustration. Remove the shims from both the sides of differential case. Backlash shims are not to be interchanged during assembly. If Backlash shims are damaged, replace with new shims during assembly. There is no identification provided on the shim, Needs to be measured by micro meter. Remove the bearing caps from both the ends. Mount the (MST 0502AUA0013ST - R Axle Diff Case Bearing Puller Adapter) and (MST 0502AUA0012ST - Axle Bearing Puller) on side bearing cone as steps shown below. Remove the side bearing cone by tightening the screw rod using 24 mm ring spanner and remove the bearing cone from the differential case. Hold the top plate using 36 mm open end spanner while tightening. It is always preferred to replace side bearings, but one can confirm free rolling of bearings and reuse if they are defect free. Similarly remove ring gear other side bearing cone as steps shown below. Using 14 mm socket spanner remove the ring gear mounting bolts. Ring gear mounting bolts are opposite threaded. Loosen in clock wise direction. Tap ring gear with a mallet to free it from case If required and remove. Follow Steps 15 to 18 to remove Side Gears & Pinion Mate Gears for Open Differential. Using MST 0502AUA0033ST - Front Axle Diff Case Pin Remover &Installer; and hammer remove the differential gear locking pin. Using hammer and punch, Remove the differential shaft from differential case as shown in illustration. To remove side gears and pinion mate gears, rotate the side gears, this will allow the pinion mate gears to turn to opening of the case. Remove the pinion and side gears. Check the differential gear condition, any damage replaces it. Inspect cross pin for excessive wear, replace it if necessary. Always replace differential pinion gears and side gear both along with washer as a complete set. Do not mix new gears with old gears, as this may cause uneven wear and short gear life. Position the carrier assembly on the suitable stand to facing the companion flange side. Hold the companion flange using (MST 203\u2013 Companion Flange Holding Tool) and Using 32 mm deep socket spanner loosen and remove the companion flange mounting nut. Using mallet tap and remove the companion flange, washer and dust cup. If companion flange shows wear in the area of seal contact, it should be replaced. Using a mallet, tap the pinion assembly and remove the pinion assembly from the differential housing. Fit a nut of pinion before tapping to avoid thread damage. Hold the pinion with hand to avoid falling. Gear teeth have sharp edges. Handle gears carefully to avoid injury. Remove the collapsible Washer. Discard collapsible spacer. New one is required to be used during assembly Assemble (MST 0502AUA0014ST - R Axle Pinion Inner Bearing Puller Adapter) and (MST 0502AUA0012ST - Axle Bearing Puller) as shown in the illustration. Tighten the screw rod using 24 mm ring spanner to remove the pinion inner bearing. Hold the top plate using 36 mm open end spanner while tightening. Remove the pinion head bearing & remove the shims from the pinion. Collect shims and keep them together. Replace shims if found damaged. Remove the pinion oil seal by using screw driver. Ensure not to damage the oil seal mating surface while remove the Oil seal. Gently pull-out and remove the pinion outer bearing. Using suitable punch and hammer remove the outer bearing cap. Using suitable punch and hammer remove the inner bearing cap. Ring gear and pinion is supplied as a set. They are matched with each other during manufacture. Matching numbers on both pinion and ring gear are etched for verification. Refer Fig. A or Fig. B for more details. If a new gear set is used, verify numbers on pinion and ring for matching before proceeding with assembly. Standard mounting distance from center line of ring gear to back face of pinion is 109.525 mm . This dimension is controlled by selecting shims, which are positioned between the inner pinion bearing and pinion shoulder. Best running position of gear set is achieved by proper shim selection. On the bottom face of pinion, a number is etched. It can be a plus (+) number, a minus (-) number or Zero (0). Required pinion shim selection is achieved with help of this number. Pinion offset always in thou (1 thou = 0.0254 mm). Fig. A shows ring and pinion etched with inch identification. Fig. B shows ring and pinion etched with metric identification. If no offset on pinion face then assume it zero. Shims with different thicknesses are available for selection. Use tables below as a guide for selecting correct thickness of shims either for addition or for subtraction from old shim pack. TABLE \u2014 Pinion Shim Selection (Formula = Old Pinion offset \u2014 New Pinion offset) If Old Shim Not Available then below mentioned gauge method is recommended for Pinion Shim Selection. Position the rear axle housing on a suitable stand. Position the (MST 0502AUA0016ST - Rear Axle Pinion Height Master Block) over the inner bearing cup seating area as shown. Position the (MST 0502AUA0015ST - Rear Axle Pinion Height Setting Gauge) on the differential housing as shown. Using feeler gauge measure the distance between the MST\u2019s as shown and the value assumed as \u2018A\u2019 . For example consider the value obtained as 1.51 mm. Convert the obtained value in \u201cmm\u201d into \u201cThou\u201d (1.51x39 = 59 Thou). Now see the etched value on pinion, the value assumed as \u2018B\u2019 (For example consider the offset value as +4) Now to get the final shim size, the formula is Shim thickness (In Thou) = A \u2013 (+B or \u2013 B). i.e, (59 \u2013 4 = 55 Thau) Convert the Thou value to mm ( 55 x 0.0254 = 1.40 mm) , which is the final shim thickness required. Select shim pack based on Pinion Shim Selection Procedure to position the pinion at correct mounting distance as per value etched on pinion stem for best running position. Mount the pinion positioning shim pack on pinion. Position the pinion inner bearing on pinion & press the bearing by using (MST 0502AUA0017ST - R Axle Pinion Inner Brg Press Dolly). Insert a new collapsible spacer. Collapsible spacer should rest in between pinion inner and outer bearing and it can be fitted in any direction. Always use new collapsible spacer, never use old one. Install the Inner bearing cup by using (MST 0502AUA0018ST - Pinion Inner bearing cup installer) and (MST 0707BBA0003ST - Universal mandrel) on banjo gear carrier housing. Install the Outer bearing cup by using (MST 0502AUA0019ST - Pinion outer bearing cup installer) and (MST 0707BBA0003ST - Universal mandrel) on banjo gear carrier housing. Install the pinion on the axle banjo housing and provide a support for pinion in the bottom. Using (MST 0502AUA0017ST - R Axle Pinion Inner Brg Press Dolly) and hammer press the pinion outer bearing. Place oil slinger on pinion outer bearing cone. Place and Press oil seal on banjo gear carrier housing using (MST 0502AUA0004ST - Rear Axle Pinion Oil Seal Installer). Apply a light coat of oil to the lip of oil seal. Install the dust cap into the companion flange. Install the companion flange on the banjo housing. Install the companion flange mounting nut. Hold the companion flange using (MST203 - Companion Flange Holding Tool) and torque tighten the companion flange mounting nut. Tighten nut to Initial torque as 270 Nm. Measure the Pinion Rotational Torque (PTTR), It should be within 2.5 - 3.5 Nm. If measured Pinion Rotational Torque (PTTR) not within 2.5 - 3.5 Nm, Then tighten nut to incremental torque from 270 Nm onwards to 330 Nm until specified PTTR ( Pinion torque to rotate) is achieved. Excessive care must be taken during bearing preload torque adjustment. Do not over tighten, loosen and then retighten nut. Do not exceed specified bearing preload torque . Measure and ensure the Final Pinion Rotational Torque (PTTR), It should be within 2.5 - 3.5 Nm. (PTTR SPEC : 2.5 to 3.5 Nm) If preload torque is exceeded, a new collapsible spacer must be installed and torquing sequence as above to be repeated. Follow Steps 17 to 20 to Install Side Gears & Pinion Mate Gears for Open Differential. Assemble both side gears and thrust washers, hold them in place with one hand and then assemble the pinion mate gears with thrust washer to hold the side gears in place. An easy way to assemble the side gears and pinion mate gears is to have all parts lubricated before assembly. Rotate the side gears until the holes of the spherical washers and pinion mate gears line up with the holes in the case by the help of engaging the splines of axle shaft to side gears. When both the cross bore hole matched and insert the differential shaft. Use a drift to line holes of the gears up with case. Assemble differential shaft and pull out drift. Be sure vertical lock pin hole is lined up with that of the case, and that pinion mate washers are in place and lined up with gear and case. Align the differential shaft hole, insert the lock pin and fix using (0502AUA0033ST - Differential gear lock pin removal tool) and hammer. Assemble ring gear to the differential case using mounting bolts. Tighten the bolts to specified torque value in recommended sequence. Always use new ring gear bolts. Ring gear mounting bolts have LH threads. While Installation torque in anti-clocking direction. Assemble (MST 0502AUA0020ST - Rear Axle Dummy Bearing) on to differential case. Place differential case assembly into housing. Push the differential case assembly towards the pinion side and insert the shims pack on the LH side (Back to ring gear) and Insert the shims pack on the RH side (Teeth side). Remove the shims (6 Thou) from LH Side and add to RH Side for backlash tolerance. Install dial gauge and locate tip of indicator on the surface of one of the ring gear teeth and measure the backlash at three equally spaced points (Each 120 degree rotation space), confirm the Backlash tolerance is (0.15 to 0.25 mm). Fix the Dial Gauge on Housing, Set the Dial Indicator 0 on Ring gear teeth as shown. Hold the pinion flange at the bottom side. Rotate the ring gear by using ring spanner & measure the backlash. Backlash variation at three points should not more than 30% . These corrections are made by switching shims from one side of differential case to other. High backlash is corrected by moving ring gear closer to pinion (Move Shims from RH to LH). Low backlash is corrected by moving ring gear away from pinion (Move Shims from LH to RH). Remove dial gauge and take out diff case & remove the dummy differential bearings. Press bearing on Differential case assembly by using (MST 0502AUA0021ST - R Axle Diff Case Brgs Pressing tool). Repeat the same procedure for installation of bearing on other side. Install the Differential bearing caps on both the sides. Install differential case assembly into carrier with the help of mallet. Carelessness while installing differential case assembly may result in injury. Install the shims on both the sides of differential case. Backlash shims are not to be interchanged during assembly. If Backlash shims are damaged, replace with new shims during assembly. Assemble bearing caps using mounting bolts. Ensure correct fitment of caps by matching letters on caps and carrier on either side. Tight the bearing cap bolts to specified value. Install dial gauge and locate tip of indicator on the surface of one of the ring gear teeth and measure the ring gear and pinion backlash at three equally spaced points (Each 120 degree rotation space), confirm the Backlash tolerance is (0.15 to 0.25 mm). Fix the Dial Gauge on Housing, Set the Dial Indicator 0 on Ring gear teeth as shown. Hold the pinion flange at the bottom side. Rotate the ring gear by using ring spanner & measure the backlash. Backlash variation at three points should not more than 30% . These corrections are made by switching shims from one side of differential case to other. High backlash is corrected by moving ring gear closer to pinion (Move Shims from RH to LH). Low backlash is corrected by moving ring gear away from pinion (Move Shims from LH to RH). If backlash is as per specification, check ring gear and pinion tooth contact pattern. If backlash is as per specification, check ring gear and pinion tooth contact pattern as below. The TOE of the gear is the portion of the tooth surface at the end towards the center. The HEEL of the gear tooth is the portion of the tooth surface at the outer-end. The TOP LAND of a gear tooth is the surface of the top of the tooth. Every gear has a characteristic pattern. Flat face of the carrier assembly and flat surface of the banjo beam must be free of any oil film or foreign material. Apply Locktite RTV Sealant 5060 to flat surface of banjo beam. Ensure that sealer bead is on the inside of bolt holes. Bead must be 3 to 6 mm high and 3 to 6 mm wide. For additional information refer to Differential carrier assembly R &R section. ",
+ "file": null,
+ "display_order": 236
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Fill the differential fluid. For additional information refer to Differential fluid filling procedure. For additional information refer to rear axle oil draining procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Rear Axle Shaft Assembly LH. For additional information refer to Rear Axle shaft Assembly LH \u2013 R&R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the Rear Axle Shaft Assembly RH. For additional information refer to Rear Axle shaft Assembly RH \u2013 R&R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, Unscrew rear propeller shaft mounting bolts and detach propeller rear end and properly hang the shaft. Torque : 65 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew gear carrier to banjo housing mounting bolts. Using 17 mm socket spanner, Unscrew rear stabilizer bar bracket mounting bolts and detach the bracket partially. Torque tightening should be done without load and with the tyres on level ground. Ensure to add washer only for bottom mounting of stabilizer bar. Torque : 70 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 5 mm allen key, hold the rear stabilizer bar link bottom mounting then using a 18 ring spanner, loosen and remove the top mounting nut from stabilizer bar. Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140038.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Remove the rear axle gear carrier from vehicle. Clean the sealant on the gear carrier. Refit in the reverse order of removal. Apply Locktite Sealant 5060 during Installation and Ensure that sealer bead is on the inside of screw holes and pattern as shown below. Bead must be 3 to 6 mm high and 3 to 6 mm wide. For additional information refer to Rear Axle Oil Refilling procedure. ",
+ "file": null,
+ "display_order": 30
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "1. Check the gear carrier, cracks, damage, wear or distortion, replace it if necessary.
2. Check the axle case for yield, deformation or cracks, replace if necessary.
",
+ "file": null,
+ "display_order": 31
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 116,
+ "sys_id": "THAR.LX-0008-Rear Axle",
+ "subsys_id": "THAR.LX-0008-Rear Axle-Rear Toner Wheel",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Toner Wheel",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A140048.jpg",
+ "myid": 1234,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Rear Toner Wheel-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140048.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31098.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31099.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the rear axle shaft assembly. Using circlip plier, remove the toner wheel circlip. By using hydraulic press, remove toner wheel along with Rear bearing carrier assembly & dust shield. Take sufficient care not to damage the toner ring while removing. Replace the toner ring and bearing once removed. Refit in the reverse order of removal. Check differential oil level, top up the oil if required. Carry out Parking Brake Adjustment. For additional information refer to Parking Brake Adjustment Section.
2. Inspect the Rear bearing carrier assembly for any damage, Replace if necessary.
",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 113,
+ "sys_id": "THAR.LX-0008-Rear Axle",
+ "subsys_id": "THAR.LX-0008-Rear Axle-Rear Axle Assembly",
+ "systems": "Rear Axle",
+ "sub_systems": "Rear Axle Assembly",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A140025.jpg",
+ "myid": 1231,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Rear Axle Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140025.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31051.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/31052.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove rear brake drum LH and RH. Detach the hand brake cable both the sides(LH&RH;)from brake shoes. Remove the hand brake cable lock clips from both the sides (LH & RH) and detach the hand brake cables from back plate. Remove the hand brake holding spring on the axle from LH & RH side. For additional information refer to Bundy Tube Rear Hose to LH Wheel - R&R section. ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the bundy tube rear hose to RH wheel. For additional information refer to Bundy Tube Rear Hose To RH WheeL - R&R section. ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the flexible hose LH & RH side locking from the axle. Using a 10mm socket spanner, Unscrew wheel speed sensor mounting bolts and detach the sensors. Torque:9\u00b11Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140015.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Provide a jack to support the rear axle assembly. For additional information refer to Rear Propeller Shaft - R&R section. ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the stabilizer bar rear. For additional information refer to Stabilizer Bar Rear - R&R section. ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Link",
+ "content": "THAR.LX-0008,1012,1224",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using a 24 mm socket spanner, loosen and remove the upper link mounting bolt/nut. Torque : 230 \u00b1 20 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170029.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 21mm ring spanner. Torque tightening should be done without load and with the tyres on level ground. Using a 24 mm socket spanner, loosen and remove the lower arm mounting bolt/nut. While loosening the nut, hold the bolt using 21mm ring spanner. Torque tightening should be done without load and with the tyres on level ground. Torque:230\u00b120Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using a 17 mm socket spanners, loosen and remove the both rear shock absorbers bottom side mounting bolts and nuts. Torque Value: 110\u00b111Nm , Torque Wrench Type - Open end Torque Wrench ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. While loosening the nut, hold the bolt using 15mm ring spanner Remove the rear coil spring and pad securely from vehicle. Pay attention while Installation . Locking lug to be matched with hole on Rear Coil spring dome bracket of Chassis. Yellow coloured PU sleeve should be on chassis side while assembling the coil spring ashown in illustration. Carefully remove the rear axle assembly from vehicle. Refit in the reverse order of removal. Check differential oil level,top up the oil if required. All Suspension Torque tightening should be done without load and with the tyres on level ground.
2. Check the axle case for yield, deformation or cracks, replace if necessary.
3. Inspect rear axle for any oil leakage, seepage.
",
+ "file": null,
+ "display_order": 57
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 227,
+ "sys_id": "THAR.LX-0008-en-SM-Instrument Panel",
+ "system_name": "Instrument Panel",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1020,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 232,
+ "sys_id": "THAR.LX-0008-Instrument Panel",
+ "subsys_id": "THAR.LX-0008-Instrument Panel-IP Top Cover Assembly LH",
+ "systems": "Instrument Panel",
+ "sub_systems": "IP Top Cover Assembly LH",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A220020.jpg",
+ "myid": 1345,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-IP Top Cover Assembly LH-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220020.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12271.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12272.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Glove Box Assembly. Remove the IP grab handle cover. Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts. Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting screws. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle. Partially detach the door edge beading and using a trim removal tool, remove the IP LH side cover. By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt. Torque : 8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector. Take out the IP LH side top cover with Passenger air bag from the IP. Using a 10 mm ring spanner, loosen and remove the air bag mounting bolt from IP top cover. Torque :4.5\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Expand the PAB module holder both sides using screw driver and detach the PAB separately from IP top cover. Using a star screw driver, Unscrew LH side AC vent mounting screws. Carefully release the vent locking clips from the cover and detach the vent. Check for any external damages or damaged locking clips, Replace if necessary. Inspect the PAB module for any damage. Replace if found any. Inspect the PAB module connector for any damage. Inspect the PAB module trim for any damage. Remove the Combination Switch.
Remove the A Pillar Upper Trim LHS & RHS. Remove the Glove Box Assembly.
Using a trim removal tool, Remove the cluster bezel. Partially detach the door edge beading and using a trim Removal tool, Remove the IP side trim RH side. Using star screw driver, Unscrew Driver side top cover mounting screw and remove the cover. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220073.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew the cluster mounting screws. Torque : 2 \u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Partially Detach Cluster and disconnect the electrical connector. Remove the Instrument Cluster. Remove the Floor Console Assembly. Using trim removal tool, Remove IP side vertical trim LHS And RHS. partially detach the switch bang assembly and remove electric connector to take out from the vehicle. Detach the USB Docking station bezel and disconnect the electrical connectors. Disconnect Driver switch bank electrical connector. Remove the IP grab handle cover. Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts. Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting bolts. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle. Partially detach the door edge beading and using a trim removal tool , remove the IP side trim LH side. By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt. Torque : 8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector. Remove IP Speaker Grill from LH and RH Sides. Disconnect speaker electrical connectors from both the sides. Using a trim removal tool Detach the infotainment trims. Using a star screw driver, Unscrew the infotainment mounting screws. Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220085.jpg",
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Partially detach infotainment and disconnect the electrical connectors. Remove the infotainment from Instrument panel. Using 10 mm socket spanner, Unscrew instrument panel mounting bolts. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1004.jpg",
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1005.jpg",
+ "display_order": 80
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1006.jpg",
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1007.jpg",
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1008.jpg",
+ "display_order": 83
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290094.jpg",
+ "display_order": 84
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290095.jpg",
+ "display_order": 85
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "Description",
+ "content": "Carefully remove the instrument panel from vehicle. Install in the reverse order of removal. check for any external damages or damaged locking clips, Replace if necessary. Using trim removal tool remove the cluster bezel. Using a trim removal tool, remove the IP panel assembly driver side. Partially detach the door edge beading and using a trim removal tool, remove the IP RH side cover. Using star screw driver, Unscrew driver side IP cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the driver side IP cover. Using star screw driver, Unscrew AC vent mounting screws. Remove the RH side AC vent. Carefully release the vent locking clips from the cover and detach the vent. Install in the reverse order of removal. check for any external damages or damaged locking clips, Replace if necessary. Remove the Instrument Panel Assembly. Using a star screw driver, Unscrew the Instrument Panel AC & defroster Duct mounting screws and remove the ducts. Using a star screw driver, Unscrew IP driver switch bank mounting screws. Torque : 1.5 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the Driver Switch bank from Instrument Panel. Using a star screw driver, Unscrew IP centre air vent mounting screws. Remove the Centre Air Vents from Instrument Panel. Install in the reverse order of removal. check for any external damages or damaged locking clips, Replace if necessary. Using trim removal tool remove the cluster bezel. Using a trim removal tool, remove the IP panel assembly driver side. Partially detach the door edge beading and using a trim removal tool, remove the IP RH side cover. Using star screw driver, Unscrew driver side IP cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the driver side IP cover. Using star screw driver, Unscrew AC vent mounting screws. Remove the IP AC Vent RH. Carefully release the vent locking clips from the cover and detach the vent. ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220127.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. check for any external damages or damaged locking clips, Replace if necessary. Remove the Instrument Panel Assembly. Using 10 mm socket spanner, Unscrew fuse box mounting bolts. Torque : 5.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect ignition key barrel electrical connector. Detach the bonnet cable from the lever. Using a 12 mm socket spanner, loosen the steering intermediate shaft top bolt and remove bottom mounting bolts and detach the intermediate shaft bottom from the steering column. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew steering column mounting bolts and nuts. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220108.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "using mm socket spanner, loosen and remove the Ip RH & LH speaker from Cross Car Beam. Torque : 3 \u00b1 1Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220109.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Disconnect the IP wiring routing clips and HVAC unit electrical connector. Remove the Scuttle Grill. Using 12 mm socket spanner, Unscrew CCB front facing mounting bolts. Using 13 mm socket spanner, Unscrew CCB bottom mounting bolts. Torque : 22\u00b13 Nm ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220115.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew CCB LHS & RHS mounting bolts/nuts. Torque : 22\u00b13 Nm ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220112.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew CCB LHS & RHS side bottom mounting bolts. Torque : 22\u00b13 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220118.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew CCB to HVAC unit mounting screws. Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Remove the Cross Car Beam from vehicle. Install in the reverse order of removal. check for any external damages, cracks or bends on the cross car beam, Replace if necessary. Using star screw driver unscrew the panel assembly floor console RH screvits and detach the panel from vehicle Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220005.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console LH screvits and detach the panel from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Loosen and Remove Gear Knob and Transfer case shifter knobs Remove the gear shifter cover with trim Remove the rummier mat from the cup holder Remove the 4WD selection knob by rotating it in anti-clock wise direction. Pull and fold the gear shifter boot from gear shifter bezel. Partially detach the bezel from the console. Excessive pull may leads to damage of the electrical connector Disconnect the AT gaiter electrical connector from the bezel. Carefully remove the bezel trim from the TGS lever. Handle bezel assembly carefully to prevent it from damage or scratches. Using trim removal tool, carefully remove the floor console top trim with transfer case shifter boot Using 10 mm socket spanner, Unscrew floor console LH and RH side mounting bolts Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220048.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew floor console LH and RH side mounting screws Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220049.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Remove the bottle holder rubber mat Using 10 mm socket spanner, Unscrew floor console mounting bolts Using 10 mm socket spanner, Unscrew floor console LH and RH side mounting bolts Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220052.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Lift the floor console and disconnect the floor console electrical connector Remove the floor console from vehicle. Remove the power window switch assembly from floor console. Install in the reverse order of removal. Check floor console assembly for any damage, replace if found any. Unlock glove box lock and remove the glove box assembly from IP Using star screw driver, remove the handle mounting screws Remove the glove box handle from the glove box assembly Install in the reverse order of removal. Check the glove box for damage, replace if necessary Using a 10 mm socket spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Glove Box Assembly. Remove the IP grab handle cover. Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts. Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting screws. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle. Partially detach the door edge beading and using a trim removal tool, remove the IP LH side cover. By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt. Torque : 8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector. Take out the IP LH side top cover with Passenger air bag from the IP. Using a star screw driver, Unscrew LH side AC vent mounting screws. Remove the IP AC Vent LH. Carefully release the vent locking clips from the cover and detach the vent. Check for any external damages or damaged locking clips, Replace if necessary. The tachometer indicates the real-time engine speed in thousands of RPM(revolutions per minute). Each division is 500 RPM. Operating the engine at very high RPM may lead to excessive engine wear and low fuel economy. Maintain steady engine speed below 2500 RPM and do not accelerate or decelerate abruptly. Do not over-accelerate the engine during idling, this can cause severe engine damage and would be treated as abuse of the engine which is not covered by warranty The speedometer indicates the real time road surface speed of the vehicle in kilometers per hour. The vehicle speedometer is affected by size of the tyres used. If the size of the tyres are changed from those fitted at the factory, the speedometer might not display the correct road surface speed and distance travelled Using trim removal tool, remove the cluster bezel mounting clips and remove the cluster bezel. Using trim removal tool, remove the IP side trim. Using star screw driver, Unscrew IP cover mounting screw and detach the IP cover using trim removal too. Using star screw driver, Unscrew instrument cluster mounting screw. Torque : 2 \u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect cluster electrical connector and remove instrument cluster. Refit in the reverse order of removal Check for any damage or crack, replace if found. Disconnect the TMC electrical connector then detach from the routing clips. Using 13 mm open end spanner, loosen and remove the TMC to EHCU Primary & Secondary bundy tubes from TMC side flare nuts. Torque :16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using hose clip plier, release brake fluid reservoir tank to clutch TMC hose clip then detach the hose. Using 12 mm combination spanner, Unscrew TMC mounting nuts and remove the TMC assembly from the brake booster. Torque : 16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130187.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Check and top up the brake fluid, If required. For additional information refer to Brake bleeding procedure. ",
+ "file": null,
+ "display_order": 17
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for master cylinder external damage, if found replace. Remove the front brake pad assembly.
Using 14 mm socket spanner, loosen and remove the brake hose banjo bolt then detach the brake hose. Torque :24 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Replace the banjo bolt washers with new ones always while installation, else brake fluid leakage may happen. Using 19 mm socket spanner, loosen and remove the caliper assembly mounting bolts. Torque : 95 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the caliper assembly from the vehicle. Install in the reverse order of removal. Check and top up the brake fluid, If required. Carry-out the brake bleeding procedure.
Inspect the caliper for any physical damage. Replace if found any. Using trim removal tool, remove the IP panel trim driver side. Using Nose plier, remove the R-clip and the clevis pin from the pedal shank. Using 12 mm socket spanner, loosen and remove the pedal box top mounting bolt. Torque :25 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the pedal box mounting nuts then remove the brake pedal box assembly. Torque :25\u00b15.0 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4D180003.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the brake pedal assembly for any physical damage. Replace if found any. Using 13 mm open end spanners, loosen and remove the TMC to primary and secondary bundy tubes flare nuts on EHCU side. Torque :16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130026.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 11 and 13 mm open end spanners,loosen and remove the EHCU to FL,FR,RL, RR output bundy tubes flare nuts on EHCU side. Torque : 16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Carefully detach the bundy pipe without any bend. if the bundy tube bends, Constant pressure will not be maintained. Disconnect the EHCU electrical connector. Using 12 mm socket spanner, Unscrew air cleaner housing mounting bolts to partially detach and keep aside. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanners, Unscrew EHCU mounting bolts and remove the EHCU assembly with EHCU mounting bracket. Torque : 23 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner , Unscrew EHCU mounting nuts from the bracket. Torque : 8 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130196.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "After removing the bundy tubes from EHCU, seal each port of ECHU with dummy plugs to avoid dust entry Do not give any impact to hydraulic unit and take at most care not to allow dust to enter the hydraulic unit. Do not place hydraulic unit on its side or upside down. Handling it in inappropriate way will affect its original performance. Take sufficient care while installation and ensure correct bundy is connected to the specified inlet port.Use colour code for identification. Install in the reverse order of removal. Check and top up the brake fluid, If required. Carry-out the brake bleeding procedure. For additional information refer to Brake bleeding procedure. Check the EHCU for any external damage, if found replace. Disconnect battery negative connector. Disconnect the wheel speed senor electrical connector. Detach the wheel speed sensor cable from the routing clips. Using 10 mm socket spanner, loosen and remove the wheel speed sensor mounting bolt then remove the sensor. Torque :9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130035.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the sensor for any physical damage. Replace if found any. Inspect the sensor for foreign particles segregation. Clean if found. Inspect the sensor connector for any damage. Remove the Floor Console. Using 10 mm open end spanner, loosen and remove the parking brake adjusting nut. Detach the parking brake cable from parking brake lever. Disconnect the parking brake switch electrical connector. Using 12 mm socket spanner, Unscrew parking brake lever assembly mounting nuts. Torque :25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the parking brake switch from parking brake lever assembly. Install in the reverse order of removal. For additional information refer to Parking brake adjustment section. ",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the park brake lever for any physical damage. Replace if found any. Remove the front caliper assembly. Blow dry compressed air into the caliper gradually through the inlet port connected to banjo bolt, to gradually move the piston out of the caliper. Remove the piston from the caliper housing. Remove the dust cover from the caliper housing. Remove the rubber seal from the groove in the caliper housing. Piston Outer surface should be free from nicks, score or rust and should feel smooth to touch. Do not use emery paper on piston surface, Replace if found any. Caliper Housing bores should be free from score, pitting, and corrosion, Replace if found any. Carefully refit the rubber seal. Clean all the internal parts thoroughly with fresh brake fluid or alcohol. Do not use mineral oil like kerosene, petrol, diesel etc. If the piston does not move smoothly, remove it and examine the sealing ring for correct seating in its groove. Fit the other end of the piston boot on to the caliper housing. Refit the front caliper assembly. For additional information refer to Caliper assembly \u2013 R &R; section. Press the lock and disconnect the electrical connector from the brake switch. Place the brake pedal in release position. Turn the brake switch in anti-clock wise direction to get the brake switch free from adjuster lock. Insert the brake switch (A) in adjuster (B) till the switch plunger get completely pressed against brake pedal (at this point switch body will rest on brake pedal). Ensure no play between adjuster and the mounting bracket . Replace the adjuster if play is observed. While replacing new Switch with adjuster - Adjuster is to be snapped on mounting bracket. Ensure no play between the adjuster and mounting. Rotate the brake switch in clock wise direction till the switch gets locked. After locking the switch, the gap between the switch body and brake pedal will set to 1 \u00b10.15mm. Connect the brake switch electrical connector. Disconnect the brake switch electrical connector. Rotate the brake switch in anti-clockwise direction and remove the brake switch. Install in the reverse order of removal. Carry out brake switch adjustment setting. Inspect the brake switch for any damage. Replace if required. Inspect the connector for any damage. Check proper fitment of connector. 2 post lift/ 4 post lift and turn engine OFF.
2. Open the bonnet and lock it in open position using bonnet stay rod.
",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Clutch/Brake Fluid - Mahindra Maximile DOT 4 Genuine Brake fluid. Capacity - 1.75 Liters (Including bleeding quantity). Entire bleeding operation should be done with engine ON condition. In case of fluid reservoir or brake fluid replacement, bleeding of brake circuit is required. Always use recommended fluid and do not mix different brand fluids. Always use fresh and clean fluid from a sealed container. Do not pump the brake pedal at any time while bleeding (i. e. when the bleeding screw is opened). Air in the system will be further compressed into small bubbles and distributed throughout the hydraulic system and will result in additional bleeding operations. Do not reuse the drained fluid. Fluid level in the reservoir must be at MAX level at the start of bleeding and should be checked after bleeding each brake circuit and top up as required. Open brake fluid reservoir cap. Pull-out the bleeding nipple dust cap from both front & Rear (RH and LH) bleeding nipple. Connect a transparent tube into rear LH side bleeding nipple and using a 9 mm ring spanner, loosen the brake fluid nipple then allow the brake fluid to drain. Press the brake pedal gently to drain the fluid completely. Collect the brake fluid in the container and tighten the brake fluid nipple then detach the hose from bleeder nipple. Connect a transparent tube into rear RH side bleeding nipple and using a 9 mm ring spanner, loosen the brake fluid nipple then allow the brake fluid to drain. Press the brake pedal gently to drain the fluid completely. Collect the brake fluid in the container and tighten the brake fluid nipple then detach the hose from bleeder nipple. Connect a transparent tube into front LH side bleeding nipple and using a 8 mm ring spanner, loosen the brake fluid nipple then allow the brake fluid to drain out completely. Press the brake pedal gently to drain the fluid completely. Collect the brake fluid in the container and tighten the brake fluid nipple then detach the hose from bleeder nipple. Connect a transparent tube into front RH side bleeding nipple and using a 8 mm ring spanner, loosen the brake fluid nipple then allow the brake fluid to drain. Press the brake pedal gently to drain the fluid completely. Collect the brake fluid in the container and tighten the brake fluid nipple then detach the hose from bleeder nipple. Hand tighten all the bleeding nipples. Fill recommended brake fluid up to \u201cMAX\u201d mark on the brake fluid reservoir. Press and release brake pedal gently several times, so that brake fluid will get circulated throughout the circuit.
During the bleeding process, it has to be ensured that the fluid level in the reservoir does not drop below minimum. Refer the below illustration for the bleeding sequence. Connect a transparent tube into Rear LH side bleeding nipple and insert the other end of tube in a transparent container. Ensure other end of tube is submerged in liquid, else chances for air entry is high. Always use transparent tube for better visibility of air bubbles. Press and release the brake pedal 3 - 4 times gently to the full stroke and hold the pedal in depressed condition. Ensure proper quantity of brake fluid in the reservoir throughout the bleeding procedure. Using a 9 mm ring spanner, loosen the brake fluid nipple and allow the brake fluid to drain. Air bubbles will escape from brake circuit to container through transparent pipe and the bubbles will be clearly visible. Tighten the bleeder screw as soon as there is no air bubbles visible in the transparent tube. Continue procedure steps 2 - 4 till there is no air bubbles visible in the transparent tube. Remove the transparent tube and firmly tighten the brake fluid nipple. Follow steps from 1\u2013 6 for Rear RH side brake. Refit the bleeding nipple dust cap on both REAR RH and LH bleeding nipples. Connect a transparent tube into Front LH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Ensure other end of tube is submerged in liquid, else chances for air entry is high. Always use transparent tube for better visibility of air bubbles. Press and release the brake pedal 3 - 4 times gently to the full stroke and hold the pedal in depressed condition. Ensure proper quantity of brake fluid in the reservoir throughout the bleeding procedure. Using a 8 mm ring spanner, loosen the brake fluid nipple and allow the brake fluid to drain. Air bubbles will escape from brake circuit to container through transparent pipe and the bubbles will be clearly visible. Tighten the bleeder screw as soon as there is no air bubbles visible in the transparent tube. Continue procedure Steps 10 \u2013 12 till there is no air bubbles visible in the transparent tube. Remove the transparent tube and firmly tighten the brake fluid nipple. Follow steps from 9 \u2013 14 for Front RH side brake. Refit the bleeding nipple dust cap on both Front RH and LH brake bleeding nipples. Maintain recommended brake fluid up to MAX mark on the brake fluid reservoir. Refit the brake fluid reservoir cap. During the tool-bleeding process, ensure that the fluid level in the reservoir does not drop below minimum. Connect i-SMART diagnostic tester and turn the ignition \u201cON\u201d . Launch i-SMART Select ABS ECU and Navigate to Write Data. Routine screen will appear. Click on \u201cROUTINE SELECTION\u201d drop down list and select \u201cREPAIR BLEEDING\u201d. Click on \u201cSTART ROUTINE\u201d to initiate the tool bleeding. Ensure the fluid level in brake fluid reservoir is at \u201cMAX\u201d mark. Connect a transparent tube into rear LH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Loosen and open the rear LH bleeding screw and then press \u201cOK\u201d button. Click on \u201cYES\u201d button to proceed for \u201cBleeding phase I\u201d. The following pop up window appears once the \u201cBleeding phase I\u201d ends. Close the rear LH bleeding nipple once the above mentioned pop up window appears. Ensure other end of tube is submerged in liquid, else chances for air entry is high. After pressing \u201cYES\u201d button, Press and hold the brake pedal for 3 seconds and then release for 0.5 seconds. Continue above procedure till \u201cBleeding phase I \u201d ends Connect a transparent tube into front LH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Loosen and open the front LH bleeding screw and then press \u201cOK\u201d button. Click on \u201cYES\u201d button to proceed for \u201cBleeding phase II\u201d. The following pop up window appears once the \u201cBleeding phase II\u201d ends. Ensure other end of tube is submerged in liquid, else chances for air entry is high. After pressing \u201cYES\u201d button, Press and hold the brake pedal for 3 seconds and then release for 0.5 seconds. Continue above procedure till \u201cBleeding phase II \u201d ends. Close the front LH bleeding nipple once the above mentioned pop up window appears. Connect a transparent tube into front RH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Loosen and open the Front RH bleeding screw and then press \u201cOK\u201d button. Ensure other end of tube is submerged in liquid, else chances for air entry is high. Click on \u201cYES\u201d button to proceed for \u201cBleeding phase III\u201d. The following pop up window appears once the \u201cBleeding phase III\u201d ends. After pressing \u201cYES\u201d button, Press and hold the brake pedal for 3 seconds and then release for 0.5 seconds. Continue above procedure till \u201cBleeding phase III\u201d ends. In bleeding phase III, pump motor switches ON and OFF in a pre defined intervals. While pump motor is ON, brake pedal pulsations can be felt along with the motor operating sound. Connect a transparent tube into Rear RH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Loosen and open the Rear RH bleeding screw and then press \u201cOK\u201d button. Ensure other end of tube is submerged in liquid, else chances for air entry is high. Click on \u201cYES\u201d button to proceed for \u201cBleeding phase IV\u201d. The following pop up window appears once the \u201cBleeding phase IV\u201d ends. Press \u201cOK\u201d button to complete brake bleeding through i-SMART. After pressing \u201cYES\u201d button, Press and hold the brake pedal for 3 seconds and then release for 0.5 seconds. Continue above procedure till \u201cBleeding phase IV\u201d ends. In bleeding phase IV, pump motor switches ON and OFF in a pre defined intervals. While pump motor is ON, brake pedal pulsations can be felt along with the motor operating sound. Once again carry-out mechanical bleeding. For additional information refer to Manual bleeding section. Check brake/clutch pedal for sponginess. If found spongy, repeat the entire procedure of bleeding. Check and ensure there is no leakage from pipes and joints. Do not spill brake fluid on the vehicle, it may damage the paint, if the brake fluid does contact the paint, wash it off immediately with water. Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. The fluid reservoir cap/ container should not be opened with dirty hands. Avoid direct water spray on reservoir while washing engine compartment. If Maximile DOT 4 Brake fluid is not used and in emergency conditions, use brake Fluid Meeting SAE J1703 FMVSS NO.116 DOT 4 OR IS 8654 TYPE-2 Specification and change it at 30,000 kms or 2 years whichever is earlier. During the bleeding operation ensure the container and pipe used is of transparent for better visual.
2. Open the bonnet and lock it in open position using bonnet stay rod.
Brake and Clutch Fluid - Mahindra Maximile DOT 4 Genuine Brake fluid.Brake and Clutch Fluid - 1.75 Liters (Including bleeding quantity).
2. Check the reservoir for leakage and check the level of fluid, if found less top up till MAX mark.
3. Always maintain fluid level at MAX mark on reservoir.
",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130134.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Check for Brake Fluid leakages",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for brake fluid leakage at master cylinder primary & secondary tubes. Check for brake fluid leakage at EHCU primary, secondary and outlets tubes. Check for brake fluid leakage or seepage at front bundy tube I to front bundy tube II connections (Both LH & RH side). Check for brake fluid leakage or seepage at front bundy tube to flexible hose (Both LH & RH side). Check for brake fluid leakage at front caliper inlet & bleeding nipple (Both LH & RH side). Check for brake fluid leakage or seepage from rear RH & LH bundy tube joints shown in illustration. Check for brake fluid leakage or seepage from rear LH bundy tube II & tube III joints shown in illustration. Check for brake fluid leakage at rear RH/LH flexible hoses. Check for brake fluid leakage at rear wheel cylinder inlet & bleeding nipple (Both LH & RH side). Using trim removal tool, remove the IP panel trim driver side. Using Nose plier, remove the R-clip and the clevis pin from the pedal shank. Using 12 mm socket spanner, loosen and remove the pedal box top mounting bolt. Torque :25 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the pedal box mounting nuts then remove the brake pedal box assembly. Torque :25\u00b15.0 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130330.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the brake pedal assembly for any physical damage. Replace if found any. Using a 21 mm wheel spanner, remove wheel mounting nuts and then remove the front wheel. For vehicles with Alloy wheels,measuring can be done without removing the wheels. Insert the Brake pad gauge between caliper housing and edge of brake pad backing plate and contact Tip of tool housing (A) on rotor machined surface as shown. Brake pad gauge should be in perpendicular to rotor surface while measuring. Push the Rear barrel (E) of tool inward and rotate the barrel to rotate Probe tip (B) of the tool as shown. Release the barrel (E) outward upto the probe tip (B) in contact with surface of brake pad back plate as shown. Rotate Knurled ring (D) of rear measuring barrel in same direction to view quick reference color pattern (C) and find actual brake pad thickness (In mm). Refer Brake Pad Thickness Vs Quick reference colors table mentioned below.
Wear Limits
11.35 mm. 10.35 mm. Follow the Step 2 to 7 for measuring thickness of Inboard Brake Pad.
30 mm. 28 mm. Refit the front wheel back with the help of mounting nuts and torque tighten it to specified torque value. Follow the above procedure for front other side wheel brake pad and disc inspection. Remove and inspect the brake pads if the vehicle is reported for the following concerns, 1. Brake Shudder 2. Brake Noise 3. Brake Squeal and any other brake related concerns If any one pad is worn out (inboard /outboard) then replace both the pads. If pads on one wheel only are worn, even then replace the other wheels also. Rotate the disc and make sure it is free to rotate. If it is not free to rotate, inspect and rectify. The Pads in the Pad kit should be replace on the respective caliper i.e. assemble < RH > marked pads on RH Caliper and < LH > marked pads on LH Caliper. If the pads are to be reused make sure they are assembled back in the same position as they were when removed i.e., inboard pad on to the piston side and outboard pad to the wheel side. This is possible only when at the time of removal these pads are marked for their positions and kept aside. Never lubricate the pad seating areas as it may lead to jamming. Never polish pad lining with sandpaper. If lining is polished with sandpaper, hard particles of sandpaper will be deposited in lining and may damage disc. When pad lining requires correction, replace it with a new one. After assembly of pads, apply brake pedal 5 - 6 times in static condition in order to make the pads align properly. It is recommended to apply light braking during the road test and avoid heavy and continuous braking during the initial 200kms of run or until the new pads are performing satisfactorily. Never lubricate the pad seating areas as this may lead to jamming. Always ensure that the anti rattle pad clips (small low abutment clip \u2013 sLAC) are replaced whenever the pads are replaced. Always ensure the grease (Wolfracote) between clip & carrier whenever the sLAC clips are removed/replaced. Don\u2019t overload or pull the retraction loop during pad assembling. Don\u2019t use deformed clips & don\u2019t damage the clips during pad insertion. Remove the primary bundy tube.
Remove the secondary bundy tube.
Using hose clip plier detach the vacuum hose clip and remove hose from the brake booster. Disconnect the brake booster electrical connector and detach from the routing clips. Using hose clip plier, release the brake fluid reservoir tank to clutch TMC hose hose clip then detach the hose. Using cutting plier, remove the R-clip then remove the clevis pin. Using 12 mm socket spanner, Unscrew brake booster mounting nuts and remove the brake booster with TMC. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130024.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Carry out brake switch adjustment setting. Check and top up the brake fluid, If required. Carry-out the brake bleeding procedure.
Check for the booster diaphragm if found check & replace the assembly. Disconnect battery negative terminal. Disconnect the wheel speed senor electrical connector. Detach the wheel speed sensor cable from the routing clips. Using 10 mm socket spanner, loosen and remove the wheel speed sensor mounting bolt then remove the sensor. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130227.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the sensor for any physical damage. Replace if found any. Inspect the sensor for foreign particles segregation. Clean if found. Inspect the sensor connector for any damage. Using a 21 mm wheel spanner, Loosen and remove the rear LH wheel. Using a star screw driver, Loosen and remove drum mounting screw. Clean the brakes by blowing compressed air. Check the wheel cylinder for oil leakage. (It is recommended to check the oil seepage from wheel cylinder by lifting the dust boots.) Check the brake lining for wear/cracks. Measure the brake lining thickness by using Vernier caliper. The minimum usable thickness of the rear brake liner is 4.6 mm. Replace when thickness falls Minimum thickness of lining below 1 mm. The brake shoe must be replaced before the rib starts touching the drum. Measure the wear of the brake lining at the maximum worn out place. Place the drum in its position and install the mounting screw. Refit the LH wheel and torque tighten the nuts to specified value. Whenever the brake shoes are replaced, replace both RH & LH assemblies as a set to prevent car from pulling to one side when braking. If there is significant difference in the thickness of the liner on the left and right sides, check parking brake operation/ wheel cylinders piston for free movement. Apply and release the parking brake 5 times to condition the cables for normal use and Put the parking brake lever into the released position. Check both the rear wheels for free rotation. Position the parking brake lever at 5th notch position. Check both the rear wheels for free rotation, if the wheels are rotate then tighten the adjusting nut 14 mm till the rear wheels can no longer be rotated using hands. Apply and release the parking brake 5 times. Set the parking brake lever into the released position. The rear wheels must be able to turn freely. If not, loosen the adjusting nut gradually until the wheel can turn freely. Brake pads convert the kinetic energy of the car to thermal energy by friction. Two brake pads are contained in the brake caliper with their friction surfaces facing the brake disc which are pressed together against the rotating disc to slow/stop the vehicle. Using 21 mm wheel spanner remove mounting nuts and remove the front RH wheel. Remove front caliper lower mounting bolt using 12 mm socket spanner. Lift the caliper upwards as shown in the illustration. Pull the Brake Pad outwards upto pad contact with clip as shown in the illustration. Twist the pad in anti clock wise direction, lift the pad upwards and remove the pad. Follow Step 4 & 5 for remove another pad. While inserting the pads between the carrier and disc care should be taken that the friction material should be towards the disc. Rotate the disc and make sure it is free to rotate. If it is not free to rotate, inspect and rectify. Before inserting the pads ensure that caliper is returned fully to its position. (Push the caliper inside if necessary.) Never polish pad lining with sandpaper. If lining is polished with sandpaper, hard particles of sandpaper will be deposited in lining and may damage disc. When pad lining requires correction, replace it with a new one. While fitting the guide pin ensure that the straight portion of the pin matches with the ear of the calliper body. The Pads in the Pad kit should be replace on the respective caliper i.e. assemble RH marked pads on RH Caliper and LH marked pads on LH Caliper. If the pads are to be reused make sure they are assembled back in the same position as they were when removed i.e., inboard pad on to the piston side and outboard pad to the wheel side. This is possible only when at the time of removal these pads are marked for their positions and kept aside. Never lubricate the pad seating areas as it may lead to jamming. After assembly of pads, apply brake pedal 5 - 6 times in static condition in order to make the pads align properly. It is recommended to apply light braking during the road test and avoid heavy and continuous braking during the initial 200 kms of run or until the new pads are performing satisfactorily. Never lubricate the pad seating areas as this may lead to jamming. Always ensure that the anti rattle pad clips (small low abutment clip \u2013 sLAC) are replaced whenever the pads are replaced. Always ensure the grease (Wolfracote) between clip & carrier whenever the sLAC clips are removed/replaced. Ensure that the sLAC clips are placed properly and fitted in correct direction in the caliper bracket as shown in the illustration. Ensure that the sLAC clips are replaced/swapped diagonally as shown in the illustration. Ensure that no damage or no deformation of retraction loop in the sLAC clips before fitment. Don\u2019t overload or pull the retraction loop during pad assembling. Don\u2019t use deformed clips & don\u2019t damage the clips during pad insertion. Ensure the proper fitment of all the small low abutment clip (sLAC) . Replace sLAC clips with a new one if found any damage or crack. Refit the brake pad by pushing the pad inside the clips in angled approach as shown in the illustration. Rotate the pad in clockwise direction to vertical position and push the pad inside to caliper. Ensure pad touching the clip retraction. Move the caliper downwards and bring back to its original position. For easy movement, pull the caliper outwards a bit and move it down. Chances for piston seal damage is high, so take adequate precaution while moving the caliper downwards. If the pads are changed with a new one, push both the pistons inside before moving the caliper downwards. Refit the caliper bottom mounting bolt and torque tighten to specified torque value. Ensure the sliding pins are greased well, whenever removed or replaced. Torque : 31 \u2013 38 Nm ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit the front RH wheel back with the help of mounting nuts and torque tighten it to specified torque value. Torque : 140\u00b110 Nm ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Follow the same procedure for front LH brake pad and caliper inspection. If any one pad is worn out (inboard /outboard) then replace both the pads. If pads on one wheel only are worn, even then replace the other wheels also. Using 21 mm wheel spanner, Loosen and remove the rear LH wheel. Using star screw driver, Loosen and remove drum mounting screw. Using flat screw driver, slide the parking brake retaining lever and Using plier, remove the parking brake cable. Disconnect the parking brake cable connection from the liner assembly. Using plier, remove the liner spring holder. Gently expand and remove the liner assembly carefully. Remove the auto-adjuster and adjuster lever. Using flat end screw driver detach the top shoe return spring and the bottom shoe return spring and remove the liners. Align the shoes and fit bottom return spring. Refit the auto-adjuster and auto-adjuster lever. Refit the top shoe return spring. Refit the liner kit assembly. Refit the liner spring holder. Using plier slide the parking brake retainer lever & fix the parking cable. Refit the brake drum with the help of mounting screw. Refit the LH wheel and torque tighten the nuts to specified value. Whenever the brake shoes are replaced, replace both RH & LH assemblies as a set to prevent car from pulling to one side when braking. If there is significant difference in the thickness of the liner on the left and right sides, check parking brake operation/ wheel cylinders piston for free movement. For additional information refer to brake shoe \u2013 R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the hand brake cable lock clip and detach the hand brake cable from back plate. Using 11 mm open end spanner, Loosen brake bundy tube flare nut wheel cylinder end. Torque : 16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew Wheel cylinder mounting bolts and remove the cylinder. Using 17 mm socket spanner, loosen and remove axle shaft mounting nuts. Torque : 90 \u2013 100 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using MST (0505AAA0001ST puller rear axle shaft banjo) remove rear axle shaft, dust shield with brake liner assembly from vehicle. To avoid the back plate falling down,using a plastic tag tie it with any other fixed member before the shaft is pulled out. Clean sealant on the axle housing flange, Back Plate and apply new sealant on the housing. Apply Locktite Sealant 5060 during Installation and Ensure that sealer bead is on the inside of screw holes as shown above. Bead must be 3 to 6 mm high and 3 to 6 mm wide. Remove Back plate from vehicle. Install in the reverse order of removal. Check and top up the brake fluid, If required. For additional information refer to Brake bleeding procedure. ",
+ "file": null,
+ "display_order": 25
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the brake back plate any external damage & also check the brake back plate usable thickness, if required replace. For additional information refer to Front wheel \u2013 R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Front stabilizer bar assembly.
Using 24 mm socket spanner, loosen and remove the front lower control arm mounting nuts on chassis. While loosening the nut, hold the bolt using 24 mm ring spanner. Torque tightening should be done without load and with the tyres on level ground. Torque Value: 250 \u00b1 20 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 19 mm socket spanner, loosen and remove strut fork mounting bolt. Torque : 120 \u00b1 12 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Ensure to insert the washer before Install the bolt. Using a cutting plier, remove the cotter pin from the ball joint. Never reuse the split pin, always replace with a new one. Using a 24 mm socket spanner, loosen and remove lower arm ball joint mounting nut. Torque : 130 \u2013 150 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Using a 22 mm socket spanner, loosen and remove knuckle bracket mounting bolts, remove the knuckle lower half. Torque tightening should be done without load and with the tyres on level ground. Using a hammer, tap strut fork and release it from lower arm. Remove the lower control arm mounting bolts from the vehicle frame. Torque Value: 250 \u00b1 20 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the lower control arm from the vehicle. Install in reverse order of removal. Pay attention while Installation. Torque tightening should be done without load and with the tyres on level ground. LH and RH identification sticker available on part for orientation. Camber and caster bolt marking position required at center. Camber and caster bolt should be fitted in the direction of Arrow shown in illustration. Place the Pan hard on suitable base block. Place the suitable dolly on the Pan hard bush One end. Using a hydraulic press or hammer remove the Pan hard bush one end. Place the Pan hard other end on base block and place the dolly on Pan hard bush. Using a hydraulic press or hammer remove the Pan hard bush other end. Place the Pan hard one end on base block and place the bush installer (MST:0401BAA0043ST) .on the bush. Using a hydraulic press or hammer,Install the Pan hard bush One end. Panhard bush should be fitted in center of panhard and ensure to maintain equal distance on both side of panhard as shown. Place the Pan hard other end on base block and place the bush installer (MST:0401BAA0043ST) .on the bush. Using a hydraulic press or hammer,Install the Pan hard bush other end. Remove the Front Upper Control Arm. Place the base block (MST: 0401BAA0033ST) and place the collar support (MST: 0401BAA0037ST) . on the base block. Place the upper arm one end on the base block. Place the upper arm bush remover (MST: 0401BAA0040ST) on the bottom bush. Place the Pin cage (MST: 0401BAA0041ST) & the support cage (MST: 0401BAA0013ST) as shown. Using a hydraulic press remove the upper arm one side (bottom) bush. Place the upper arm other end on the base block (MST: 0401BAA0033ST) and collar support (MST: 0401BAA0037ST) . Place the upper arm bush remover (MST: 0401BAA0040ST) on the bush. Place the upper arm dummy bush (MST: 0401BAA0042ST) on the upper side bush seating hole. Place the upper arm pin cage (MST: 0401BAA0041ST) & the support cage (MST: 0401BAA0013ST) as shown. Using a hydraulic press remove the other side bush. Place the Upper arm on the base block (MST: 0401BAA0033ST) & collar support (MST: 0401BAA0037ST) and place the bush over the upper arm. Place the bush installer (MST: 0401BAA0043ST) on the bush. Using a hydraulic press, Install the upper arm one side bush. Place the Upper arm other side on the base block (MST: 0401BAA0033ST) & collar support (MST: 0401BAA0037ST) and place the bush over the upper arm. Place the bush installer (MST:0401BAA0043ST) .on the bush. Using a hydraulic press, Install the upper arm bush. Refit the Front Upper Control Arm. Rear Upper Link is used to compensates the longitudinal load to the vehicle. Using a 24 mm socket spanner, loosen the mounting bolt and nut in the chassis end then remove nut from the link. Torque : 230 \u00b1 20 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 21 mm ring spanner. Torque tightening should be done without load and with the tyres on level ground. Torque Wrench Type - Open end Torque Wrench for LH chassis & axle ends Using a 24 mm socket spanner, loosen and remove the link mounting nut from the axle end. Torque : 230 \u00b1 20 Nm Torque Wrench Type - Open end Torque Wrench for LH chassis & axle ends While loosening the nut, hold the bolt using 21 mm ring spanner Torque tightening should be done without load and with the tyres on level ground. Using a appropriate jack support slightly lift the rear axle. Using a 17 mm socket spanners, loosen and remove the both rear shock absorbers bottom side mounting bolts and nuts. Torque tightening should be done without load and with the tyres on level ground. While loosening the nut, hold the bolt using 15 mm ring spanner. Remove the respective side coil spring. Jack up the rear axle slightly. Remove the rear upper link chassis end mounting bolt then remove the front and rear upper link from the vehicle.
2. Inspect the upper link bushes for any damage, crack or material deterioration. Replace the bushes if found any.
",
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+ "display_order": 31
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 148,
+ "sys_id": "THAR.LX-0008-Suspension",
+ "subsys_id": "THAR.LX-0008-Suspension-Rear Lower Link Bushes Overhaul",
+ "systems": "Suspension",
+ "sub_systems": "Rear Lower Link Bushes Overhaul",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170276.jpg",
+ "myid": 1263,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Rear Lower Link Bushes Overhaul-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/VST-0074_Rear Suspension Rear lower Link Bushes Removal & Installation.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Rear Lower Link. Place the base block (MST:0401BAA0033ST) & place the Rear Lower and Upper Link Coller (MST : 0401BDD0001ST) . Place the Lower link one end on the base block. Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) on the lower link one end bush. Using a hydraulic press, remove the lower link one end bush. Place the Lower link other end on the base block. Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) on the lower link other end bush. Using a hydraulic press, remove the lower link other end bush. Place the Lower link one end on then base block and place the bush over the lower link. Place the Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press While Installation ensure to maintain Bush Void at 45\u00b0 angle as shown. Ensure to Install the Bush with Void end should be fitted in Chassis end on vehicle. Place the Lower link other end on the base block and place the bush over the lower link. Place the Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press. Refit the Rear Lower Link. For additional information refer to Front wheel R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner , loosen and remove the brake hose routing bracket mounting nut. Using a 19 mm socket spanner , loosen and remove the strut fork mounting bolt at lower arm end and detach it. Torque : 120 \u00b1 12 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Using hammer, tap strut fork gradually and release strut fork from lower arm. Using a 17 mm ring spanner, loosen and remove the strut top mounting nuts from chassis. Torque Value: 40 \u00b1 5Nm Torque Wrench Type - Open end Torque Wrench Detach Wheel speed sensor routing clips from upper control arm. Using 14 mm socket spanner and 18 mm open end spanner, unscrew upper arm bolt and nut and detach partially. Torque Value: 97\u00b1 10 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170137.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Remove front strut assembly from front suspension. LH and RH identification sticker available on part for orientation. Using a 17 mm socket spanner and 19 mm open end spanner, loosen the fork mounting bolt and nut and remove fork from strut assembly. Install in reverse order of removal.
2. Check for oil leakage from the shock absorber.
",
+ "file": null,
+ "display_order": 32
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 149,
+ "sys_id": "THAR.LX-0008-Suspension",
+ "subsys_id": "THAR.LX-0008-Suspension-Rear Upper Link Bushes Overhaul",
+ "systems": "Suspension",
+ "sub_systems": "Rear Upper Link Bushes Overhaul",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170276.jpg",
+ "myid": 1264,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Rear Upper Link Bushes Overhaul-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Removal",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/VST-0073_Rear Suspension Rear upper Link Bushes Removal & Installation.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Rear Upper Link. For additional information refer to Rear Upper Link \u2013 R &R; section. Place the base block (MST:0401BAA0033ST) & place the Rear Lower and Upper Link Coller (MST : 0401BDD0001ST) . Place the upper link one end on the base block. Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) over the upper link one end bush and Using a hydraulic press, remove the bush. Place the upper link other end on the base block. Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) on the upper link other end bush and Using a hydraulic press, remove the bush. Place the upper link one end on then base block and place the bush over the upper link. Place the Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press. While Installation ensure to maintain Bush Void at 45\u00b0 angle as shown. Ensure to Install the Bush with Void end should be fitted in Chassis end on vehicle. Place the upper link other end on the base block and place the bush over the upper link. Place the bush & Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press. Refit the Rear Upper Link. Using a appropriate jack support and slightly lift the rear axle. Using a 24 mm deep socket spanner, loosen and remove the pan hard rod mounting nut and bolt from chassis side. Torque : 230\u00b1 20 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt with the help of 21 mm deep socket. Torque tightening should be done without load and with the tyres on level ground. Using a 21 mm socket spanner, loosen and remove the pan hard rod mounting bolt from axle side. Torque : 230\u00b1 20 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Remove pan hard rod separately. Yellow color all round marking added on Pan hard rod to identify chassis end. Install in reverse order of removal. After installation of pan hard rod remove the jack support. Pay attention while Installation. Bolt should be fitted in the direction of Arrow shown in illustration. While Installation, ensure to refit the Anti Rotation Bracket in the axle end bold side.
2. Check upper control arm front and rear bush condition (both LH & RH) for wear & tear, cracks & shift. Replace if necessary.
3. Check the ball joint boots for damage, cracks, replace if necessary.
4. Check shock absorber bushes, shock absorber dust boot, stabilizer bar bushes, stabilizer bar link boots, bump stop for wear & tear, cracks and shift, replace if necessary.
",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170083.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Rear Suspension Bushes",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "1. Check the lower link, pan hard rod, Upper link, stabilizer bar and stabilizer bar links bushes for any damage/crack or deterioration. Replace the bushes if found any.
2. Check shock absorber bushes, dust boot & bump stop for wear, crack and shift.
",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170082.jpg",
+ "display_order": 6
+ }
+ ]
+ },
+ {
+ "procedure_name": "Lower Control Arm",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect front suspension lower control arm for any bend, damage or crack. Inspect front suspension upper control arm for any bend, damage or crack. Inspect front suspension stabilizer bar for any bend, twisting, damage or crack. Inspect rear suspension stabilizer bar for any bend, twisting, damage or crack. Inspect rear suspension lower link for any bend, damage or crack. Inspect rear suspension upper link for any bend, twisting, damage or crack. Inspect rear suspension panhard rod for any bend, twisting, damage or crack. Inspect front & rear suspension stabilizer bar link for any bend, twisting, damage or crack. While tightening the link & torquing ensure that wheels are resting on the ground/ 4 post lift. If it is not done, the ride quality will get adversely affected. Remove the Front Lower Control Arm. Place the base block (MST:0401BAA0033ST) & place the Front Lower Arm Big End Bush Collar (MST : 0401BBB0001ST) on the base block. Place the Lower arm big bush end over the fixture. Place the LCA big bush remover (MST: 0401BAA0038ST) and Front Lower Arm Bushs Support tool (MST: 0401BBB0002ST) on the big end bush. Place the Pin cage (MST:0401BAA0019ST) & the support cage (MST:0401BAA0013ST) as shown. Using a hydraulic press, remove the lower arm big end bush. Place the LCA small bush end on the base block (MST: 0401BAA0033ST) and LCA small bush collar support (MST : 0401BAA0036ST) . Place the Lower arm small bush end over the fixture. Place the LCA small bush remover (MST: 0401BAA0039ST) & Front Lower Arm Bushs Support tool (MST : 0401BBB0002ST) over the lower arm bush. Place the dummy bush (MST: 0401BAA0016ST) on the big end bush seating hole. Place the Pin cage (MST: 0401BAA0019ST) & support cage (MST: 0401BAA0013ST) as shown. Using a hydraulic press, remove the LCA small bush. Place the lower arm on the base block (MST: 0401BAA0033ST). Place the bigger end bush on the lower arm & place the bush installer (MST: 0401BAA0044ST)on the bush. Lower arm big end bush has Void profile and While Installation ensure to maintain Bush Void at appropriate angle as shown. Using a hydraulic press, Install the lower arm big end bush. Place the lower arm small end on the base block (MST: 0401BAA0033ST) Place the lower arm small end bush & the installer (MST: 0401BAA0045ST). Using a hydraulic press, Install the lower arm small end bush. Refit the Front Lower Control Arm. Support the rear axle using the appropriate hydraulic jack. Using a 17 mm socket spanners, loosen and remove the both rear shock absorbers bottom side mounting bolts and nuts. Torque Value : 110\u00b111 Nm Torque Wrench Type - Open end Torque Wrench While loosening the nut, hold the bolt using 15 mm ring spanner Torque tightening should be done without load and with the tyres on level ground. Remove the rear coil spring and pad securely from vehicle. Install in reverse order of removal. Pay attention while Installation. Locking lug to be matched with hole on Rear Coil spring dome bracket of Chassis. Yellow coloured PU sleeve should be on chassis side while assembling the coil spring ashown in illustration.
2. Inspect the coil spring pad for any damage. Replace if found.
",
+ "file": null,
+ "display_order": 21
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 152,
+ "sys_id": "THAR.LX-0008-Suspension",
+ "subsys_id": "THAR.LX-0008-Suspension-Troubleshoot - Suspension",
+ "systems": "Suspension",
+ "sub_systems": "Troubleshoot - Suspension",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1466,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Troubleshoot - Suspension-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Symptom possible causes remedy",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/14506.pdf",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Components Inspection and action table",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/14507.pdf",
+ "display_order": 2
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 144,
+ "sys_id": "THAR.LX-0008-Suspension",
+ "subsys_id": "THAR.LX-0008-Suspension-Assembly Front Strut Overhaul",
+ "systems": "Suspension",
+ "sub_systems": "Assembly Front Strut Overhaul",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A170158.jpg",
+ "myid": 1259,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Assembly Front Strut Overhaul-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Disassembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Front strut assembly. Using a spring compressor compress the strut coil spring. Ensure that the spring compressor is tightened with the spring, else expansion of the spring cause severe injury Using a 6 mm open end spanner hold the shock absorber & using a 16 mm ring spanner remove the mounting nut. Remove the shock absorber washer & bush. Remove the bracket coil spring guide assembly. Remove the coil spring seat. Remove the compressed coil spring. Remove the shock absorber bush. Remove the bump stopper cap. Remove the shock absorber dust seal. Remove the front bump stopper. Remove the shock absorber.
2. Inspect the dust seal for damage, if found replace.
3. Check the bush condition, if worn out please replace.
",
+ "file": null,
+ "display_order": 28
+ }
+ ]
+ },
+ {
+ "procedure_name": "Assembly",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Install the front bump stopper on the shock absorber. Install the shock absorber dust seal. Install the bump stopper cap. Install the shock absorber bush. Install the compressed spring. Install the coil spring seat. Install the coil spring bracket. Install the shock absorber washer & bush. Install the mounting nut. Install the top mounting nut. Torque tighten the nut to specified value. Torque : 40 \u2013 45 Nm Torque Wrench Type - Open end Torque wrench ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the spring compressor tool. For additional information refer to Front wheel \u2013 R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a cutting plier, remove the cotter pin from the ball joint. Never reuse the split pin, always replace with a new one. Using a 24 mm socket spanner, loosen and remove the upper control arm ball joint nut. Torque : 90 \u2013 110 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Detach the wheel speed sensor routing clips from the upper control arm. Using a 18 mm ring spanner, hold the mounting nut & using an 14 mm socket spanner loosen the bolt, remove the bolts & nuts. Torque : 97 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Detach and remove the upper control arm. Install in reverse order of removal. Pay attention while Installation. Bolt should be fitted in the direction of Arrow marks shown in illustration. Remove the Rear Shock Absorber. Place the rear shock absorber one end on the suitable base block. Place the suitable dolly on the rear shock absorber bush. Using a hydraulic press or hammer remove the rear shock absorber bush. Place the rear shock absorber one end on then base block and place the bush over the rear shock absorber. Place the bush & suitable dolly over the bush and Refit the bush by loading the hydraulic press. Refit the Rear Shock Absorber. Shock absorber is a tubular hydraulic device placed near each wheel to dampen the spring oscillations. One end of the shock absorber is attached to the frame and the other end on rear axle. The hydraulic shock absorber only dampens oscillations due to road irregularities. It does not support the weight of the vehicle. Shock absorber is Double Acting hydraulic telescopic Shock Absorber type. Support the rear axle using the appropriate hydraulic jack and lift the vehicle to compress the coil springs. Using a 17 mm socket spanners, loosen and remove the bottom mounting bolts and nuts of rear shock absorbers from the rear axle. Torque Value : 110\u00b111 Nm Torque Wrench Type - Open end Torque Wrench Torque tightening should be done without load and with the tyres on level ground. While loosening the nut, hold the bolt using 15 mm ring spanner. Using a 14 mm socket spanner, loosen and remove the top mounting bolts of both rear shock absorbers from the chassis. Torque Value : 65\u00b110Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Remove the shock absorber from the vehicle. Install in reverse order of removal. Pay attention while Installation. Bolt should be fitted in the direction of Arrow shown in illustration. Ensure the arrow on Rear Shock absorber should be on rear side of vehicle.
2. Inspect the shock absorber bushes for any damage.
",
+ "file": null,
+ "display_order": 22
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 135,
+ "sys_id": "THAR.LX-0008-Suspension",
+ "subsys_id": "THAR.LX-0008-Suspension-Wheel Alignment",
+ "systems": "Suspension",
+ "sub_systems": "Wheel Alignment",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J10-MAT-0510",
+ "cover_image": null,
+ "myid": 1250,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 21,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 55,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 110,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 149,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 179,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 231,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 275,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 301,
+ "kilometers_applicable": 1
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 357,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 394,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 427,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0008-Wheel Alignment-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Wheel alignment (adjustment of Camber, Caster and Toe) is part of standard automobile maintenance that consists of adjusting the angles of the wheels so that they are set to the specification. The purpose of these adjustments is to reduce tyre wear, and to ensure that vehicle travel is straight and true (without pulling to one side). Wheel alignment consists of adjusting the angles of the wheels so that they are perpendicular to the ground and parallel to each other. The purpose of these adjustments is maximum tyre life and a vehicle that tracks straight and true when driving along a straight and level road. The symptoms of a vehicle that is out of alignment are: Uneven or rapid tyre wear, Pulling or drifting away from a straight line, Wandering on a straight level road, Spokes of the steering wheel off to one side while driving on a straight and level road. Before doing wheel alignment, ensure front and rear tyre pressure are as per specifications. Vehicle to be run for some distance before starting the wheel alignment. This will settle the load on each tyre. \u2022 Ensure that the turn table & roller plate move freely to avoid suspension block & no rocking of turn tables. Check for any damage of the rims or bushes & suspension joints/ wheel end for play. Ensure that the front turntables & rear plates are at the same level. Do the setting of steering wheel for Straight Ahead Position (SAP) and lock the steering column rotation. Refer the wheel alignment specification chart for the front Suspension. Refer below decision tree for wheel alignment. Wheel Alignment Sequence ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U3A130002.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "If above sequence is not followed, it will lead to incorrect wheel alignment even though individual adjustments are done correctly. Run Out Compensation ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Park the vehicle on 4 post wheel alignment equipment to do the run-out compensation. Refer wheel alignment equipment manufacturer's guide lines while doing run-out compensation. Refer the procedure given below for SAP setting ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "1. Keep the wheels on turntables of the wheel alignment machine.
2. Rotate the steering wheel to LHS lock position.
3. From LHS lock position, rotate steering wheel to RHS Lock position.
4. Count the number of turns of steering wheel from LHS to RHS lock position.
5. From RHS lock position, rotate steering wheel exactly half the number of turns towards LHS.
6. Lock the steering wheel.
7. If the steering straight ahead does not match the wheel straight ahead, then adjust the OBJ of the desired side.
8. Ensure that the silent bushes in the front suspension are in satisfactory condition.
9. Ensure that the front suspension fasteners are tightened to specified torque.
10. Ensure that there is no play in steering linkages and suspension ball joints.
11. Follow instruction manual of wheel aligning system manufacturer.
",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Wheel Alignment - Check & Adjust ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Wheel alignment consists of adjusting the angles of the wheels so that they are parallel to each other and perpendicular to the ground, thus maximizing tyre life and ensures straight and true tracking along a straight and level road. Specification for Wheel Alignment Front Suspension ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21715.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "Front Suspension Steering Angle Parameters ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21716.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Wheel alignment procedure to be done in vehicle unladen condition only. Do wheel alignment only according to manufacturer's specifications. Front tyre should have uniform wear and inflated to recommended pressure. Ensure that hub play is correct. Ensure that the front suspension fasteners are tightened to specified torque. Ensure that there is no play in steering linkages and suspension ball joints. Camber is defined as the inward or outward tilt of the top of the wheel as viewed from the front. While adjusting camber angle vehicle should be unladen and nobody should sit inside. The camber values should be within: 0\u2070 \u00b1 0.2\u2070 The difference between two wheels should be within: 0\u2070\u00b1 0.4\u2070. Using a 24 mm socket spanner, loosen the camber bolt locking nut. While loosening hold the bolt with the help of a 24 mm ring spanner. To adjust camber angle, rotate the camber bolt using 24 mm ring/socket , to clockwise or anti clockwise direction. Clockwise rotation will reduce the camber angle and anti-clockwise rotation will increase the camber angle. After adjusting camber angle tighten the camber bolt locking nut and recheck the camber angle. The angle between the vertical line and king pin, which fixes the steering knuckle and front axle, (steering column which connects the top and bottom ball joints in the independent axle type) when viewed the tyres from the side is called caster angle. While adjusting caster angle vehicle should be unladen. The values should be within: 4.2\u00b0 \u00b10.4\u00b0. The difference between two wheels should be within: 0\u00b0 \u00b1 0.4\u00b0. Adjust caster bolt until red zone becomes green. (Only if wheel alignment is out of specs). Using a 24 mm socket spanner, loosen the caster bolt locking nut. While loosening the nut, hold the bolt using 24 mm ring spanner. To adjust castor angle, rotate the caster bolt to clockwise or anti clockwise direction using 24 mm socket spanner. Clockwise rotation will decrease the caster angle and anti-clockwise rotation will increase the caster angle. Toe is the difference of measured distances between the front ends of the tyres (A) and the rear ends of the tyres (B) along the same axle when viewed the wheels from the top. Front Toe In to be adjusted individually on LH and RH side tie rod ends. Front Total toe between two wheels should be within: 0.23\u2070 \u00b1 0.1\u2070. The difference between two wheels should be within: 0\u00b0 \u00b1 0.4\u00b0. Using a 19 mm open end spanner, hold tie rod end first and then loosen tie rod end lock nut with the help of 19 mm open end spanner. Using a 14 mm open end spanner, Toe-in is adjusted by varying the length of tie rods. While adjusting toe-in, adjust the length of both the tie rods by rotating them in the same direction such that their lengths remain equal at all times. Perform steering angle sensor (SAS) calibration if steering wheel is removed and adjusted during straight ahead position setting and procedure as below. After adjusting the length of tie rods, recheck toe in and then hold tie rod end with 19 mm open end spanner and then tightening locknut with 19 mm open end spanner.
2. Connect the i-SMART diagnostic tester and turn the ignition ON .
3. Launch i-SMART Select ABS ECU and Navigate to Write Data .
4. Select the WRITE DATA tab.
",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170207.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "1. Click on \u201cROUTINE SELECTION\u201d drop down list and select \u201cSteering Angle Sensor Calibration\u201d .",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170208.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Click on \u201cSTART ROUTINE\u201d to initiate the SAS Calibration. Ensure the Steering Wheel is at center and the front wheels are straight. The following pop up window appears once the SAS Calibration completed. Press \u201cOK\u201d button to complete SAS Calibration through i-SMART. Front ride height : Front wheel arch center (Bottom Surface) to ground. Rear ride height : Rear wheel arch center (Bottom Surface) to ground.Ride Heights of different variants ",
+ "file": null,
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21732.jpg",
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "R16 SF 6S - Rim Size 16, Side Facing 6 Seater. R16 FF 4S - Rim Size 16, Front Facing 4 Seater. R18 FF 4S - Rim Size 18, Front Facing 4 Seater Ensure below before Checking Ride height Correct Wheel alignment values. Recommended Tyre pressure. Fuel tank filled 90%. Spare Wheel mounted If ride height is not within limits, then check (Measure ride heights only when the vehicle is on plain ground.) Correct tyre pressure. Coil spring damage. Loosened suspension mounting bolts. Rubber bushes of UCA and LCA.
Prior to inspect the ball joint, inspect the wheel bearings for any play. Inspect the ball joint for relative movement by, grasp the top and bottom of the wheel and rock it in and out along the wheel\u2019s vertical axis.Observe any relative movement between the wheel knuckle and ball joints. Ensure wheel nuts/bolts are not in loosen condition while checking, as that may cause movement when rocking the wheel. If relative movement play is little or no play then the ball joint is in good condition. If relative movement play that seems excessive or noises, then Visual check the ball joints. Any noises or play heard towards the top are most likely indicative of a problem with the upper ball joint, while, any play or noise coming from the bottom of the wheel are probably indicative of a problem with the lower ball joint. Check 2 (On Vehicle) ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Take a pry bar and place it between the lower control arm and the steering knuckle, the two parts that are connected together by the ball joint and attempt to pry them apart. Loose ball joints will have an excessive amount of play and movement when you pry on them, may even make knocking or clicking sounds. Check 3 (On Vehicle) \u2013 Visual Inspection ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170172.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Inspect the ball joints for any signs of rust, damage to the dust boot, grease leakage, or other potential problems that may indicate a need for replacement. Check the looseness of ball joints in Control arms. Check 4 (Off Vehicle) ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the Ball joints from Vehicle. Refer Respective Ball Joints R&R; Section. Check the ball joint for free rotational torque by rotate the ball pin through the periphery of ball joint cup for checking the movement. Replace the ball joint only if movement is found jerky during rotation. Check the Axial lift by holding the ball Joint and lifting the ball pin in upward direction. If the play was observed more than 0.5 mm replace the ball joint. Lift the ball pin by one hand & hold the lower end of ball joint grounded by other hand. Rear Lower Link is used to provide articulation for rear suspension in vertical direction. It also supports the lower end of the axle. Using a 24 mm socket spanner loosen and remove the rear lower link front and rear mounting nuts and bolts. Torque Value: 230 \u00b1 20 Nm Torque Wrench Type - Open end Torque Wrench for LH chassis side While loosening the nut, hold the bolt using 21 mm ring spanner. Torque tightening should be done without load and with the tyres on level ground. Detach the rear wheel speed sensor routing from the lower link. Remove the rear lower link from the vehicle. Install in reverse order of removal. Pay attention while Installation. Bolt should be fitted in the direction of Arrow shown in illustration. Remove the Front Door Trim. For additional information refer to Front Door Trim R &R; section. Using 10 mm socket spanner, unscrew glass channel mounting nuts and detach the run channel beading from the channel and take out the channel from door. Torque :5\u00b11 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380042.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the door latch electrical connector. Detach the mounting link from latch to exterior door handle. Detach link from the handle lever. Using a 5 mm Allen key, Unscrew the latch to door mounting Allen screws. Torque : 7 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380046.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380047.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the front door latch assembly separately. 7 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the latch assembly for any damage, replace if found. Inspect the linkages for any damage or bend. Open the bonnet and lock it using bonnet stay rod. . Using a star screw driver, loosen and remove both side front splash shield mounting screw rivets. Remove both front splash shields from vehicle . Using a 10 mm socket spanner, loosen and remove the front stone guard front mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250064.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen and remove the rear stone guard rear mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250033.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the stone guard mounting screw rivets. Remove the stone guard from the vehicle. Disconnect the fog lamp electrical connectors LH & RH sides. Pull and remove the front bumper top panel trim clips and remove the panel. Using a 10 mm socket spanner, Unscrew front bumper mounting nuts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Hood Catcher Both.PNG",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "using a 13 mm socket spanner, Unscrew front bumper bottom mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12.PNG",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew front bumper top side mounting bolts. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/13.PNG",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front bumper top centre mounting screw rivets. Remove the front bumper assembly from the vehicle. Using a 13 mm socket spanner, Unscrew front bumper center bracket mounting bolts and remove the front bumper center mounting bracket. Torque : 10.0\u00b11 Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250060.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the front grill mounting screw rivets. Using a star screw driver, loosen and remove the bottom side front grill mounting screw rivets. Using a 10 mm socket spanner, loosen and remove the front grill mounting bolts. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250062.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Remove the front grill assembly from the vehicle. Using a 10 mm socket spanner, Unscrew hood catcher mounting nuts both the sides. Torque : 7 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380104.jpg",
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Remove the hood catchers from the vehicle. Install in the reverse order of removal. Inspect the hood catcher for any damages. Replace if found any Remove the Front Door Window Glass. For additional information refer to Front Door Window Glass R &R; section. Disconnect the front door window glass motor electrical connector. Using a 10 mm socket spanner, loosen and remove the front door window glass mechanism to door mounting nuts. Torque : 10.50 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380035.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380036.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the front door window glass mechanism separately. Install in the reverse order of removal. Inspect the glass for any damage. Replace if found. Inspect the regulator for any damages, Replace if found any For additional information refer to Tail Door Trim R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380063.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380064.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a star screw drive, unscrew tail door handle top mounting screw and remove the cover. Carefully pull and detach the outer door handle from tail door. Using a star screw driver, unscrew handle inside support mounting screw from the tail gate. Torque : 1.3 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal. Inspect the rear door exterior handle for any damages. Replace if found any. Pull out the bonnet latch cable and open the bonnet. Lock it using bonnet stay rod. Disconnect cable guide and link from latch. Detach cable from routing clips. Press the lock and pull lever to detach bonnet cable lever with cable and take out the cable from the vehicle. Install in the reverse order of removal. Inspect the latch assembly for any damage, replace if found. For additional information refer to Tail Door Trim \u2013 R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "For Softtop Variants,
Remove the Tail Door Inner Handle.
",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.LX-0008,1026,1394",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380052.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect tail door latch electrical connector. Disconnect latch lever from the key lock and handle. Using a 5mm allen key, unscrew the tail door latch mounting screw. Torque : 7 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380055.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380056.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully detach tail door latch. Install in the reverse order of removal. Inspect the latch assembly for any damage, replace if found. Remove the Front Door Window Glass Regulator LH. For additional information refer to Front Door Window Glass regulator LH R &R; section. Using a T20 torx socket spanner, unscrew the regulator motor mounting screws. Torque : 2.5 to 3 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the glass for any damage. Replace if found. Inspect the regulator for any damages, Replace if found any. Remove the Intercooler Assembly. Disconnect cable guide and link from latch. Using a 10 mm socket spanner, unscrew bonnet latch mounting nuts. Torque : 10.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380073.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the bonnet latch from hood. Install in the reverse order of removal. While Installation, hand tighten the latch mounting nuts first and align the latch in appropriate position And ensure smooth locking of latch in holding bracket , finally torque tighten the mounting nuts. Inspect the bonnet latch for any damage, replace if found. For additional information refer to the Wiper Washer Nozzle Front - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the stay rod. For additional information refer to the Stay Rod - R&R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280052.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the wiper hose routing clips from the bonnet. Remove the bonnet rubber beading from the bonnet. Using 12 mm socket spanner, loosen and remove the bonnet catcher bracket mounting bolts (Both sides). Torque : 13.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260054.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260053.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using T40 socket spanner, loosen and remove the bonnet mounting bolts. Torque : 24\u00b14 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260061.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the bonnet from the vehicle. Install in the reverse order of removal. Inspect the bonnet hinges for any crack or damage. Replace if found. Remove Side window RH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Remove Side window LH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Unzip the tail gate window, detach the tail gate bar locking from rear RH & LH belt rails remove the tailgate window. Unhook the \u2018C\u2019 pillar cover from rear RH & LH belt rails and fold the cover at top of the soft top. Using a T30 socket spanner, loosen and remove the belt rear rail Mounting bolts and remove the belt rail from the vehicle. Follow the same procedure for LH side. Remove the seal from the body. Install in the reverse order of removal. Inspect the tail door half seal for any damage or wears. Replace if found any. For additional information refer to Front Door Trim RH- R&R Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260122.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Detach the key handle lever from the key lock set. Detach lock holding bracket and remove key lock from the vehicle. Install in the reverse order of removal. For additional information refer to Tail Door Trim RH- R&R Section. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260129.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Detach the key handle lever from the key lock set. Detach lock holding bracket and remove key lock from the tail door. Install in the reverse order of removal. Remove Glove Box Assembly. Using Screw driver, remove Glove box Latch mounting screws and remove the latch from the glove box. Using Screw driver, Remove Lock from Latch by pressing lock locking clips. Install in the reverse order of removal. Using vehicle key open the fuel filler door. Using Screw driver, detach lock holding bracket and remove key lock from the fuel lid door. Install in the reverse order of removal. Inspect the key locks for any damage or wears. Replace if found any. Pull the door outer handle and slowly close the door with outer door handle pulled in condition. Check and feel for the condition of latch fouling with striker. If the latch fouling with the striker then loosen the striker mounting screws and align the striker so that there is no fouling. Tighten the striker mounting screws to specific torque Torque : 23.5 \u00b1 2.5 ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "Ensure that door closing should be smooth and latch is not foul on the striker Follow the same procedure for other doors. Lift and open the tail gate glass. Using a screw driver carefully lift and open the gas strut lock at both the ends. Carefully remove tail gate glass gas strut. Install in the reverse order of removal. Inspect the gas strut assembly for any damage, replace if found. Remove the tail door electrical connector and remove the wiring routing clips from the tail door. Using a screws driver, loosen and remove the mounting screws from the hinges. Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260018.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, loosen and remove the stopper mounting bolt from the Body. Torque : 23.5\u00b12.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260119.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the hinge mounting bolts inside tail door. Torque : 50\u00b15 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260033.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Ensure to hold the tail door with spare wheel properly while remove, failing will lead door falling down which may lead to personal injuries. Using 12 mm socket spanner, loosen and remove the Hinge Mounting bolts from body. Torque :27\u00b14 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the tail door hinges for any physical damage, replace if found. Lower the window glass to prevent from damage. Disconnect door accessory electrical connector. Protect the electrical connectors to avoid water entry, which may leads to short circuit. Detach the wiring harness bunch from holding bracket \u2018A\u2019 Pillar end. Using 12 mm socket spanner, Unscrew door stopper mounting bolts BIW end. Using T40 Torx Socket, Unscrew door hinge pin at bottom of the hinge. Carefully lift and remove the door assembly from vehicle. Refit in the reverse order of removal. Key IN Reminder & Park Lamp Reminder will not function in case of driver door is removed. Roof lamp will not work with respect to door status Lock & Unlock functions will not work through Master Actuator in case of driver door is removed Hinge pin can break if overtightened during door reinstall \u2014 Max. Torque 10 Nm. Doors are heavy, Take at most care when removing the doors, Failing to this may cause personal injury After Door removal vehicle will be left with only IRVM (as ORVM\u2019s fitted on doors) In such scenario driving the vehicle on road is not permitted as per regulations. Do not drive your vehicle on public roads with the doors removed as you will lose the protection they can provide. This procedure is furnished for use during off-road operation only All occupants must wear seat belts during off-road operation with doors removed. Disconnect the Door wiring harness electrical connector and detach WH bunch from \u2018A\u2019 pillar lower. Using 12 mm socket spanner, Unscrew door stopper mounting bolt BIW side. Torque : 23.5 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260006.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew door hinge mounting bolts from body. Torque : 50 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260041.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the door assembly from vehicle. Support the door while removing the bolts. Using star screw driver , Unscrew door hinge mounting screw door end. Torque : 24\u00b1 4.0 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Before tightening the bolts align the door assembly correctly, else door operation won\u2019t be smooth.. Refit in the reverse order of removal. Do the door alignment, if required. Inspect the door hinge for any damage. Replace if required. Disconnect the demister electrical connectors. Using 4 mm Allen key, Unscrew glass hinge mounting screws. Torque : 2.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260077.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260076.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260118.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using the screw driver Unlock the strut to detach the strut and remove the glass. Ensure to hold the Rear Windshield glass while detach the struts, failing to hold leads to glass falling. Using 10 mm socket spanner, Unscrew strut bracket mounting bolts from glass. Torque : 5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Ensure not to over tigthen the strut bracket mounting bolts while Installation. Remove strut mounting grommet and cap nuts from the glass. Install in the reverse order of removal. Inspect the rear windshield glass for any damage or wears. Replace if found any. Remove the spare wheel carrier. For additional information refer to the Tail Door Trim - R&R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the tail door latch. For additional information refer to the Tail Door Inner Handle - R&R section. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the tail door outer handle . For additional information refer to the tail door Stopper section. ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the tail door lock. For additional information refer to the Tail Door Lock section. ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the tail door weather strip from the tail door. Remove the tail door electrical connector and remove the wiring routing clips from the tail door. Using a Screws driver, loosen and remove the mounting screws from the hinges. Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260018.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, loosen and remove the Stopper Mounting bolt from the Body. Torque : 50\u00b15 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260119.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, loosen and remove the hinge mounting bolts inside tail door. Torque : 50\u00b15 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260016.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Remove the tail door from vehicle. Install in the reverse order of removal. Inspect the tail door for any physical damage, replace if found Remove the hard top assembly. Remove the seal from the body. Install in the reverse order of removal. Inspect the tail door half seal for any damage or wears. Replace if found any Remove the scuttle grill. Using T40 socket spanner, loosen and remove the bonnet mounting bolts. Torque : 24\u00b14 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260058.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the bonnet hinge mounting bolts from the body and detach hinge. Torque : 24\u00b14 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260055.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the hood hinge from the bonnet. Install in the reverse order of removal. Inspect the bonnet hinges for any crack or damage. Replace if found. For additional information refer to Front LH wheel Hub \u2014 R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0009,1014,1245",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Front Stabilizer Bar. For additional information refer to Front Stabilizer Bar \u2014 R&R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front LH wheel speed sensor mounting bolt and remove the sensor.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150026.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": " Torque : 9 \u00b1 1 Nm",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the wheel speed sensor routing clips from the upper control arm.",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170123.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using cutting plier, remove upper arm ball joint cotter pin.",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150027.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Never reuse the cotter pin, always replace with a new one.",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 24 mm socket spanner, unscrew upper arm ball joint mounting nut.",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150028.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": " Torque : 90 \u2013 110 Nm",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using suitable lever, partially detach the knuckle and remove the drive shaft.",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150029.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Pull the drive shaft downwards and remove it.",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150030.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150031.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal.",
+ "file": null,
+ "display_order": 24
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Move the joint up, down, left, right, and in axial direction. Check for any rough movement or significant looseness.Position the Special tool support piece inside the axle housing and using MST 0502AUA0002ST Front Axle Shaft Inboard Oil Seal Puller, remove the Oil seal from the housing. Replace the Inboard Oil Seal once removed. Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, refit the Oil seal on the housing. Inspect the axle shaft Inboard Oil Seal for any damage, Replace if necessary. Using MST 0502AUA0002ST Front Axle Shaft Inboard Oil Seal Puller, remove the Oil seal from the housing. Replace the Inboard Oil Seal once removed. Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, refit the Oil seal on the housing. Refit Front LH drive shaft. Inspect the axle shaft Inboard Oil Seal for any damage, Replace if necessary. Remove Front LH drive shaft. Replace the Inboard Oil Seal once removed. For additional information refer to E-Disconnect stone guard \u2013 R&R section. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect E \u2013 Disconnect electric connector. Using 10 mm socket spanner, Unscrew electric disconnect housing mounting bolts and Carefully remove the E-Disconnect Housing with Fork . Torque : 17\u00b12 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A150265.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using circlip plier remove the intermediate shaft circlip from housing. Tool should not damage the splines on the axle shaft this affects disconnect operation. Pull out the axle shaft from wheel end side of e-disconnect housing. Using MST 0502AUA0008ST Front Axle Tube Needle Bearing Puller, remove the Needle bearing from e-disconnect housing LH side. By using MST 0502AUA0007ST - F Axle Tube Needle Bearing Dolly, Install the LH Side needle bearing In the disconnect housing. Clean and Insert the axle shaft through wheel end side of the disconnect housing. Align the shifter sleeve on the intermediate shift through disconnect housing window and Install the circlip on the axle shaft with the help of circlip tool. Ensure there should not be excessive play between two shafts this affects the disconnect. Install the new cover gasket while locating in the dowel on the disconnect housing. Ensure to use New Gasket while Installation. Ensure the cleanliness of disconnect housing cover face and cover resting face. Do not bent the wrap the Gasket while installing. Gasket orientation is fixed by dowel on the disconnect housing hence it will fit in one direction only. Bent or warped cover gasket may lead to leak during running. Locate the disconnect cover on the dowel and install the bolts. Tighten the mounting bolts to specified torque value. Ensure to use New bolts while Installation. Apply locktite sealant on the bolts while installing, this avoid the leakthrough cover. Torque : 17\u00b12 Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Connect e-Disconnect electrical connector. For additional information refer to E-Disconnect stone guard \u2013 R&R section. ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, refit the Oil seal on the housing. Refit Front LH drive shaft. Inspect the Front axle Tube Needle Bearing for any damage, Replace if necessary Using 8 mm socket spanner, Unscrew front propeller shaft mounting bolts/nuts at front axle end. Torque : 19\u00b13 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Front LH drive shaft. For additional information refer to Front differential oil draining and filling procedure. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove Front RH Wheel Hub. Using 10 mm socket spanner, Unscrew front RH wheel speed sensor mounting bolt and remove the sensor. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Detach the wheel speed sensor from routing bracket. Using cutting plier, Remove upper arm ball joint cotter pin. Never reuse the cotter pin, always replace with a new one. Using 24 mm socket spanner, unscrew upper arm ball joint mounting nut and remove the ball joint. Torque : 90 \u2013 110 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. For additional information refer to E-Disconnect stone guard \u2013 R&R section. ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Disconnect E \u2013 Disconnect electric connector. Provide a jack to support front axle. Using 19 mm socket spanner, unscrew front axle mounting bolts and partially remove the axle downwards. Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Partially detach the knuckle an remove the drive shaft by using a suitable lever. Pull the drive shaft downwards and remove it. Remove the front axle assembly from Vehicle. Install in the reverse order of removal. For additional information refer to Front differential oil draining and filling procedure. ",
+ "file": null,
+ "display_order": 39
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the axle shaft for straightness, cracks, damage, wear or distortion, replace it if necessary. Check the axle case for yield, deformation or cracks, replace if necessary. Inspect front axle for any oil leakage, seepage. Drain the Front Differential Oil. For additional information refer to Front differential oil draining and filling procedure. Remove the Front Axle Assembly. Mount the Front Axle Assembly on a suitable stand. Using 15 mm socket spanner, Unscrew front axle RH bracket mounting bolts and remove the RH bracket. Using 13 mm socket spanner, Unscrew differential assembly cover bolts and remove the cover. Clean the sealant on cover & banjo housing. Liquid sealant is used to seal cover with banjo beam. Scrap the sealant and clean the cover and banjo surfaces. Using 10 mm socket spanner, Unscrew e-disconnect cover assembly mounting bolts and remove the cover with shifter fork & motor. Using 10 mm socket spanner, Unscrew e-disconnect motor mounting bolts and remove the e-disconnect motor. Hit the shift shaft on suitable block and remove the shift shaft, shaft fork & spring from the disconnect cover. Using MST 0502AUA0002ST - Front Axle Shaft Inboard Oil Seal Puller, remove housing LH Oil seal. Replace the Inboard Oil Seal once removed. Position the Special tool support piece inside the axle housing and using MST 0502AUA0002ST Front Axle Shaft Inboard Oil Seal Puller, remove the RH Oil seal from the housing. Using circlip plier remove the intermediate shaft circlip from housing. Tool should not damage the splines on the axle shaft this affects disconnect operation. Pull out the axle shaft from wheel end side of e-disconnect housing. Remove the shifter shaft thrust washers from e-disconnect housing. Remove the shifter sleeve from edisconnect housing. Using MST 0502AUA0008ST Front Axle Tube Needle Bearing Puller, Needle bearing from e-disconnect housing LH side. Remove LH Side differential shaft from the housing wheel end side. Using 16 mm socket spanner, Remove the Differential bearing caps mounting bolts. Remove the Differential bearing caps. Identification marks are punched on bearing cap; this is to ensure correct bearing cap is installed on correct side. Ensure correct bearing caps used While reassembly. Mount MST 0502AUA0030ST Front Axle Expander on carrier and Spread carrier by rotating nut on expander. Do not spread more than 0.5 mm. Using MST 0502AAA0001ST - Tommy Bars-X, Pry out differential case from carrier. Remove the expander from housing. Mount the MST 0502AUA0023ST \u2014 Front Axle Diff Case Bearing Puller Adapter and Using MST 0502AUA0012ST \u2014 Axle Bearing Puller on side bearing cone and remove the bearing from differential case assembly. Identify shims and side bearings on both sides, they are not to be interchanged during assembly. Similarly remove ring gear other side bearing cone by using MST 0502AUA0023ST \u2014 Front Axle Diff Case Bearing Puller Adapter and MST 0502AUA0012ST \u2014Axle Bearing Puller. Identify shims and side bearings on both sides, they are not to be interchanged during assembly. Using 17 mm socket spanner, Remove the ring gear mounting bolts and remove the ring gear. If require tap ring gear by mallet to remove the ring gear. By Using MST 0502AUA0033ST \u2014 Front Axle Diff Case Pin Remover & Installer and hammer, remove the roll pin retaining the cross shaft. Using suitable punch & hammer, remove the cross pin from case. To remove side gears and pinion mate gears, rotate the side gears, this will allow the pinion mate gears to turn to opening of the case. Remove pinion mate gears and spherical washers behind the gears. Lift out the side gears and thrust washers. Using MST 203 - Wrench Universal Joint Flange Holding tool hold the companion flange and remove the pinion nut and washer using 30 mm socket spanner from the differential housing. Using mallet tap and remove the companion flange along with dust cover. If not able to remove the companion flange tapping by mallet, use suitable 2 Jaw puller for removal. If companion flange shows wear in the area of seal contact, it should be replaced. Using a mallet, tap the pinion assembly and remove the pinion assembly from the differential housing. Make a centre punch and tap at top of the pinion assembly by using a mallet. Hold the pinion with hand to avoid falling. Gear teeth have sharp edges. Handle gears carefully to avoid injury Discard collapsible washer. Remove the Pinion Oil seal By using Screw driver/ Oil Seal Puller. Remove the slinger and outer bearing. Turn Carrier and Using MST 0502AUA0028ST Front Axle Pinion Inner Bearing Cone Remove Adapter and MST 0502AUA0032ST Front Axle Universal Handle, Remove the Inner Pinion bearing cone. Turn Carrier and Using MST 0502AUA0029ST \u2014 Front Axle Pinion outer Bearing Cone Remove Adapter and MST 0502AUA0032ST \u2014 Front Axle Universal Handle, Remove the outer Pinion bearing cone. Using the MST 0502AUA0022ST Front Axle Pinion Inner Bearing Puller Adapter and MST 0502AUA0012ST Axle Bearing Puller, Remove the Pinion Inner Bearing. Take out the pinion shims from the pinion. Using MST 0502AUA0006ST Front Axle Tube Cyl Roller Bearing Puller, Remove the Cylindrical roller bearing from disconnect housing. Inspect all bearings and races for pitting or uneven wear. The inner carrier bearing races should not spin on the carrier journals. The carrier races should fit snugly in the differential housing. Inspect the carrier race bores for grooves from spinning races. The side gear bores inside the carrier should not have any abnormal wear. Inspect all gear teeth for pitting, chips, breaks, and for signs of uneven wear and overheating. Inspect the axles for pitted, grooved or dull and rough bearing surfaces. Inspect gear teeth of side gears and pinion mate gears for wear and cracks. Inspect external teeth of side gears for wear & cracks. Inspect cross pin for excessive wear. Replace if necessary. If replacement of one gear is required, then both side gears, pinion mate gears and washers have to be replaced. Always replace gears as a complete set, do not mix new gears with old gears, as this may cause uneven wear and short gear life. Ring gear and pinion is supplied as a set. They are matched with each other during service. Matching numbers on both pinion and ring gear are etched for verification. Refer illustration shown below for more clarity. If a new gear set is used, verify numbers on pinion and ring for matching before proceeding with assembly. Standard mounting distance from centre line of ring gear to back face of pinion is 103.5 \u00b1 0.1 mm. This dimension is controlled by selecting shims, which are positioned between the inner pinion bearing cone and pinion gear. Best running position of gear set is achieved by proper shim selection. This dimension for front live axle will be different. On the bottom face of pinion, a number is etched. It can be a plus (+) number, a minus (-) number or Zero (0). Required pinion shim selection is achieved with help of this number. If alphabet 'm' appears on pinion face shim, selection has to be done in mm (Metric). If alphabet 'm' does not appear on pinion face, shim selection has to be done in inches (English). Shims with different thicknesses are available for selection. Use tables shown below for selecting correct thickness of shims either for addition or for subtraction from old shim pack. Ring and pinion etched with inch identification. Refer Table A. Ring and pinion etched with metric identification. Refer Table B. Observe the marking on pinion. If \u2018m\u2019 is found etched on the face, refer table B. If not refer table A.
",
+ "file": null,
+ "display_order": 137
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Position the MST 0502AUA0010ST - Front Axle Pinion Height Master Block on the pinion inner bearing setting area. Fix the dial gauge on MST 0502AUA0009ST Front Axle Pinion Height Setting Gauge and set dial gauge to zero reading on surface plate. Place the MST 0502AUA0009ST Front Axle Pinion Height Setting Gauge with Dial gauge on differential housing as shown. Rock the MST 0502AUA0009ST Front Axle Pinion Height Setting Gauge and load the Dial gauge on MST 0502AUA0010ST - Front Axle Pinion Height Master Block and measure the reading on Dial Gauge (X mm). Say X mm for example which is measured by using special tool - 0.79 mm (i.e X = 0.79 mm) Convert mm to thau, i.e (0.79*39) = 31 Thau Then see the Pinion off set i.e (+ 2) Thou (For example) Final shim size = 31 - 2 = 29 Thau Convert to mm = 29*0.0254 = 0.74 mm If Pinion offset is Positive (+), then subtract the pinion offset value. If Pinion offset is Negative (-), then add the pinion offset value. Using MST 0502AUA0026ST Front Axle Pinion Inner Bearing Cone Press Dolly and MST 0502AUA0032ST Front Axle Universal Handle, refit the pinion inner bearing cone into carrier housing. Using MST 0502AUA0027ST - Front Axle Pinion Outer Bearing Cone Press Dolly and MST 0502AUA0032ST - Front Axle Universal Handle, refit pinion outer bearing cone into carrier housing. Place shims selected as per Shim Selection procedure on pinion gear. Using MST 0502AUA0025ST Front Axle Pinion Inner Bearing Press Dolly, Install pinion inner bearing cone. Take care to avoid damaging the pinion teeth while installing the bearing. Place the Pinion outer Bearing cone and slinger into housing. Using MST - 0502AUA0031ST Front Axle Pinion Oil Seal Installer, Install the New pinion seal into housing. Ensure to replace New Oil seal while Install. Apply a light coat of oil to the lip of oil seal. Install a new collapsible spacer into pinion shaft. Collapsible spacer should rest on bearing inner race and pinion shoulder and it can be fitted in any one direction. Assemble the Pinion into differential housing. Install the end yoke, washer and new pinion mounting nut. Hold the end yoke using (MST203 - Companion Flange Holding Tool) and torque tighten the mounting nut. Tighten nut to Initial torque as 217 Nm. Measure the Pinion Rotational Torque (PTTR), It should be within 17 \u2013 34 Kgf\u2013cm (1.7 to 3.3 Nm) If measured Pinion Rotational Torque (PTTR) not within (1.7 to 3.3 Nm), Then tighten nut to incremental torque from 217 Nm onwards to 678 Nm until specified PTTR ( Pinion torque to rotate) is achieved Excessive care must be taken during bearing preload torque adjustment. Do not over tighten, loosen and then retighten nut. Do not exceed specified bearing preload torque Measure and ensure the Final Pinion Rotational Torque (PTTR), It should be within 17 \u2013 34 Kgf\u2013cm (1.7 - 3.3 Nm) PTTR SPEC : 17 \u2013 34 Kgf\u2013 cm (1.7 to 3.3Nm) If preload torque is exceeded, a new collapsible spacer must be installed and torquing sequence as above to be repeated If only oil seal needs to be changed, measure rotating torque of pinion with the help torque measuring tool. In this case use new collapsible spacer and keep same rotational torque of pinion as before. Apply grease to new side gear thrust washers and hubs of side gears. Assemble both side gears. Apply grease to new pinion spherical washers, and pinion mate gears. Assemble pinion mate gears. Assemble both side gears and thrust washers, hold them in place with one hand and then assemble the pinion mate gears with thrust washer to hold the side gears in place An easy way to assemble the side gears and pinion mate gears is to have all parts lubricated before assembly Always replace gears as a complete set. Do not mix new gears with old gears, as this may cause uneven wear and shorter gear life Rotate the side gears until the holes of the spherical washers and pinion mate gears line up with the holes in the case by the help of engaging the splines of axle shaft to side gears. When both the cross bore hole matched and insert the differential shaft Use MST 0502AUA0033ST Front Axle Differential Case Pin Remover and Installer to line holes of the gears up with case Assemble differential shaft and pull out MST. Be sure vertical lock pin hole is lined up with that of the case, and that pinion mate washers are in place and lined up with gear and case. Align the differential shaft hole, insert the lock pin and fix using (0502AUA0033ST - Differential gear lock pin removal tool)and hammer. Always replace with new Lock pin while Installation. When roll pin bottoms out, stake (peen) metal of case over pin in two places, 180 degrees apart. Assemble MST 0502AUA0011ST Front Axle Dummy Bearings on to differential case as shown in the illustration. Assemble the differential case with Dummy Bearings on housing (Without Ring Gear). Mount the magnetic dial indicator with magnetic base, locate its tip on that surface of case. Force differential assembly to the extreme in the direction towards indicator, With force still applied set indicator to 0.00. Force differential assembly to the extreme end in opposite direction. Repeat above steps until the same reading is obtained, Record reading in the format given as 'A'. Remove dummy bearing and keep aside. Assemble ring gear to the differential case using mounting bolts. Tighten the bolts to specified torque value in recommended sequence. Torque : 95 - 122 Nm ",
+ "file": null,
+ "display_order": 217
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Notice",
+ "content": "Always use new ring gear bolts. Assemble MST 0502AUA0011ST Front Axle Dummy Bearings on differential case as shown in the illustration. Position differential assembly into housing and Mount the magnetic base dial indicator on housing and locate the tip of indicator on the surface of one of the ring gear screws. Force differential case assembly away from pinion gear. With force still applied set indicator to zero. Force differential case assembly and ring gear to mesh with pinion gear. Rock the ring gear to allow teeth to mesh, Repeat to obtain the reading and continue the procedure until the same reading is obtained. Record reading in the format given as' B'. Remove dial indicator and dummy differential bearings from differential housing. Calculate the Ring Gear Backlash & Differential Bearing Preload shims based on below calculation. Install the selected shim pack in between side bearing and carrier assembly. Using MST 0502AUA0024ST Front Axle Differential Case Bearing Dolly, Install side bearing cone on hub of differential assembly. It is always preferred to replace side bearings once pulled out. But one can confirm free rolling of bearings and reuse it, if they are defect free. Install the selected shim pack in between other side bearing and carrier assembly. Using MST 0502AUA0024ST Front Axle Differential Case Bearing Dolly, Install other side bearing cone on hub of differential assembly. It is always preferred to replace side bearings once pulled out. But one can confirm free rolling of bearings and reuse it, if they are defect free. Install spreader and dial indicator and expand the carrier. Never expand the differential housing over 0.5 mm to avoid distortion. Remove dial indicator from the differential housing. Install differential case assembly into carrier with the help of mallet. Ensure differential case shim is behind the bearing cap. Carelessness while installing differential case assembly may result in injury. Position the bearing caps and install the mounting bolts and torque tighten the bolts to specified torque. Torque : 47 - 68 Nm ",
+ "file": null,
+ "display_order": 252
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "Notice",
+ "content": "Ensure correct fitment of caps by matching letters on caps and carrier on either side. Remove the expander from differential housing. Check ring gear and pinion backlash at three equally spaced points with dial indicator. Backlash tolerance is 0.13 to 0.20 mm and should not vary more than 0.08 mm between the three points checked. Fix the Dial Gauge on Housing, Set the Dial Indicator 0 on Ring gear teeth as shown. Hold the pinion flange at the bottom side. Rotate the ring gear by using ring spanner & measure the backlash. High backlash is corrected by moving ring gear closer to pinion. Low backlash is corrected by moving ring gear away from pinion. These corrections are made by switching shims from one side of differential case to other. If backlash is as per specification, check ring gear and pinion tooth contact pattern. Interpretation of Contact Pattern The TOE of the gear is the portion of the tooth surface at the end towards the centre. The HEEL of the gear tooth is the portion of the tooth surface at the outer end. The TOP LAND of a gear tooth is the surface of the top of the tooth. Every gear has a characteristic pattern. Measure and ensure the Final Total Torque To Rotate (TTTR) at pinion nut, It should be within 28 - 51 Kgf-cm (2.8 - 5 Nm). TTTR SPEC : 28 - 51 Kgf-cm (2.8 - 5 Nm). Using MST 0502AUA0005ST Front Axle Tube Cyl Roller Bearing Dolly, Install the RH housing cylindrical roller bearing through the oil seal bore In the housing. Using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, Install the RH side housing Oil seal. Clean the intermediate shaft and insert the shims in intermediate shaft. Push intermediate shaft in same way the direction used during removal. Install the synthetic bush in the bore of axle shaft with the help of light nylon mallet. Press force must not so high which may damage the bush during pressing. Insert the thrust washers in the sequence opposite to removal in the disconnect housing. Insert the axle shaft through wheel end side of the disconnect housing. Install the circlip on the axle shaft with the help of circlip pressing tool. Check end play with dial gauge at the axle shaft end. End play should be 0.025 to 0.1 mm. End play can be adjusted by adding/ deleting shims from the intermediate shaft. After adjusting end play, remove the circlip & axle shaft from the housing. Install the shifter sleeve on the intermediate shift through disconnect housing window while aligning with the splines on it. shift splines and shifter sleeve must be free from foreign particles and burr Insert the axle shaft through wheel end side of the disconnect housing. Install the circlip on the axle shaft with the help of circlip pressing tool. Ensure there should not be excessive play between two shafts this affects the disconnect. Insert the spring and shaft fork through the disconnect cover window while aligning the spring into bore in the cover and sitting in the slit of shift fork. Insert the shaft shift fork in the opposite way of removal ensuring that it passing through shift fork as well as spring. Orientation of the shift fork is important and it should be in same way while was removing. Ensure old spring is discarded and to use spring during installation. Ensure cleanliness of the disconnect housing cover, shift fork shaft , shift fork and spring. Press the shaft shift fork in the bore by hand. Install the new cover gasket while locating in the dowel on the disconnect housing. Ensure to use New Gasket while Installation. Ensure the cleanliness of disconnect housing cover face and cover resting face. Do not bent the wrap the Gasket while installing. Gasket orientation is fixed by dowel on the disconnect housing hence it will fit in one direction only. Bent or warped cover gasket may lead to leak during running. Locate the disconnect cover on the dowel and install the bolts. Tighten the mounting bolts to specified torque value. Torque : 17\u00b12 Nm. Ensure to use New bolts while Installation. Apply locktite sealant on the bolts while installing, this avoid the leak through cover. Install the electrical motor on the cover assembly and tighten the screw with specified torque. Torque : 12.5\u00b13.5 Nm. Ensure that the 'O' ring on the electrical motor is not cracked or damaged if so replace the 'O' ring as new one. By using MST 0502AUA0007ST - F Axle Tube Needle Bearing Dolly, Install the LH Side needle bearing In the disconnect housing. By using MST 0502AUA0003ST Front Axle Shaft Inboard Oil Seal Installer, Install the housing LH side Oil seal. Apply the uniform sealant bid along the carrier cover face and avoiding the bolt holes as far as possible. Use Anabond A-676 or 3M sealant on the cover plate. Ensure the cleanliness of the carrier cover face before Installation. Install the carrier cover plate and locate it on the cover plate mounting studs on the carrier. Install cover plate bolts and tighten them to specified torque value. Torque : 38 - 45 Nm. Discard the old bolts and Use new bolts for cover plate mounting as the bolts are coming with sealant patch on it and during sealant patch wears off. Reusing cover bolts may leads to leakage from cover bolts sides. Refit the Front Axle Assembly. Remove E-Disconnect motor. Using 10 mm socket spanner, Unscrew electric disconnect housing mounting bolts. Torque : 17\u00b12 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Carefully remove the E-Disconnect Housing with Fork . Refit in the reverse order of removal. While Installation Apply Locktite sealant on the E-Disconnect Housing bolts to avoid the leak through cover. Check the E-Disconnect motor, connector for any damage, Replace if necessary. For additional information refer to Front Stabilizer\u2013 R&R Section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front LH wheel speed sensor mounting bolt and remove the sensor. Torque: 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the wheel speed sensor routing clips from the upper control arm. Using cutting plier, remove upper arm ball joint cotter pin. Never reuse the cotter pin, always replace with a new one. Using 24 mm socket spanner, unscrew upper arm ball joint mounting nut. 90 \u2013 110 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Using suitable lever, partially detach the knuckle and remove the drive shaft. Pull the drive shaft downwards and remove it. Install in the reverse order of removal. Move the joint up, down, left, right, and in axial direction. Check for any rough movement or significant looseness. Check the drive shaft boot for cracks or other damage, and for grease leakage. If damaged, disassemble the drive shaft to verify the damage, repair or replace if necessary. Check the splines for wear and tear. E-Disconnect stone guard \u2013 R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect E \u2013 Disconnect electric connector. Using 10 mm socket spanner, unscrew E \u2013 Disconnect motor mounting bolts. Torque : 12.5\u00b13.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the E-Disconnect motor Refit in the reverse order of removal. While Installation ensure to replace the New O Ring for E \u2013 Disconnect motor Check the E-Disconnect motor, connector for any damage, Replace if necessary. Position the vehicle on 2 post lift/ 4 post lift. Front Axle Oil \u2013 Mahindra 'MAXIMILE ELITE' New Generation Genuine Differential Fluid. Capacity \u2013 1.25 Litres.Using 10 mm square bit spanner, loosen and remove front axle filler plug. Using 10 mm square bit spanner, loosen and remove front axle drain plug and drain the entire oil. Wait till the entire oil get drained. Place a tray beneath the front axle for collecting the oil while draining. Refit the drain plug and torque tighten to specified value. Clean the drain plug and differential housing with a clean cloth before refitting. Torque : 34 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": "Refill specified quantity of recommended differential oil into differential assembly. Never reuse drained oil. Always use recommended oil only. Never mix different types of oil and use. Clean filler plug area properly using a cloth before filling the oil. Check the oil level and ensure its up to the level. Ensure that the oil level is up to lower most point of the filler plug. Refit the filler plug back and torque tighten to specified value. Torque : 34 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "Clean the filler plug with a clean cloth before refitting. Recommend to use only Mahindra 'MAXIMILE Elite' new generation genuine differential fluid. In case of non availability of 'Maximile' brand, other brands meeting API GL5, SAE 80W-90 specification can be used as second preference and oil change period should be reduced as 20,000 km. Verify the customers concern. Visually inspect the front axle for any noticeable signs of mechanical damage. If an obvious cause is found during the inspection, correct the same before proceeding to the next step. If the cause is not found visually during the inspection, refer to the troubleshooting chart. Check for oil level and condition. Check for any oil leakage in the differential assembly, gasket and axle shaft oil seal. Check for any noise in the bearing, pinion gear, crown wheel and planet gears. Remove rear front facing Seat Back Rest Assembly. Open the seat cover strip back side of back rest assembly. Press the lock and remove the head rest. Unzip the seat cover LH & RH sides. Press the lock and remove the head rest guide inside seat cover. Detach the seat cover with foam from the frame and remove from back rest frame. Install in the reverse order of removal. Check for any damages. Replace if required. Check for any damages on seat trims. Replace if required. Remove Driver Seat Back Rest Assembly. Open the seat cover strip back side of back rest assy. Unzip the seat cover LH & RH sides. Pull and detach the lumber support handle. Press the lock and remove the head rest guide inside seat cover. Remove foam with cover from back rest frame. Excessive pull or improper removal may leads to damage the foam and seat cover. Install in the reverse order of removal. Check for any damages.Replace if required. Check for any damages on foam and cover. Replace if required. Remove the Driver Seat Back Rest foam with Cover. Using star screw driver, Unscrew lumber support Mechanism mounting screws and remove mechanism Disconnect lumber support cable link from back rest frame. Using star screw driver, Unscrew luggage hook mounting screw and remove it from the frame assy. Separate the driver seat back rest frame. Install in the reverse order of removal. Check the frame for any damages. Replace if required. Remove Driver Seat Back Rest Foam with Cover. Using Nose Plier, Remove the copper ring locks and remove cover from foam. Take extreme care to not to damage the foam and seat cover. Install in the reverse order of removal. Check the foam for any damages. Replace if required. Check for seat cover any damages. Replace if required. For additional information refer to the Rear Seat Recliner Covert - R&R section. ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Detach the seat folding cable from the lock and remove the cable. Remove the cable from the bottom cushion routing bracket. Remove the cable from the seat. Install in the reverse order of removal. Check seat folding cable for any damages. Replace if found. Remove Driver Seat Back Rest Assembly. Unlock the seat cover lock from the bottom side. Using Nose plier and Screw driver, Remove the seat cover locking rings. Using star screw driver, Unscrew seat side cover mounting screw and remove the cover. Detach the cover with foam. Install in the reverse order of removal. Check the Cushion and Frame Assembly for any damages. Replace if required. For additional information refer to Diver Seat Assembly - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove seat recliner and height adjustment handle cover. By using star screw driver remove seat height adjustment handle mounting screws & remove the handle. By using star screw driver, remove LH & RH valance cover mounting screws and detach the covers. Detach back cushion cover lock from seat bottom. Using T50 torx socket spanner, Unscrew back rest mounting bolts. Torque: 47.5 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B230111.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Detach the back rest from Seat assembly. Press the Lock and remove the head rest from the back rest assembly. Install in the reverse order of removal. Check for any damages. Replace if required. Check for any damages on seat trims. Replace if required. Remove the Rear Front Facing Bottom Cushion. Remove the copper locks from the rear front facing bottom cushion. Detach the both side the cable from the lock. Remove the both routing bracket cable tie from the seats. Remove the bottom cushion from the frame assembly and separate the Bottom Cushion Frame. Install in the reverse order of removal. Install in the reverse order of removal. Check for any damages on seat trims. Remove the Wiper Motor & Link Assembly. By using screw driver partially remove the wiper link from the motor. Using a 10 mm open end spanner loosen and remove the wiper motor link assembly mounting bolt. Torque : 10 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the wiper motor separately. Install in the reverse order of removal. Check the motor for any damage. Replace if found any. Check the linkage for any damage. Replace if found any. For additional information refer to Front Gril Assembly - R&R Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a screw driver, Carefully remove the dust tray from vehicle. Disconnect wiper motor electrical connector. Using a 10 mm open end spanner, loosen and remove the wiper motor mounting bolts. Torque : 10.50 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the wiper motor and link assembly from vehicle. Install in the reverse order of removal. Check the motor for any damage. Replace if found any. Check the linkage for any damage. Replace if found any. Remove the Roof Speaker LH & RH. For additional information refer to Roof Speaker - R&R section. Remove the Roof Tweeter LH & RH. For additional information refer to Roof Tweeter - R&R section. Using a trim removal tool pull out center bow trim and disconnect roof lamp electrical connector. Disconnect the sound bar electrical connector. Using 10 mm socket spanner, Unscrew sound bar mounting bolts. Detach the Wiring Harness from routing and remove from the sound bar assembly. Install in the reverse order of removal. Inspect the Wiring Harness for any physical damage. Replace if found. Inspect the connector for any damage. For additional information refer to Driver Sun Visor - R&R Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Co-Driver Sun Visor. For additional information refer to Co-Driver Sun Visor - R&R Section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280010.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using Torx screw driver, Unscrew Centre bow trim mounting screw and detach the bow trim. Torque Value: 5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280011.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the MIC electrical. Remove the MIC from Centre bow trim. Install in the reverse order of removal. Inspect the MIC unit for any damage. Inspect the electrical connectors for any damage. Using trim removal tool remove the infotainment center bezel. Using trim removal tool remove infotainment top side cover. Using star screw driver, Unscrew infotainment mounting screws. Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1016.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect Infotainment electrical connectors. Remove the Infotainment unit. Install in the reverse order of removal. Inspect the infotainment unit for any damage. Inspect the electrical connectors for any damage. Using star screw driver remove front LH wheel arch mounting screw rivets. Using T25 socket spanner remove the antenna mounting screw. Torque Value: 3 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A280048.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the antenna electrical connector through wheel arch. Remove the antenna assembly separately. Inspect the antenna assembly and connector for any physical damage. Replace if found. Using star screw driver unscrew the panel assembly floor console RH screvits and detach the panel from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console LH screvits and detach the panel from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew vertical ascent RH mounting screw and detach the vertical ascent RH from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew vertical ascent LH mounting screw and detach the vertical ascent LH from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "partially detach the switch bang assembly and remove electric connector to take out from the vehicle. Carefully pull and remove the Audio Unit port Assembly. Disconnect the Audio Unit port electrical connectors and 12 volt electric connector. Using star screw driver unscrew the ,Audio Unit port mounting screws. Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the USB and DOC station assembly from the trim. Install in the reverse order of removal. Inspect the USB and DOC station assembly unit for any damage. Inspect the electrical connectors for any damage. Remove the Infotainment Assembly. Using star screw driver, Unscrew cluster bezel mounting screw and remove the bezel. Cut the GNSS antenna wire routing tag. Install in the reverse order of removal. Inspect the GPS Antenna for any damage. Inspect the electrical connector for any damage. Using star screw driver unscrew the panel assembly floor console RH screvits and detach the panel from vehicle. Using star screw driver unscrew the panel assembly floor console LH screvits and detach the panel from vehicle. Using star screw driver unscrew vertical ascent RH mounting screw and detach the vertical ascent RH from vehicle. Using star screw driver unscrew vertical ascent LH mounting screw and detach the vertical ascent LH from vehicle. partially detach the switch bang assembly and remove electric connector to take out from the vehicle. Carefully pull and remove the Audio Unit port Assembly. Disconnect the Audio Unit port electrical connectors and 12 volt electric connector. Using a small screw driver pull out the power port and remove the power port. Install in the reverse order of removal. Inspect the 12V power point for any physical damage. Replace if found. Position the vehicle on 2 post lift/ 4 post lift. Turn the ignition OFF. Connect the i-SMART diagnostic tester and turn the ignition ON. Select Dearborn Electronics India Pvt Ltd. \u2014 Garuda and then click START. THAR from the list of vehicles displayed as in following window then select the THAR_ BS6.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W653.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Click on the GENERATE button on the bottom right side of the Express View screen to generate DTC report. This will generate and store a report. Once completed, i-SMART will prompt to open Excel file. If any DTC is active, Refer Diagnostic manual for more information. Connect the miniSMART Bluetooth VCI on DLC and turn the ignition ON. Pair the Bluetooth of android tablet / smartphone with miniSMART VCI. Launch the miniSMART App and select the THAR from the vehicle list. Connect the miniSMART Android and select each \u201cECU\u201d from the list of controllers. From the list, select DTC Fetch. The ECU will be analysed and the registered DTCs will be displayed, then take screen shots of all registered DTCs and their Freeze Frame data by clicking over the DTC / FF icon, for records. If any DTC is active, Refer Diagnostic manual for more information. Repeat the above steps 4 to 7 for other ECU\u2019s present in the vehicle. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect engine WH connector ECU end and detach harness from routing clips. Disconnect AC compressor electrical connector. Using 12 mm socket spanner, Unscrew ignition coil ground connector mounting nut. Disconnect Variable oil pump solenoid electrical connector. Disconnect upstream Lambda sensor electrical connector and connector holder. Disconnect Engine oil pressure sensor electrical connector and routing clip. Disconnect WGTelectrical connector. Disconnect Dump valve electrical connector and routing clip. Disconnect VVT IN (Intake Phaser) electrical connector. Disconnect VVT Out (Outlet Phaser) electrical connector. Disconnect Throttle Valve Actuator & Position Sensor electrical connectors. Disconnect Spark plug (4 nos) electrical connectors. Disconnect downstream lambda sensor electrical connector and routing clip. Disconnect Exhaust CAM sensor electrical connector. Disconnect Intake CAM phase sensor electrical connector. Disconnect Crankshaft Sensor electrical connectors. Disconnect Coolant temperature sensor electrical connector. Disconnect FIP electrical connector. Disconnect Common rail electrical connector. Disconnect Injector (4 nos) electrical connector. Disconnect Knock sensor electrical connector & routing clips. Disconnect Alternator connector & routing clip. Using 8 mm socket spanner, Unscrew starter motor solenoid switch electrical connector. Torque : 2.5\u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Disconnect reverse switch electrical connector. Disconnect GNS electrical connector. Disconnect transfercase switch electrical connector. Detach Engine WH on intake manifold side. Using 10 mm socket spanner, Unscrew engine WH carrier mounting bolts. Disconnect engine WH inter connector, Holding clip and routing clip fire wall end. Detach the WH harness from engine assembly. Detach engine wiring harness from engine compartment. Install in the reverse order of removal. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove HVAC Control Panel (Manual). Carefully pull the Telltale Bank from inside. Disconnect the Telltale Bank electrical connectors and 12 volt electric connector and remove the Assy from IP. Using star screw driver remove Telltale bank mounting screws. Torque : 1.5 \u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the telltale bank. Install in the reverse order of removal. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the telltale bank for any external damage, If any replace it. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Instrument Panel Assembly. Using 10 mm socket spanner, Unscrew fuse box mounting bolts. Torque : 4 .0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the RH side door to IP interconnector and holding clip. Disconnect engine compartment to IP RH side inter-connector and holding clips. Disconnect the MBFM electrical connectors. Using 10 mm socket spanner, Unscrew ground cable mounting nuts and detach the connectors. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Disconnect the ignition key barrel electrical connectors. Disconnect the HVAC assembly electrical connectors. Disconnect LH door electrical connector. Disconnect the IP to Roof wiring harness inter-connector. Disconnect LH side IP to engine interconnectors with holding clip. Using 10 mm socket spanner, Unscrew earth cable mounting nuts. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Remove the IP wiring routing clips from CCB. For additional information refer to Front LH Scuff Plate \u2013 R&R Section. ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Detach the LH B pillar partially. Disconnect the Pre tensioner electrical connectors LH side. Disconnect the LH seat electrical connector and routing clips. Disconnect the Airbag ECU electrical connector. Using a 10 mm socket spanner, Unscrew earth cable mounting nut and disconnect the cable. Disconnect the parking brake switch electrical connector. For additional information refer to Front RH Scuff Plate \u2013 R&R section. ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Detach the RHS B pillar partially. Disconnect the Pre tensioner electrical connectors RH side. Disconnect the floor console inside wiring Harness routing clips. Disconnect the RH seat electrical connector and routing clips. Remove the wiring harness from vehicle. Install in the reverse order of removal. Ensure proper engagement of all the connectors Ensure proper engagement of all the wiring harness mounting clips Ensure proper routing of wiring harness Torque tighten the earth mounting nuts to specified values Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove A Pillar Upper Trim LH. Disconnect speaker electrical pigtail inter-connector. Detach MIC wire from routing. Detach roof wiring harness from routing clips. Disconnect IP to roof WH inter-connector and holding clip with routing clips. For additional information refer to IP TOP Cover with PAB Assembly LH \u2013 R&R section. ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Detach WH routing clip and from vehicle. Install in the reverse order of removal Inspect the wiring harness for any external damage, If any replace it. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Rear RH Tail Lamp Assembly. For additional information refer to Rear RH Tail Lamp Assembly \u2013 R&R section. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect floor to tail door interconnector and holding clips. Detach the tail door WH grommet. Disconnect BIW pigtail inter-connector and connector holding clip. For additional information refer to Tail Door Trim - R&R Section. ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect door latch electrical connector. Remove the Tail Door Wiring Harness from vehicle. Install in the reverse order of removal. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the cable. Disconnect the MBFM electrical connectors. Detach the IP wiring harness holding clip from MBFM bracket. Using 10 mm socket spanner, Unscrew MBFM bracket mounting bolts from BIW and remove MBFM with bracket from the vehicle. Torque : 6.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew MBFM mounting bolts from the bracket and detach the MBFM. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A370057.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the MBFM and bracket for any external damage, If any replace it. Service Reminder Indicator Reset Procedure ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Service Reminder Indicator - Reset.mp4",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "In the instrument cluster, the service reminder alert will start popping up in the cluster screen at 200 kms before the actual kilometers at which the service is due. This will continue at every ignition cycle. It is necessary to reset the service reminder once the service is rendered to the vehicle. If not reset, the service alert will continue to pop up at every ignition cycle, till it is reset by using recommended procedures. Press the OK button on Driver side switch bank and simultaneously turn the ignition ON. Release the OK button within 5 seconds after ignition on. Check and ensure that the service reminder alert is OFF in the cluster. The above procedure would reset the Service Reminder Alert till the next scheduled maintenance. Service reminder alert is provided with the intent of reminding the customer about a pending service visit hence, perform this SOP only after the vehicle has actually undergone servicing. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect the EMS ECU GASOLINE-K connector. Disconnect the HFM sensor C 19 connector. For additional information refer to Splash shield - R&R section. ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner remove earth cable mount nut and a routing clip. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove LH Side marker lamp connector with a routing clip. Disconnect LH side turn lamp electrical connector. Disconnect LH DRL connector and detach grow mat to take out connector. Disconnect LH Head lamp and levelling motor(HLLD) electrical connectors. Disconnect Horn electrical Connectors (2Nos) and 3 routing clip. Disconnect Electrical fan electrical connector. Disconnect LH Crash sensor electrical connector. Disconnect fog lamp electrical connector routing clips. Disconnect ambient temperature sensor electrical connector. Using 10 mm socket spanner, Unscrew engine compartment fuse box mounting bolts. Torque : 10\u00b11 Nm ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using 8 mm socket spanner remove fuse box positive cable mounting nut and disconnect from battery fuse connection. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Disconnect engine WH inter connector, Holding clip. Detach WH routing clips from fire wall. Using 10 mm socket spanner unscrew earth cable mounting nut from fire wall and detach cable. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Remove Air Cleaner Assembly. Using 10 mm combination spanner Remove LH fender ground mounting nut and detach it. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Disconnect brake fluid level sensor electrical connector. Disconnect ABS ECU electrical connector. Disconnect HVAC triple pressure switch electrical connector. Disconnect RH Crash sensor electrical connector. For additional information refer to Splash Shield Front RH - R&R section. ",
+ "file": null,
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Disconnect RH fog lamp electrical connector routing clips. Disconnect RH head lamp electrical connector. Disconnect RH head lamp levelling motor(HLLD) electrical connector. Disconnect RH side marker lamp electrical connector with a routing clip. Disconnect Front RH indicator and DRL connector and detach grow mat to take out connector. Using 10 mm socket spanner unscrew earth cable mounting nut from RH fender and detach cable. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "Description",
+ "content": "Detach WH routing clips from fender. Disconnect engine compartment to IP electrical connectors. Disconnect accelerator pedal electrical connector. Disconnect brake switch electrical connector with a routing clip. Disconnect clutch sensor electrical connector. Detach WH routing clips and take out wiring. Detach WH from inside to outside. Remove the scuttle Grill. Disconnect Wiper motor electrical connector and a routing clip. Disconnect IP to Engine compartment wiring harness inter-connectors. Disconnect engine compartment to chassis WH inter-connector. Disconnect washer tank electrical connector. Detach Engine compartment Wiring Harness from engine compartment. Install in the reverse order of removal. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Torque tighten the earth mounting nuts to specified values. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the e-disconnect stone guard. For additional information refer to edisconnect stone guard - R&R section. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the Front RH wheel speed sensor C 361 connector. Detach wiring harness routing clips on front cross member. Disconnect the e-disconnect motor C 231 connector. Disconnect the front LH wheel speed sensor C 360 connector. Detach wiring harness routing clips on chassis. Disconnect engine compartment WH to Chassis WH inter-connector. Detach routing clips on chassis LH side. Disconnect the chassis to FDM C 485 F inter-connector. Disconnect the rear LH wheel speed sensor C 362 connector. Detach routing clips on chassis rear LH side . Disconnect the chassis to bumper C 434 F inter-connector. Disconnect the DEF pigtail C 707 F inter-connector. . Detach rear chassis routing clips. Disconnect the rear RH Wheel Speed Sensor C363 connector. Detach routing clips on chassis rear RH side. For additional information refer to Rear LH Tail Lamp Assembly \u2013 R&R section. ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner unscrew LH tail lamp earth cable mounting nut and detach it. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Detach routing clip and grow mate. For additional information refer to Rear RH Tail Lamp Assembly \u2013 R&R section. ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner unscrew RH tail lamp earth cable mounting nut and detach it. Disconnect the tail lamp RH C 153 connector. Disconnect the tail lamp LH C 154 connector. Disconnect the chassis to tail gate-2 C 708 F inter- connector. Disconnect the chassis to tailgate-3 C 709 F inter-connector. Remove the chassis wiring harness from vehicle. Install in the reverse order of removal. Ensure proper engagement of all the connectors. Ensure proper engagement of all the wiring harness mounting clips. Ensure proper routing of wiring harness. Torque tighten the earth mounting nuts to specified values. Connect diagnostic tool connector and clear any DTC\u2019s if registered. Inspect the wiring harness for any external damage, If any replace it. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the sensor from the routing slot. Take out the sensor and disconnect the electrical connector. Install in the reverse order of removal. Inspect the ambient temperature sensor for any external damage, If any replace it. Using a star screw driver, loosen and remove the front splash shield mounting screw rivets from both the sides of vehicle. Remove the front splash shield both the sides from vehicle. Using a 10 mm socket spanner, loosen and remove the front stone guard front mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen and remove the rear stone guard rear mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the stone guard mounting screw rivets. Remove the stone guard from the vehicle. Disconnect the fog lamp electrical connectors LH & RH sides. Pull and remove the front bumper winch cover clips and remove the panel. Using 10 mm socket spanner, Unscrew front bumper mounting nuts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290004.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew front bumper bottom mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front bumper top side mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front bumper top centre mounting screw rivets.. Remove the front bumper assembly from the vehicle. Install in the reverse order of removal. Inspect the front bumper assembly for any crack or damage. Replace if found. For additional information refer to Remove Front Turn Indicator And DRL LH - R&R Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Splash Shield Front LH. For additional information refer to Splash Shield Front Lower LH - R&R Section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Link",
+ "content": "THAR.LX-0009,1024,1373",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250181.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a screw driver, unscrew the antenna from the fender LH. Torque : 3\u00b11 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the front grill mounting screw rivets. Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm combination spanner, Unscrew show lock mounting nut fender end. Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250139.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew fender top mounting bolts. Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250142.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew fender side mounting bolts. Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew fender bottom mounting bolts. Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew fender mounting bolts door side. Torque : 10\u00b12.0 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the fender from vehicle. Refit in the reverse order of removal. Inspect the fender panel for any damage. Replace if found. For additional information refer to Cladding Rear Wheel Arch RH - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Cladding Rear Wheel Arch LH. For additional information refer to Cladding Rear Wheel Arch LH - R&R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A260100.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a star screw driver,loosen and remove the rear fender RH/ LH side mounting screws. Using a star screw driver , loosen and remove the rear bumper bottom side mounting screwrivets. Using a star screw driver , loosen and remove the rear bumper side mounting screws. Using 10 mm socket spanner, Unscrew the rear bumper mounting bolts body end. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Flip the bumper and disconnect the electrical main connectors and remove rear bumper. Remove the wiring routing clips from the bumper assembly. Disconnect the rear parking sensor electrical connectors. Disconnect license plate electrical connector. Remove the rear bumper wiring harness. Remove the parking sensors with holder. Remove the license plate lamp from rear bumper assembly. Inspect the rear bumper assembly for any crack or damage. Replace if found. Remove the hard top assembly. Inspect the Hard-Top windshield upper frame Seal and replace if needed when the seal loses its softness or if found any damages.
Follow the below steps for replacement of Hard-Top windshield upper frame Seal
Remove the X-mas tree clips by trim remover from over the roof rail outer frame. Then pull the seal by manually, due to this seal has fixed with two-way pasting tape. Clean the surface by digresses cloth. Peel the sticker label sheet from the new Seal, then paste on the roof rail outer frame followed by press the X-mas tree clips. The Seal must be replaced along with X-mas tree clips, when the seal loses its softness or if found any damages, don't reused the X-mas tree clips. This seal is for preventing the water leakage and wind noise only. Seal coming with Two-way pasting tape. Install in the reverse order of removal. Using a star screw driver, Unscrew hard top quarter glass frame mounting screws from the rear window. Pull - out the glass beading from Quarter Glass. Carefully push from inside to outside and remove the rear window from the vehicle. Install in the reverse order of removal. While Installation always replace with New frame mounting screws Inspect the hard top quarter glass for any damage/crack etc. Replace if found any Inspect the hard top quarter glass mounting fasteners for any damage. Replace the fasteners if required For additional information refer to B pillar lower trim \u2013 R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the centre roof bow trim.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.LX-0009,1023,1359",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Open the top cover and Using a 14 mm socket spanner, loosen and remove the seat belt upper mounting bolt. 38 \u00b16 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210071.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the upper trim from vehicle. Install in the reverse order of removal. Inspect the B-pillar upper trim for any damage/crack/cut etc. Replace if found any. Inspect the B-pillar upper trim fasteners for any damage. Replace the fasteners if found any damage.. Remove the Hardtop Assembly. Remove the Seal from the vehicle. Install in the reverse order of removal. ",
+ "file": null,
+ "display_order": 8
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the Front Lateral trim for any damage/crack/cut etc. Replace if found any. Inspect the Front Lateral trim mounting legs for crack/bend etc. Remove Side window RH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Remove Side window LH Velcro and Unzip the window. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250125.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250122.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Unhook the window from the vertical and horizontal belt rail and remove the window. Unzip the tail gate window, detach the tail gate bar locking from rear RH & LH belt rails remove the tailgate window. Unhook the \u2018C\u2019 pillar cover from rear RH & LH belt rails and fold the cover at top of the soft top. Using a T30 socket spanner, loosen and remove the belt rear rail Mounting bolts and remove the belt rail from the vehicle. Follow the same procedure for LH side. Using a T30 socket spanner, loosen and remove the belt center rail Mounting bolts and remove the belt rail from the vehicle Follow the same procedure for LH side. Using T30 socket spanner, loosen and remove the belt vertical rail mounting bolts and remove the belt rail from the vehicle. Follow the same procedure for LH side. Remove the belt corner rail from the vehicle. Follow the same procedure for LH side. Using T30 socket spanner, loosen and remove the belt door rail mounting bolts and remove the belt rail from the vehicle. Follow the same procedure for LH side. Install in the reverse order of removal. Inspect the Seal/rail for any damage/crack/cut etc. Replace if found any. Using a trim removal tool pull out center bow trim and disconnect roof lamp electrical connector Remove the centre bow trim from the vehicle. Remove the roof lamp from bow trim. Install in the reverse order of removal. Inspect the trim for any damage/crack/cut etc. Replace it if found. Remove the B Pillar Upper Trim. Using a 10 mm socket spanner unscrew Grab handle mounting bolts. 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner unscrew front lateral trim mounting bolt. 2 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the Front lateral trim. Install in the reverse order of removal. Inspect the Front Lateral trim for any damage/crack/cut etc. Replace if found any. Inspect the Front Lateral trim mounting legs for crack/bend etc. For additional information refer Driver Sun Visor \u2013 R&R. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove co-driver sun visor. For additional information refer Co-Driver Sun Visor \u2013 R&R. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a T40 Torx Socket spanner unscrew centre bow trim mounting screws. 5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a trim removal tool carefully detach the trim and remove electrical connector. Detach the MIC carefully from the trim.. install in the reverse order of removal. Inspect the trim for any damage/crack/cut etc. Replace it if found . Remove Front Roof Bow Trim. Remove Front Lateral Trim. For additional information refer to Front Lateral Trim \u2013 R&R section. Using a 10 mm socket spanner unscrew A pillar trim mounting bolt. Torque : 2 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the A pillar upper trim from vehicle. Install in the reverse order of removal. Inspect the A-pillar upper trim for any damage/crack/cut etc. Replace if found any. Inspect the A-pillar upper trim mounting legs for crack/bend etc. When the engine is stopped and the ignition switched off, the battery feeds accessories which are directly connected to battery, such as alarms, clock, radio code and certain computers that operate continuously. Dark currents are considered normal if they do not exceed a few tens of milli amperes. If the value is more than that, one or more permanent electrical component is drawing too much current. They can be isolated by withdrawing the fuses one by one until the faulty circuit is identified. A multi-meter is the best tool for these measurements. A current clamp cannot accurately measure currents of less than 1 A. The measurement must be taken at the battery itself. Before carrying out leakage current test, Turn all accessories OFF. Switch OFF the ignition and remove the key. Close all doors and windows. Wait for minimum 3 Minutes and then do the checking procedure. In multi-meter, current selection should be in milliampere. Set the current measuring range of the ammeter to 10 A. Disconnect the negative terminal from the battery. Connect the positive terminal of multimeter (Red probe) with the negative terminal removed from the battery and connect the negative terminal of multimeter (black probe) with negative pole of the battery. Read the value in multi-meter. If the current measured is more than permissible value (For MT Variants \u2013 7 mA (Max) & for AT Variants \u2013 12 mA (Max)) ,check for any: Loose connection in ground points. Check for any active loads ( like roof lamp,etc;). Hydrometer is a float-type device used to determine the State-of-Charge by measuring the specific gravity of the electrolyte in each cell. It is an accurate way of determining a battery's state of charge and weak or dead cells. Wear suitable eye protectors (goggles). With the help of a flat end screw driver, remove the vent caps or covers from the battery. Squeeze the hydrometer bulb and insert the pickup tube into the cell close to the battery positive terminal. Slowly release the bulb to draw in only enough electrolyte to cause the float to rise. Do not remove the tube from the battery Read the specific gravity indicated on the float. Be sure the float is drifting free, and does not contact with sides of the barrel. Read the hydrometer at eye level. Disregard the slight curvature of liquid on the float. Note the reading for all the cells. The difference in specific gravity readings should not be more than 0.05. The specific gravity for fully charged battery is as follows: AMARON -1.270 \u00b1 0.010 at 27\u00b0C ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080030.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": " Specific gravity readings. By measuring the specific gravity of the electrolyte, you can identify whether the battery is fully charged, requires charging, or must be replaced. Specific gravity varies with the temperature. If the electrolyte temperature is substantially above 27\u00b0 C add seven points (0.007) to the observed specific gravity reading for every 10\u00b0 C by which the actual temperature is above 27\u00b0 C. Deduct seven points per 10\u00b0 C where the observed reading is below 27\u00b0 C to obtain the temperature corrected reading at 27\u00b0 C. Inspect battery electrolyte specific gravity whenever required. ",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 36,
+ "sys_id": "THAR.LX-0009-Charging System",
+ "subsys_id": "THAR.LX-0009-Charging System-Alternator",
+ "systems": "Charging System",
+ "sub_systems": "Alternator",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B080011.jpg",
+ "myid": 1116,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0009-Alternator-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Component Location Index",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080011.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25367.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25368.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the cable. Using 10 mm socket spanner, loosen and remove the engine feed cover mounting bolts. Using 14 mm socket spanner, rotate the auto tensioner in anti-clockwise direction and detach the accessory belt. Disconnect the alternator electrical connector. Remove alternator positive cable cover. Using 12 mm socket spanner, loosen and remove the alternator positive cable nut. Using 12 mm socket and ring spanner, Remove the alternator top mounting bolt and nut. Using 12 mm socket spanner, loosen and remove the alternator bottom mounting bolt and nut. Carefully remove the alternator from engine compartment. Install in reverse order of removal. Check alternator pulley for any damage. Check free play of alternator pulley. Check alternator drive belt for any damage. If found replace with a new one. Park the vehicle on a level ground. Open the bonnet and lock it in open position using bonnet stay rod. Connect the MDX - 650P battery tester to battery terminals connecting probes on the battery posts respectively. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": " When you start a new test, the last test results in memory are overwritten. Remember to record or print the results if you need to retain them. Press the Enter button and confirm the BATTERY LOCATION by selecting the \u201cIN VEHICLE\u201d in the tester using navigation button Up or Down . ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25354.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": " Press the Enter button and confirm the POST TYPE by selecting the \u201cTOP POST\u201d in the tester using navigation button Up or Down . ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25355.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": " Press the Enter button and confirm the APPLICATION by selecting the \u201cAUTOMOTIVE\u201d in the tester using navigation button Up or Down . ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25356.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": " Press the Enter button and confirm the BATTERY TYPE by selecting the \u201cREGULAR FLOODED\u201d in the tester using navigation button Up or Down . ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25357.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": " Press the Enter button and confirm the BATTERY STANDARD by selecting the \u201cJIS\u201d in the tester using navigation button Up or Down . ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25358.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": " Press the Enter button and get the recommended JIS Number value by pressing button Up or Down . ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25359.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25360.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": " Press the Enter button and perform the TESTING. ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25361.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": " Once the TESTING done, the initial battery result will be display. ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25362.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": " Press the PRINT button to get the hard copy print out. ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25363.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25364.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": " Disconnect the battery tester probes from battery terminals. ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": " Follow the below table for Battery Testing test results condition and remedial action ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25365.jpg",
+ "display_order": 29
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 42,
+ "sys_id": "THAR.LX-0009-Charging System",
+ "subsys_id": "THAR.LX-0009-Charging System-Charging System Technical Spec",
+ "systems": "Charging System",
+ "sub_systems": "Charging System Technical Spec",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1122,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0009-Charging System Technical Spec-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Battery Specifications",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/17514.jpg",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 38,
+ "sys_id": "THAR.LX-0009-Charging System",
+ "subsys_id": "THAR.LX-0009-Charging System-Open Circuit Voltage Test",
+ "systems": "Charging System",
+ "sub_systems": "Open Circuit Voltage Test",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1118,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0009-Open Circuit Voltage Test-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": " Open Circuit Voltage Test Turn ON the head lamp high beam for 30 seconds to remove any surface charge. Digital voltmeter checks the battery\u2019s open circuit voltage. Analogue meters do not show accurate readings and should be avoided. Turn OFF the head lamp, disconnect the battery and connect the digital voltmeter across the battery terminals. Note the readings in the voltmeter. A fully charged battery will have an open-circuit voltage based on below table value. Verify the customers concern. Visually inspect the charging system for any noticeable signs of mechanical or electrical damage. If any obvious cause is found, correct the same before proceeding to the next step. Check the electrolyte level. Add distilled water to all the cells which require water. Ensure the electrolyte level between MIN and MAX marks. Refit the vent plugs properly. Topping up should be done with distilled water only. Never use normal water or mineral water to top battery electrolyte. Vent holes should be clear Clean the terminals. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": " Tighten terminals to specified torques. Check battery electrolyte level whenever required. ",
+ "file": null,
+ "display_order": 9
+ }
+ ]
+ },
+ {
+ "procedure_name": "Battery Specifications",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25387.jpg",
+ "display_order": 10
+ }
+ ]
+ },
+ {
+ "procedure_name": "Specific Gravity",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": " Specific Gravity v/s With% Charge v/s With OCV Do battery electrolyte level inspection when required. ",
+ "file": null,
+ "display_order": 13
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 37,
+ "sys_id": "THAR.LX-0009-Charging System",
+ "subsys_id": "THAR.LX-0009-Charging System-Battery",
+ "systems": "Charging System",
+ "sub_systems": "Battery",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B080001.jpg",
+ "myid": 1117,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0009-Battery-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/battery1.png",
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080001.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "The battery is an electrochemical device which converts the chemical energy into the electrical
energy.
The battery (12 V) is designed to function as a resource of electrical energy to supplement the charging system for short durations while the engine is running and when the electrical ncurrent demands of the vehicle exceed the output of the charging system.
",
+ "file": "/files/battery1.png",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25378.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25379.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. Using 10 mm socket spanner, loosen battery positive cable mounting nut and disconnect the cable. Using 13 mm socket spanner, loosen and remove the battery holding clamp mounting nuts. Remove the battery from the vehicle. Install in reverse order of removal. Check for cracks in the battery case and broken terminals which allows electrolyte leakage. Check for any cracked or broken cables/connections, and replace the cables if necessary. Check for corrosion on terminals and dirt/acid on the battery case top. Clean the terminals and the battery case top with mixture of water and baking soda. A battery wire brush tool can also be used to clear heavy corrosion on the terminals. Prevent further corrosion by applying petroleum jelly to the outside of the terminals. The driver airbag module is located in the steering wheel and its function is controlled by the airbag ECU. A bag within the module inflates to protect the driver in the event of a collision severe enough to deploy the system.
The driver airbag module connects to the steering column wiring harness via a rotary coupler called as clock spring. Within the driver airbag module there is a squib which, when given the correct current by the airbag ECU, inflates the airbag by initiating a chemical reaction. In deployment, the airbag inflates within a fraction of a second and then deflate at a controlled rate as the driver body regions; typically head and chest interact with airbag. Vents in the airbag control its deflation.
",
+ "file": "/files/W4A210041.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210029.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/32033.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/32034.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Steering Column Shrouds. Turn the steering wheel to 90\u00b0 counter clockwise direction from the steering wheel straight position and using a screw driver press the RHS DAB lock then release the lock. DAB locks are made up of plastic, ensure to press the locks softly by screwdriver. Turn the steering wheel to 90\u00b0 clockwise direction from the steering wheel straight position and using a screw driver press the LHS DAB lock then release the lock. DAB locks are made up of plastic, ensure to press the locks softly by screwdriver. Gently pull-out the DAB module from the steering wheel. Using a small flat end screw driver release the lock of the DAB electrical connector, then disconnect the DAB and horn electrical connectors. While refit ensure wires are routed out of the snapping zones to avoid damage. Remove the DAB module separately. Install in the reverse order of removal. Inspect the DAB module for any physical damage. Replace if found any Inspect the DAB connector for any damage. The Passenger Airbag Module is a bag within the module inflates to protect the passenger in the event of a collision severe enough to deploy the system and located on LH side of Instrument panel, above the glove box and its functioning is controlled by the airbag ECU.
Within the passenger airbag module is a squib which, when given the correct current by the airbag ECU, inflates the airbag by initiating a chemical reaction. In deployment, the airbag inflates within a fraction of a second and then deflates at a controlled rate as the passenger body regions; typically head and chest interact with airbag. Vents in the airbag control its deflation.
",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210035.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210045.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/32012.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/32013.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A080024.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Glove Box Assembly. Remove the IP grab handle cover. Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts. Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220023.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting screws. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220024.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle. Partially detach the door edge beading and using a trim removal tool, remove the IP LH side cover. By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt. Torque : 8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220076.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220066.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector. Take out the IP LH side top cover with Passenger air bag from the IP. Using a 10 mm ring spanner, loosen and remove the air bag mounting bolt from IP top cover. Torque :4.5\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210046.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Expand the PAB module holder both sides using screw driver and detach the PAB separately from IP top cover. Install in the reverse order of removal. Inspect the PAB module for any damage. Replace if found any. Inspect the PAB module connector for any damage. Inspect the PAB module trim for any damage. The Airbag ECU is installed on the floor panel under the floor console. It deploys the proper Airbag according to the signals from the impact sensors. This ECU communicates with other ECU\u2019s through CAN directly. Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Front console assembly. For additional information refer to Front Console Assembly R&R section. Using star screw driver remove the Airbag ECU Cover screw from airbag ECU. Disconnect the SRS/ Airbag ECU electrical connectors. Using a 10 mm socket spanner, loosen the SRS/ Airbag ECU mounting nuts on the floor panel. Torque :8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210052.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the SRS/ Airbag ECU from the body. Install in the reverse order of removal. Inspect the airbag ECU for any damage, replace if found any. Inspect the airbag ECU connectors for any damage. Using a 10 mm Ring spanner & open end spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B080003.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front splash shield lower mounting screws. Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts. Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield. Disconnect the front Crash sensor electrical connector. Using a 10 mm socket spanner, loosen and remove the front Crash sensor mounting bolt from the vehicle. Torque :8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210057.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the front crash sensor from the vehicle. Install in the reverse order of removal. Inspect the front crash sensor for any damage. Replace if found. Using vehicle key open the fuel filler door. Rotate fuel filler lid cap anti-clock wise direction and remove the cap. Using 10 mm socket spanner unscrew fuel filler neck mounting bolts. Torque : 5 \u00b1 1.0 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner loosen hose clamp and remove fuel filler hose pipe end and detach the hose. Torque : 6 \u00b1 1.0 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect fuel vent and fuel vapour line quick couplers. Disconnect fuel filler hose routing clip and remove the hose from vehicle. Refit in the reverse order of removal. Inspect fuel filler pipe assembly for any physical damage, replace if found any. Inspect fuel filler pipe assembly for any leakage. Rectify if found any. Fuel Delivery Module delivers the fuel to the low pressure line and to measure the fuel level in the tank. Fuel delivery module consists ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040092.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Float assembly for fuel level status. An electric motor with in build reservoir for pumping the fluid at a pressure of 4 bar from the tank to the fuel rail. An fuel-pressure regulator valve for regulating the fuel pressure. The entire fuel delivery module is immersed in fluid and the electric motor is lubricated by fuel itself. Remove Fuel tank assembly. Disconnect the FDM electrical connector. Remove fuel tank protection cover screw nuts and detach cover from tank. Press the lock and disconnect the fuel supply line and return line pipe from the fuel delivery module and remove the hoses from the fuel tank. Using shaft and mallet carefully hammer on the FDM lock in counter clock wise direction and release it. Carefully remove FDM unit from fuel tank. Install in the reverse order of removal. Always replace the O ring with a new one once FDM removed. Ensure the FDM top flange extension should be matched with the arrow mark on the fuel tank shell as shown in the above illustration Using a suitable metal shaft and hammer, tap the FDM lock ring to get properly lock. Inspect fuel delivery module for any damage. Inspect the float assembly operation and for any damage. Fuel System Low Pressure Circuit Test Gauge ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040231.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Fuel System Low Pressure Circuit Test Gauge tool kit is used to diagnose Fuel System Low pressure circuit related concerns only. Without removing FDM Assembly or Fuel Tank assembly from vehicle, we can able to check the Fuel Delivery Module supply pressure. Any blockages/ choke or air entrapment in Fuel line low pressure circuit can be diagnosed by using this Kit. Above steps are for removal of Residual pressure in Gasoline vehicles. Detach the fuel line quick coupler from the fuel supply pipe inter connection end. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Detach the fuel line quick coupler from the FIP. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Engage the Female adapter of gauge with the fuel supply pipe interconnection (Filter to FIP) Qwik fix connector. Connect the male Qwik fix connector of gauge with the FIP inlet. Turn the Ignition ON, FDM starts operating. Note down the maximum pressure reading. Allowable pressure Range of New Thar Gasoline vehicles : 5.2 to 5.4 bar. Turn the Ignition OFF and remove the Fuel Gauge. Connect the fuel line to FIP Inlet pipe and fuel supply pipe interconnection. The fuel tank is a reservoir for the fuel and incorporates the Fuel delivery module inside Disconnect fuel vent hose quick coupler from gasoline tank. Using hose clamp plier release fuel filler hose spring band clamp and disconnect the hose fuel tank endr. Disconnect fuel vapour hose quick coupler from gasoline tank fuel filter side. Disconnect the fuel vapour quick couplers in the tank supply end. Disconnect the fuel tank supply pipe quick coupler. Disconnect the fuel tank return hose quick coupler. Disconnect fuel tank electrical connector. Provide Jack to support the fuel tank. Using 13 mm socket spanner unscrew fuel tank mounting bolts. Torque : 55 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the tank Assembly from vehicle. Install in the reverse order of removal. Check for fuel leakage in the fuel tank. Check for any external damage, if found please replace. Disconnect fuel rail pressure sensor electrical connector. Before working on the high pressure side fuel components (Fuel Injection Pump, High Pressure Pipe, Fuel Rail & Injectors) turn the engine off, disconnect fuel supply hose quick coupler at FIP end and wait for Ten minutes. The fuel system is a non \u2013 return fuel system and fuel pressure within the system is very high. Failure to follow above instruction will result in personal injury Eye protection and a mask must be worn at all times while working near any fuel related components. Failure to follow this instruction will result in personal injury Using 24 mm deep socket spanner, Loosen and remove fuel rail pressure sensor. Torque : 25 \u00b1 3.0 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040026.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal. Fuel Rail sensor should be remove & refit only 5 times, ensure to replace New Assembly beyond 5 times Inspect the rail sensor for any damage. Replace if found. Inspect the rail sensor for any damage. Replace if found. Disconnect FDM electrical connector routing clip and detach WH. Detach the fuel tank vapour pipe from routing and tank end. Drain the fuel from the tank. Remove fuel tank bracket mounting push clips and detach the bracket. Refill the fuel in the tank. Install in the reverse order of removal. Check for fuel leakage in the fuel tank Check for any external damage, if found please replace. Check for free movement of float assembly without any restriction. Fuel System Low Pressure Circuit Test Gauge ",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A040231.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Fuel System Low Pressure Circuit Test Gauge tool kit is used to diagnose Fuel System Low pressure circuit related concerns only. Without removing FDM Assembly or Fuel Tank assembly from vehicle, we can able to check the Fuel Delivery Module supply pressure. Any blockages/ choke or air entrapment in Fuel line low pressure circuit can be diagnosed by using this Kit. This high pressure fuel line connects High pressure pump with fuel rail and supplies compressed high pressure fluid to fuel rail. Using 17 mm open end spanner loosen the HP pipe mounting from FIP and common rail ends. Torque : 22.5 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040061.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before working on the high pressure side fuel components (Fuel Injection Pump, High Pressure Pipe, Fuel Rail & Injectors) turn the engine off, disconnect fuel supply hose quick coupler at FIP end and wait for Ten minutes The fuel system is a non \u2013 return fuel system and fuel pressure within the system is very high. Failure to follow above instruction will result in personal injury Eye protection and a mask must be worn at all times while working near any fuel related components. Failure to follow this instruction will result in personal injury Remove the HP pipe from vehicle. Refit in the reverse order of removal. Inspect the high pressure fuel pipe for any damage. Replace if found any. Inspect the high pressure fuel pipe for leakage, rectify if found. Remove the Fuel Delivery Module Assembly. Press the clip and unlock the sensor from the mount, move the level sensor in upward direction with moderate strength & remove the sensor assembly from the FDM. Detach the wiring from the level sensor housing. By Using suitable pin take out the wiring pins from sensor. Pressing the both sided snap-on tabs of the cable connector through the opening of the housing and cover carefully and simultaneously pull out the wire connectors from float unit. Prior to the Installation, both the wiring connector snap-on tabs have to be bent back to the right position as shown below (By using Knife or suitable tool). Plug the wiring connectors pins on the New sensor housing at appropriate place with moderate force. Ensure to Plug the wiring connectors pins on the New sensor housing at appropriate slots based on wiring colours as shown The firm snap-on of the wire connectors is to be examined by a moderate pulling examination. Attach the wiring from the level sensor housing. Lock the sensor on the mount & refit the sensor assembly on the FDM. Refit the Fuel Delivery Module Assembly. Check for free movement of float assembly without any restriction. Inspect the float assembly for proper working condition. Check for any damage in float assembly, If any damage found replace it. Position the vehicle on 2 post lift/ 4 post lift and turn engine OFF. Press the lock and disconnect the filter inlet hose quick coupler from the filter. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Press the lock and disconnect the filter outlet hose quick coupler from the filter. Remove the fuel filter from mounting bracket lock and remove the filter from the vehicle. Refit the fuel filter in the vehicle on mounting bracket lock. Ensure arrow mark on the fuel filter assembly should be pointing towards vehicle front (Arrow mark indicating that the fuel flow direction towards engine). Always use recommended filter only. Reconnect the fuel filter fuel outlet line quick coupler. All are quick fix connectors, press gently and remove it carefully; avoid seal damages. Reconnect the fuel filter fuel inlet quick coupler. Check and ensure proper fitment of fuel lines, any leakage can lead to fire. Remove High Pressure Pipe (Pump to Rail). Before working on the high pressure side fuel components (Fuel Injection Pump, High Pressure Pipe, Fuel Rail & Injectors) turn the engine off, disconnect fuel supply hose quick coupler at FIP end and wait for Ten minutes. The fuel system is a non \u2013 return fuel system and fuel pressure within the system is very high. Failure to follow above instruction will result in personal injury. Eye protection and a mask must be worn at all times while working near any fuel related components. Failure to follow this instruction will result in personal injury. Using 10 mm socket spanner unscrew oil dipstick guide mounting bolt, nut and keep aside dipstick guide. Torque : 11 \u00b11.0 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect fuel rail electrical connector. Disconnect injector electrical connectors. Using 12 mm socket spanner loosen and remove the fuel rail mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully remove the Fuel Rail Assembly with injectors. Injectors Combustion Seals should be replaced with new ones when ever removing & refitting the Fuel Rail Assembly from the cylinder head. Remove the Combustion Seal by using plastic lever or plastic pliers or Nose plier. The Combustion Seal can be stretched until it breaks or can be removed off the component. When removing Combustion Seal, no metallic fixtures (pliers, fork, scissors, cutter, trimmer) are allowed to be used, which may damage injector sealing surface. Only plastic fixtures can be used Take care not to damage the surface of the injector Inspect the sealing surface and replace the complete injector in case there is a defect on sealing surface (such as a tool mark) properly Clean the Combustion Seal groove & injector tip by bathing it in an appropriate cleaning fluid, before assembling the Combustion Seal. Position the injector in vertical position (O-ring in the upper side) in the cleaning bath for 10 to 15 min, not above the middle of the Valve Body Cleaning fluid must not content acids and/or substances not recommended to get in contact with steel or PA and avoid oil, lubricant, grease Can use P3-Galvaclean20 (Henkel) cleaning fluid with a concentration of 20 to 80 g/l diluted in demineralized water pre heated at 50\u00b0C Cleaning fluid must not get in the connector and/or inside the injector and non metallic parts of the injector Does not use brush, emery paper or ultrasonic device on clean the injector Inspect the sealing surface and replace the complete injector in case there is a defect on sealing surface (such as a tool mark) The surfaces of the new Combustion Seal must be clean and free of grease. The geometry of the groove must not be damaged or modified. Place the Combustion Seal installation special tool on the injector tip. Insert and push the sealing ring by using pushing tool over the sealing ring tool until it snaps into the groove. The seal must be completely free of grease and oil Remove the Combustion Seal installation special tool from injector tip. Insert the injector to the sizing special tool and turn 180\u2070 so that the seal fits well in the groove. Remove Injector from the sizing tool by turning it in the reverse direction. Check that the Combustion Seal has not been damaged during assembly to the injector and ensure seal must fit properly in the relative groove. Inspect the Fuel rail for any damage. Replace if found. Check injectors, Injector clips for any external damage, If found replace. Inspect the Injectors connectors for any damage. Replace if found. Refit in the reverse order of removal. After Installation, Running the engine at idle for few minutes and Check for fuel leakage in fuel rail and injector assembly. If found rectify the same. Carry out Injector routine procedure - using i-SMART. For additional information refer to the diagnostic manual. During assembly in Fuel Rail, no hammers or impact tools should be used which could directly bear on or affect the High Pressure Fuel Injector Fuel Rail Assembly should be remove & refit only 5 times, ensure to replace New Assembly beyond 5 times The Purge valve is a solenoid valve in a plastic housing which is controlled by the EMS ECU. The Purge valve controls the hydrocarbon vapours flow into Intake manifold in accordance with the engine\u2019s operating status. Disconnect the vapour hose quick coupler purge valve end. Using hose clamp plier release vapour hose spring band clamp and disconnect the hose. Disconnect purge valve electrical connector. Detach purge valve from holding bracket on the intake manifold. Refit in the reverse order of removal. Inspect the hose for any physical damage, replace if found any. Inspect the hose for any leakage. Rectify if found any. The high pressure pump (Direct Type) receives drive from intake cam shaft. The rotation of camshaft lifts and releases the roller tappet up and down according to the cam profile. The upward motion of Roller tappet compresses the plunger of pump which pressurizes the fuel and thus high pressure fuel gets feed to fuel rail through the delivery port on the top Once the roller tappet comes down, plunger comes back to its normal position. This cycle is continued to provide high pressure fuel to fuel Rail Using 17 mm open end spanner loosen the HP pipe mounting from FIP and common rail ends Torque : 22.5 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040061.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Before working on the high pressure side fuel components (Fuel Injection Pump, High Pressure Pipe, Fuel Rail & Injectors) turn the engine off, disconnect fuel supply hose quick coupler at FIP end and wait for Ten minutes. The fuel system is a non \u2013 return fuel system and fuel pressure within the system is very high. Failure to follow above instruction will result in personal injury Eye protection and a mask must be worn at all times while working near any fuel related components. Failure to follow this instruction will result in personal injury Remove the HP pipe from vehicle Press the lock and disconnect the fuel inlet pipe pump end All are quick fix connectors, press gently and remove it carefully; avoid seal damages Disconnect FIP electrical connector Disconnect FIP electrical connector Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect FIP electrical connector Replace the FIP O Ring with a new one when installing Remove roller tappet from the high pressure pump housing Refit in the reverse order of removal While Installation, Ensure that the projection in the roller tappet should be matched with slot in the cylinder head for correct orientation Inspect the FIP for any physical damage, replace if found any Inspect the Roller Tappet for any physical damage, replace if found any It is an electromechanical device, which is used to inject the fuel to the cylinder head. The quantity of fuel injected in the combustion chamber is controlled by an electronic control module. Before working on the high pressure side fuel components (Fuel Injection Pump, High Pressure Pipe, Fuel Rail & Injectors) turn the engine off, disconnect fuel supply hose quick coupler at FIP end and wait for Ten minutes. The fuel system is a non \u2013 return fuel system and fuel pressure within the system is very high. Failure to follow above instruction will result in personal injury. Eye protection and a mask must be worn at all times while working near any fuel related components. Failure to follow this instruction will result in personal injury. Remove the Fuel Rail Assembly. Pull & Remove the injector locking clips from the dedicated groove on the Injectors and detach the fuel injectors from the fuel rail. Injector Clip, O-ring & Backup ring should be replaced with new ones when ever removing & refitting the Fuel Injector from the Rail Assembly Injectors Combustion Seals should be replaced with new ones when ever removing & refitting the Fuel Rail Assembly from the cylinder head If Injector/Injectors struck with Cylinder Head and not able to remove from head, Injector can be removed by using Injector removal tool and follow the below steps Insert the Injector removal tool twisting shaft and lateral sliding it onto injector and making sure the extraction socket of twisting shaft below the extraction bump on injector. Assemble the torsion pin with twisting shaft, twist it clockwise and counter clockwise. Ensure not to apply a more torque (Not greater than 5 Nm) Extract the injector from the cylinder head pulling it out with the tool. if not able to remove injector from cylinder head, extract the torsion pin and insert the shot mass on to twisting shaft. Then insert torsion pin. Hit the torsion pin with the shot mass to extract the injector from the cylinder head. Extract the injector together with spring clip after injector separate from the cylinder head. An excessive impulsive application of the pull-out load by an extraction tool might damage the injector in an irreversible way which may not be apparent visually. In this case it is strongly recommended to replace the injector Remove the O-ring by using hand or plastic lever or plastic pliers. The O-ring can be stretched until it breaks or can be removed off the component. Remove the Backup ring by using hand or plastic pliers. When removing O-ring, Backup ring, no metallic fixtures (pliers, fork, scissors, cutter, trimmer) are allowed to be used, which may damage injector sealing surface. Only plastic fixtures can be used Take care not to damage the surface of the injector Inspect the sealing surface and replace the complete injector in case there is a defect on sealing surface (such as a tool mark) Install the New Backup ring by gently rolling it over the O-ring Adapter upper collar and position it into the proper position inside the groove. Check that the Backup ring fit properly in the relative groove Install the New O-ring by gently rolling it over the O-ring adapter upper collar and position it into the proper position inside the groove. The O-ring must be always at the fuel side, the back up ring must be below the O-ring respect to the fuel side Inspect the Fuel rail for any damage. Replace if found. Check injectors, Injector clips for any external damage, If found replace. Inspect the Injectors connectors for any damage. Replace if found. Insert the injector locking clips in the dedicated groove on the Injectors and attach the fuel injectors on the fuel rail. Position the injector in front of the injector cup in such a way that the rib of the spring clip is aligned with the Ushape feature on the external of the injector cup Insert the injector into the fuel rail cup up to the complete engagement of the clip rib over the U-shape feature Inspect accurately the sealing surfaces of the fuel rail prior to reassemble the injectors. In case of defect (such as a tool mark) replace the fuel rail Refit the Fuel Rail Assembly.For additional information refer to Fuel Rail Assembly - R&R section. After Installation, Running the engine at idle for few minutes and Check for fuelleakage in fuel rail and injector assembly. If found rectify the same. Carry out Injector routine procedure - using i-SMART. For additional information refer to the diagnostic manual. During assembly in Fuel Rail, no hammers or impact tools should be used which could directly bear on or affect the High Pressure Fuel Injector Fuel Rail Assembly, Injector should be remove & refit only 5 times, ensure to replace New Assembly beyond 5 times Canister (charcoal filter) traps the hydrocarbon vapours from the tank and supply this hydrocarbon vapours to intake manifold by Purge valve for rich air fuel mixture. Disconnect vapour line quick couplers canister end. Using 13 mm socket spanner unscrew canister mounting bolts. Torque : 10 \u00b1 2.0 Nm Detach fuel supply hose from canister and take out canister. Refit in the reverse order of removal. Inspect Canister for any physical damage, replace if found any. Inspect Canister for any leakage. Rectify if found any. For additional information refer to Wheel \u2013 R&R Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the tyre from the rim. For additional information refer to Tyre - R&R Section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a T10 Socket Spanner, loosen and remove the TPMS sensor mounting screw and detach the sensor. The TPMS and Valve cannot be replaced separately.These can be replaceable as assembly. The valve must be positioned just left of the start position to avoid sensor damage. Do not touch the sensor with the tyre tool. Starting to mount the tyre from the valve location is a wrong fitment. The fixing tool/ stem may hit the sensor and damage it. Start from the opposite direction. By using suitable TPMS removal/Installer tool, remove the valve from the rim. Install in the reverse order of removal. Ensure that the TPMS Sensor is not damaged while removing the tyre. Check the tyre inner surface for cuts and punctures. TPMS Manual Learning is the process by which the identities of 5 sensors installed inside the tyres are learnt & programmed in to the memory of receiver module. It should be mandatory to performe on any of the following conditions or operations done. Any of the old TPMS sensors are damaged & sensors are replaced. Any of the tyre among 5 tyres are replaced. if any of the tyres or set of tyres are shuffled or swapped in position. If tyres rotation operation is performed. If observed that the alert indications in TPMS screen are not correlating with respect to their actual position in vehicle. Once the manual learning is initiated the sensors inside the tires needs to triggered by leaking the air from each tire one at a time and should be completed within 90 secs post to each event for learning all 5 tires. Do not perform Manual learning process at the same time on two vehicles with in the radius of 20 meters. It is mandatory that manual learning of tyres should follow the sequence of \u2018front left tyre position, front right tyre, rear right tyre, rear left tyre and spare tyre\u2019. It is required to ensure the tires are having pressure > 32 psi & < 36 psi before initiating the manual learning process. It is mandatory that manual learning of tyres should follow the sequence of \u2018front left tyre position, front right tyre, rear right tyre, rear left tyre and spare tyre\u2019. It is required to ensure the tires are having pressure > 32 psi & < 36 psi before initiating the manual learning process. Post to manual learning all tire should be filled with recommended tyre pressure value. At any point of time during the learning process if learning takes more than 90 secs of time for each tire position then the system shall exit the learning mode and show the Learning not successful screen. At a time, only one tyre can be swapped with the spare wheel and then follow the learning procedure. Position the vehicle on a flat surface. Press the Scroll Up arrow button on Driver side switch bank and simultaneously turn the ignition ON. Wait for cluster\u2019s tachometer & speedometer self-check rotation and then release the arrow button. Identifying weather the learning is initiated. Infotainment will show popped out screen TPMS Learning screen. TPMS telltale in cluster shall keep blinking. Three vehicle siren chirps will be heard. If failed to enter in to manual learning mode. Try initiating the manual learning once again. Check if reverse gear is engaged, if engaged disengage it. Check MBFM, Infotainment & Cluster software versions. Check if variant coding is done in all three. Check if Scroll Up arrow button on Driver side switch bank button is working fine. TPMS learning procedure must be done in the below sequence: Front left tyre Front right tyre Rear right tyre Rear left tyre Spare tyre Start leaking the air from front left tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If front left tyre is learned 1 siren chirp sound is heard and FL tyre shows learned in infotainment system. Start leaking the air from front right tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If front right tyre is learned 1 siren chirp sound is heard and FR tyre shows learned in infotainment system. Start leaking the air from rear right tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If rear right tyre is learned 1 siren chirp sound is heard and RR tyre shows learned in infotainment system. Start leaking the air from rear left tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If Rear left tyre is learned 1 siren chirp sound is heard and RL tyre shows learned in infotainment system. Start leaking the air from the spare wheel tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If spare tyre is also learned then 1 siren chirp sound is heard and ALL tyres show learned at respective tyre positions and \u2018All tyres Learned successfully\u2019 in the center of the screen. At any point of time during the learning process, if learning takes more than 90 seconds of time for each tyre position then the system shall exit the learning mode and show the \u201cLearning not successful\u201d screen. After tyre rotation or TPMS sensor replacement, TPMS must be learnt,otherwise the system will show TPMS malfunction indicator. TPMS learning need to be carried out whenever : Tyre rotation happens. 2 or more wheels are swapped. TPMS sensor is replaced. MBFM is replaced. The TPMS should not be used as a tyre pressure gauge while adjusting vehicle tyre pressure. No two vehicles should be done with manual learning process at a time in same location with in radius of 20 meters. Post to manual learning all tire should be filled with recommended tyre pressure value Verify the customer concern. Visually inspect the transfer case for any noticeable signs of mechanical damage. If an obvious cause is found during the inspection, correct the same before proceeding to the next step. If the cause is not visually evident, verify the symptom and refer to troubleshooting chart. Mechanical ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Check for any oil leakage in the transfer case. Check the yoke, flange and drive gear for any damage. Check for loose mounting bolts. Remove the gear shifter level knob and 4WD selection knob by rotating them in anticlock wise direction. Using trim removal tool, remove the gear selection rod cover with trim. For AT Variants top trim removal follow (Steps 3 - 8) : Pull and fold the gear shifter boot from gear shifter bezel . Partially detach the bezel from the console. Excessive pull may leads to damage of the electrical connector. Disconnect the AT gaiter electrical connector from the bezel. Carefully remove the bezel trim from the TGS lever. Handle bezel assembly carefully to prevent it from damage or scratches. Using trim removal tool, carefully remove the floor console top trim with transfer case shifter boot. Detach the transfer case cable abutment from the shifter bracket by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Using 13 mm socket spanner unscrew transfer case shifter lever assembly mounting nuts. Take out the shifter and tilt the lever assembly gear shifter lever side to remove the TC shifter cable 'R' clip. Detach the TC shifter cable from shifter assembly. Remove the transfer case shifter from the vehicle. Inspect the transfer case shifter for any damage. Replace if found any. Position the transfer case cable on shift lever bracket. Install the shifter cable locking R clip. Position the transfer case shifter lever assembly. Position the transfer case shifter lever at 2H position. Ensure that the transfer case link should be in 2H position on transfer case (Extreme Rear end position from front of the vehicle). Refit the transfer case cable abutments on shift lever bracket. Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. Refit the shifter lever assembly mounting nuts. Tighten the mounting nuts to specified torque value. Torque value :22.51\u00b14 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from '2H' to other range. If Shifting not smooth Carry-out Transfer Cable setting. For AT Variants top trim Installation follow (Steps 8 \u2013 12) : Connect the AT gaiter electrical connector with the bezel. Refit the bezel trim with shifter bezel. Handle bezel assembly carefully toprevent it from damage or scratches Unfold the gear shifter boot and refit the boot with gear shifter bezel. Refit the 4WD selection knob by rotating it in clock wise direction. Refit the Manual transmission gear selection rod cover with trim. Refit gear shifter level knob and 4WD selection knob by rotating them in clock wise direction. Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from 'N' to other range. Inspect that engine can be started with shift lever only 'N' or 'P', but not in other range (For AT variants). Inspect that indicating lamp can be turned on correctly in PRND positions (For AT variants). Using MST 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the transfer case shifter cable from the transfer case ball pins. Detach the transfer case cable abutment from the cable bracket on transmission by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Using 10 mm socket spanner unscrew shifter cable grommet mounting bolts on fire wall. Remove the gear shifter level knob and 4WD selection knob by rotating them in anticlock wise direction. Using trim removal tool, remove the gear selection rod cover with trim For AT Variants top trim removal follow (Steps 6 \u2013 11) : Remove the 4WD selection knob by rotating it in anti-clock wise direction.Pull and fold the gear shifter boot from gear shifter bezel. Partially detach the bezel from the console. Excessive pull may leads to damage of the electrical connector. Disconnect the AT gaiter electrical connector from the bezel. Carefully remove the bezel trim from the TGS lever. Handle bezel assembly carefully to prevent it from damage or scratches. Using trim removal tool, carefully remove the floor console top trim with transfer case shifter boot. Remove the floor console side trim mounting screw rivet and remove the trim both sides. Detach the transfer case cable abutment from the shifter bracket by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Detach the transfer case cable from the cable bracket routing clamp. Using nose plier, remove cable cross pin from the transfer case shifter and detach shifter cable. Keep the Transfercase shifter in 4L position while remove R Clip. Detach the cable from lever and take out from vehicle. Keep the Transfercase shifter in 2H position while remove the cable. Inspect the transfer case for any damage. Replace if found any. Position and route the cable inside the vehicle. Move shifter to 2H position and attach the cable with the shifter lever. Keep the Transfercase shifter in 2H position while refit the cable. Refit shifter cable R clip with the transfer case shifter cable. Keep the Transfercase shifter in 4L position while refit R Clip. Attach the transfer case cable abutment with the shifter bracket by pressing locking clip. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Attach the transfer case cable with the cable bracket routing clamp. Refit the floor console side trim and install the mounting screw rivet. Refit the gear selection rod cover with trim. Refit gear shifter level knob and 4WD selection knob by rotating them in clock wise direction. For AT Variants top trim Installation follow (Steps 9 \u2013 13) : Connect the AT gaiter electrical connector with the bezel. Refit the bezel trim with shifter bezel. Handle bezel assembly carefully to prevent it from damage or scratches. Unfold the gear shifter boot and refit the boot with gear shifter bezel. Refit the 4WD selection knob by rotating it in clock wise direction. Refit shifter cable grommet and install the mounting bolts on fire wall. Ensure the cable grommet should get assemble from outside of the cabin. Torque Value : 10 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Position the transfer case lever at 2H position on transfer case (Extreme Rear end position from front of the vehicle). Refit the transfer case cable abutments on transmission cable brackets. Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. For adjust cable length, move the cable quick adjuster outer cover in forward direction and unlock the QA clip. Adjust the cable length to fix the cable on link ball pin. After adjusting the length, position the quick adjuster body on link ball pin. Once quick adjuster body snap on ball pin, press the QA clip towards arrow mark shown to lock it fully and release the cable quick adjuster outer cover. Ensure the proper locking by confirming/ hearing the click noise while install. Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from '2H' to other range. Using 10 mm socket spanner, Loosen the battery negative terminal mounting nut and disconnect the cable. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Rear Propeller Shaft Assembly. For additional information refer to Rear Propeller Shaft R&R Session. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 8 mm socket spanner, loosen and remove the front propeller shaft mounting C clamp bolts from the transfer case. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the transfer case electrical connector. Using a 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool , detach the transfer case cable from the transfer case ball pins. Pressing locking clip and detach the transfer case cable abutment from the cable bracket on transmission and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Provide a jack to support the transmission. Using a 12 mm socket spanner, loosen and remove the transmission bed mounting bolts. Torque: 70\u00b15 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 14 mm, 15 mm socket and ring spanners, unscrew transmission cross member mounting bolts, nuts and detach it. Torque: 65 \u00b110.0 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using a 15 mm socket spanner, loosen and remove the transfer case mounting nuts Torque: 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110044.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Heading",
+ "content": "For Automatic Transmission
",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Torque Value",
+ "content": "Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110042.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using 12 mm ring spanner unscrew transfercase rear facing top mounting bolt.",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Torque Value",
+ "content": "Torque : 45 \u00b1 5.0 Nm",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110043.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using 12 mm ring spanner unscrew transfercase rear facing top mounting bolt.",
+ "file": null,
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A110029.jpg",
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Remove the transfer case from the vehicle. Install in reverse order of removal While Installation of transfer case cable abutments on transmission cable brackets, Ensure the cable abutment legs are properly snapped by hand on the bracket by confirming/ hearing the click noise while install. After Installation of Transfer Case Assembly on vehicle, Carry-out below cable setting Procedure. For adjust cable length, move the cable quick adjuster outer cover in forward direction and unlock the QA clip. Adjust the cable length to fix the cable on link ball pin. After adjusting the length position the quick adjuster body on link ball pin. Once quick adjuster body snap on ball pin, press the QA clip towards arrow mark shown to lock it fully and release the cable quick adjuster outer cover. Ensure the proper locking by confirming/ hearing the click noise while install. Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from '2H' to other range. Check transfer case oil level & top up if required. Inspect the transfer case for any damage. Replace if found any For additional information refer to Transfer case fluid Drain & Filling Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Transfer case from the vehicle. Position the transfer case on the suitable Wooden/ Nylon blocks. Ensure the oil is drained prior to disassembly of the transfer case. Using a Special tool MST 203 Companion Flange Holding Tool, hold the transfer rear flange. Using a 30 mm socket spanner, loosen and remove rear flange center nut. Torque Value : 340 - 370 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120130.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a magnetic stick, take out flange washer and remove seal from transfer case rear flange. Ensure the use New washer & Seal while installation. Using a mallet, remove the transfer case rear flange. Use suitable 2 Jaw puller to remove the flange, In case of flange not able to remove by mallet. Using a 10 mm square bit spanner, remove the transfer case draining & filling oil plugs from the cover. Using a 15 mm socket spanner remove the assembly cover mounting bolts and remove the mounting bolts & identification tag. Separate the front assembly cover and the rear case assembly. To avoid damage of the metal surface, apply limited force to the bosses on the cover and the transfer case while breaking the sealant bond. Using a flat end screw driver, remove transfer case Rear output shaft oil seal from the cover. Remove the Spacer from the cover. Separate the return spring from the front assembly cover by pulling them outwards. Using flat screw driver& circlip plier, remove the ball bearing snap ring. Rotate the cover and by using MST 0707BBA0003ST - Universal Mandtral remove the ball bearing from the cover. By using suitable Internal puller, pull out the needle bearing from the cover. Care must be taken not to damage the metal surface while removing the needle bearing. Position the transfer case casing and remove the shift collar hub from the output shaft. Remove the 2W-4W lock up assembly and lock up fork together from output shaft and separate lock up fork from the 2W-4W lock up assembly. To dismantle 2W-4W lockup assembly, remove snap ring, lock up hub return spring from lock up collar. Using a circlip plier & flat screw driver, remove the snap ring from the output shaft and remove the spacer. Remove the drive chain with sprocket and drive sprocket from the output shaft. Separate the drive chain, driven sprocket and drive sprocket. Remove the magnet from the slot in the case. Remove the coupler from the case. Remove the output shaft and the gear rotor (Gearotor) pump from the case. Rotate and align the guide pin of the shaft to the slot on the pump body and Separate the gear rotor pump and strainer assembly from the output shaft. By using nose plier, remove the hose clip and remove the hose from pump and remove the strainer. Remove the rail shaft assembly from the case. Remove the reduction hub and the reduction fork from the case. Separate the reduction hub and the reduction fork. Remove the two shift fork facings from the shift fork assembly (if required). Using a Special tool MST 203 Companion Flange Holding Tool, hold the transfer case output shaft yoke. Using a 30 mm socket spanner, loosen and remove rear output shaft yoke center nut. Torque Value : 340 - 370 Nm ",
+ "file": null,
+ "display_order": 93
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A120141.jpg",
+ "display_order": 94
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "Description",
+ "content": "Using a magnetic stick & flat screw drive , take out flange washer and remove seal from transfer case output shaft yoke. Ensure the use New washer & Seal while installation. Using a mallet, remove the transfer case rear flange. Use suitable 2 Jaw puller to remove the flange, In case of flange not able to remove by mallet. Remove the lower output shaft from the casing. Using a 15 mm socket spanner, remove the adapter assembly, input shaft and carrier assembly bolts. Take out the adapter assembly with input shaft and carrier assembly. Using an outer circlip plier, Expanding the long ends snap ring unlock the bearing lock circlip and remove the input shaft and carrier assembly. Remove snap ring and oil seal from adapter assembly. Remove the input shaft bearing retaining ring. Remove the ASM Carrier from the input shaft. Remove the sun gear snap ring from ASM Carrier. Remove the thrust plate & sun gear from ASM Carrier. By using suitable Internal puller, remove the copper bush from the input shaft. By using suitable Internal puller, remove the needle bearing from the input shaft. By using 17 mm Open end spanner, remove the Breather (For MT variants located at Adapter plate & for AT variants at Adapter case assembly). By using 13 mm socket spanner, remove the hexagonal nut of the shift shaft. By using T25 torx spanner, remove the transfer case and shift cam torx screws. By using flat end screw driver & mallet, remove the clip ring and pull out shift shaft & lever. Remove shift lever from shift shaft. By using flat end screw driver, remove the \u2018o\u2019 ring from shift shaft. Remove 4L assist spring and roller, shifter cam. Remove plunger and spring from the transfer case. By using 24 mm ring spanner, remove 4WD indicator switch from the transfer case (If required). By using flat end screw driver, remove the oil seal from the assembly case. By using flat end screw driver, remove the retaining ring from the assembly case. By using MST 0707BBA0003ST \u2014 Universal Mandtral remove the ball bearing from the case. By using cutting plier, remove the dowel pin from transfer case. Do not remove the ring gear shown in the below figure from the case. Before cleaning, check the magnet for the presence of metal particles which indicate internal chipping of the transfer case. Using a cleaning solvent, clean the old oil and dirt deposits. Before cleaning, check the magnet for the presence of metal particles which indicate internal chipping of the transfer case. After cleaning dry the parts with low pressure (20 psi maximum) compressed air. Lubricate the ball bearings and needle bearing with ATF oil. Protect lubricated bearings from dust. Always replace the hose coupling, O-ring , oil seal and flange/Yoke Nut with new parts. Visually check all the parts for damage. Referring to normal gear tooth face, specifically inspect the uneven wear and chips of gear tooth. Replace or repair if necessary Insert dowel pins to the ring gear casing Dropping of heavy/large objects will damage the part and cause personal injury. Press the ball bearing to the front casing by using MST\u2019s (0707AUA0005ST - Trasfer case Case Covers Ball Bearing Pressing tool) & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Check the ball bearing for functionality prior to installation. Using a snap ring removal tool/screw driver install the retainer ring to the front casing. Install the new output oil seal into the case by using 0707BBA0001ST-Transfer Case Output Shafts Oil Seal Installer & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Check the oil seal prior to installation. In case of any external damages are observed, then replace the oil seal. Install new \u2018O\u2019 ring on the shift shaft and lubricate it. Refit the shift shaft in to the shift lever. Position spring and plunger in the hole of the transfer case. Partially Insert star splined end of the shift shaft into the transfer case. Position shift cam into transfer case with flat end of cam approximately parallel with front face of case (as shown in the picture). Install clip ring in groove near inside end of shift shaft. Install 4L assist spring in groove of shift cam and slot of transfer case. Refit the transfer case and shift cam torx screws by using screwdriver. Make sure that shift shaft is fully engaged so that second screw end enters groove in shaft. Refit the hex nut of the shift shaft, Torque tighten mounting nut to specified value. Install 4WD indicator switch to transfer case. Press the needle bearing into the input shaft by using MST 0707AUA0003ST - T Case Input Shaft Sleeve Pressing tool & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Press the new sleeve bearing into the input shaft by using MST 0707AUA0004ST - T Case Input Shaft NRB Pressing tool & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Refit the input shaft to the carrier assembly by matching the splines. Install the thrust plate, thrust washer onto the input shaft. Position and press the bearing onto the input shaft by using a MST 0707AUA0002ST - T Case Input Shaft Ball Brg Pressing tool. Install the retaining on the input shaft assembly by using circlip plier. Invert from adapter assembly. Install snap ring by making sure that snap ring is correctly install in the groove. Using a circlip plier expand the snap ring and insert the carrier assembly with input shaft to the adapter case. (Ensure that planet carrier assembly on the work bench is such that the retaining rings\u2019 mounting groove faces upward. Press spiral the pin into the front adapter. Using a suitable MST, refit an oil seal from the carrier assembly body by using a MST 0707BAJ0001ST \u2014 Transfer Case Input Shaft Oil Seal Installer - MT (or) 0707BAJ0001ST \u2014 Transfer Case Input Shaft Oil Seal Installer - AT & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Apply a 1.6 mm bead of sealant on the mounting face for the transfer case. Refit the adapter input shaft and carrier assembly to the case, and using a 16 mm socket spanner, tighten the mounting nuts to specified torque. Refit the breather nipple. Position the output shaft in the transfer case. Position the output shaft in transfer case, and install the end yoke assembly, seal, washer and the lock nut. Using a suitable MST yoke holder, socket spanner and torque wrench, tighten the front flange mounting lock nut to specified torque. Install the two forks facing on the reduction shift fork assembly. Install the reduction hub in to the fork. Refit the reduction hub and reduction shift fork into the planet carrier. Slide roller of fork in to the cam groove. Insert shift rail in reduction fork bore, to match with case bore. Align rotor slot of the pump and slot of the pump body in line. Align the slide the pump assembly on output shaft over pump pin. Align the guide pin of the shaft to the slot on the pump body and slide the pump assembly onto the output shaft over pump pin. Assemble the strainer and hose to the gear rotor pump. Install the output shaft and gear rotor pump assembly into the reduction hub housing by matching the splines. Couple strainer with case and insert the magnet into the transfer case slot. Refit the magnet into body. Position the drive sprocket to the rear output shaft end and driven sprocket to the front output shaft end. Install the drive chain onto the sprockets. Holding each sprocket with drive chain tight and parallel with transfer case, install the drive chain assembly to the output shaft. Holding each sprocket with the drive chain tight and parallel with the transfer case, install the drive chain assembly to the output shaft. Rotate the driven sprocket slightly to engage splines on the front output shaft. Install the spacer to the front output shaft. Install the snap ring into the groove of the front output shaft. Install the lockup hub and return spring to the lockup collar and insert the snap ring. Install new facings to the fork. Engage the lockup fork in the groove in 2WD-4WD lockup assembly and slide this group down over output shaft and rail shaft. Check the ball bearing prior to installation. In case of any external damages are observed, then replace the ball bearing. Install shift collar engaging splines on output shaft and in 2WD-4WD lockup assembly. Position the cover with the open end facing up on the table. Position the end of the needle bearing with the identification mark and up the press into the cover by using a suitable MST 0707AUA0006ST\u2014 T Case Rear Cover NRB Pressing tool & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Press the ball bearing into cover by using MST 0707AUA0005ST \u2014 T Case Covers Ball Brg Pressing tool & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Install snap ring over the ball bearing into cover by using screw driver or circlip plier. Install the return spring over rail shaft in the transfer case. Position the cover with the open end facing down on the table. Install the spacer over output shaft spline in the cover assembly. Press the new oil seal into the cover assembly by using MST 0707BBA0001ST \u2014 Transfer Case Output Shafts Oil Seal Installer & 0707BBA0003ST \u2014 Universal Mandtral - Oil Seal/ Bearing Installer. Apply 1.6 mm bead of Loctite RTV598 to the transfer case mounting surface. Installation of cover, align the transfer case with cover. Do not use excessive force. Align the cover holes with the transfer case dowel pins. Align the cover bearing with output shaft. Align the cover blind hole with rail shaft and make sure that return spring is not cocked. Refit the front and rear housing cover mounting bolts along with identification tag and torque tighten the bolt to specified value. Install the two oil plugs to the cover, torque tighten the nut to specified value. Install the flange and washer and lock nut to the output shaft. Do not fully tighten the bolts at this stage. Holding the flange by flange holder torque tighten the nut to specified value. Refit the Transfer case on the vehicle. For additional information refer to Transfer case fluid Drain & Filling Section. ",
+ "file": null,
+ "display_order": 378
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 95,
+ "sys_id": "THAR.LX-0009-Transfer Case",
+ "subsys_id": "THAR.LX-0009-Transfer Case-Transfer Cable Setting",
+ "systems": "Transfer Case",
+ "sub_systems": "Transfer Cable Setting",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A120016.jpg",
+ "myid": 1207,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0009-Transfer Cable Setting-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Transfer Cable Setting",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Position the transfer case shifter lever at 2H position. Ensure cable cross pin is properly fitted on transfer case shifter. Ensure the transfer case cable abutment is properly fitted on shifter bracket. Ensure the transfer case cable abutment is properly fitted on transmission cable bracket. Using a 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the transfer case cable from the transfer case ball pins. Ensure that the transfer case link should be in 2H position on transfer case (Extreme Rear end position from front of the vehicle). For adjust cable length, move the cable quick adjuster outer cover in forward direction and unlock the QA clip. Adjust the cable length to fix the cable on link ball pin. After adjusting the length, position the quick adjuster body on link ball pin. Once quick adjuster body snap on ball pin, press the QA clip towards arrow mark shown to lock it fully and release the cable quick adjuster outer cover. Ensure the proper locking by confirming/ hearing the click noise while install. Inspect that shift lever can be shift smoothly and accurately when shifting shift lever from '2H' to other range. Position the vehicle on a 2 post /4 post lift. Transfer case Oil \u2013 MAHINDRA 'MAXIMILE POWER STEERING FLUID' Genuine Power Steering Fluid.Capacity \u2013 1.2 Litres.Using a 10 mm square bit spanner, remove the oil filling plug from the transfer case. Place a tray beneath the drain plug for collecting the oil while draining. Using a 10 mm square bit spanner, loosen and remove the drain plug. Collect the drained oil in a suitable container. Refit the drain plug. Torque tighten the drain plug to specified value. 34\u00b16 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Fill recommended transfer case fluid with the help of a mechanical pump through filler plug. Ensure that the oil level by insert the 8 mm allen key and check the oil level mark. Refit the filler plug and torque tighten the filler plug to specified torque value. 34\u00b16 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Recommend to use only MAHINDRA 'MAXIMILE POWER STEERING FLUID' Genuine Power Steering Fluid. In case of non-availability of Genuine fluid, SHELL MAKE 'SPIRAX S3 ATF MD3' can be used. In emergency conditions, fluid meeting DEXRON III specification can be used and oil change interval should be at every 40000 km. It is a structure of a pipe, which carries air into the combustion chamber in an engine The primary function of the intake manifold is to evenly distribute the air to each intake port in the cylinder head. Even distribution is important to optimize the efficiency and performance of the engine Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable. Disconnect the purge valve vapor hose quick coupler and disconnect the hose intake manifold end. Pull out the purge valve from holding bracket and hose routing to partially detach purge valve vapor hose. Using hose clamp plier, Release breather hose clamp, routing clip and detach hose intake manifold end. Disconnect MAP sensor electrical connector. Using T25 Torx socket spanner, Unscrew boost pressure & temperature sensor mounting bolt and remove it. Torque : 4 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew engine oil dipstick guide routing bracket mounting bolt. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew intake manifold support bracket mounting bolt manifold end. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 16 mm ring spanner, Loosen and remove NVH cover mounting stud on intake manifold. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew intake manifold mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Carefully remove the intake manifold from engine compartment. Replace the gaskets to the intake manifold whenever removed from the engine. Install in the reverse order of removal. Check the intake manifold for the external damage. If any damage found replace it. The intercooler typically an air-to-air heat exchanger. Intercooler cools the air compressed by the turbocharger by reducing its temperature and increasing the density of the air supplied to the engine and thus improving the volumetric efficiency by increasing intake air charge density through nearly isobaric (constant pressure) cooling. The cooled air density improves, helping in increasing the power output and improving the fuel consumption. The intercooler is fitted with separate Electric fan for further better cooling Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable Using 7 mm socket spanner, Loosen intercooler inlet and outlet hose clips and detach hoses intercooler end Torque : 6.5 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020279.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect boost pressure & temperature sensor electrical connector Using 10 mm socket spanner, remove boost pressure & temperature sensor mounting bolt and detach it Torque : 2.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect intercooler electric fan electric connector Using 10 mm socket spanner, Unscrew degassing tank mounting bolts to partially detach the tank Torque : 4.5\u00b10.5Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew intercooler fan mounting nuts Remove the Intercooler fan from intercooler assembly While installing the fan, Ensure to align the arrow mark on Top side as shown below Using 13 mm socket spanner, Unscrew Intercooler mounting bolts Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew Intercooler mounting bolts Install in the reverse order of removal Check for the intercooler for external damage. If found replace it Inspect intercooler hoses for any damage. Replace if found any Inspect intercooler rubber Isolators for any damage. Replace if found any Inspect the Intercooler Fan Assembly for any external damage, Replace the fan assembly if required The boost pressure & temperature sensor is used to monitor the intake air pressure & temperature at the intercooler outlet. The sensor is an NTC type sensor. EMS ECU uses signal from this sensor for Air-intake system control & flow rate modelling. Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable. Disconnect the boost pressure & temperature sensor electrical connector. Using 10 mm Socket Spanner, Unscrew boost pressure & temperature sensor mounting bolt. Torque : 2.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the boost pressure & temperature sensor. Install in the reverse order of removal. Check for any external cracks or damage, replace if found any. Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable. Disconnect HFM sensor electrical connector and routing clip. Using a 10 mm socket spanner, Unscrew HFM sensor mounting bolts and detach sensor from air clear assembly. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020252.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew air cleaner assembly mounting bolts from BIW. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully take out the air cleaner assembly and air intake dirty duct. Using 5 mm Allen key, loosen and remove the dirty side duct mounting bolts from the air cleaner assembly then separate the air cleaner assembly. Install in the reverse order of removal. Check the air cleaner housing for the external damage. If any damage found replace it. Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable Disconnect Intercooler fan electrical connector Using 10 mm socket spanner, Unscrew intercooler electric fan mounting nuts Carefully remove the fan assembly Install in the reverse order of removal While installing the fan, Ensure to align the arrow mark on Top side as shown below Inspect the Intercooler Fan Assembly for any external damage, Replace the fan assembly if required The air cleaner element is Non woven +Pleated Media type (Dry Type). Filtration happens in two stages. Coarser particles are filtered in first stage by foam media and fine particles are filtered by Paper media in second stage. The dust and other fine particles which are sucked inside along with air gets trapped in the air cleaner while passing through the filter element. Don\u2019t tap or hit the filter element. Park the vehicle on level work bay. Open the bonnet and lock it in open position using bonnet stay rod. Using 5 mm allen key, Unscrew air cleaner dirty duct mounting screws and lift the top housing. The air filter element should be inspected and replaced from time to time, when driving under the following conditions: Unpaved road. Dusty air-polluted road. Long-term driving in rainy weather. Gently take out the air cleaner element from the housing. Clean the inner side of the air cleaner housing using a lint free cloth. Refit the air filter element gently inside the air cleaner housing. During Installation ensure to keep foam side of the filter element in the bottom side Ensure dust should not fall inside the clean hose area while fitting. Always use recommended genuine air filter element. Do not tap or hit the new filter element. Position the air cleaner assembly top cover and refit the mounting screws. Torque : 10 Nm ",
+ "file": null,
+ "display_order": 25
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 348,
+ "sys_id": "THAR.LX-0009-Air Intake",
+ "subsys_id": "THAR.LX-0009-Air Intake-HFM Sensor Cleaning",
+ "systems": "Air Intake",
+ "sub_systems": "HFM Sensor Cleaning",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B020018.jpg",
+ "myid": 1502,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0009-HFM Sensor Cleaning-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "The HFM sensor is used to find out the mass flow rate of air entering into fuel injection internal combustion engine The air mass information is necessary for the ECU to balance and deliver the correct fuel quantity to the engine. Possible Customer Complaints/ Symptoms ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Root Cause ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Wrong indication of the air flow to the ECU from the HFM sensor. This is due to the deposition of oil & dust particles on sensor element Logic ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Under normal driving conditions, if required boost pressure is not generated by the turbocharger, the smoke limitation map limits the fueling to avoid smoke due to lack of air If oil/ other soot particles are deposited on the HFM sensor element, the HFM sensor will not read the actual airflow and may report a lesser value to the ECU, thereby limiting the fuelling.This brings down the vehicle performance below acceptable limits. In such cases, the HFM sensor performance can be restored by cleaning the sensor with Petrol thoroughly as per the procedure given below Take Petrol in a container such that HFM sensor unit can be immersed completely. Ensure that the electrical connector is not immersed in the petrol bath Allow the HFM sensor unit to immerse in Petrol for about 5-10 min. Petrol once used should not be re-used for cleaning the HFM sensor. Remove the sensor assembly from the Petrol bath and remove the Petrol completely from the sensor. Allow the sensor to get dry Blow pressurized air jet (Pressure between 3 to 5 bars) from a distance of 10 to 15 cm from one end of the sensor so as to remove any Petrol content present in the mesh. Intake manifold pressure & temperature sensor is mounted located at the plenum of the intake manifold. This sensor continuously monitors the variation in intake air pressure & temperature. EMS ECU uses this information for fuel correction & turbocharger pressure control Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable. Remove the engine top encapsulation cover Disconnect pressure & temperature sensor electrical connector. Using T25 Torex socket spanner, loosen and remove the pressure & temperature sensor mounting bolt. Torque : 4 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully remove the sensor from intake manifold. Install in the reverse order of removal. Check for any external cracks, replace if found any. Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable. Disconnect the throttle valve electrical connector. Using 7 mm socket spanner, loosen intercooler outlet hose clip and detach the hose throttle end. Torque : 6.5 \u00b1 0.6Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew throttle valve mounting bolts. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully remove throttle body from intake manifold. Install in the reverse order of removal. Check for any external cracks, replace if found any. The HFM sensor is used to find out the mass flow rate of air entering into fuel injection internal combustion engine. The air mass information is necessary for the ECU to balance and deliver the correct fuel quantity to the engine. Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable. Disconnect the HFM sensor electrical connector. Using a 7 mm socket spanner, loosen the hose clip and detach hose from HFM sensor. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew the HFM sensor mounting bolts. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew the HFM sensor mounting bolts. Install in the reverse order of removal. Check for any external cracks, replace if found any. Check for the obstruction of the air flow, if found please replace. The air cleaner element is Non woven +Pleated Media type (Dry Type). Filtration happens in two stages. Coarser particles are filtered in first stage by foam media and fine particles are filtered by Paper media in second stage. The dust and other fine particles which are sucked inside along with air gets trapped in the air cleaner while passing through the filter element. Don\u2019t tap or hit the filter element. Park the vehicle on level work bay. Open the bonnet and lock it in open position using bonnet stay rod. Using a 5 mm allen key, Unscrew air cleaner top housing mounting allen screws and lift the top housing. The air filter element should be inspected and replaced from time to time, when driving under the following conditions: Unpaved road. Dusty air-polluted road. Long-term driving in rainy weather. Gently take out the air cleaner element from the housing. Clean the inner side of the air cleaner housing using a lint free cloth. Blow the compressed air from the top clean side of filter element. Blow the compress air from the top clean side of filter element (From Paper side) Do not blow the air from bottom dirty side (Foam side) While cleaning, ensure the air pressure should be less than 2 bar. Clean the inner side of the air cleaner housing using a lint free cloth. Gently insert the air cleaner element inside the air cleaner housing. During Installationensure to keep foam side of the filter element in the bottom side Ensure dust should not fall inside the clean hose area while fitting. Always use recommended genuine air filter element. Do not tap or hit the new filter element. Refit the air cleaner top housing and install the mounting allen screws. Torque : 10 Nm ",
+ "file": null,
+ "display_order": 28
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 131,
+ "sys_id": "THAR.LX-0009-en-SM-Wheel & Tyre",
+ "system_name": "Wheel & Tyre",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1014,
+ "active_status": true,
+ "Assets": [],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 138,
+ "sys_id": "THAR.LX-0009-Wheel & Tyre",
+ "subsys_id": "THAR.LX-0009-Wheel & Tyre-Front Wheel",
+ "systems": "Wheel & Tyre",
+ "sub_systems": "Front Wheel",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A160002.jpg",
+ "myid": 1511,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0009-Front Wheel-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160002.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/56070.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/56071.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 21 mm Wheel spanner/ deep socket spanner, loosen and remove the wheel mounting bolts. Torque :140\u00b110 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the mounting bolts and then remove the wheel. Install in the reverse order of removal. Check for any external damage in the tyre or the rim, if found replace. Check for any foreign material on tyre or rim, remove if found. Torque :50\u00b17.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the spare wheel carrier from the vehicle. Install in the reverse order of removal. Check for any external damage in the spare wheel carrier , if found replace. Using 21 mm socket spanner, loosen and remove the wheel nuts on the spare wheel carrier. Torque :70\u00b110 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the spare wheel from the vehicle. Install in the reverse order of removal. Check for any external damage in the tyre or the rim, if found replace. Check for any foreign material on tyre or rim, remove if found. Position the vehicle on 2 post lift. Tyres on the front and rear side of vehicles operate at different loads and perform different steering, handling, and braking functions. For these reasons, they wear at unequal rates and develop irregular wear patterns. Rotation will increase tread life. help to maintain mud, snow, and wet traction levels, and contribute to a smooth quiet ride Follow the recommended tyre rotation frequency for your type of driving more frequent rotation is permissible f desired. The reasons for any rapid or unusual wear should be corrected prior to rotation being performed It is recommended to rotate the tyres as per Maintenance Schedule. TPMS Learning needs to be carried out for vehicle models equipped with TPMS (Tyre Pressure Monitoring System), procedure as below. Position the vehicle on a flat surface. Press the Scroll Up arrow button on Driver side switch bank and simultaneously turn the ignition ON. Wait for cluster\u2019s tachometer & speedometer self-check rotation and then release the arrow button. TPMS learning procedure must be done in the below sequence: Front left tyre Front right tyre Rear right tyre Rear left tyre Spare tyre Start leaking the air from front left tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If front left tyre is learned 1 siren chirp sound is heard and FL tyre shows learned in infotainment system. Start leaking the air from front right tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If front right tyre is learned 1 siren chirp sound is heard and FR tyre shows learned in infotainment system. Start leaking the air from rear right tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If rear right tyre is learned 1 siren chirp sound is heard and RR tyre shows learned in infotainment system. Start leaking the air from rear left tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If Rear left tyre is learned 1 siren chirp sound is heard and RL tyre shows learned in infotainment system. Start leaking the air from the spare wheel tyre for 30 to 40 seconds & stop for 5 seconds. Repeat until the tyre gets learnt. If spare tyre is also learned then 1 siren chirp sound is heard and ALL tyres show learned at respective tyre positions and \u2018All tyres Learned successfully\u2019 in the center of the screen. At any point of time during the learning process, if learning takes more than 90 seconds of time for each tyre position then the system shall exit the learning mode and show the \u201cLearning not successful\u201d screen. After tyre rotation or TPMS sensor replacement, TPMS must be learnt, otherwise the system will show TPMS malfunction indicator. TPMS learning need to be carried out henever : Tyre rotation happens. 2 or more wheels are swapped. TPMS sensor is replaced. MBFM is replaced. The TPMS should not be used as a pressure gauge while adjusting vehicle tyre pressure. No two vehicles should be done with manual learning process at a time in same location with in radius of 20 meters. Post to manual learning all tire should be filled with recommended tyre pressure value. For additional information refer to front WHEEL - R&R Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using chisel Remove the drive shaft mounting nut caulking. Using 36 mm socket spanner, loosen and remove Drive shaft mounting nut by Applying brake. Torque : 240 \u2013 260 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the caliper stem mounting bolts then hang the caliper. Torque : 31 \u2013 38 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Pull the Brake Pad outwards upto pad contact with clip as shown in the illustration. Twist the pad in anti clock wise direction, lift the pad upwards and remove the pad. Using 19 mm socket spanner, loosen and remove the caliper bracket mounting bolts then remove the caliper bracket. Torque : 90 \u2013 100 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using star screw driver, remove the brake disc mounting screw and detach the disc from the front wheel hub. Remove the disc separately. Using 19 mm socket spanner, loosen and remove Hub mounting bolts and remove the hub with carrier plate. Torque : 87 - 90 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Front Wheel Hub3.png",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Before assembly clean the mating faces of the front wheel hub and brake disc. Check for any external damage in the wheel hub, if found replace. Check for any wheel hub bearing condition, if found replace. Proper Tyre inflation pressure is essential to the safe and satisfactory operation of your vehicle. Three primary areas are affected by improper Tyre pressure:Safety Economy Ride Comfort and Vehicle Stability Proper Tyre inflation contributes to a comfortable and safe ride. Over inflating produces a jarring and uncomfortable ride. Both under inflation and over inflation affect the stability of the vehicle and can produce a feeling of sluggish response or over responsiveness in the steering. Unequal Tyre pressures can cause erratic and unpredictable steering response or may cause the vehicle to drift left or right. Improper inflation pressures can cause uneven wear patterns to develop across the Tyre tread. These abnormal wear patterns will reduce tread life resulting in a need for earlier Tyre replacement. Under inflation also increases Tyre rolling resistance and results in higher fuel consumption. TYRE PRESSURE LABEL ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A160038.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Tyre Label is located on the driver side inner B-pillar. This label tells you important information about tyre size designed for your vehicle, and the tyre inflation pressures for the front & rear tyres. Never overload the vehicle. Overloading can cause tyre failure, affect vehicle handling, and increase your stopping distance, resulting in an accident and/ or personal injury. Improper inflated tyres can adversely affect vehicle handling or can fail unexpectedly, resulting in an accident and or personal injury. If weight is not equally distributed around the wheel, unbalance centrifugal force by the wheel rotation produces vibration. As the centrifugal force is produced proportional to the square of the rotating speed, the wheel weight should be balanced even at high speed. There are two types of the tire and wheel balancing: static and dynamic. Abnormal vibration may also occur due to unbalanced rigidity or size of tyres. Static Balance ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A180032.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "When the free rotation of the wheel is allowed, the heavier part is stopped on the bottom if the wheel weight is unbalanced and this is called Static Unbalance . Also, the state at which tyre's stop position is not same is called Static Balance when the wheel is rotated again. If the part A is heavier as shown in the figure, add the balance weight corresponding to unbalanced weight from B to A to maintain the static balance. If the static balance is not maintained, tramping, up and down vibration of the wheels, occurs. Dynamic Balance ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A180033.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "The static unbalance of the wheel creates the vibration in the vertical direction, but the dynamic unbalance creates the vibration in the lateral direction. As shown in the figure (A) , if two parts, (2) and (3), are heavier when the wheels are under the static balance condition, dynamic unbalance is created, resulting in shimmy, left and right vibration of the wheels, and the torque Fxa is applied in the axial direction. To correct the dynamic unbalance, add the balance weight of a same weight for two points of the circumference of the rim, M1 and M2, as shown in the figure (B) , and apply the torque in the opposite direction to the torque Fxa to offset in order to ensure smooth rotation of the wheel. The wheel should always be balanced and aligned in order to provide: Enhanced tyre life. Driving safety and steering control. Better performance of the vehicle. Unbalanced tyre may lead to premature tyre wear and driver fatigue due to vibration.Tyres should always be balanced when they are mounted on wheels for the first time. When they are remounted after repair. When there are signs of shimmy or vibrations. Deposits of mud, dust must be cleaned from inside of the rim. Remove stones from tread, clean the tyre and rim before balancing to achieve better results. Each tyre should be inspected for any damage. The type of balance weights, when used, must be in accordance with the profile of the rim flange. Refer below recommendations for usage of balance weights. For balancing a wheel, follow the manufacturer\u2019s (of balancing machine) manual for balancing instructions, recommendations and any other additional information. Using 21 mm Wheel spanner/ deep socket spanner, loosen and remove the wheel mounting bolts. Torque :140\u00b110 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the mounting bolts and then remove the wheel. Install in the reverse order of removal. Check for any external damage in the tyre or the rim, if found replace. Check for any foreign material on tyre or rim, remove if found. Remove the TGS lever assembly. Using 10 mm socket spanner unscrew ATcable grommet mounting bolts. Torque : 13 \u00b1 2.0 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using MST - 0703AAD0009ST (Shifter and selector cable eye end removal tool) detach the shifter cable from gear shifter link ball pin. Detach the abundant from routing bracket and remove the shifter cable from bracket. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Take out the shifter cable. Install in reverse order of removal. Carry out AT cable settings. For additional information refer to AT cable setting procedure. While replacing new TGS lever, Ensure to remove the N position lock. Check for proper shifting of gears in TGS lever and transmission. While refitting gear shifter cable , Ensure the gear shifter link and TGS lever in N (Neutral) position. After installation check the shifter link at various gear positions (PRND). For additional information refer to Gear Shifter link Position Inspection section. Check for any external damage, if found please replace. Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. Torque : 6.0 \u00b1 0.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect AT input speed sensor electrical connector and routing clip. Disconnect the transfercase electrical connector and routing clip. Disconnect AT output speed sensor electrical connector and routing clip. Disconnect AT valve body electrical interconnector. Disconnect AT Neutral switch electrical connector Disconnect AT wiring harness interconnector and holding clip and remove the wiring harness. Install in reverse order of removal. Check for any external damage, if found please replace. Remove the radiator LH & RH seal. For additional information refer to the Radiator LH & RH Seal R&R section. Press and disconnect the oil inlet hose quick coupler and routing clips oil cooler end. Press and disconnect the oil outlet hose quick coupler oil cooler end. Using 10 mm socket spanner unscrew T oil cooler mounting bolts and remove oil cooler. Torque : 5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110127.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Check and top up the AT oil if required. For additional information refer to AT oil level check and filling procedure. Check and ensure that there are no oil leaks. Check for any external damage, if found please replace. Remove the front grill assembly. Using 10 mm socket spanner unscrew radiator seal LH mounting bolt. Using screw driver remove the radiator seal LH mounting push clip and detach guard from the vehicle. Press and disconnect the oil hose quick coupler and detach routing clips oil cooler end. Press and disconnect the oil hose quick coupler and disconnect the hose at inter connection end. Remove the hose routing to remove hose. install in reverse order of removal. Check the AT oil level and top up if required. For additional information refer to AT oil level inspection and filling procedure. Check for any external oil leakage. Rectify if found. Disconnect the AT oil cooler inlet and outlet hoses thermal bye pass valve end both the sides. Ensure to close the bypass tubes with dummy caps to avoid dust entry Using 10 mm socket spanner unscrew thermal bypass valve bracket mounting bolt from engine oil sump. Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the thermal bypass valve from the vehicle. Install in reverse order of removal. Check for the AT oil level and top up if required. For additional information refer to AToil level checking and Filling procedure. Check for ATF oil leakage and ensure that there are no oil leaks. Check for any external damage, if found please replace. Remove the automatic transmission with transfercase. Disconnect the transfercase electrical connector and routing clip from transfercase. Using 12 mm socket spanner unscrew transfercase shifter cable abundant routing bracket mounting bolts. Torque : 25 \u00b1 3.0 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner unscrew AT shifter cable routing bracket mounting bolts. Using 12 mm socket spanner unscrew AT shifter cable routing bracket mounting bolts. Torque : 25 \u00b1 3.0 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner unscrew transfercase front facing mounting bolts. Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner unscrew transfercase rear facing bottom mounting bolt. Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 12 mm ring spanner unscrew transfercase rear facing top mounting bolt. Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the transfer case from AT assembly. Using 12 mm socket spanner unscrew AT distance plate mounting bolts and remove distance plate. Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110237.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Disconnect AT input speed sensor electrical connector and routing clip. Disconnect AT output speed sensor electrical connector and routing clip. Disconnect AT Neutral switch selector electrical connector. Disconnect AT valve body electrical connector interconnection end. Disconnect AT Wiring harness interconnector holding clip. Using 12 mm socket spanner unscrew AT shifter cable abundant bracket mounting bolts. Torque : 25 \u00b1 3.0 Nm ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using 19 mm socket spanner unscrew AT oil cooler oil inlet and outlet hose banjo bolts and remove the hoses. Torque : 30 \u00b1 3.0 Nm ",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Using 13 mm ring spanner unscrew gear shifter link mounting nut and remove the shifter link. Torque : 15 \u00b1 2.0 Nm ",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110056.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. While Replace New Automatic transmission ensure to completely drain the ATF from the oil cooler and tubes. Check the Transmission oil level and topup if needed. For additional information refer to transmission oil level inspection and refilling procedure . Check and ensure that there are no oil leaks. Carry out Service routine (Clear learned data in EEPROM) while replace New AT Assembly. Carry out Initial Learning while replace New AT Assembly. Inspect that shift lever can shift smoothly and accurately when shifting shift lever from N to other range. Inspect that engine can be started with shift lever only N or P, but not in other range. Inspect the gear shifter indicator in the instrument cluster be turned on correctly while in P-R-N-D positions. If any of the above conditions are not fulfilled, Kindly check & adjust Selector position switch & shifter cable. Check for any external damage, if found please replace. Check for any external oil leakage. Rectify if found. Using 19 mm socket spanner unscrew AT oil cooler oil Inlet hose banjo bolt and remove hose. Torque : 30 \u00b1 3.0 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect the AT oil cooler oil outlet hose thermal bye pass valve end. Ensure to close the bypass tubes with dummy caps. Detach the hose from the routing clip. Install in reverse order of removal. Check the AT oil level and top up if required. For additional information refer to AToil level inspection and filling procedure. Check for any external oil leakage. Rectify if found. Make sure to clean dirt, sand or other foreign matter from the Automatic transmission assembly before removing components. Clean components and surrounding area prior to removal. Ensure that all parts are neatly stored in the appropriate container/tray as they removed, failing may leads to difficult while reassemble the components. Do not use cotton gloves or shop rags as frayed strings might get caught in the unit.Thus, work with your bare hands or use plastic gloves. Do not drain the ATF when it is hot, wait until it has cooled down. Recommend to use only Mahindra ATF NWS9638 Special Automatic Transmission Fluid and Never mix 2 different oils. Always replace gaskets, O rings and oil seals etc. with new ones. Do not overfill transmission, fluid foaming and shifting problems can result. When connecting the connector, Ensure the connector is fully engaged by connecting it until you hear a click that signals engagement. Keep work areas clean and organized. Pick up tools and use tool cabinets to keep walkways clear and free from clutter. Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Provide a jack to support to transfer case. Using a 18 mm socket spanner, loosen and remove the transmission bed mount nuts. Using 14 mm & 15 mm socket/Ring spanner unscrew cross member mounting bolts and nuts then remove the cross member. Using 24 mm socket spanner, remove the filler plug from transmission. Using 14 mm socket spanner, remove the drain plug and the gasket. Drain the ATF & Measure Quantity ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1060.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Drain the Automatic transmission fluid and Measure the Drained fluid quantity . Install the drain plug with new gasket and tighten the drain plug with specified torque. Torque : 20 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": "Always replace the drain plug gasket with a new one. Disconnect the AT wiring harness electrical connector from the AT pigtail. Using 10 mm socket spanner, remove transmission oil pan sub-assembly mounting bolts. Remove the oil pan sub-assembly and gasket from the transmission housing. Take sufficient care not to damage the fitting surfaces of the transmission housing and the transmission oil pan sub-assembly. Take sufficient care not to deform the transmission oil pan sub-assembly. Remove the oil cleaner magnets from the oil pan sub-assembly. Examine the chips and particles in the oil pan sub-assembly and on the oil cleaner magnet to determine what type of wear has occurred in the Automatic Transmission. Steel (Magnetic) = Bearing, Gear and Plate wear.Brass (Non-magnetic) = Bushing wear.Using 10 mm socket spanner, Remove temperature sensor clamps mounting bolts and pull out the sensors clamp and sensors from the valve body. Disconnect valve body solenoid electrical connectors using small screw driver by pressing the connector location as shown in the illustration. Ensure to smoothly unlock the wiring connector from solenoid by using small screw driver and Take sufficient care not to damage the connectors while remove. Using 10 mm socket spanner, remove transmission WH inter connector mounting bolt and pull out the transmission wiring harness. Take sufficient care not to damage the wiring harness. Take sufficient care not to pull out the harness forcibly. Insert the transmission wiring harness in the housing and Install the transmission WH inter connector mounting bolt and torque tighten the bolt. Always ensure to replace the New O ring of the transmission wire connector while Installationand coat the O ring with ATF while install. Torque : 5.4 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1074.jpg",
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Connect the solenoid electrical connectors. When connecting the connector, Ensure the connector is fully engaged by connecting it until you hear a click noise to ensure proper engagement. Install the oil temperature sensors and sensor clamps to the valve body assembly by the mounting bolts and torque tighten the bolts (A & B) to specified value. Bolt \u201cA\u201d can be used in different lengths \u2014 M6 x 1.0 x 14 mm or M6 x 1.0 x 12 mm For A = 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Torque Value",
+ "content": "For B = 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install the 4 oil cleaner magnets to the oil pan subassembly. Clean the transmission oil pan subassembly. Clean the oil cleaner magnet before installing. Clean oil from oil pan gasket fitting surface of the housing and the mounting bolt holes. Install a new oil pan gasket on the oil pan subassembly. Always replace the Oil pan gasket with a new one. Ensure to align the gasket in correct position on the oil pan sub assembly as shown in the illustration. Take sufficient care not to damage the fitting surfaces of the Transmission housing and the oil pan subassembly. Take sufficient care not to deform the oil pan subassembly. Install the oil pan sub assembly mounting bolts to the housing. Tighten the bolts to specified torque value. Torque : 7.4 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Make sure that there is no oil or foreign matter on the oil pan gasket seal surface and oil pan subassembly contact surface. Install the oil pan gasket properly so that there is no slack in the oil pan gasket, and that the seal surface's entire circumference is level. Make sure that the oil pan gasket drop prevention protrusions are set on the oil pan subassembly. When tightening the oil pan subassembly, make sure that the oil pan gasket is not pinched between the oil pan gasket tightening area's sleeve and the housing seal surface. Connect the AT wiring harness electrical connector to the AT pigtail. Position & Install the cross member mounting bolts and nut then tighten to specified torque value. Torque: 65 \u00b1 10.0 Nm ",
+ "file": null,
+ "display_order": 84
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Install the transmission bed mount nuts and tighten the nuts to specified torque value. Torque: 110 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the jack support from transfer case. Torque: 110 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 90
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "ATF Refilling ",
+ "file": null,
+ "display_order": 91
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1085.jpg",
+ "display_order": 92
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "ATF Refilling Refill the ATF (Drained quantity + 0.5 Ltrs) through filling hole by using hose/funnel and tighten the filler plug. Always use the clean hose/funnel for refilling and hose/funnel should be used only for ATF refilling purpose. Always replace the filler plug O ring with a new one. Recommend to use only Mahindra ATF NWS9638 Special Automatic Transmission Fluid and Never mix 2 different oils. Do not overfill transmission, fluid foaming and shifting problems can result. Tighten the battery negative cable mounting nut. Torque : 6.0 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 98
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Check AT oil level and top-up if required. For additional information refer to AToil level inspection and Filling procedure. Check for oil leak between contact surface of oil pan and housing. Inspect that shift lever can shift smoothly and accurately when shifting shift lever from N to other range. Inspect that engine can be started with shift lever only N or P, but not in other range. Inspect the gear shifter indicator in the instrument cluster be turned on correctly while in P-R-N-D positions. If any of the above conditions are not fulfilled, Kindly check & adjust Selector position switch & Cable. Remove the Transfer Case Assembly. For addition information refer to Transfer Case R&R section. Using a screw driver, remove Rear Housing Oil Seal from transmission. Refit oil seal by using special tool 0701CAJ0002ST - AT Oil Pump/ Rear Housing Oil Seal Installer - 4WD/2WD. Coat the Rear Housing Oil Seal with ATF while install. Refit the Transfer Case Assembly. For addition refer to Transfer Case R&R section. Check AT oil level and top-up if required. For additional information refer to AT oil level inspection and Filling procedure. Inspect the Rear Housing Oil Seal for any damage. Replace if found any. If the automatic transmission or the TCU is replaced, or the TCU software is overwritten, be sure to initialize the learned values and perform initial learning. Warm-up ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Raise the ATF temperature by leaving the vehicle idling or performing a drive. Check the ATF temperature using the Diagnostic tool and make sure it is between 65\u00b0C and 80\u00b0C. If the oil temperature is outside this range, need to bring it inside the range. Do not attempt to raise the oil temperature by stalling the engine. If the fluid temperature is not between 65\u00b0C and 80\u00b0C, initial learning cannot be performed. Before learning, check for shift shock or variable speed shock. Garage shift learning ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "With the vehicle stationary, depress the brake pedal and keep the shift lever in the N position for 3 seconds. Then, move the shift lever from the N position to the D position, and keep the shift lever in the D position for 3 seconds. Repeat this procedure 5 times. Ensure the transmission oil temperature is between 65\u00b0C and 80\u00b0C. Gear shift control learning ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "With the shift lever in the D position and the throttle opening amount between 25 and 35%, drive until 6th gear is selected and a vehicle speed of 110 km/h or higher is reached. Then, release the accelerator pedal and let the car coast, and finally bring the vehicle to a stop within 60 seconds. Repeat this procedure 10 times. Check learning results ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Check that variable speed shock and shift shock have decreased compared to the conditions before learning. Partially detach the TGS leather boot from bezel and fold the boot to top side. Partially detach the bezel from the console. Excessive pull may leads to damage of the electrical connector. Disconnect the electrical connector and remove the bezel. Ensure the AT shifter cable end is properly fitted on TGS housing ball pin. Ensure the AT cable abutment is properly fitted on shifter bracket. Position the AT TGS lever at Neutral (N) position. Position the M8 bolt of approx. 60 mm length to the TGS housing hole for ensuring lever in neutral position. Ensure TGS lever position is parallel to Arrow mark shown after inserting M8 bolt. Ensure the ATcable abutment is properly fitted on auto transmission cable bracket. Using 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the shifter cable from gear shifter link ball pin. Position the AT cable link to Neutral (N) position at Automatic transmission assembly as shown below. By fastening M6 bolt for matching shifter link hole with transmission hole and ensure Neutral (N) position. For adjust cable length, move the cable quick adjuster outer cover in forward direction and unlock the QA clip. Adjust the cable length to fix the cable on link ball pin. After adjusting the length, position the quick adjuster body on link ball pin. Once quick adjuster body snap on ball pin, press the QA clip towards arrow mark shown to lock it fully and release the cable quick adjuster outer cover. Ensure the proper locking by onfirming/ hearing the click noise while install. After adjustment remove the M6 & M8 olt from cable link & shifter housing. Inspect that shift lever can shift smoothly and accurately when shifting shift lever from N to other range. Connect the electrical connector on bezel. Attach the bezel on console. Refit the TGS leather boot on bezel. Check that there are no oil leaks from the contact surfaces between the Auto Transmission and Engine, the housings, extension/adapter and oil pan, each oil seal, and each O ring. Oil leak from contact surface between Auto Transmission and Engine Check for oil leak to judge whether it is from the Auto Transmission or Engine. If it is from the Auto Transmission, oil may be leaking from the oil pump oil seal or oil pump O ring, If there are any leak found, Replace the required part. Oil leak from contact surface between housing and case Check for oil leak from the housing contact surface, If there are any leak found, it is necessary to apply appropriate sealant again. Oil leak from contact surface between extension/adapter and case Check for oil leak at the extension/adapter contact surface, If there are any leak found, it is necessary to apply sealant again. Oil leak from contact surface between oil pan and case Check for oil leak between contact surface of oil pan and case, If there are any leak found, it is necessary to replace the gasket. Oil leak from oil seal Check for oil leak at the Oil pump oil seal, AT Rear end oil seal or Manual shaft oil seals, If there are any leak found, replace the oil seal with a new one. Oil leak from Washers /\u201cO\u201d rings Check for oil leak from any of the Washers/ \u201cO\u201d rings, If there are any leak found, replace the Washers/ \u201cO\u201d ring with a new one. Oil leak from AT Oil cooler & Oil lines Check for oil leak from the oil lines at Oil cooler/ Automatic transmission banjo bolts & Oil lines, If there are any abnormalities found, replace the required components. Do not damage the oil seal lips, housing, case or extension/adapter contact surfaces. Park the vehicle and Position the TGS lever in N position. Position the AT shifter link to Neutral (N) position at Automatic transmission assembly as shown below By fastening M6 bolt for matching shifter link hole with transmission hole and ensure Neutral (N) position. Using 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the shifter cable from gear shifter link ball pin. Using 13 mm socket spanner, remove the shifter link mounting nut and remove the shifter link & M6 bolt. Position the AT gear shifter link and Install M6 bolt for matching shifter link hole with transmission hole and ensure Neutral (N) position. Refit the shifter link mounting nut and torque tight the nut to specified value. Torque : 15 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Attach the shifter cable with gear shifter link. Position the TGS shifter lever in N position & Ensure that the shifter link should be in N position on AT Assy while attach the cable & adjust cable length if needed. Inspect Manual valve lever position for various modes (PRND) at Selector Position Switch are below. Inspect that shift lever can shift smoothly and accurately when shifting shift lever from N to other range. Inspect that shift lever can shift smoothly and accurately when shifting shift lever from N to other range. Inspect the gear shifter indicator in the instrument cluster be turned on correctly while in P-R-N-D positions. If any of the above conditions are not fulfilled, Kindly check & adjust Selector position switch & shifter link. Be sure to perform a function check under the conditions below. Perform after engine inspection and adjustment. Perform with ATF temperature (50-80 \u00b0C) under ordinary driving conditions. The A/C, lights, etc., are turned off. Cruise control is off. In order to prevent sudden start of the vehicle, be sure to lock it before function check. Apply the parking brake and chock the wheels. Start the engine. Depress the brake pedal and allow the engine to idle. Move the shift lever from the N position to the D or R position and, Using timer, check how long it takes until a light shift shock is felt. Perform the test at least 3 times and calculate the average. When performing the test wait for 1 minute between the tests. Apply the parking brake and chock the wheels. Start The Engine. Fully depress the brake pedal with your left foot, move the shift lever to the D or R position, fully depress the accelerator pedal with your right foot, and quickly check the imum engine rpm. Specification Range : 2309 \u00b1 150 rpm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "As this test causes a sudden rise in the ATF temperature, do not continue the test more than 5 seconds. Perform the test at least 3 times and calculate the average. Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. Torque : 6.0 \u00b1 0.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect the TCU electrical connectors. Using 10 mm socket spanner, unscrew TCU mounting nuts and remove the TCU. Torque : 9 \u00b1 1.0 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110164.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Carry out Initial Learning while replace New AT Assembly. Check for any external damage, if found please replace. Park the vehicle and Shift the TGS lever to N position. Remove AT gear shifter bezel. For additional information refer to AT gear shifter Bezel - R&R section. Rotate transfercase shifter knob in anti clock wise and remove it from the shifter. Using trim removal tool, carefully remove the floor console top trim with transfer case shifter boot. Disconnect the TGS lever electrical connector. Using 13 mm socket spanner unscrew TGS lever Assembly mounting nuts. Torque : 22.5 \u00b1 3.0 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 0703AAD0009ST \u2014 Shifter and selector cable eye end removal tool, detach the cable link from TGS assembly. Carefully remove the shifter cable abundant and remove the TGS assembly. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Install in reverse order of removal. For additional information refer to AT cable setting procedure. ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Notice",
+ "content": "While replacing new TGS lever, Ensure to remove the N position lock. Check for proper shifting of gears in TGS lever and transmission. While refitting gear shifter cable , Ensure the gear shifter link and TGS lever in N (Neutral) position After installation check the shifter link at various gear positions (PRND). For additional information refer to Gear Shifter link Position Inspection section . Inspect the TGS lever assembly for any damage. replace if required. Make sure to clean dirt, sand or other foreign matter from the Automatic transmission assembly before removing components. Clean components and surrounding area prior to removal. Ensure that all parts are neatly stored in the appropriate container/tray as they removed, failing may leads to difficult while reassemble the components. Do not use cotton gloves or shop rags as frayed strings might get caught in the unit.Thus, work with your bare hands or use plastic gloves. Do not drain the ATF when it is hot, wait until it has cooled down. Recommend to use only Mahindra ATF NWS9638 Special Automatic Transmission Fluid and Never mix 2 different oils. Always replace gaskets, O rings and oil seals etc. with new ones. Do not overfill transmission, fluid foaming and shifting problems can result. When connecting the connector, Ensure the connector is fully engaged by connecting it until you hear a click that signals engagement Keep work areas clean and organized. Pick up tools and use tool cabinets to keep walkways clear and free from clutter. Drain the Automatic transmission fluid. Remove the automatic transmission with transfer case. Using 14 mm socket spanner, Remove torque converter holding bracket mounting bolts and remove the bracket. Carefully remove torque converter from the AT assembly. Take sufficient care not to damage the oil pump seal during removal of torque converter. Take sufficient care not to drop the Torque converter assembly Using a screwdriver, position the drive gear on the oil pump assembly in the center and install the Torque converter assembly on the transmission assembly. Take sufficient care not to damage the oil pump oil seal. Take sufficient care not to drop the Torque converter assembly. Take sufficient care not to pinch fingers. Inspect installation position of torque converter assembly. Measure the dimension from the end face of the converter housing to the Torque converter assembly as shown in the figure and check that the Torque converter assembly is installed properly. SPEC : Over than 18.15 mm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refit the Torque converter holding bracket. Refit the automatic transmission with transfer case. Refill the Automatic transmission fluid. Check AT oil level and top-up if required. For additional information refer to AToil level inspection and Filling procedure. Inspect the Torque Converter assembly for any external damage, Replace if required. Remove the Selector Position Switch. For addition information refer to Selector Position Switch (NSW) - R&R Section. Using a screw driver, remove Manual Shaft Oil Seal from transmission. Refit oil seal by using special tool 0701AAJ0017ST - Manual Shaft Oil Seal Installer . Spec : 0 \u00b1 0.5 mm (From the end of the housing). ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W3008.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Refit the Selector Position Switch. For addition information refer to Selector Position Switch (NSW) - R&R Section. Check AT oil level and top-up if required.For additional information refer to AT oil level inspection and Filling procedure. Inspect the Manual Shaft Oil Seal for any damage. Replace if found any. Using 19 mm socket spanner unscrew AT oil cooler oil outlet hose banjo bolt and remove hose. Torque : 30 \u00b1 3.0 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect the AT oil cooler oil outlet hose thermal bye pass valve end. Ensure to close the bypass tubes with dummy caps. Detach the hose from the routing clip. Install in reverse order of removal. Check the AT oil level and top up if required. For additional information refer to AToil level inspection and filling procedure. Check for any external oil leakage. Rectify if found. Remove the AT Shifter link. For addition information refer to AT Shifter Link - R&R Section. Using a screw driver, remove Manual Shaft Oil Seal from transmission. Refit oil seal by using special tool 0701AAJ0017ST - Manual Shaft Oil Seal Installer. Spec : 0 \u00b1 0.5 mm (From the end of the housing). Refit the AT Shifter link. For addition information refer to AT Shifter Link - R&R Section. Check AT oil level and top-up if required.For additional information refer to AT oil level inspection and Filling procedure. Inspect the Manual Shaft Oil Seal for any damage. Replace if found any Refer the Service diagnosis chart to troubleshoot an error. Additional tests & diagnostic procedures may be necessary for specific automatic transmission complaints that cannot be isolated using only the diagnostic chart. Perform failure diagnosis by following the steps below. Only the basic procedure is described here. Before performing failure diagnosis, first perform basic steps (1) through (5) to pinpoint the area of the malfunction. Then perform troubleshooting while referring to inspection items. Effective procedures are described for each failure diagnosis item according to the system. Malfunctioning vehicle comes in for service Analyze symptoms of malfunction expressed by customer. Check with the customer about the circumstances and conditions at the time of malfunction occurred and capture what, when, where, and in what circumstances the malfunction occurred in detail. In order to perform a correct diagnosis, confirm the symptoms of the malfunction properly without preconceptions. In order to confirm the symptoms of the malfunction properly, it is extremely important to ask the customer about the circumstances at the time the malfunction occurred. Even information such as malfunctions that occurred in the past that are thought to be unrelated or the repair record may be useful sometimes, so it is necessary to gather as much information as possible. Pre-inspection ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using battery voltage tester, inspect the battery voltage with the engine stopped. Specified value (10 to 14 V). Inspect locations that can be visually checked, such as fuse blowout, harness disconnection or short circuit, and the connection state of connectors. Check diagnosis code (Vehicle Data Record) ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Warm up the engine sufficiently. Using Diagnostic tool, check the diagnosis code and Vehicle Data. When a diagnostic code is stored, data (vehicle data) is also stored in the TCU. Record it along with the Diagnostic Code. DTC is shown in the Trouble Code Chart. For additional information refer to Diagnosis Manual. If no diagnosis code is stored, check for symptoms of the malfunction and then perform a Road Test and Function Check. Use the data obtained at the time of checking for symptoms of the malfunction. For additional information refer to Road test procedure section. Road test procedure section. For additional information refer to Time lag test procedure section. Time lag test procedure section. For additional information refer to stall test procedure section. stall test procedure section. Using Diagnostic tool, delete the diagnosis code and Vehicle Data. Diagnosis code and Vehicle Data cannot be cleared by simply disconnecting the cable from the negative terminal of the battery. Be sure to use the Diagnostic tool to clear them. Check symptoms of malfunction (recheck diagnosis code) ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Based on the information gathered from the customer and vehicle data, re-create the circumstances and environment in place when the malfunction occurred and check. Troubleshoot by diagnosis code ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Referring to Flow Chart of Troubleshooting by Trouble Code, check the content corresponding to the stored diagnosis code and inspect the circuits and parts corresponding to the malfunctioning system. For additional information refer to Diagnosis Manual. Inspect circuits and parts ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Referring to Inspection, inspect circuits and parts to pinpoint the location of the malfunction. For additional information refer to Diagnosis Manual. Repair malfunction ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Conduct repair or replacement to correct the pinpointed location of the malfunction. Completion test ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "After repair, part replacement, and/or adjustment to correct the location of the malfunction, check for symptoms of the malfunction to make sure the phenomenon does not occur. Using Diagnostic tool, delete the stored diagnosis code and vehicle data. If the TCU or automatic transmission was replaced, be sure to clear the learned values, and perform initial learning. The purpose of the road test is to accurately grasp the symptoms of the malfunction and to check completion after repairs are finished. Be sure to perform a road test under the conditions below. Perform after engine inspection and adjustment. Perform with ATF temperature (50-80\u00b0C) under ordinary driving conditions. The A/C, lights, etc., are turned off. Cruise control is off. When performing a road test on public roads, first check the safety of the road. Be sure to perform a function check under the conditions below. Perform after engine inspection and adjustment. Perform with ATF temperature (50-80 \u00b0C) under ordinary driving conditions. The A/C, lights, etc., are turned off. Cruise control is off. In order to prevent sudden start of the vehicle, be sure to lock it before function check Apply the parking brake and chock the wheels. Start the engine. Depress the brake pedal and allow the engine to idle. Move the shift lever from the N position to the D or R position and, Using timer, check how long it takes until a light shift shock is felt. Specification Range ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4026.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Perform the test at least 3 times and calculate the average. When performing the test wait for 1 minute between the tests. Apply the parking brake and chock the wheels. Start The Engine. Fully depress the brake pedal with your left foot, move the shift lever to the D or R position, fully depress the accelerator pedal with your right foot, and quickly check the maximum engine rpm. Specification Range : 2309 \u00b1 150 rpm Specification Range ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "As this test causes a sudden rise in the ATF temperature, do not continue the test more than 5 seconds. Perform the test at least 3 times and calculate the average. Make sure to clean dirt, sand or other foreign matter from the Automatic transmission assembly before removing components. Clean components and surrounding area prior to removal. Ensure that all parts are neatly stored in the appropriate container/tray as they removed, failing may leads to difficult while reassemble the components. Do not use cotton gloves or shop rags as frayed strings might get caught in the unit.Thus, work with your bare hands or use plastic gloves. Do not drain the ATF when it is hot, wait until it has cooled down. Recommend to use only Mahindra ATF NWS9638 Special Automatic Transmission Fluid and Never mix 2 different oils. Always replace gaskets, O rings and oil seals etc. with new ones. Do not overfill transmission, fluid foaming and shifting problems can result. \u2022 When connecting the connector, Ensure the connector is fully engaged by connecting it until you hear a click that signals engagement. Keep work areas clean and organized. Pick up tools and use tool cabinets to keep walkways clear and free from clutter. Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery,check for the audible sound of EWP ON. Remove the Oil Strainer Assembly. Disconnect the AT wiring harness electrical connector from the AT pigtail. Using 10 mm socket spanner, Remove temperature sensor clamps mounting bolts and pull out the sensors clamp and sensors from the valve body. Disconnect valve body solenoid electrical connectors using small screw driver by pressing the connector location as shown in the illustration. Ensure to smoothly unlock the wiring connector from solenoid by using small screw driver and Take sufficient care not to damage the connectors while remove. Using 10 mm socket spanner, remove transmission WH inter connector mounting bolt and pull out the transmission wiring harness. Take sufficient care not to damage the wiring harness. Take sufficient care not to pull out the harness forcibly. Remove the O ring from the transmission wire connector. Using 10 mm socket spanner, remove detent spring mounting bolt and remove the cover and detent spring. Using 10 mm socket spanner, remove valve body assembly mounting bolts and remove the valve body. Be careful not to drop the Valve body assembly. Remove the transmission housing gaskets. By using Nose plier, remove the brake drum gaskets from the housing. Apply a thin layer of ATF on new brake drum gaskets and install them on the transmission housing. Ensure to fix the drums side shown in the Illustration should be fixed in the case side. Always ensure to replace the New brake drum gaskets while install. Apply a thin layer of ATF on new transmission gaskets and install them on the transmission housing. Always ensure to replace the New transmission gaskets while install. Position the Valve Body assembly and Insert the manual valve lever into the groove on the end of the manual valve. Install the Valve Body assembly with the new bolts to the Transmission housing and torque tighten the bolts to specified value. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W710.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Always ensure to replace the New Valve Body bolts while install. Ensure to Install the appropriate length bolts as shown in the Illustration. M6 x 1.0 x 25 mm M6 x 1.0 x 36 mm M6 x 1.0 x 50 mm Install the detent spring and detent spring cover with the bolt to the housing and torque tighten the bolt to specified torque. Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W712.jpg",
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": " Ensure to align the center of the detent spring roller with the center of the manual valve lever. Insert the transmission wiring harness in the housing and Install the transmission WH inter connector mounting bolt and torque tighten the bolt. Always ensure to replace the New O ring of the transmission wire connector while Installationand coat the O ring with ATF while install. Torque : 5.4 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W716.jpg",
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Connect the solenoid electrical connectors. When connecting the connector, Ensure the connector is fully engaged by connecting it until you hear a click noise to ensure proper engagement. Install the oil temperature sensors and sensor clamps to the valve body assembly by the mounting bolts and torque tighten the bolts (A & B) to specified value. Bolt \u201cA\u201d can be used in different lengths \u2014 M6 x 1.0 x 14 mm or M6 x 1.0 x 12 mm For A = 10 \u00b1 2 Nm For B = 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W720.jpg",
+ "display_order": 76
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Connect the AT wiring harness electrical connector on the AT pigtail. Refit the Oil Strainer Assembly. For addition information refer to Oil Strainer Assembly \u2013 R&R section. Tighten the battery negative cable mounting nut. Torque : 6.0 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Check AT oil level and top-up if required. For additional information refer to AT oil level inspection and Filling procedure. Check for oil leak between contact surface of oil pan and housing. Carry out Service routine (Clear learned data in EEPROM) while replace New Valve Body Assembly. Carry out Initial Learning while replace New Valve Body Assembly. Inspect that shift lever can shift smoothly and accurately when shifting shift lever from N to other range. Inspect that engine can be started with shift lever only N or P, but not in other range. Inspect the gear shifter indicator in the instrument cluster be turned on correctly while in P-R-N-D positions. If any of the above conditions are not fulfilled, Kindly check & adjust Selector position switch & shifter link. Using 13 mm socket spanner, loosen and remove the electric stone guard mounting bolts. Torque : 4.0 \u00b1 0.5Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove e-disconnect fom the vehicle. Disconnect the oil cooler hose from the intermediate hose cooler end. Disconnect the oil cooler hose from the bypass valve to intermediate hose nd. Detach the hose from the routing clip and remove from the vehicle. Install in reverse order of removal. Check the AT oil level and top up if required. For additional information refer to AToil level inspection and filling procedure.</b</li> Inspect the hose for any crack & damage. Check for any external oil leakage. Rectify if found. Remove the automatic transmission with transfer case. Lock the flex plate using MST (0307ABH0001ST \u2013 Flywheel Locking Tool). Using 19 m socket spanner, unscrew flex plate mounting bolts. Torque : 50 \u00b1 3.0 Nm + 45\u00b0 \u00b1 1\u00b0 ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the Flex plate and back plate from crank shaft rear end. Install in reverse order of removal. Check the flex plate for any external damage, if found please replace. Check the back plate for any external damage, if found please replace. Inspect & ensure Gear Shifter Link Position at Neutral (N) as shown below. By fastening M6 bolt for matching shifter link hole with transmission hole and ensure Neutral (N Mode). Inspect & ensure Gear Shifter Link Position at Drive (D) Mode as shown below. Inspect & ensure Gear Shifter Link Position at Reverse (R) Mode as shown below. Inspect & ensure Gear Shifter Link Position at Parking (P) Mode as shown below. Transmission Oil \u2013 ATF NWS9638 Special Automatic Transmission Fluid.Total Oil Capacity \u2013 9.5 Liters.Top up Oil Quantity \u2013 0.5 Liters.Shift the TGS lever position to P. Lack of ATF volume: Oil pump vacuums air and causes lowness of line pressure, causing clutch slipping or lubrication failure of each part, resulting in burning out. Over level ATF volume: Gears in automatic transmission, etc., agitate ATF and cause bubbling and deterioration. When driving in this condition, ATF volume rises and ATF may blow off from the breather. Using 5 mm Allen key, remove the over flow plug and confirm for ATF dripping from the over flow hole and tighten the over flow plug to specified torque. Torque : 20 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110230.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "If ATF does not drop, remove the filler plug and fill the additional ATF until ATF drops from the overflow plug. Using 24 mm socket spanner, remove the filler plug and add 0.5L of ATF through filling hole by using Syringe (150ml or 300 ml) with hose and tighten the filler plug with specified torque. Torque : 39 \u00b1 15 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110225.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Always replace the filler plug O ring with a new one. Recommend to use only Mahindra ATF NWS9638 Special Automatic Transmission Fluid. Never mix 2 different oils. Connect the diagnostic tool and turn the ignition ON. Select THAR from the list of vehicle models and Select the \u201cTHAR_BS6\u201d. From the list of controllers shown, select \u201cTCU\u201d and click on \u201cLIVE DATA\u201d & click \u201cTRANSMISSION\u201d tab for ATF temperature reading (\u201cTransmission Oil temperature\u201d). Start engine and wait until ATF temperature reaches 44\u00b0C. Do not raise the temperature by performing a stall test. Shift TGS lever position from P to D and return to P, perform this operation 2 times. Spend more than 2 seconds per each position (P-R-N-D) while shifting from P to D and return. Confirm the ATF temperature between 44 - 54 \u00b0C in diagnostic tool. Using 5 mm Allen key, remove the over flow plug and check ATF drops from the overflow hole and wait until ATF flow becomes drop by drop. If ATF doesn\u2019t drops from the overflow hole then ATF level is low and check for oil leakage/ seepage at AT components and rectify. Refit the overflow plug and tighten the overflow plug with specified torque. Torque : 20 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Caution",
+ "content": "Always replace the overflow plug washer with a new one. Be sure to wipe off spilled ATF completely after tighten overflow plug. If not, it will cause Misjudge of oil leakage. Using 13 mm socket spanner, loosen and remove e-disconnect stone guard mounting bolts. Torque : 4.0 \u00b1 0.5Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4C110090.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect the oil cooler hose from the bypass valve end. Disconnect the oil cooler hose from the intermediate hose cooler end. Detach the hose from the routing clip and remove from the vehicle. Install in reverse order of removal. Check the AT oil level and top up if required. For additional information refer to AToil level inspection and filling procedure. Check for any external oil leakage. Rectify if found. Inspect the hose for any crack & damage. Park the vehicle and ensure to keep the transfercase shifting knob in 2H and AT gear shifter lever (TGS) in 'N' position. Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. Torque : 6.0 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove Engine Fead cover. For additional information refer to Engine Fead Cover - R&R section. Using 13 mm socket spanner unscrew starter motor positive cable mounting nut. Torque : 12 \u00b1 2.0 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner unscrew starter motor solenoid cable mounting nut. Torque : 2.5 \u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner unscrew starter motor mounting bolts and remove starter motor. Torque : 44 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 1 4 mm socket spanner unscrew transmission LH top mounting bolt. Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner unscrew transmission RH mounting bolts. Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner loosen and remove torque convertor mounting bolts. Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Notice",
+ "content": "Rotate the crank pulley using 24 mm ring spanner to access the torque convertor mounting bolts. Ensure to hold the crank pulley while loosen the torque convertor mounting bolts. To access the other torque convertor bolts; rotate the crank pulley to 60 degree respectively. Carefully remove and refit torque convertor mounting bolts, Failing may leads to fall of bolts inside the AT housing. Remove the exhaust intermediate pipe. For additional information refer to Exhaust Intermediate Pipe - R&R section. Remove the exhaust front pipe. For additional information refer to exhaust front pipe - R&R section. Using 13 mm and 16 mm ring and open spanners unscrew rear propeller shaft mounting bolts and nuts rear axle end. Torque : 65 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using 14 mm ring and open end spanners unscrew rear propeller shaft mounting bolts and nuts transfer case end and remove propeller shaft from the vehicle. Torque : 65 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using 13 mm combination spanner Unscrew front propeller shaft mounting nuts from transfercase end. Torque : 25 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using 8 mm socket spanner unscrew front propeller shaft mounting bolts front axle end and remove propeller shaft from vehicle. Torque : 19 \u00b1 3.0 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using MST - 0703AAD0009ST (Shifter and selector cable eye end removal tool) detach the shifter cable from gear shifter link ball pin. Detach the abundant from routing bracket and remove the shifter cable from bracket. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Using MST - 0703AAD0009ST (Shifter and selector cable eye end removal tool) detach the transfer case cable from the transfer case ball pins. Detach the transfer case cable abutment from the cable bracket on transmission by pressing locking clip and pull up the abutments. Abutment Clip to be pressed till the cable comes out of Shifter Bracket (Lock), then detach cable from the Bracket. Do hold this cable damper to pull the cable from bracket. Don\u2019t hold this cable guide tube to pull the cable from bracket, it will lead guide tube to breakage. Disconnect the AT wiring harness electrical connector from the inter-connector. Disconnect the AT oil inlet & outlet hoses from thermal bypass valve end. Ensure to close the bypass tubes with dummy caps. Provide a jack to support transmission. Using 14 mm socket spanner unscrew transmission bed mounting bolts. Torque: 70 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": "Using 14 mm & 15 mm socket/Ring spanner unscrew cross member mounting bolts and nuts and remove the cross member. Torque: 65 \u00b1 10.0 Nm ",
+ "file": null,
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner unscrew AT transmission bottom mounting bolts. Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Carefully remove the AT assembly with transfercase. Attach MST 0701FAJ0001ST \u2013 AT Torque convertor Holding Tool with AT to hold torque converter. Install in reverse order of removal. Remove the AT Torque convertor Holding Tool and measure the end face distance. Measure the distance from the end face of the converter housing to the Torque onverter assembly as shown in the figure (Distance should be more than 18.15 mm ) and check that the Torque converter assembly is installed properly. Check AT oil level and top-up if required. For additional information refer to AT oil level inspection and Filling procedure. Inspect that shift lever can shift smoothly and accurately when shifting shift lever from N to other range. Inspect that engine can be started with shift lever only N or P, but not in other range Inspect the gear shifter indicator in the instrument cluster be turned on correctly while in P-R-N-D positions. If any of the above conditions are not fulfilled, Kindly check & adjust Selector position switch & Cable. Inspect the ATassembly for any external damage, Replace if required. Remove the front grill assembly. Press and disconnect the oil hose quick coupler oil cooler side. Press and disconnect the oil hose quick coupler Radiator side. Detach the routing clip and remove hose from the vehicle. Install in reverse order of removal. Check the AT oil level and top up if required.For additional information refer to AT oil level inspection and filling procedure. Check for ATF oil leakage and ensure that there are no oil leaks. Check for any external oil leakage. Rectify if found. Using 13 mm socket spanner, loosen and remove the e - disconnect stone guard mounting bolts. Torque : 4.0 \u00b1 0.5Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect the AT oil hose quick coupler radiator and interconnector end. Detach the hose routing clip and take out from the vehicle. Install in reverse order of removal. Check the AT oil level and top up if required. For additional information refer to AToil level inspection and filling procedure. Check for any external oil leakage. Rectify if found. Perform failure diagnosis by following the steps below. Only the basic procedure is described here. Before performing failure diagnosis, first perform basic steps (1) through (5) to pinpoint the area of the malfunction. Then perform troubleshooting while referring to inspection items. Effective procedures are described for each failure diagnosis item according to the system. Malfunctioning vehicle comes in for service. Analyze symptoms of malfunction expressed by customer. Check with the customer about the circumstances and conditions at the time of malfunction occurred and capture what, when, where, and in what circumstances the malfunction occurred in detail. In order to perform a correct diagnosis, confirm the symptoms of the malfunction properly without preconceptions. In order to confirm the symptoms of the malfunction properly, it is extremely important to ask the customer about the circumstances at the time the malfunction occurred. Even information such as malfunctions that occurred in the past that are thought to be unrelated or the repair record may be useful sometimes, so it is necessary to gather as much information as possible. Pre-inspection ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Using battery voltage tester, inspect the battery voltage with the engine stopped. Specified value (10 to 14 V). Inspect locations that can be visually checked, such as fuse blowout, harness disconnection or short circuit, and the connection state of connectors. Check diagnosis code (Vehicle Data Record) ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Warm up the engine sufficiently. Using Diagnostic tool, check the diagnosis code and Vehicle Data. When a diagnostic code is stored, data (vehicle data) is also stored in the TCU. Record it along with the Diagnostic Code. DTC is shown in the Trouble Code Chart. For additional information refer to Diagnosis Manual. If no diagnosis code is stored, check for symptoms of the malfunction and then perform a Road Test and Function Check. Use the data obtained at the time of checking for symptoms of the malfunction. For additional information refer to Time lag test procedure section. For additional information refer to stall test procedure section. Using Diagnostic tool, delete the diagnosis code and Vehicle Data. Diagnosis code and Vehicle Data cannot be cleared by simply disconnecting the cable from the negative terminal of the battery. Be sure to use the Diagnostic tool to clear them. Check symptoms of malfunction (recheck diagnosis code) ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Based on the information gathered from the customer and vehicle data, re-create the circumstances and environment in place when the malfunction occurred and check. Troubleshoot by diagnosis code ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Referring to Flow Chart of Troubleshooting by Trouble Code, check the content corresponding to the stored diagnosis code and inspect the circuits and parts corresponding to the malfunctioning system. For additional information refer to Diagnosis Manual. Inspect circuits and parts ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Referring to Inspection, inspect circuits and parts to pinpoint the location of the malfunction. For additional information refer to Diagnosis Manual. Repair malfunction ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Conduct repair or replacement to correct the pinpointed location of the malfunction. Completion test ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "After repair, part replacement, and/or adjustment to correct the location of the malfunction, check for symptoms of the malfunction to make sure the phenomenon does not occur. Using Diagnostic tool, delete the stored diagnosis code and vehicle data. If the TCU or automatic transmission was replaced, be sure to clear the learned values, and perform initial learning. Finished ",
+ "file": null,
+ "display_order": 24
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 61,
+ "sys_id": "THAR.LX-0009-Automatic Transmission",
+ "subsys_id": "THAR.LX-0009-Automatic Transmission-Selector Position Switch Inspection",
+ "systems": "Automatic Transmission",
+ "sub_systems": "Selector Position Switch Inspection",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W1053.jpg",
+ "myid": 1173,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0009-Selector Position Switch Inspection-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect & ensure Selector Position Switch at Neutral (N) Mode as shown below. Manual valve lever angel should be matched with switch projection (Marking) as shown in the figure. Manual valve lever position for various modes (PRND) at Selector Position Switch is below. By using 7 mm Open end spanner rotate the Manual valve lever and ensure P-R-N-D mode positions. Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. Torque : 6.0 \u00b1 0.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect the AT WH pigtail interconnector and routing clips. Using 10 mm socket spanner unscrew \u2014 WH grommet mounting bolts on the fire wall side. Torque : 10 \u00b1 1.0 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using screw driver unscrew floor console side trim mounting screw rivets and remove the trim. Disconnect the WH connector from IP WH and routing clips. Detach the WH from vehicle. Install in reverse order of removal. Check for any external damage, if found please replace. Transmission Oil \u2013 ATF NWS9638 Special Automatic Transmission Fluid.Total Oil Capacity \u2013 9.5 Liters.Lack of ATF volume Oil pump vacuums air and causes lowness of line pressure, causing clutch slipping or lubrication failure of each part, resulting in burning out. Over level ATF volume When driving in this condition, ATF volume rises and ATF may blow off from the breather. Overfilling results in ATF over heating. Shift the TGS lever position to P. Using 24 mm socket spanner, remove the filler plug from transmission. Using 14 mm socket spanner, remove the drain plug and the gasket. Drain the Automatic transmission fluid. Install the drain plug with new gasket and tighten the drain plug with specified torque. Torque : 20 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Always replace the drain plug gasket with a new one. Refill the ATF (9.5 Ltrs) through filling hole by using hose with funnel. Always use the clean hose/funnel for refilling and hose/funnel should be used only for ATF refilling purpose. Recommend to use only Mahindra ATF NWS9638 Special Automatic Transmission Fluid and Never mix 2 different oils. Do not overfill transmission, fluid foaming and shifting problems can result. Refit the filler plug on transmission, tighten the filler plug with specified torque. Torque : 39 \u00b1 15 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Always replace the filler plug O ring with a new one. Check AT oil level and top-up if required. For additional information refer to AT oil level inspection and Filling procedure. Park the vehicle and Position the TGS lever in N position. Ensure the gear shifter link in Neutral (N) Mode as shown below. By Using M6 size bolt lock the shifter link rod in N position as shown in fig. Disconnect the NSW switch Electrical connector. Unlock the Washer and use a 24 mm socket spanner to remove the switch mounting nut. Torque : 6.9 \u00b1 0.9 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner unscrew switch mounting bolt from casing. Torque : 12.75 \u00b1 2.95 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "By Using screw driver take out the switch from the manual lever and take out from the vehicle. Install in reverse order of removal. Position the Manual lever at N osition, lever position should be matched with switch projection (Marking) as shown in the figure. Ensure to lock the washer after fitment of mounting nut. Ensure to remove M6 Bolt mounted on the gear shifter link. Inspect Manual valve lever position for various modes (PRND) at Selector Position Switch are below. Inspect that shift lever can shift smoothly and accurately when shifting shift lever from N to other range. Inspect that engine can be started with shift lever only N or P, but not in other range. Inspect the gear shifter indicator in the instrument cluster be turned on correctly while in P-R-N-D positions. If any of the above conditions are not fulfilled, Kindly check & adjust Selector position switch & shifter link. Inspect the NSW switch for any damage, Replace if required. Make sure to clean dirt, sand or other foreign matter from the Automatic transmission assembly before removing components. Clean components and surrounding area prior to removal. Ensure that all parts are neatly stored in the appropriate container/tray as they removed, failing may leads to difficult while reassemble the components. Do not use cotton gloves or shop rags as frayed strings might get caught in the unit.Thus, work with your bare hands or use plastic gloves. Do not drain the ATF when it is hot, wait until it has cooled down. Recommend to use only Mahindra ATF NWS9638 Special Automatic Transmission Fluid and Never mix 2 different oils. Always replace gaskets, O rings and oil seals etc. with new ones. Do not overfill transmission, fluid foaming and shifting problems can result. Keep work areas clean and organized. Pick up tools and use tool cabinets to keep walkways clear and free from clutter. Using 10 mm socket spanner, Loosen the battery negative cable mounting nut and disconnect the cable. Should not remove the battery connection when the EWP is ON, Ensure to disconnect only when the EWP is off, Failing to do may affect the dozing module performance. Before disconnecting the battery, check for the audible sound of EWP ON. Remove the AT Oil Pan Assembly. Using 10 mm socket spanner, remove mounting bolts and remove oil strainer from the valve body assembly. Remove the O ring from the oil strainer. Apply a thin layer of ATF on new O ring and install on the oil strainer. Always replace the O ring with a new ne. Position and Install the oil strainer mounting bolts on valve body assembly, torque tighten the bolts to specified value. Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Refit AT Oil Pan Assembly. For additional information refer to AT Oil Pan Assembly - R&R section. Tighten the battery negative cable mounting nut. Torque : 6.0 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Check AT oil level and top-up if required. For additional information refer to AT oil level inspection and Filling procedure. Check for oil leak between contact surface of oil pan and housing. Inspect that shift lever can shift smoothly and accurately when shifting shift lever from N to other range. Inspect that engine can be started with shift lever only N or P, but not in other range. Inspect the gear shifter indicator in the instrument cluster be turned on correctly while in P-R-N-D positions. If any of the above conditions are not fulfilled, Kindly check & adjust Selector position switch & Cable. Remove the Torque Converter. For addition information refer to Torque Converter \u2013 R&R section. Using a screw driver, remove Oil Pump Oil Seal from transmission. Refit oil seal by using special tool 0701CAJ0002ST - AT Oil Pump/ Rear Housing Oil Seal Installer - 4WD/2WD. Refit the Torque Converter. For addition information refer to Torque Converter R&R section. Check AT oil level and top-up if required. For additional information refer to AT oil level inspection and Filling procedure. Inspect the Oil Pump Oil Seal for any damage. Replace if found any. Check that there is no foreign matter in ATF. In case of surplus metal powder or lining powder, it is considered wear-out of internal automatic transmission components. Check that ATF does not change color. In a case of becoming clouded, especially, it is possible that water is mixed in, so inspect cooling system. The purpose of the road test is to accurately grasp the symptoms of the malfunction and to check completion after repairs are finished. Be sure to perform a road test under the conditions below. Perform after engine inspection and adjustment. Perform with ATF temperature (50-80\u00b0C) under ordinary driving conditions. The A/C, lights, etc., are turned off. Cruise control is off. When performing a road test on public roads, first check the safety of the road.Road Test Procedure. Remove the Instrumental Panel Assembly. Using a star driver, loosen and remove the IP driver side switch bank mounting screws. Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270121.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Detach the IP driver side switch bank from the Instrumental Panel Assembly. Install in the reverse order of removal. Inspect the IP driver side switch bank condition, if required replace. By using Trim Removal tool, remove the bezel rest from front door RH. Disconnect the electrical connector from the bezel. Using flat screw driver detach the switch from the bezel. Install in the reverse order of removal. Check the mounting clips condition to avoid rattling and falling down. Check the switch condition. If required replace. Pull and remove the tail lamp cover from vehicle. Using 10 mm socket spanner, loosen and remove tail lamp mounting bolts and partially detach it. Torque : 4 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270044.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect tail lamp electrical connector. Remove tail lamp from vehicle. Install in the reverse order of removal. Inspect the tail lamp/ rear lamp assembly for any physical damage/crack etc. Inspect the glass for fading. Inspect the condition of bulbs. Inspect the connectors for proper fitment. Remove the IP center switch bank assembly. Using a star driver, loosen and remove the center switch mounting screws. Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270005.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the center switch from IP center switch bank assembly. Install in the reverse order of removal. Check the mounting clips condition to avoid rattling and falling down. Check the switch condition. If required replace. Remove front grill assembly. Pull the lock disconnect head lamp electrical connectors. Using 10 mm socket spanner, loosen and remove the head lamp mounting bolts. Torque : 6 \u00b11Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270022.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Carefully remove the head lamp assembly separately. Install in the reverse order of removal. Inspect the head lamp for any damage, crack and glass fading. Inspect the bulbs. Remove tail lamp cover from tail lamp. Using 10 mm socket spanner unscrew tail lamp mounting bolts. Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270044.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect tail lamp electrical connector. Remove and turn the backup lamp bulb socket in the direction of the arrow. Remove the reverse lamp bulb from holder. Install in the reverse order of removal. Check the bulb condition to avoid rattling and falling down. Check the bulb condition. If required replace. Using a star screw driver, Unscrew front splash shield lower mounting screws (Front side screws). Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nut. Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the front side of shield to access front turn indicator and DRL. Disconnect the front turn indicator and DRL electrical connectors. Using a 10 mm socket spanner loosen and remove the front turn indicator and DRL mounting bolts. Torque : 4\u00b11 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270112.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully remove front turn indicator and DRL. Refit in the reverse order of removal. Inspect the front turn indicator and DRL for any damage, replace if required. Using a star screw driver, Unscrew front splash shield lower mounting screws. Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts. Torque : 6.5 \u00b10.7 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield. Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270047.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Rotate the bulb holder in anti clock wise direction and remove the holder with bulb. Remove the bulb from the holder. Install in the reverse order of removal. Check the bulb condition to avoid rattling and falling down. Check the bulb condition. If required replace. Using a star screw driver, Unscrew front splash shield lower mounting screws. Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts. Torque : 6.5 \u00b10.7Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield. Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270037.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect the electrical connector. Using hand, Push the side marker lamp assembly from the cladding and remove. Remove the Side Marker Lamp from vehicle. Install in the reverse order of removal. Inspect the side marker lamp assembly for any physical damage/crack etc. Inspect the glass for fading. Inspect the condition of bulbs. Inspect the connectors for proper fitment. Remove tail lamp cover from tail lamp. Using 10 mm socket spanner unscrew tail lamp mounting bolts. Torque :4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270044.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect tail lamp electrical connector. Remove the bulb from holder by turning the bulb in counter clock wise direction. Gently pull out the bulb from holder. Install in the reverse order of removal. Check the bulb condition to avoid rattling and falling down. Check the bulb condition. If required replace. Using a star screw driver, Unscrew front splash shield lower mounting screws. Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts. Torque : 6.5 \u00b1 0.7 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield. Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270058.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect parking lamp electrical connector. Rotate and remove the bulb holder from vehicle. Remove bulb from holder by turning the bulb in counter clock wise direction. Detach the bulb from holder. Install in the reverse order of removal. Check the bulb condition to avoid rattling and falling down. Check the bulb condition. If required replace. RIGHT TURN INDICATOR ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "For inspection, push the lighting control stalk clockwise (to stop position B) to indicate a right turn. The instrument cluster arrow lamp pointing towards the right flashes along with the right side turn signal lamps with chime indicating your intention of turning towards right After you have completed your right turn, the stalk will automatically return to the neutral position. Both the right turn lamp and the right turn signal lamp switch OFF. LEFT TURN INDICATOR ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "For inspection, push the lighting control stalk anti-clockwise (to stop position A) to indicate a left turn. The instrument cluster arrow lamp pointing towards the left flashes along with the left side turn signal lamps with chime indicating your intention of turning towards left.</li</ul> LAMPS OFF ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "For inspection, rotate the outer rotary switch on the lighting control stalk aligning the \u2018Arrow\u2019 on the switch to \u2018O\u2019 on the stalk to switch OFF all lamps. LANE CHANGING ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "For inspection of signal a lane change, move the light control stalk clockwise or anti-clockwise to the limit point of free movement of the lever and release. The turn signals will flash three times and stop. PARKING LAMPS ON ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "For inspection, rotate the outer rotary switch on the lighting control stalk aligning the \u2018arrow\u2019 on the switch to the \u20181st d\u00e9tente\u2019 position on the stalk to switch ON the parking lamps. HEAD LAMP ON ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "For inspection, rotate the outer rotary switch on the lighting control stalk aligning the \u2018Arrowt\u2019 on the switch to the \u20182nd d\u00e9tente\u2019 position on the stalk to switch ON the head lamps. HEAD LAMP HIGH BEAM/LOW BEAM ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "For inspection, with the head lamp ON, push the lighting control stalk down (away) from steering wheel to switch ON the head lamp high beam. The head lamp high beam tell-tale lamp in the instrument cluster illuminates indicating high beam option selected. With the head lamp high beam ON, pull the lighting control stalk up towards the steering wheel to switch ON the head lamp low beam. HEAD LAMP FLASH ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "For inspection, pull the lighting control stalk (from the head lamp low beam position) towards the steering wheel to instantaneously flash the head lamp high beam. The head lamp flash works even when the head lamp is OFF. FOG LAMPS OFF ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "For inspection, align the inner rotary switch on the lighting control stalk to the fog lamp off \u2018dot\u2019 on the inner fixed stalk as shown to switch OFF the fog lamps. FRONT FOG LAMPS ON ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "To inspect the front fog lamps, switch ON the ignition and the parking lamps. Turn the inner rotary switch on the lighting control stalk to align to the fog lamp symbol on the inner fixed stalk as shown. The front fog lamp indicator in the instrument cluster indicates the operation status. HAZARD WARNING LAMP ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "For inspection, press the hazard switch ON, All the turn signal lamps flash. To turn OFF, press the switch again. CENTER ROOF LAMP ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "The Roof lamp switch has three operation modes to choose from;
The lamp remains permanently ON in this position irrespective of the door open status. The lamp remains permanently OFF in this position. The lamp remains in AUTO mode in this position. WIPER CONTROL STALK ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Wiper Off For inspection, move the wipe stalk in neutral position (B). Wiper remains OFF.
Flick-Wipe (Mist) For inspection, push the wipe control stalk to position A for a flick-wipe, hold to operate the wipe continuously (simultaneously lift the wiper stalk towards the steering wheel to operate the wash). The stalk automatically comes back to position B when released.
Intermittent (INT) Mode For inspection, push down the stalk down to position C. In the INT mode, the wiper operates on preset intervals.
Low Speed Wiping For inspection, push the wipe control stalk up to the position D to operate the wiper at a fixed low speed.
High Speed Wiping For inspection, push the wiper control stalk up to position E to operate the wiper at a fixed high speed.
FRONT WIPE/WASH ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "For inspection, pull/lift the wiper control stalk towards the steering wheel from any position to activate the front wipe/wash function. Washer fluid is sprayed on the front windshield and the wipers wipe the windshield 3 times after the washer spray is stopped and wipe once after 4 sec. Hold the stalk in position for continuous spray of washer fluid. HORN ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "For inspection, press the pad on the steering wheel to sound the horn. The horn functions even when the ignition has been switched OFF. STOP LAMP/HIGH MOUNTED STOP LAMP ",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "For inspection, Press the brake pedal and the Stop Lamp /high mounted stop lamp will illuminate. REVERSE LAMP ",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "For inspection, Engage the reverse gear and the reverse lamp will illuminate. Vehicle & head lamp aiming board should place on the same level surface Check and ensure all four tyre pressures as per specification. Head lamp levelling switch position is on zero (0). Vehicle needs to be parked 10 meters or 3 meters away from the aiming board. (L = 10 meters / 3 meters which is the distance from starting point of front tyre to the aiming board as shown in illustration below).Select the aiming board according to the value of \u201cL\u201d. Head lamp Alignment by Visual Method.
Refer below illustration for \u201cL= 10 Meters\u201d. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270086.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refer illustration for \u201cL= 3 Meters\u201d. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270091.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Refer the illustration for the head lamp adjustment arrangement ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270087.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270088.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Refer the illustration for the head lamp aiming board dimensions of Head Lamps ",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ },
+ {
+ "procedure_name": "Low Beam Setting Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270089.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270090.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Refer below illustration for the head lamp aiming board dimensions of Head Lamps ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "Low beam & high beam aiming settings are common. Hence if adjust low beam, high beam will also get aligned with low beam. Using 5 mm socket spanner, rotate the adjusting screw on motor to vary the Low beam cut-off pattern in vertical direction. Clockwise rotation \u2013 Downwards. Anti-clockwise rotation \u2013 Upwards. Using star screw driver, rotate the RH side lamp adjusting screw to vary the low beam cut-off pattern in horizontal direction. Clockwise rotation \u2013 Left Side Anti-clockwise rotation \u2013 Right Side. RH & LH Head lamps are common for New THAR vehicle. Using star screw driver, rotate the LH side lamp adjusting screw to vary the low beam cut-off pattern in horizontal direction. Clockwise rotation \u2013 Right side. Anti-clockwise rotation \u2013 Left side. Check the function of system, by operating the switch from '0' to '3' and observe the cutoff pattern movement in downward direction accordingly. At zero position of switch, the cut- off should come at \u201ch\u201d heights 833 mm (For L= 10,000 mm) & 924 mm (For L=3,000 mm) on screen. Low beam & high beam aiming settings are common. Hence if adjust low beam, high beam will also get aligned with low beam. Remove the switch bank driver side. Remove the aiming switch lock by using flat screw driver. Insert the screw driver one side to release lock & release other side. Detach the IP driver side switch bank from the vehicle. Install in the reverse order of removal. Inspect the aiming switch condition, if required replace. Using a star screw driver, Unscrew front splash shield lower mounting screws. Using 10 mm socket spanner, Unscrew front splash shied mounting plastic mounting nuts. Torque :6.5\u00b10.7 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250192.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew front splash shied mounting bolt and partially detach the shield. Torque : 4 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A270033.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect front indicator electrical connector. Rotate and remove the bulb holder from vehicle. Remove bulb from holder by turning the bulb in counter clock wise direction. Install in the reverse order of removal. Check the bulb holder condition to avoid rattling and falling down. Check the bulb condition. If required replace. Using star screw driver unscrew the panel assembly floor console RH screvits and detach the panel from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290031.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console LH screvits and detach the panel from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290034.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew vertical ascent RH mounting screw and detach the vertical ascent RH from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290033.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew vertical ascent LH mounting screw and detach the vertical ascent LH from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290035.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290036.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290036.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "partially detach the switch bank assembly and remove electric connector to take out from the vehicle. Install in the reverse order of removal. Inspect the center switch for any physical damage. Replace if found. Remove the Convertible Soft top Canopy. Remove the support centre Rexine rivets other side. Remove the Support Side Rexines rivets RH & LH. Using star screw driver, loosen and remove the Bow 1 Injection Mould mounting screws (locate 1 screw at bottom side of centre rexine support). Using star screw driver, loosen and remove the Latch mounting screws. Remove the Bow 1 Injection mould from front side bow and remove the Convertible Soft top Frame Complete assembly. Refit in the reverse order of removal. Inspect the Convertible Soft top Frame Complete assembly for any crack or damage. Replace if any. Remove Side window RH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Remove Side window LH Velcro and Unzip the window. Unhook the window from the vertical and horizontal belt rail and remove the window. Unzip the tail gate window, detach the tail gate bar locking from rear RH & LH belt rails remove the tailgate window. Unhook the \u2018C\u2019 pillar cover from rear RH & LH belt rails and fold the cover at top of the soft top. Slide the Sun visors and Remove the Footman's loops from front header. While unlock the Footman loop hook from the front header metal bracket, ensure to press & move the softtop assembly slightly in forward direction and release the hook from the bracket. Slide back the convertible top from front header to rear and roll up properly. Properly Roll up the convertible soft top assembly in the rear side as shown in fig . Unlock two Quick release knuckle RH & LH from main pivot brackets . Lift the convertible soft top assembly upwards (both sides) , silding towards rear and take out assembly from the vehicle. Lift the convertible soft top assembly upwards (both sides), sliding towards front and position on the vehicle as shown. Align the convertible soft top assembly both sides & Lock the two Quick release knuckle to RH & LH main pivot brackets . Properly open rolled convertible soft top assembly from the rear side. Slide convertible top from rear end to front header and position on front header properly. Lock the Footman's loops to the front header and slide the Sun visors. Lock the Footman loop hook on the front header metal bracket & press the loop handle While locking ensure top plastic support project on top of the header metal bracket for proper locking as shown. Unfold and Hook the \u2018C\u2019 pillar cover to rear RH & LH belt rails . Attach the tail gate bar locking to rear RH & LH belt rails and zip tailgate window. Position and hook LH side window to the vertical and horizontal belt rail. Zip the window and refit the LH Side window Velcro . Position and hook RH side window to the vertical and horizontal belt rail. Zip the window and refit the RH Side window Velcro . Check the Convertible Soft Top Assembly for any damage, replace if required. Remove the Spare Wheel Carrier. Remove the air extractor from the vehicle. Refit in the reverse order of removal. Inspect the air extractor for any crack or damage. Replace if any. Remove Front Roof caps using trim remover and Using a T30 socket spanner, loosen and remove the roof front top mounting bolts. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250214.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250215.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250216.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250217.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Rear Roof caps using trim remover and Using a T30 socket spanner, loosen and remove the roof rear top mounting bolts. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240016.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A240018.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a trim remover pull out center bow trim and disconnect roof lamp electrical connector. Ensure to use trim remover while removing centre roof bow trim, and avoid the press clip damage. Replace the press clip for proper fixing, if it is damaged. Remove the centre bow trim from the vehicle. Using a T30 socket spanner, loosen and remove the roof top mounting bolts inside bow trim. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250102.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250103.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "By Using T30 Torx Socket Spanner remove the RH & LH roof side upper frame mounting bolts. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250104.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250104.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "By Using T30 Torx Socket Spanner remove the RH & LH roof side lower frame mounting bolts Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250206.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250207.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "By Using T30 Torx Socket Spanner remove the RH & LH rear lower bracket mounting bolts. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250208.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250209.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a T30 socket spanner, loosen and remove the roof top mounting bolts from roll cage. Torque : 10\u00b12 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250108.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Disconnect the HMSL electrical connector. Insert and split the panel with trim remover, in between Hard-Top and frame mounting plate. Lift and Carefully remove the hard top assembly from the vehicle with sufficient manpower and keep it in Trolly bench or flat working bay. Use the recommended safety equipment\u2019s; Safety goggles, Cotton gloves, Safety shoes etc. while lifting the Hard-Top. Prepare the Hard-Top assembly for installation
Remove the dust & strain marks by Steel wire brush. (as shown in illustration) Clean with degreaser cloth for silicon sealant application. Don't use ordinary solvent for HardTop cleaning. (it may result some undefined problems in Hard-Top). Inspect the Hard-Top windshield upper frame Seal and replace if needed when the seal loses its softness or if found any damages. Follow the below steps for replacement of Hard-Top windshield upper frame Seal Remove the X-mas tree clips by trim remover from over the roof rail outer frame. Then pull the seal by manually, due to this seal has fixed with two-way pasting tape. Clean the surface by degreaser cloth. Peel the sticker label sheet from the new Seal, then paste on the roof rail outer frame followed by press the X-mas tree clips. The Seal must be replaced along with X-mas tree clips, when the seal loses its softness or if found any damages, don't reused the X-mas tree clips. This seal is for preventing the water leakage and wind noise only. Seal coming with Two-way pasting tape. Before Installation, Apply the silicon sealant on inner side edges of Hard-Top by manual Sealant gun. A triangular V- shaped notch will provide the optimal bead shape. (Height 4 mm/ width 5 mm). After sealant application, immediately fix the Hard-Top assembly, with help of sufficient manpower. Silicon sealant must be applied for water leakage and wind noise prevention. Refit in the reverse order of removal. While Installation hand tighten all the Hard top mounting bolts first for proper positioning and finally torque tighten all the bolts. Don\u2019t over tighten the screws to avoid the thread slipping and other damages. While Installation properly position the Hard top dowels in the body for proper positioning & fitment. Inspect the hard top assembly for any damage. Replace if found. Tools Required: ",
+ "file": null,
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250184.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using 12 mm socket and 13 mm combination spanner, Unscrew front bracket mounting bolt and nut. Using 12 mm socket and 13 mm combination spanner, Unscrew front centre bracket mounting bolt and nut. Using 13 mm socket combination spanner, Unscrew rear bracket mounting bolt. Remove the front foot step assembly from vehicle. Front extreme portion of foot step is not to stand, Since front portion is aesthetic part to merge the design theme with cladding. Refit in the reverse order of removal. Check for any damages or crack in foot step assembly. Replace if found. Tools Required ",
+ "file": null,
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250007.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Pull out cover cap from the wiper arm. Using a 13mm socket spanner, loosen and remove the Wiper arm mounting nuts. Torque : 15 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250009.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the wiper arms from vehicle. Using a star screw driver, loosen and remove the Scuttle Grill mounting screws . Torque : 1.9\u00b10.5Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250010.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the Scuttle Grill mounting Scrivets . Remove the Scuttle Grill from the vehicle. Refit in the reverse order of removal. Inspect the Scuttle grill for any damage. Replace if found. Inspect the mounting push buttons, replace if required. Using a star screw driver, loosen and remove the front splash shield mounting screw rivets from both the sides of vehicle. Remove the front splash shield both the sides from vehicle . Using a 10 mm socket spanner, loosen and remove the front stone guard front mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250064.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen and remove the rear stone guard rear mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250033.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the stone guard mounting screw rivets. Remove the stone guard from the vehicle. Disconnect the fog lamp electrical connectors LH & RH sides. Pull and remove the front bumper top panel trim clips and remove the panel. Using a 10 mm socket spanner, Unscrew front bumper mounting nuts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290005.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "using a 13 mm socket spanner, Unscrew front bumper bottom mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290006c5695d.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew front bumper top side mounting bolts. Using a star screw driver, Unscrew front bumper top centre mounting screw rivets. Remove the front bumper assembly from the vehicle. Using a 13 mm socket spanner, Unscrew front bumper center bracket mounting bolts and remove the front bumper center mounting bracket. Torque : 10.0\u00b11 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250060.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the front grill mounting screw rivets. Using a star screw driver, loosen and remove the bottom side front grill mounting screw rivets. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250061.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the front grill mounting bolts. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250062.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250063.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Remove the front grill assembly from the vehicle. Using star screw driver, Remove centre grill mounting screws and locking clips from front facia. Remove the centre grill from front facia. Refit in the reverse order of removal. Inspect the front bumper assembly for any crack or damage, Replace if found any. Check the front grill assembly for any external cracks, replace if found any. Remove the Soft top canopy. Using a 10 mm socket spanner, loosen and remove the rear side cover LH mounting bolts. Using a 10 mm socket spanner, loosen and remove the rear side cover RH mounting bolts. Carefully remove the rear side covers LH and RH sides. Using a 10 mm socket spanner, loosen and remove the rear side member RH mounting bolts. Carefully remove the rear side member RH from vehicle. Using a 10 mm socket spanner, loosen and remove the rear side member LH mounting bolts. Carefully remove the rear side member LH from vehicle. Using a 10 mm socket spanner, loosen and remove the rear centre panel assembly mounting bolts. Using a T40 torx socket spanner, loosen and remove the rear structure frame mounting torx bolts. Remove the rear structure frame from vehicle. Refit in the reverse order of removal. Check the rear structure frame for any external cracks and damages, replace if found any. Remove the convertible soft top assembly. Using a star screw driver, loosen and remove Canopy mounting screws from the front side bow assembly RH and LH. Remove the lock from the RH and LH Front side bow assembly. Using star screw driver, loosen and remove Canopy mounting screws from Front side bow assembly inner side. Remove the Canopy from the front side bow assembly. Detach or unlock the spring from the Bow 2 Pivot assembly & remove Canopy from Bow 2 Pivot assembly . Using star screw driver, loosen and remove the canopy mounting screws from bow 2 pivot assembly and detach canopy. Using star screw driver, loosen and remove the canopy mounting screws from bow 3 assembly and detach canopy. Remove the Center Support Rexine Rivets. Remove the Canopy from the Frame. Remove the Cable with Spring from the Canopy (RH &LH). Refit in the reverse order of removal. While Installation, Insert the cable from bracket side to Spring side (Insert spring inside from top) Inspect the convertible soft top canopy for any crack or damage. Replace if any. For additional information refer to the Front Door Inner Trim - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250283.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect the electrical connector from the ORVM. Using 10 mm socket spanner, loosen and remove the mounting nuts from the ORVM. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250275.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250276.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the ORVM from the vehicle completely. Refit in the reverse order of removal. Inspect the ORVM for any crack or damage. Replace if any. Tools Required ",
+ "file": null,
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove front lateral trim. Remove Roof Speaker trim assembly. Open the top cover and Using a 14 mm socket spanner, loosen and remove the seat belt upper mounting bolt. Torque :38 \u00b16 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A210081.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the seat belt lower mounting bolt. Torque :38 \u00b16 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250023.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the hand support belt. Remove the floor mate partially from the vehicle. Using a 13mm socket spanner, loosen and remove the roller gage bar rear mounting bolt. Torque : 25 \u00b1 4Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250026.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 13mm socket spanner, loosen and remove the roller gage bar front mounting bolt. Torque : 25 \u00b1 4Nm ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250027.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 13mm socket spanner, Unscrew roller gage bar side mounting bolts. Torque : 25 \u00b1 4Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250028.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the roller gage bar from vehicle. Remove the roller bar cover and separate roller gage bar. Refit in the reverse order of removal. Check for any damages or crack in roller gage bar assembly. Replace if found. Using a 10 mm socket spanner, loosen and remove the rear mounting tube pipe structure mounting bolts. Remove the welcro from the rear tubes . Remove the side cover from window bracket LH and RH sides. Using a 10 mm socket spanner, loosen and remove the front mounting tube pipe structure mounting bolts. Using a star screw, loosen and remove the canopy front LH and RH screw rivets. Using a 10mm socket spanner, Unscrew canopy front end mounting bolts. Remove the Canopy from the vehicle. Refit in the reverse order of removal. Check the canopy assembly for any external cracks, replace if found any. Remove the HVAC Mode Actuator. Using star screw driver, Unscrew plate mode main link mounting screws and remove the link. Remove the lever sub assembly and lever foot from the plate mode main link. Install in the reverse order of removal. Inspect the plate mode main link for any damage. Replace if found. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. ",
+ "file": "",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Air Cleaner Assembly. ",
+ "file": "",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.LX-0009,1000,1003",
+ "file": "",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the Steering Lower Intermediate Shaft. ",
+ "file": "",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Link",
+ "content": "THAR.LX-0009,1017,1302",
+ "file": "",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 12 mm open end spanner, Remove suction and discharge hose mounting nut from compressor. ",
+ "file": "",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Torque Value",
+ "content": "Torque Value: 14.0+1.0 Nm",
+ "file": "",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A200093.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the AC/water pump belt. For additional information refer to AC/Water Pump Belt - R&R. ",
+ "file": "",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Disconnect the AC compressor electrical connector. ",
+ "file": "",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A200094.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Remove the compressor mounting nuts from the crank case. ",
+ "file": "",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Torque Value",
+ "content": "Torque : 25 \u00b1 3 Nm",
+ "file": "",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A200095852b7a.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the compressor from the vehicle. ",
+ "file": "",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": "",
+ "file": "/files/W4A200095.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. ",
+ "file": "",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Refit the Steering Lower Intermediate Shaft. ",
+ "file": "",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Link",
+ "content": "THAR.LX-0009,1017,1302",
+ "file": "",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Refit the Air Cleaner Assembly. ",
+ "file": "",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Link",
+ "content": "THAR.LX-0009,1000,1003",
+ "file": "",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Remove the AC/water pump belt. For additional information refer to AC/Water Pump Belt - R&R. ",
+ "file": "",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Recharge the A/C gas. For additional information refer to Refrigerant Recovery Recycling and Recharging Procedure. ",
+ "file": "",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both liquid tube and discharge hose mounting joints without any damage. Damage to the O-ring may cause A/C refrigerant leakage which leads to A/c failure. ",
+ "file": "",
+ "display_order": 27
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the compressor for any physical damage. Replace if found. Inspect the clutch pulley for any damage. Replace if found. Inspect the drive belt and Pulley for any physical damage. Replace if found. ",
+ "file": "",
+ "display_order": 28
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 215,
+ "sys_id": "THAR.LX-0009-Heating, Ventilation And Air Conditioning (HVAC)",
+ "subsys_id": "THAR.LX-0009-Heating, Ventilation And Air Conditioning (HVAC)-AC Pipe (Compressor To Condenser)",
+ "systems": "Heating, Ventilation And Air Conditioning (HVAC)",
+ "sub_systems": "AC Pipe (Compressor To Condenser)",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A200088.jpg",
+ "myid": 1320,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0009-AC Pipe (Compressor To Condenser)-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200088.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/50007.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/50009.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Recover AC gas. For additional Information refer to Refrigerant Recovery Recycling and Recharging Procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Do not release the refrigerant into the atmosphere. Use approved recovery/ recycling equipment to capture the refrigerant whenever the air conditioning System is discharged. Always wear eye and hand protection (goggles and gloves) when working with any Refrigerant or air conditioning system. Close the high pressure and low pressure refrigerant lines with dust caps to avoid air entry and/or contamination. Remove Front Grill Assembly. Using 12 mm Combination Spanner, Unscrew the AC pipe compressor side mounting nut. Torque : 14.0+1.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200070.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew radiator LH seal mounting bolt and remove the seal. Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200071.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Remove HVAC pipe condenser side mounting nut. Torque : 6.0+1.0 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both pipe ends mounting joints without any damage. Damage to the Oring may cause A/C refrigerant leakage which leads to A/c failure. Remove the HVAC pipe assembly from the vehicle. Install in the reverse order of removal. For additional Information refer to Refrigerant Recovery Recycling and Recharging Procedure. ",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the AC pipe for any damage. Replace if found. Using screw driver, remove the floor console RH panel assembly scrivet and detach the panel from the vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220004.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220005.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the floor console LH panel assembly scrivet and detach the panel from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220006.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220007.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the RH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1547.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1549.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the LH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220010.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1548.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Partially detach bezel HAVC control panel assembly and disconnect electrical connectors. Disconnect Heater, Mode selection control cables from the HVAC control panel. Disconnect the cable routing clips and take out the bezel Assembly with HVAC control panel. By using star screw driver, remove the HVAC control panel mounting screws and remove the panel from the bezel assembly. Torque : 1.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200160.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200161.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the HVAC Control Panel Assembly for any damage. Replace if found. Disconnect the HVAC blower motor electrical connector. Using star screw driver, loosen and remove the blower motor mounting screw. Remove the blower motor from the HVAC unit assembly. Install in the reverse order of removal. Rotate the blower motor and check for any noise due to bearing wear. Check the blower motor fan blade for damage. Replace the blower motor if necessary. Whenever over voltage/under voltage situation will occur over ignition Line. These voltages will get sense by MCU and based on these sense voltages panel functionality will disabled or in case of under/over Voltage system will not detect any switch command. It is a kind of Security over connector Pins except Power supplies Pins. If any shorting occur on connector pin either short to battery or short to ground there should be no damage to control panel or circuitry. Over Current/Short to Ground: Face Indicator on off with Frequency 1000 mSec Interval. Short to Battery/ Actuator Stuck: Face Indicator on off with Frequency 500 mSec Interval. Over Current/Short to Ground: Air Intake Indicator on off with Frequency 1000 mSec Interval. Short to Battery/ Actuator Stuck: Air Intake Indicator on off with Frequency 500 mSec Interval. Over Current/Short to Ground: Defrost Indicator on off with Frequency 1000 mSec Interval. Short to Battery/ Actuator Stuck: Defrost Indicator on off with Frequency 500 mSec Interval. AC Indicator Blink with 500 mSec Frequency. The purpose of the condenser is to dissipate the heat accumulated during gas evaporation and compression. Once it is cooled, the gas becomes a liquid and remains under high pressure. To improve thermal exchange, the fluid is exposed to air flow produced by the engine cooling fans and vehicle movement.This step allows for fluid expansion. Its location is in front of the radiator. From compressor high pressure high temperature refrigerant is introduced into the top of the condenser as the gas moves through the condenser it gets cooled. As the refrigerant cools, it condenses and exits the bottom of the condenser as a high pressure low temperature liquid. Do not release the refrigerant into the atmosphere. Use approved recovery/ recycling equipment to capture the refrigerant whenever the air conditioning System is discharged. Always wear eye and hand protection (goggles and gloves) when working with any Refrigerant or air conditioning system. Close the high pressure and low pressure refrigerant lines with dust caps to avoid air entry and/or contamination. For AT Variants. ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the AT Oil Cooler Assembly. Using 10 mm socket spanner, Unscrew HVAC Suction and return pipe mounting nuts. Torque : 6.0+1.0 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both pipes mounting joints without any damage. Damage to the O-ring may cause A/C refrigerant leakage which leads to A/c failure. Using 10 mm socket spanner, Unscrew condenser mounting bolts from radiator end. Torque : 5 \u00b11 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200075.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Remove the radiator bottom seal mounting bolts and detach it. Torque : 7\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200196.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200074.jpg",
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Detach the ambient temperature sensor from the routing clip. Carefully remove the condenser from vehicle. Install in the reverse order of removal. Inspect the condenser for any physical damage, leakages etc. Replace if found any. Inspect for any foreign materials on condenser. Clean if found. Check and ensure free flow of condenser. Using screw driver, remove the floor console RH panel assembly scrivet and detach the panel from the vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220004.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220005.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the floor console LH panel assembly scrivet and detach the panel from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220006.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220007.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the RH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1541.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1542.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the LH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220010.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1543.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Partially detach HAVC control panel bezel and remove the mode cable from HVAC control panel end and routing clip. Remove the driver side IP panel assembly. Disconnect the mode cable from HVAC unit end. Remove the cable from the vehicle. Install in the reverse order of removal. Inspect the HVAC mode cable for any damage, Replace if required. Inspect the Mode Cable locks for any damage, Replace if required. Remove the Glove Box Assembly. Disconnect the electrical connector from the temperature actuator. Using star screw driver, Unscrew temperature actuator mounting screws. Remove the temperature actuator. Install in the reverse order of removal. Inspect the actuator for mechanical damage. Check and clean the connector pins for sulphation and deposits. performed AC PERFORMANCE TEST - Check the grill temperature (Engine Idle condition): Close Door test (Grill temperature individually from 4 vents). Open Door test (Grill temperature individually from 4 vents). Grill Temperature closer to Ambient Temperature \u2013 Go to Step 2. Connect the diagnostic Tool and DTC registered in EMS ECU. Yes \u2013 fix the error, clear the DTC and check the AC Performance. NO \u2013 GO to Step 3. Using Diagnostic tool actuate the compressor Clutch. No \u2013 Clutch Not actuating \u2013 Check the clutch condition, circuit and rectify or replace. Yes \u2013 Clutch Actuating as per input Go to Step 4. Check the compressor Drive Belt Condition and tightness. Yes \u2013 Matching the Specification \u2013 Go to Step 5. No \u2013 Replace the Drive Belt. Check The compressor condition. Yes - Compressor Overheating and Noisy \u2013 Replace the Compressor. Compressor in good condition \u2013 Go to Step 6. Check the System Refrigerant Quantity by using reconnector Equipment. Yes \u2013 The Refrigerant quantity is less (Gas Leakage) \u2013 Perform pressure test and Vacuum test by maintaining the pressure. Fix the leakage if any and charge the Refrigerant to recommended quantity and top up 50 ml compressor Oil. Then Go to Step 7. Check the grill temperature (Engine Idle condition). Close Door test (Grill temperature individually from 4 vents). Open Door test (Grill temperature individually from 4 vents) match the Recommended temperature \u2013 Go to Step 8. Perform test Drive and check the Temperature and any reproduce of the insufficient cooling. NO \u2013 Hand back the vehicle to customer Yes \u2013 Replace the HVAC System. Carefully remove the heater core assembly. Install in the reverse order of removal. Refit the Evaporator Assembly.For additional information refer to Evaporator Assembly \u2013 R&R Section. For additional information refer to AC Gas Recharging Procedure. ",
+ "file": null,
+ "display_order": 11
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Inspect the heater core assembly for any damage. Replace if found. Inspect the evaporator coil for free flow. If found any obstruction Repair/Clean or replace. Remove the IP lower panel from the vehicle. Disconnect the mode actuator electrical connector. Using star screw driver, Unscrew mode actuator mounting screws. Remove the mode actuator. Install in the reverse order of removal. Inspect the actuator for mechanical damage. Check and clean the connector pins for sulphation and deposits. Park the vehicle on level work bay. Open the left front door. Open the glow box and detach the stopper by pressing it. Disengage the glow box from the assembly. Press and remove the HVAC particulate filter cover from HVAC unit. Remove the HVAC particulate filter. Install the HVAC particulate filter on HVAC unit. Install the HVAC particulate filter cover. Engage the glow box stopper and refit the glow box in its position. While installing the filter take sufficient care to prevent bent, damage etc. Close the co-driver door. Use only genuine filter element. Never clean and reuse the HVAC particle filter element. Disconnect the blower motor and actuator electrical connectors and its routing clips. Using 10 mm socket spanner, Unscrew the blower case assembly mounting bolts. Using screw driver, Heater coil holding bracket mounting screws. Using a star screw driver, Unscrew expansion valve cover mounting screw. Disconnect the HVAC resistor electrical connector. Using a star screw driver, Unscrew the resistor mounting screw and remove the resistor. Using star screw driver, Unscrew evaporator cover mounting screws. Detach thermistor from evaporator and remove the evaporator with cover. Remove the evaporator from the cover and separate the evaporator. Detach the thermistor trim from HVAC assembly and Disconnect the thermistor electrical connector and holding clip. Remove the thermistor from the HVAC unit assembly. Install in the reverse order of removal. Refit the HVAC Unit Assembly. For additional information refer to AC Gas Recharging Procedure. ",
+ "file": null,
+ "display_order": 43
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the evaporator coil for any damage. Replace if found. Inspect the blower and evaporator unit for any damage. Inspect the evaporator coil for free flow. If found any obstruction repair/clean or replace. Inspect the evaporator coil for any foreign particles. Clean if found. Inspect the thermistor for any physical damage. If found replace. Inspect the thermistor for proper functioning. Using screw driver, remove the floor console RH panel assembly scrivet and detach the panel from the vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220004.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220005.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the floor console LH panel assembly scrivet and detach the panel from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220006.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220007.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the RH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1538.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1539.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using screw driver, remove the LH vertical ascent mounting screw and detach it from vehicle. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220010.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1540.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Partially detach HAVC control panel bezel and remove the heater cable from HVAC control panel end and routing clip. Open the glove box and remove the glove box by removing the glove box lock. Disconnect the heater cable from the HVAC unit end. Remove the cable from the vehicle. Install in the reverse order of removal. Inspect the HVAC heater cable for any damage, Replace if required. Inspect the heater Cable locks for any damage, Replace if required. Position the vehicle on 2 post lift/ 4 post lift. Check the HVAC drain pipe locking grommet fitment condition on BIW. Ensure that pipe is straight downwards. Do not pull the water drain pipe excessively. Remove the driver side IP panel assembly. Remove mode selector cable from HVAC assembly. Using star screw driver, Unscrew plate mode main link mounting screws and remove the link. Remove the lever sub assembly and lever foot from the plate mode main link. Install in the reverse order of removal. Inspect the plate mode main link for any damage. Replace if found. Remove the Cross Car Beam (CCB) Assembly. For additional information refer to AC gas recovery procedure. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm open end spanner, Remove the HVAC Pipe mounting nut from expansion valve end. Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both liquid tube and discharge hose mounting joints without any damage.Damage to the O-ring may cause A/C refrigerant leakage which leads to A/c failure. Detach heater inlet and outlet hose quick couplers. Do not open the degassing tank cap when the coolant is hot. Failure to follow this instruction will lead to personal injury. Before removing the heater core hoses, open the degassing tank cap for releasing the coolant pressure. Coolant will leak, while removing the heater core hoses, as a result drain the coolant into a container. Using 10 mm Socket Spanner, Unscrew the HVAC unit assembly mounting bolt and nuts. Torque : 7 \u00b11 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 7 \u00b11 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Torque Value",
+ "content": "Torque : 7 \u00b11 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200098.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200099.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200100.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200101.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm Socket Spanner, Remove the HVAC earth cable mounting nut. Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200104.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the HVAC unit assembly from vehicle. Torque : 5\u00b11 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200102.jpg",
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200103.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Refit the Cross Car Beam. For additional information refer to AC gas recovery procedure. ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Start the engine, check the coolant level. Refill if required. Check the coolant leak when engine is started. Check the A/C system cooling and operation. Inspect the HVAC assembly for any physical damages. Repair if found. Inspect the kinematics for proper functioning. Inspect the actuators / cables for proper operation. Inspect the filter element and clean/replace if required. Disconnect air fresh and recirculation actuator electrical connector. Using star screw driver, Unscrew the actuator mounting screws. Remove the air fresh and recycling actuator. Install in the reverse order of removal. Inspect the actuator for mechanical damage. Check and clean the connector pins for sulphation and deposits. Do not release the refrigerant into the atmosphere. Use approved recovery/ recycling equipment to capture the refrigerant whenever the air conditioning System is discharged. Always wear eye and hand protection (goggles and gloves) when working with any Refrigerant or air conditioning system. Close the high pressure and low pressure refrigerant lines with dust caps to avoid air entry and/or contamination. For additional Information refer to Refrigerant Recovery Recycling and Recharging Procedure. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Front Grill Assembly",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.LX-0009,1024,1368",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the Air Cleaner Assembly. Using 10 mm open end spanner, Liquid pipe mounting nut from expansion valve end. Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200061.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Remove Liquid pipe routing bracket mounting nut from the vehicle. Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200062.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, loosen and remove the suction hose routing bracket mounting nut. Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Torque Value",
+ "content": "Torque : 8.0+1.0 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200063.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200129.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect the pressure switch electrical connector. Using 10 mm socket spanner, Unscrew radiator LH seal mounting bolt and detach it. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1536.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew Liquid pipe mounting nut from condenser end. Torque : 6.0+1.0 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Caution",
+ "content": "During installation, fix the new O-ring into both end of liquid tube mounting joints without any damage. Damage to the O-ring may cause A/C refrigerant leakage which leads to A/c failure. Remove the liquid pipe from the vehicle. Install in the reverse order of removal. Refit the Air Cleaner Assembly. Refit the Front Grill Assembly. For additional Information refer to Refrigerant Recovery Recycling and Recharging Procedure. ",
+ "file": null,
+ "display_order": 39
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the suction hose assembly for any physical damage, leakages etc. Replace if found any. Inspect for any foreign materials on condenser. Clean if found. Check and ensure free flow of condenser. For additional information refer to IP Centre Switch Bank Assembly - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew HVAC control unit mounting screws. Torque : 1.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220033.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the HVAC Control panel. Install in the reverse order of removal. Inspect the HVAC Control Panel Assembly for any damage. Replace if found. By using screw driver remove the TVD screw. Torque : 14 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 14 mm ring and socket spanners unscrew rear propeller shaft mounting bolts and nuts from transfer case end. Torque : 55 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the TVD assembly from vehicle and hang the Rear propeller shaft aside. Using a nose plier, pull-down the double torsion Spring downwards and detach from pedal box and then gently pullout spring. Inspect the Torsional Vibration Damper (TVD) for any damage, if found replace the TVD assembly. Inspect the propeller shaft for any bend, crack, twisting and stone penetration, if found replace the propeller shaft assembly. Check the propeller shaft for any flyweights missing. Replace the propeller shaft if found. Clean the propeller shaft if any foreign materials like dirt found. If the propellers shaft unbalance is suspected then it can be verified by the following procedure, removing & rendering the propeller shaft by 180\u00b0 may eliminate some vibrations. Clean all the foreign material from propeller shaft and the universal joint. Ensure that the propeller shaft is not worn, are properly installed and are correctly aligned with the propeller shaft. Check the companion flange mounting bolts. Raise the vehicle and remove rear wheels & tyres. Install the wheel nuts to lock the brake drum. Mark & number the shaft 6 inches from pinion end at four positions 90\u00b0 apart. Run and accelerate the engine until vibration occurs. Note the intensity & the speed at which the vibration occurs. Install a screw clamp at position \u201c1\u201d. Start the engine and recheck for vibrations. If there is little vibration or no change in vibrations then move the clamp to the other 3 positions. If there is no difference in vibration at the other position then the vibration is not due to the propeller shaft imbalance. If the vibration decreases, install a second clamp and repeat the test. If the clamps cause an additional imbalance, separate the clamp (\u00bc inch above & below the mark). Repeat the vibration test. Increase the distance between the clamps until the vibration is at the lowest level. At this position bend the slack end of the clamp so that it does not loosen. Install the wheel & tyres. Lower the vehicle. If the amount of the vibration remains unacceptable then repeat the exercise at the gearbox end. After completing above procedure, if vibration is reduced, which indicates there is some imbalance in the propeller shaft. Replace the propeller shaft. Tyres that are out of round or wheels that are out of balance causes a low frequency vibration. Brake drums that are unbalanced cause a harsh low frequency vibration. Drive line vibrations can also result from loose or damaged engine mountings. Propeller shaft vibrations will keep on increasing as the vehicle speed increase. The propeller shaft does not cause a vibration that is present only in a narrow speed range. Remove the propeller shaft from vehicle. Remove dirt, rust, paint & undercoating from the propeller shaft surface. Keep the propeller shaft on surface plate along with \u2018V\u2019 block at both ends. The dial indicator must be installed perpendicular to the shaft surface. Measure the run out at the center and at the ends by rotating propeller shaft assembly by hand \u2013 away from the weld. Replace the propeller shaft if the run out is beyond the specified limit. Position the vehicle on 2 post lift/ 4 post lift. Inspect the inboard and outboard joint RH side drive shaft boots, clamps for cut, nick, loose, bend, crush or abrasion. Replace if necessary. Rotate Steering wheel from one end to other for better visualization of boots. Inspect the RH side drive shaft condition for cracks or damage. Replace if necessary. Inspect the inboard and outboard joint LH side drive shaft boots, clamps for cut, nick, loose, bend, crush or abrasion. Replace if necessary. Rotate Steering wheel from one end to other for better visualization of boots. Inspect the LH side drive shaft condition for cracks or damage. Replace if necessary. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Remove the Steering Column Shrouds. Remove the steering wheel. Disconnect the clock spring electrical connectors. Dis-engage the clock spring mountings (3 points) and lift out the clock spring assembly from the steering column. Using a flat end screw driver remove the steering angle sensor from the clock spring. Install in the reverse order of removal. If the contact coil is not aligned correctly,the steering wheel may not be able to rotate properly during turning. This kind of restricted turning ability may cause the vehicle to crash or damage the contact coil and prevent the air bags from deploying in a crash event. Carry-out the clock spring setting procedure. Failure to do clock spring setting may result in clock spring damage. Check the clock spring assembly of steering wheel for any malfunctioning or damages, replace if found any. Start the engine and place the wheels at straight ahead direction. For additional information refer to Steering straight ahead setting procedure. Turn the steering wheel until the tyres starts to move and measure the free play on the circumference of the steering wheel. Free Play Value \u00b1 5\u00b0 If the free play is out of the specified value, check the free play in steering column shaft connection and steering linkage. Replace or repair if necessary. The rack and pinion design is a simple design. However it is still susceptible to various problems in particular to leaks. If the bellows are ripped or are unable to keep the contaminant\u2019s away then it can cause damage to oil seal and subsequent leaks. One complaint, which can be present, is that the steering may be stiff and jerky when the unit is cold and as the vehicle is driven and it warms up the power assist gradually comes back. This normally indicates that grooves have worn into the bore of the pinion aluminum housing by control valve seals which may have hardened due to ageing. Wear in the centre housing causes the fluid to leak around the rack piston. Causing either steering wander or lack of straight- ahead stability. Another cause of steering wander and erratic control often accompanied by clumping, thunking noise is the deterioration of rack mounting bushings. Fluid leaks can be hard to locate. Sometimes you will see a low level in the pump reservoir but no evidence of escaping fluid. Squeeze the bellows and you will probably find that they are full of fluid. To confirm if that side of the rack is the root cause, then remove the both the bellows, clean the rack housing and then operate the system to observe the seepage directly. A rusty input shaft U joint or deteriorated flexible textile coupling could imitate rack problems Check the tyre pressure Check the accessory drive belt for any damage. Check the Tie-rod ends for bend or damage. Check the steering inner ball joints for any bend or external damage. Check ball joint rubber boots for signs of cracking or deterioration. Check inner and outer ball joints for excessive wear. Inspect all the steering bushes for signs of wear and deterioration Check the steering oil level in the reservoir. If the level is below \u201cMIN\u201d mark, top up steering fluid. Check the steering gear assembly for any external damage or steering fluid leakage. Check the power steering pressure lines for fluid leakage and deterioration. Check the power steering pump and the reservoir for fluid leakage. Check the steering gear rubber bellows for cuts, cracks, deterioration and oil traces. If the cause is not visually evident, verify the symptom and refer to the Troubleshooting Chart.
For additional information refer into Front Wheel - R&R Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "By using Star Screw driver, remove the scrivets and remove the front RH wheel arch apron. Using a 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially detach the degassing tank. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050128.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner, loosen and detach the pressure hose flare nut from the power steering pump. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190083.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner, loosen and detach the pressure hose flare nut from the power steering gear. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Position a tray below the rack to collect the fluid Using a 12 mm socket spanner, loosen and remove the routing bracket mounting bolt. Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190048.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the supply hose from the vehicle. Install in the reverse order of removal. For additional information refer to Power steering fluid filling procedure. ",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Inspect for any external damage or bent, if found replace. Power Steering Oil - MAHINDRA MAXIMILE POWER STEERING FLUID GENUINE POWER STEERING FLUID.Capacity \u2013 0.85 Litres.In case of non-availability of Genuine fluid, SHELL MAKE SPIRAX S3 ATF MD3 can be used. NO OTHER BRANDS RECOMMENDED. Rotate in anti-clockwise and remove the power steering fluid reservoir cap. Using star screw driver, remove the front stone guard screvits. Using a 10 mm & 13 mm socket spanner, loosen the front & rear mounting bolts and remove the front stone guard. Using a 10 mm socket spanner remove the steering fluid line bracket mounting bolt. Torque: 10\u00b1 2 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190048.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner,loosen the nut and disconnect pump to rack pressure hose. Torque: 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Notice",
+ "content": "Position a tray below the rack to collect the fluid. Drain the complete fluid in a neat container or bottle. Refit the pump to rack pressure hose.Torque tighten the nut to specified value. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190104.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refit the fluid line mounting clamp with the help of mounting bolt. Torque tighten the bolt to specified value. Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190048.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Fill the recommended fluid to MAX mark on reservoir. Carry-out Power steering circuit air bleeding procedure. Refit the front stone guard screvits & mounting bolts, torque tighten the bolts to specified value. Torque: 4.0 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011105.jpg",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011106.jpg",
+ "display_order": 33
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 202,
+ "sys_id": "THAR.LX-0009-Steering",
+ "subsys_id": "THAR.LX-0009-Steering-Front Steering Knuckle",
+ "systems": "Steering",
+ "sub_systems": "Front Steering Knuckle",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A190001.jpg",
+ "myid": 1307,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0009-Front Steering Knuckle-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190001.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/50002.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/50001.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the Front wheel. For additional information refer to Front Wheel \u2013 R&R Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the respective side Front Wheel Hub. For additional information refer to Front Wheel Hub \u2013 R&R Section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner , loosen and remove the wheel speed sensor mounting bolt & routing bracket mounting bolt. Torque : 8 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190008.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190009.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a cutting plier and 17 mm socket spanner, remove the tie rod end cotter pin and tie rod end nut and detach from knuckle. Torque : 45\u00b19Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a cutting plier and 24 mm socket spanner, remove the lower ball joint cotter pin and Lower ball joint nut and detach from knuckle. Torque : 130 \u2013 150 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190010.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 22 mm socket spanner, loosen and remove the knuckle Lower Half mounting bolts. Torque :140 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190011.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a cutting plier and 24 mm socket spanner, remove the upper ball joint cotter pin and ball joint nut and detach from knuckle. Torque : 90 \u2014 110 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190012.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the knuckle from the vehicle. After installation of knuckle assembly, Carry out the wheel alignment. Install in the reverse order of removal. Torque tightening should be done without load and with the tyres on level ground. Always use new split pin. Inspect for any external damage or bent, if found replace. The steering pump is a constant flow, vane type incorporating a flow control valve (with an integrated relief valve) and it is belt driven by engine. For additional information refer to Power steering fluid draining section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially detach the degassing tank. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050128.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the engine feed system cover. For additional information refer into the Engine Feed System Cover \u2013R&R Section. ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 14 mm rings spanner rotate the auto tensioner in counter clockwise Partially detach the power steering belt. Using a 17 mm open end spanner,loosen and detach the pressure hose flare nut from the power steering pump. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190083.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a hose clip plier, unclip the return hose to reservoir hose clamp from pump. Using a 12 mm socket spanner, loosen and remove the power steering pump mounting bolts. While loosening the bolt hold the nut using 12 mm ring spanner. Torque :25\u00b1 3 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190084.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the power steering pump from the vehicle. Install in the reverse order of removal. While tightening the bolt hold the nut using 12 mm ring spanner. Carry-out power steering fluid filling and bleeding procedure. Inspect the pump for any physical damage. Replace the pump if found. Inspect the pump for any fluid leakages. Inspect the pulley for any damage. For additional information refer into E-Disconnect Motor \u2013 R&R Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0009,1012,1218",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the engine feed system cover. For additional information refer to Engine Feed System Cover - R&R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the Front wheels (Both RH & LH). For additional information refer into Front Wheel - R&R Section. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "The wheels should be in straight ahead position before disconnecting the steering rack assembly from the vehicle. Using a 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially detach the degassing tank. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a cutting plier remove the cotter pin from the LH & RH tie rod . Using the 17 mm socket spanner, loosen and remove the LH & RH tie rod end ball joint nuts from the knuckle assembly. Torque : 45 \u00b1 9 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190009.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft mounting nut from the rack and pinion assembly and detach the intermediate shaft. Torque : 22\u00b14Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190044.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 17 mm open end spanner, loosen and remove the flare nuts and detach the steering rack and pinion supply and return lines. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Caution",
+ "content": "Plug the steering rack assembly inlet and outlet hose oil passage with dust cap to avoid any foreign particles entry. Drain the power steering fluid. Using a 12 mm socket spanner, loosen and remove the supply line routing bracket mounting bolt. Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190048.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Using a 19 mm socket spanner, loosen and remove the steering rack and pinion assembly mounting bolts. Torque : 85 \u00b1 13 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Notice",
+ "content": "Use open end torque wrench for tightening RH side mountingbolt. Detach the front differential breather hose routing tag. Remove the steering rack and pinion assembly from the vehicle. Install in the reverse order of removal. Always use a new cotter pin. Ensure I shaft connector is assembled as per given marking. At straight ahead condition bolt head should face top side for easy torquing. For additional information refer to Power Steering Fluid Filling Procedure section. ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Carry out the wheel alignment. Check the steering rack assembly for cracks, damages or leakages. Replace the steering rack assembly if required. Check the steering inner ball joint for any damage. Replace the steering rack assembly if required. Check the steering rack dust boot for any wear or deterioration. Replace if necessary. The combination switch is mounted on the steering column and houses the switches for head lamps, fog lamps and wipers. It comprises a central switch assembly and 2 stalks for controlling the lamps and wipers. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Disconnect the electrical connector from combination switch. Using a star screw driver, loosen and remove the mounting screw to remove combination switch. Gently remove the combination switch from the vehicle. Install in the reverse order of removal. Tighten the combination switch mounting screw as per specification over tighten will lead to damage of the switch. Inspect the combination switch for any damage. Inspect the combination switch connectors for any damage or loose connection. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Remove the steering wheel. Disconnect the ignition key barrel electrical connector. Disconnect the combination switch & clock spring electrical connectors. Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft bottom mounting bolts and detach the intermediate shaft bottom from the steering column. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190042.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering column mounting nuts then remove the steering column from the vehicle. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190039.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, loosen and remove the grommet mounting bolts then remove the grommet from vehicle . Torque : 22 \u00b1 2 Nm Torque :22\u00b12 Nm Install in the reverse order of removal. Ensure to fit the Grommet Projection should face driver side. Ensure Shaft to Grommet clearance is 5 mm in top side. Ensure to install Upper & Lower I shaft connector according to the marking. Inspect for grommet any external damage or cracks, if found replace. For additional information refer into Front Wheel - R&R Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "By using Star Screw driver, remove the scrivets and remove the front RH wheel arch apron. Using a 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially detach the degassing tank. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050128.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Detach the front differential breather hose routing clip. Using a 12 mm socket spanner loosen and remove the steering return line routing bracket mounting bolts. Torque : 10 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190090.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a hose clamp plier, unclip the hose clamp from power steering side. Using a 17 mm open end spanner, loosen the flare nut and detach the return line from the rack and pinion side. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190075.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Remove the steering return line hose gear end from the vehicle. Install in the reverse order of removal. For additional information refer to Power steering fluid filling procedure. ",
+ "file": null,
+ "display_order": 23
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect for any external damage or bent, if found replace. Place the front wheel on a turning radius measuring tool. Turn the steering wheel to the its both ends and measure the maximum steering angle. If the steering angle is out of the specified value, check and adjust the toe. Position the vehicle on a 2 post/ 4 post lift. Do not operate the steering system without power steering fluid. Failure to follow this precaution will lead to the damage of the steering system components. Whenever air enters the power steering hydraulic system, the system must be bleed to ensure free of air. Filling and bleeding the power steering system helps to ensure trouble-free operation as well as prevents the damage of the power steering system components. Inspect the fluid pressure hoses and clips for proper fitment. Rotate in anti-clockwise and remove the power steering fluid reservoir cap. Fill the power steering fluid reservoir to the \u201cMAX\u201d mark. During the bleeding procedure, ensure that the power steering fluid in the power steering fluid reservoir does not fall below the \u201cMIN\u201d mark, as air could enter into the system. Slowly turn the steering wheel to left lock position and hold for about 10 seconds. From left lock position turn the steering wheel slowly to Right lock position. Continue steps 6\u20137 till there is no air bubbles visible in the power steering fluid reservoir and smooth operation of power steering is attained. If the air bleeding is not properly performed, the life span of the power steering pump may be shortened. Top up the fluid to MAX mark on reservoir. To re-centre the clock spring , from default position rotate the clock spring in clockwise rotation (Towards right hand side) until tight (RH lock position). From RH lock position rotate the clock spring in opposite direction (anti-clockwise) approximately 3 turns and align the marks. Failure to follow the instructions can cause the clock spring failure. Clock spring if failed and not corrected can be a concern if the vehicle meets an accident which is above the threshold for airbag deployment. In such cases the airbag may not be deployed even though the signal is given. Even if airbag not deployed it will be giving a signal of airbag failure which will mean a return of customer with a complaint added on. The steering wheel is the part of the steering system that is rotated by the driver; the rest of the steering system responds to driver inputs. The steering wheel houses the driver airbag and audio controls. It is connected to the collapsible steering column. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Remove the driver air bag. Using a 17 mm socket spanner, loosen and remove the steering wheel mounting nut. Torque : 47\u00b17Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190022.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Disconnect clock spring electrical connector. Remove the steering wheel from the vehicle. Do not use excessive force to the steering wheel for removal. This may cause steering wheel bend. Gently tap if needed. While installing steering wheel ensure the splines are aligned properly and the steering wheel slides easily on the column shaft. Ensure the front wheels are in straight ahead position. Improper or incorrect removal and installation of the Restraint components will cause unintentional activation of the system which may lead to personal injury. The service operations should be followed in the correct sequence. Failure to do so may cause the SRS to unexpectedly deploy during service leading to a serious accident. Inspect the steering wheel for any external damage or bent, if found replace. The steering column is bolted to the bulk head. It is a tiltable and collapsible column. The steering column shaft is mounted on two needle bearings internally at the ends suspended by rubber mountings in the steering column assembly. An intermediate shaft connects the steering column to the steering gear. For reasons of safety, the steering column assembly incorporates a collapsible steel cage and an intermediate shaft with a deformation zone designed to crumple progressively in the event of a headon collision. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Remove the combination switch. Disconnect the ignition key barrel electrical connector. Using a Small chisel or punch hit and unscrew the mounting screw of ignition switch barrel with support of hammer. Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft bottom mounting bolts and detach the intermediate shaft bottom from the steering column. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190042.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering column mounting bolts and nuts then remove the steering column from the vehicle. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190039.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the mounting bolt and remove top intermediate shaft from column. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190108.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190040.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Ensure to Assemble Upper & Lower I shaft connector according to the marking. Inspect the steering column for any external damage or bent, if found replace. For information refer to Engine Feed System Cover - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the front RH wheel. For additional information refer into Front Wheel RH - R&R Section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "By using Star Screw driver, remove the scrivets and remove the front RH wheel arch apron. Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft bolt from the rack and pinion. Torque : 22\u00b14Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Notice",
+ "content": "While attempting to remove the intermediate shaft, lock the steering wheel at center position. Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft lower mounting bolt. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190042.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering intermediate shaft Center bracket mounting bolts. Torque : 20\u00b12.0Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190043.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the Steering intermediate shaft from the vehicle. Install in the reverse order of removal. Ensure to install Upper & Lower I shaft connector according to the marking. DO NOT HAMMER while disassembly / assembly. Ensure I shaft connector is assembled as per given marking. At straight ahead condition bolt head should face top side for easy torquing. Inspect for any external damage or bent, if found replace. Using a 10 mm socket spanner, loosen and remove the battery negative terminal and wait for about 2 minutes. Remove the steering wheel. Disconnect the ignition key barrel electrical connector. Disconnect the combination switch & clock spring electrical connectors. Using a 12 mm socket spanner, loosen the steering intermediate shaft top bolt and remove bottom mounting bolts and detach the intermediate shaft bottom from the steering column. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190042.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the steering column mounting nuts then remove the steering column from the vehicle. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190039.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the top intermediate shaft mounting bolts then remove the top intermediate shaft from the steering column. Torque : 22 \u00b1 4 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190108.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A190109.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Ensure to install Upper & Lower I shaft connector according to the marking. Inspect for any external damage or bent, if found replace. Position the vehicle on 2 post lift/ 4 post lift. Steering Rack Linkage & Boots Inspection Procedure ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the steering rack assembly RH side boots, clamps for cut, nick or abrasion,replace if necessary Check the steering rack assembly LH side boots, clamps for cut, nick or abrasion, replace if necessary. Check the steering rack assembly RH side linkage condition (Without removing boots) for play, damage, replace if necessary. Rotate Steering wheel from one end to other for better visualization of boots. Check the steering rack assembly LH side linkage condition (Without removing boots) for play, damage, replace if necessary Rotate Steering wheel from one end to other for better visualization of boots. Position the Vehicle on 2 post /4 post lift. Power Steering Oil - MAHINDRA MAXIMILE POWER STEERING FLUID GENUINE POWER STEERING FLUID.Capacity \u2013 0.85 Litres.Fluid reservoir outlet and return hose connection to reservoir. Check Power Steering fluid level , if found less than MIN mark, top up to MAX mark. Always maintain fluid level at MAX mark on reservoir. Power steering pump inlet and outlet connection. Power steering gear fluid inlet and outlet connection. Power steering rack feed tube connections. In case of non-availability of Genuine fluid, SHELL MAKE SPIRAX S3 ATF MD3 can be used. NO OTHER BRANDS RECOMMENDED. Disconnect the RPAS sensor electrical connectors. Unlock the RPAS sensors from the cover. Detach the sensors from vehicle. Check sensor, wiring, connector for any damage. Check for mud on sensor, clean gently if found. Remove the thermostat valve from the thermostat housing. Thermostat and thermometer bulb should be suspended in water. If they touch bottom or the sides then temperature in which thermostat / thermometer operate will not be correct and wrong diagnosis will take place. Insert the thermostat valve in to a container filled with water. Heat the container and measure the temperature of water by Using digital thermometer. Keep track of water temperature and respective valve opening/ travel. Thermostat should start opening at 88 \u00b1 2 \u00b0 C (0.1 mm travel). Once temperature reaches 96 \u00b1 2\u00b0 C valve should be fully open , at this moment, valve travel will be approximately 8 mm. In case thermostat valve behavior does not confirm to above specifications, it should be replaced. For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Intercooler assembly. Remove the AT Oil Cooler Assembly. Using hose clamp plier, Release radiator vent hose clip and disconnect hose radiator end. Using hose clamp plier, Release degassing tank Outlet and remove degassing tank. Using Hose clamp plier, release radiator inlet and outlet hose spring band clamps and disconnect the hoses radiator end. Disconnect the AT oil inlet hose quick coupler from radiator bottom side. Disconnect the AT oil outlet hose quick coupler from radiator top side. Using 10 mm socket spanner, Unscrew degassing tank mounting brackets mounting bolts LH & RH. Disconnect radiator fan electrical connector. Using 10 mm socket spanner, Unscrew condenser mounting bolts. Using 13 mm socket spanner, Unscrew radiator mounting bolts. Torque : 12.5 \u00b1 1.5 Nm Carefully detach the condenser and hang the condenser. Remove the radiator with Fan assembly from the vehicle. Disconnect the shroud holder clips from radiator and fan then remove the clips (Top & Bottom). Using 10 mm socket spanner, loosen sand remove fan mounting bolts and remove fan from Radiator Torque : 6.5\u00b1 1.5 Nm Detach the fan assembly from radiator bottom seating and remove the radiator fan assembly. While Installing ensure the fan bottom seating are properly seated on radiator Install in the reverse order of removal. For additional information refer to Coolant filling and de-aeration section. ",
+ "file": null,
+ "display_order": 47
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " Check the radiator fins for damage, replace if found any. Check the radiator for coolant leakage, replace if found any. Check the radiator for dust accumulation, clean with compressed air if dust accumulation is noticed. Check the radiator drain plug for any leakage. ",
+ "file": null,
+ "display_order": 48
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 391,
+ "sys_id": "THAR.LX-0009-Cooling System",
+ "subsys_id": "THAR.LX-0009-Cooling System-Resistor Radiator Fan",
+ "systems": "Cooling System",
+ "sub_systems": "Resistor Radiator Fan",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B060172.jpg",
+ "myid": 1067,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0009-Resistor Radiator Fan-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Component Location Index",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060172.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25320.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25321.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060135.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " Disconnect the electrical connectors from resistor. Using screw driver, loosen the resistor mounting screw and remove the resistor. Install the reverse order of removal. Check the resistor for any damages, if found then replace it . For additional information refer to coolant draining procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Pipe Inlet Oil Turbocharger.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.LX-0009,1001,1034",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060165.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew turbo coolant supply pipe mounting banjo bolt turbo end. Using 10 mm socket spanner, Unscrew turbo coolant supply pipe banjo bolt OCFM end. Remove the turbo coolant outlet pipe. Install in the reverse order of removal. For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " Inspect the coolant inlet pipe for any damage, Replace if found. Typical sign of failed water pump is leakage through the seal and bearings. If the water pump is leaking replace the pump as soon as possible. Water pump failure can be confirmed by below steps: Remove the drive belt. Rotate the water pump pulley and check for free rotation. Replace the water pump, if necessary. ",
+ "file": null,
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 392,
+ "sys_id": "THAR.LX-0009-Cooling System",
+ "subsys_id": "THAR.LX-0009-Cooling System-Coolant Inlet Pipe To OCFM",
+ "systems": "Cooling System",
+ "sub_systems": "Coolant Inlet Pipe To OCFM",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B060178.jpg",
+ "myid": 1068,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0009-Coolant Inlet Pipe To OCFM-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Component Location Index",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060178.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25325.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25326.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the engine coolant. For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the CATCON Assembly. For additional information refer to CATCON Assembly - R&R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010062.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": " Using 7 mm socket spanner, Loosen hose clip and detach water outlet hose pipe end. Torque : 6.5 \u00b1 0.6 Nm Using 10 mm socket spanner, Unscrew water inlet pipe mounting bolts and remove pipe. Install in the reverse order of removal. For additional information refer to Coolant filling and de-aeration section. ",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " Check coolant inlet pipe for any damage or cracks. If found replace the outlet pipe with a new one. Check coolant inlet pipe mounting for proper tightness and damages, replace the outlet pipe if required. Remove the Intercooler Fan. Using 10 mm socket spanner, loosen and remove the degassing tank mounting bolts and partially remove the degassing tank (Without disconnecting the hoses). Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060135.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": " Disconnect fan resistor electrical connector. Using 10 mm socket spanner, Unscrew fan mounting bolts. Torque : 6.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060137.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060139.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": " Disconnect the shroud holder clips from radiator and fan then remove the clips (Top & Bottom). Using 7 mm socket spanner, Loosen intercooler inlet hose clip and detach the hose intercooler end. Torque : 6.5 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050130.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": " Detach the fan assembly from radiator bottom seating and remove the radiator fan assembly. While Installing ensure the fan bottom seating are properly seated on radiator. Install the reverse order of removal. Check electric fan blades for any damages. Position the vehicle on 2 post lift/ 4 post lift. Open the bonnet and lock it in open position using bonnet stay rod. Coolant \u2013 Mahindra 'MAXIMILE ULTRA COOL' Genuine Long Life Coolant (READY TO USE COOLANT. NO NEED TO MIX WATER). Capacity \u2013 ~5.0 Litres. ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060002.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": " Coolant Level And Leak Inspection Procedure Inspect the degassing tank pressure cap for any damage or coolant leakage. Rectify the leakage if found. Check the coolant level in the degassing tank, it should be between MAX and MIN marks. Check the coolant level when the engine is cold. If found below MIN mark then top it up with 'MAHINDRA 'MAXIMILE ULTRA COOL' (ready to use coolant. no need to mix water). Inspect the degassing tank to radiator vent hose & engine vent hose for any coolant leakages, also check the mounting spring band clamp for any damage. If found any damage or leak, rectify. Inspect the engine to T connection vent hose for any coolant leakages, also check the mounting spring band clamp for any damage. If found any damage or leak,rectify. Inspect the degassing tank outlet hose assembly at every joints such as degassing tank end, T-connector connections, Turbo outlet pipe & hoses, OCFM side for any coolant leakage, also check the mounting spring band clamp for any damage. If found any damage or leak, rectify. Inspect the radiator inlet hose at radiator and engine block for coolant leakage, rectify the leakage if found. Also inspect the mounting spring band clamp for any damage,replace the mounting spring band clamp if found damaged or loose. Inspect the radiator outlet hose at Radiator & Thermostat, thermostat housing for any coolant leakage, rectify if found any leakage. Also inspect the mounting clamp for any damage, replace if found damaged or loose. Inspect the heater inlet & outlet hoses (Both sides) for any coolant leakage, also check the mounting spring band clamp for any damage. If found any damage or leak, rectify. Inspect the Heater Inlet & outlet pipes at Cylinder head & OCFM for any damage. If found any damage or leak, rectify Inspect the Turbo Inlet & outlet pipes at Turbo & OCFM for any damage. If found any damage or leak, rectify. Never remove the degassing tank cap when the engine is hot. Brand Specific. Don't use other Coolants / Water for top up. In case of emergency,Coolant meeting JIS K2234 Specification should be used (30% Concentration Diluted with Distilled water) and coolant change period has to be reduced as 30,000 KM Never mix MAHINDRA MAXIMILE ULTRA COOL with water. ",
+ "file": null,
+ "display_order": 34
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 386,
+ "sys_id": "THAR.LX-0009-Cooling System",
+ "subsys_id": "THAR.LX-0009-Cooling System-Degassing Tank",
+ "systems": "Cooling System",
+ "sub_systems": "Degassing Tank",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B060001.jpg",
+ "myid": 1062,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0009-Degassing Tank-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Degassing tank",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060001.jpg",
+ "display_order": 1
+ },
+ {
+ "step_name": "Degassing tank",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060115.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Degassing tank",
+ "content_type": "Description",
+ "content": "The degassing tank or coolant reservoir tank is made of plastic it can be visually identified like the washer tank. Function of the degassing tank is to remove air bubbles or vapour from the cooling system and to store the coolant as a reservoir. Proper filling of the coolant inside the cooling system is must in order to pressurize the system. The coolant level should be between the MAX and MIN marks on the reservoir tank after the cooling system has been cooled down. The degassing tank cap rating is 1.4 \u00b1 0.15 bar and vacuum 0.04 to 0.1 bar. For additional information refer to Engine Coolant Draining procedure. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060004.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, release the radiator vent hose spring band clamp and disconnect the hose. Never work with cooling system when the engine is hot. failing to this may cause personal injury.. Using hose clamp plier, Release the degassing tank outlet hose spring band clamp and detach hose degassing tank end. Using 10 mm socket spanner, Unscrew degassing tank mounting bolts. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050129.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully remove the degassing tank. Install in the reverse order of removal. For additional information refer to Coolant filling and de-aeration section. ",
+ "file": null,
+ "display_order": 18
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the degassing tank for any damages or blockages, replace if found replace the degassing tank. Inspect the hoses for any damages, cracks or kinks, if found replace the hose assembly. inspect the coolant hoses clamps for proper fitment, if found loose then replace the clips. Position the Vehicle on 2 post lift/ 4 post lift. Open the bonnet and lock it using bonnet retaining lever. Place a tray under vehicle for collecting the coolant. Coolant \u2013 Mahindra 'MAXIMILE ULTRA COOL' Genuine Long Life Coolant (READY TO USE COOLANT. NO NEED TO MIX WATER). Top up Capacity \u2013 ~5.0 Litres. ",
+ "file": null,
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Draining",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": " Engine Coolant Draining Procedure Switch OFF the Ignition and allow Engine to cool down. Never remove the degassing cap when the engine is hot ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/coolant replace-1.PNG",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Open the degassing tank cap.",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A011105.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": " Using star screw driver, remove the front stone guard screvits. Using a 10 mm & 13 mm socket spanner, loosen the front & rear mounting bolts and remove the front stone guard. Remove the radiator drain plug and allow the entire coolant to get drained. Place a tray beneath the drain plug to collect coolant drained. ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit the drain plug.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": " Engine Coolant Filling & De-aeration Procedure Start filling the recommended coolant in degassing tank. While filling, open the drain Plug & wait for the coolant to drop & close drain Plug. ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": " Check coolant level in degassing tank, add coolant to MAX level and close the degassing cap. Check all the hoses and clips for leakage and correct fitment. Start the engine and run at 3000 rpm for about 10 minutes. (For Thermostat Opening). Maintain Coolant level at MAX level always and ensure coolant never goes below MIN level. ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": " Switch OFF the Ignition and allow the engine to cool down, Check coolant level in degassing tank and add coolant to MAX level. Torque: 4.0 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": " Inspect the coolant circuit for any leakages. For additional information refer to Coolant level & leak inspection section. Never remove the degassing cap when the engine is hot. Never mix MAHINDRA MAXIMILE ULTRA COOL genuine coolant with water. Brand Specific. Don't use other Coolants / Water for top up. In case of emergency, Coolant meeting JIS K2234 Specification should be used (30% Concentration Diluted with Distilled water) and coolant change period has to be reduced as 30,000 KM Do not overfill the system; allow free space in the degassing tank for expansion of the fluid. ",
+ "file": null,
+ "display_order": 37
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 393,
+ "sys_id": "THAR.LX-0009-Cooling System",
+ "subsys_id": "THAR.LX-0009-Cooling System-Thermostat Assembly",
+ "systems": "Cooling System",
+ "sub_systems": "Thermostat Assembly",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B060161.jpg",
+ "myid": 1069,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0009-Thermostat Assembly-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Component Location Index",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060161.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25330.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " Remove the Coolant Inlet Pipe. Carefully remove thermostat from OCFM. Install in the reverse order of removal. Always replace the O ring with New one while removing the thermostat. For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 10
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " Check thermostat valve opening and closing temperatures, if found deviation from specified value, replace the thermostat. Check travel of thermostat valve, if found deviation from specified value, replace the thermostat. For additional information refer to coolant draining procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the CATCON Assembly. For additional information refer to CATCON Assembly - R&R Section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010183.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": " Using hose clamp plier, Release heater outlet hose clamp and detach hose. Using 10 mm socket spanner, Unscrew pipe routing bracket mounting bolt engine block end. Using 12 mm socket spanner, Unscrew pipe routing bracket mounting bolt cylinder head end. Torque : Torque : 25 \u00b1 3 Nm Using 10 mm combination spanner, Unscrew heater pipe mounting bolt OCFM end and remove pipe. Torque : Torque : 11 \u00b1 1 Nm Remove the turbo coolant outlet pipe. Install in the reverse order of removal. For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 20
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " Inspect the coolant outlet pipe for any damage, Replace if found. For additional information refer into Front Grill Assembly \u2013R&R Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A050050.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060131.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": " Using 10 mm socket spanner, Unscrew the LH and RH radiator seal mounting bolts. Torque : 4.5 \u00b10.5Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060132.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": " Using star screw driver, loosen and remove the LH and RH radiator seal mounting screw rivets. Torque : 4.5 \u00b10.5Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060133.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060134.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the both LH and RH radiator seal from the vehicle. Install the reverse order of removal. Check for any external cracks, replace if found any. Check for the obstruction of the air flow, if found please replace. For additional information refer into coolant draining and refilling procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": " Remove the Intercooler assembly. Using hose clamp plier, Release radiator vent hose clip and disconnect hose radiator end. Using hose clamp plier, Release degassing tank Outlet and remove degassing tank. Using 10 mm socket spanner, Unscrew degassing tank mounting brackets mounting bolts LH & RH. Disconnect radiator fan electrical connector. Using 10 mm socket spanner, loosen and remove fan mounting bolts and remove fan from engine compartment. Torque : 6.5\u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060137.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060139.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": " Disconnect the shroud holder clips from radiator and fan then remove the clips (Top & Bottom). Detach the fan assembly from radiator bottom seating and remove the radiator fan assembly. While Installing ensure the fan bottom seating are properly seated on radiator. ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060142.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060145.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": " Using Hose clamp plier, release radiator inlet and outlet hose spring band clamps and disconnect the hoses radiator end. Using hose plier, release vent hose spring band clamp and disconnect hose radiator end. Using 13 mm socket spanner, Unscrew radiator mounting bolts. Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060147.jpg",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B060146.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": " Using 10 mm socket spanner, Unscrew radiator LH & RH seal mounting bolts Using 10 mm socket spanner, Unscrew condenser mounting bolts and partially detach the condenser from the radiator. Remove the radiator from the vehicle. Install in the reverse order of removal. For additional information refer to Coolant filling and de-aeration section. ",
+ "file": null,
+ "display_order": 48
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " Check the radiator fins for damage, replace if found any. Check the radiator for coolant leakage, replace if found any. Check the radiator for dust accumulation, clean with compressed air if dust accumulation is noticed. Check the radiator drain plug for any leakage. Position the Vehicle on 4 post lift. Inspect and ensure the following nuts/bolts are with proper torque as recommended: Front shock absorber assembly on chassis (LH/RH). Torque value: 40 \u00b1 5Nm Torque Wrench Type - Open end Torque Wrench Front shock absorber mounting bolt on LCA (LH/RH). Torque value: 120 \u00b1 12 Nm Front stabilizer bar mounting bracket bolts. Torque value: 50 \u00b1 5 Nm Front stabilizer bar link mounting bolts on LCA (LH/RH). Torque value: 90 \u00b110 Nm Front upper control arm pivot mounting bolts on chassis (LH/RH). Torque value: 97\u00b1 10 Nm Front Lower arm mounting bolts on chassis (LH/RH). Torque value: 250 \u00b1 20 Nm Ensure to do the torquing in the nut side and holding the bolt while torquing. Knuckle bottom mounting bolts LHS & RHS. Torque value: 140 \u00b1 10 Nm Torque Wrench Type - Open end Torque Wrench Rear stabilizer bar mounting on Rear Axle (RH/LH). Torque value : 70 \u00b1 7 Nm Rear stabilizer bar link rod mounting on chassis (LH/RH). Torque value : 90 \u00b110 Nm Torque Wrench Type - Open end Torque Wrench Rear lower link mounting on chassis and axle (LH&RH). Torque value: 230 \u00b1 20 Nm Torque Wrench Type - Open end Torque Wrench for LH chassis side While torquing axle side, hold the nut by open end spanner & do the torquing in the bolt side. Rear upper link mounting on chassis and axle (LH&RH). Torque value: 230 \u00b1 20 Nm Torque Wrench Type - Open end Torque Wrench for LH chassis & axle side Rear shock absorber bottom mounting on Rear axle (LH&RH). Torque value : 110\u00b111 Nm Torque Wrench Type - Open end Torque Wrench Rear shock absorber top mounting on chassis (LH&RH). Torque value : 65\u00b110Nm Pan hard rod mountings on axle & chassis. Torque value: 230 \u00b1 20 Nm Position the vehicle on a 2 post / 4 post lift. Position the vehicle on a 2 post / 4 post lift. Check the insulators of the exhaust front pipe , intermediate pipe with muffler and tail pipe with muffler, replace if found elongated or damaged. Check the joint between exhaust tail pipe with intermediate pipe, if found leakage then replace the gasket and torque tighten the nuts to specified value. Check the joint between exhaust intermediate pipe with front pipe for any leakage, if found leakage then replace the gasket and torque tighten the nuts to specified value. Check the joint between exhaust front pipe with Catalytic Converter for any leakage, if found leakage then replace the gasket and torque tighten the nuts to specified value. Check all the exhaust joints for leakage and correct fittings. If leakage is found, check the exhaust pipe gasket. Replace if required. ",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 365,
+ "sys_id": "THAR.LX-0009-Exhaust & Emission Control",
+ "subsys_id": "THAR.LX-0009-Exhaust & Emission Control-Pipe Oil Inlet Turbocharger",
+ "systems": "Exhaust & Emission Control",
+ "sub_systems": "Pipe Oil Inlet Turbocharger",
+ "symptom": 0,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B030158.jpg",
+ "myid": 1034,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0009-Pipe Oil Inlet Turbocharger-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030158.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4783.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30495.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove turbo bottom heat shield. For additional information refer to turbo bottom heat shield - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Warning",
+ "content": "Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury. Using 10 mm socket spanner, Unscrew turbo oil supply pipe mounting banjo bolt turbo end. Torque : 18 \u00b1 2Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030012.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew turbo oil supply pipe banjo bolt OCFM end. Torque : 18 \u00b1 2Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the turbo oil inlet pipe. Install in the reverse order of removal. For additional information refer to engine oil refilling procedure - R&R section. ",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check oil inlet tube for any external damage, replace if found any. The Lambda Sensor or Heated Oxygen Sensor which is bolted into the top of the catalytic converter is called as upstream lambda sensor. The Lambda Sensor measures the residual oxygen level in the exhaust gases. A lambda value of 1 indicates engine is running at stoichiometric air fuel ratio. A minimum temperature of 300\u00b0 C is required for proper functioning of the Lambda sensor. The integrated heater ensures that the sensor functions even at extremely low exhaust gas temperatures. The Lambda Sensor is used to correct the fuel injection quantity to maintain stoichiometric air fuel ratio for combustion. Second lambda sensor is bolted to the bottom of catalytic converter. The downstream lambda Sensor is used for diagnosis of catalytic converter and to ensure good catalytic converter efficiency. The voltage output of the sensors depends upon the oxygen content in the exhaust gas. Disconnect the downstream Lambda sensor electrical connector. Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury. Using 22 mm open end spanner loosen the sensor and remove sensor from CATCON. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Check for any external damage on sensor , replace if found any. The Lambda Sensor or Heated Oxygen Sensor which is bolted into the top of the catalytic converter is called as upstream lambda sensor. The Lambda Sensor measures the residual oxygen level in the exhaust gases. A lambda value of 1 indicates engine is running at stoichiometric air fuel ratio. A minimum temperature of 300\u00b0 C is required for proper functioning of the Lambda sensor. The integrated heater ensures that the sensor functions even at extremely low exhaust gas temperatures. The Lambda Sensor is used to correct the fuel injection quantity to maintain stoichiometric air fuel ratio for combustion. Second lambda sensor is bolted to the bottom of catalytic converter. The downstream lambda Sensor is used for diagnosis of catalytic converter and to ensure good catalytic converter efficiency. The voltage output of the sensors depends upon the oxygen content in the exhaust gas. Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury Disconnect the Lambda sensor electrical connector. Using 22 mm open end spanner loosen the sensor and remove sensor from CATCON. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030142.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Check for any external damage on sensor , replace if found any. Remove the Catalytic Converter Assembly Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury. Using 12 mm socket spanner remove turbo support bracket mounting bolts. Using 7 mm socket spanner loosen clean hose clip and detach it from turbo end. Torque : 4.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner loosen Intercooler inlet hose clip and detach it from turbo end. Torque : 6.5\u00b10.6Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect turbo dump valve electrical connector. Using 10 mm socket spanner, remove turbo oil inlet pipe banjo bolt. Torque : 18 \u00b1 2Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030150.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": "Using 10 mm socket spanner remove turbo coolant inlet, outlet pipe banjo bolts. Torque : 18 \u00b1 2Nm ",
+ "file": "",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner remove turbo oil drain pipe mounting bolts. Torque : 11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner remove turbo mounting nuts. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Notice",
+ "content": "Always use new metal gasket once removed. check for any leakages While installing, Molykote to be applied on both sides of stud on exhaust manifold- turbocharger. Torquing to be done immediately after application of molykote sealant. Nuts to be re torque after initial tightening in the same sequence. Disconnect turbo electrical interconnector. Remove Turbocharger Assembly from vehicle. Disconnect turbo pigtail electrical connector and remove pigtail. Install in the reverse order of removal. For additional information refer to engine oil refilling procedure - R&R section. ",
+ "file": null,
+ "display_order": 40
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the Compressor/Turbine wheel for damage. Inspect the Compressor/Turbine wheel for rubbing. Inspect the Rotor for free rotation. Inspect the rotor play by pressing the shaft outward & rotate, It should be rotate freely. For additional information refer to turbo bottom heat shield - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Warning",
+ "content": "Do not Work with Exhaust system when it is hot. Failure to follow this instruction will result in personal injury. Using 10 mm socket spanner, Unscrew turbo oil drain pipe mounting bolts cylinder head end. Torque : 11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030151.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew turbo oil drain pipe mounting bolts turbo end. Torque : 11\u00b1 1 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the turbo oil drain pipe. Install in the reverse order of removal. For additional information refer to engine oil refilling procedure - R&R section. ",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check oil return tube for any external damage, replace if found any. The Closed coupled catalytic converter is mounted between the turbo charger and the exhaust front pipe assembly. The three way catalytic converter allows the three pollutants (CO, HC, NOx) to be converted simultaneously in a single chamber. It converts harmful carbon monoxide and hydrocarbons into water vapor & carbon dioxide and reduces NOx into nitrogen & carbon dioxide. In three way catalytic converter, Substrate is coated over with oxidation catalysts Platinum & Palladium and reduction catalyst Rhodium.High amount of substrate is loaded in the top portion & less amount in the bottom portion. Using 12 mm combination spanner remove turbo top heat shield mounting bolts and detach shield. Disconnect Upstream and Downstream lambda sensor electrical connectors Using 22 mm open end spanner remove Upstream and Downstream lambda Sensors Using 13 mm socket spanner unscrew exhaust front pipe mounting bolts CATCON end Using 13 mm socket spanner remove CATCON mounting nuts from turbocharger Using 12 mm socket spanner, Unscrew Upstream O2 sensor electrical connector holding bracket mounting bolt and remove the bracket Using 12 mm socket spanner remove CATCON bracket mounting bolts and remove the brackets Refit the CATCON mounting brackets on CATCON and hand tighten the bolts. Ensure to only hand tighten the bracket bolts in this stage for proper position of Cat con on vehicle and after that torque tighten. Place and position the CATCON inside the engine compartment. Always replace the metal gasket once removed. Install the CATCON mounting nuts on turbocharger. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Notice",
+ "content": "Ensure to apply Molykote on stud tapping threads while Installation. Torquing to be done immediately after application of molykote sealant. Tighten the CATCON bracket mounting bolts on cylinder block side to the specific torque value. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030125.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030019.jpg",
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": "Tighten the CATCON bracket mounting bolts on CATCON to the specific torque value. Torque : 25\u00b13 Nm ",
+ "file": "",
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit exhaust front pipe and install the mounting bolts CATCON end and torque tighten. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refit the Upstream and Downstream lambda sensors on the CATCON and torque tighten. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B030135.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Reconnect Upstream and Downstream lambda sensor electrical connectors. Refit turbo top heat shield and torque tighten the mounting bolts. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 59
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for any external cracks on catalytic converter assembly, replace if found any. Check for the obstruction of the air flow, replace if found any. It is a device for delivering electric current from the ignition system to the combustion chamber in the spark-ignition engine to ignite the charge by an electric spark. The timing of the spark ensure that the combustion pressure within limits and also the emissions. The spark plug has a metal threaded shell, electrically isolated from the central electrode by a porcelain insulator. The central electrode, is connected by a heavily insulated wire to the output terminal of an ignition coil. The spark plug's metal shell is screwed into the engine's cylinder head and thus electrically grounded. The central electrode protrudes through the porcelain insulator into the combustion chamber, forming spark gap between the inner end of the central electrode and the inner end of the threaded shell and designated the side, earth, or ground electrode. Position the vehicle on ground level/ 2 post lift/ 4 post lift and turn engine OFF. Open the bonnet and lock it in open position using bonnet stay rod. Disconnect the Battery Negative Cable. Remove the Engine Top NVH Cover. Do not smoke or carry lighted tobacco/open flame while working near any fuel related components. The fuel may ignite and cause personal injury. Always follow fuel handling precautions to avoid personal injury. Special care should be taken for the heating portion of the spark plug while removal or installation and storing. Do not remove the spark plug when the engine is in hot condition. Failure to follow this will cause personal injury. Before starting of the procedure, always switch off the ignition. Using a 10 mm socket spanner, loosen and remove the battery negative terminal. Remove the engine top encapsulation cover. Disconnect the ignition coil electrical connectors. Using a 10 mm socket spanner, loosen and remove Ignition coil mounting bolts and remove the Ignition coils. Using a MST 0308CBG0001ST - Spark Plug Installer Tool , loosen and remove spark plugs from cylinder head. Refit the new spark plugs and torque tighten them to the specified value. Torque Value: 20 - 25 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W152.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Tighten the spark plug to specified torque value. Over tightening may damage the spark plug. Spark plug gap is a gap between the centre and side electrodes of a spark plug. Before installing new spark plug, ensure that the specified gap is maintained between the electrodes. For Thar, Spark Plug gap should be maintained as 0.7 - 0.8 mm and Incorrect spark plug gaps can cause the following problems Rough, irregular engine Idle. Engine hesitation or stumbles while acceleration. Engine to miss or run erratically especially during idle. Poor engine performance. Engine knocking or pinging. Refit the Ignition coil mounting bolts and torque tighten to specified value. Torque Value: 10 - 12 Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W154.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Connect Ignition coil electrical connectors. Refit the engine encapsulation cover. Connect the battery negative cable mounting nut. Ignition Coil gives high voltage current to the spark plug and is basically a step up transformer. Ignition timing is decided by the EMS ECU. Using a 10 mm socket spanner, loosen and remove the battery negative terminal. Before starting of the procedure, always switch off the ignition. Do not smoke or carry lighted tobacco/open flame while working near any fuel related components. The fuel may ignite and cause personal injury. Always follow fuel handling precautions to avoid personal injury. Remove the engine top encapsulation cover. Disconnect the ignition coil electrical connectors. Using a 10 mm socket spanner, loosen and remove Ignition coil mounting bolts and remove the Ignition coils. Check for any external damage in ignition coil, if found replace. Refit the Ignition coil mounting bolts and torque tighten to specified value. Torque Value: 10 - 12 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1043.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Connect Ignition coil electrical connectors. Refit the engine encapsulation cover.. Connect the battery negative cable mounting nut. Position the vehicle on ground level/ 2 post lift/ 4 post lift and turn engine OFF. Open the bonnet and lock it in open position using bonnet stay rod. Using a 27 mm 12 point doublehexagonal socket spanner, Loosen the engine oil filter bowl. To access Oil filter cap mounting slightly move the Intercooler hose (without removing) and Carefully remove the damaging the hose. Remove the engine oil filter with bowl from engine assembly. Ensure gasket isn\u2019t in casting housing and element assembly should come along with filter cap. Carefully rotate the oil filter element in clockwise direction, pull upward and remove the filter element. Remove the filter element carefully, with no damage to the plastic snaps. Pay attention not to damage the oil bypass valve while removing the oil filter element. Smear a layer of fresh oil on new oil filter O-ring and Position the O-ring on filter cap. Replace the O-ring with new one when replacing the oil filter element. Ensure no damage to O-ring during assembly, with no sharp edges damaging O-ring or element. Ensure to fix the oil bypass valve in proper position on oil filter cap. Place the oil filter in the bowl projection, push the filter inside and rotate the filter in anti-clockwise direction to lock it. Install the fuel filter element carefully, with no damage to snaps Position the oil filter cap with filter on the oil cooler surface. Tighten the oil filter cap in clockwise direction and torque tighten cap to the specified value. Torque :25 - 30 Nm ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Don\u2019t apply improper torque which leads to damage in threads. Check the engine oil level. Start the engine and check for Oil leakage/ seepage at: Oil pan & crankcase joint. Oil pan drain plug. Oil filter joint. Recommend to use only the Mahindra genuine oil filter for better engine protection and lubricant life. Make sure for all the subassembly and components going into engine assembly should be clean and away from foreign material. For additional information refer to Engine Case Cover - R&R Section. ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010971.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove MST 0307ABH0001ST - Flywheel Locking Tool - Eagle mounting bolts and detach it. Refit engine front lifting hook and torque tighten the mounting bolts to the specified value. Using 18 mm socket spanner, unscrew engine mounting bracket nut (Both LH & RH) from engine bed. Torque : 110 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010618.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Provide engine support beam to support engine. Lift the engine with care, don\u2019t over lift since chances of damaging parts are more. Ensure none of the components are effected or damaged during lifting. Using a 14 mm combination spanner & socket spanner, unscrew LH Side engine mounting bracket mounting bolts and remove the bracket from engine compartment. Using a 6 mm square socket spanner, loosen and remove TDC locking pin plug. Torque : 20\u00b12 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010622.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Position damper pulley and install damper pulley mounting bolt on crankshaft. Insert the TDC locking pin (MST 0312ABH0001ST \u2013 Crankshaft Locking Tool - TDC Pin ) and lock the crankshaft. Ensure the crankshaft locking tool is seated properly into the slot on crankshaft and ensure the TDC locking pin insert upto Red mark in the pin as shown. Check and ensure the 1st cylinder piston position to TDC. Ensure that correct TDC locking tool is used. TDC locking hole is near crankcase left side below intake manifold (Near Engine LH Mounting bracket). If not able to position the MST in proper position into crankshaft, Slightly rotate damper pulley and align the crankshaft to insert MST:- 0312ABH0001ST Crankshaft Locking Tool - TDC Pin on crankshaft. Using 24 mm socket spanner, loosen and remove damper pulley mounting bolt and detach damper pulley. Check Crankshaft Sprocket woodruff key slot in 12\u2019o Clock Position, Intake and Exhaust camshaft cam phaser locking pin in 12\u2019o clock position. Align the MST \u2013 0310ABG0001ST Camshaft locking tool on the front side of engine in the camshaft slot as shown and fix the camshaft locking tool on cylinder head using appropriate bolts. Ensure that correct Camshaft locking tool is used. Ensure the Cam locking tool is seated properly on Cam shaft. If the tool is not properly seat on the cam shaft slot then the engine is not in proper timing and follow the below steps for Engine timing adjustment. Using 10 mm socket spanner, Unscrew chain tensioner mounting bolts and remove the tensioner. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010607.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using 8 mm Allen socket spanner, Unscrew chain tensioner LH fixed guide mounting bolt and remove the guide. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010606.jpg",
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using 8 mm Allen socket spanner, Unscrew chain tensioner RH guide mounting bolts and remove the guide. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010608.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew chain tensioner top guide mounting bolt and remove the guide. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010609.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Remove the timing chain from sprocket. Align the MST \u2013 0310ABG0001ST Camshaft locking tool on the front side of engine in the camshaft slot as shown and fix the camshaft locking tool on cylinder head using appropriate bolts. If not able to position the MST in proper position into camshaft, Slightly rotate Intake/Exhuast cam shaft and align the tool. Ensure Crankshaft Sprocket woodruff key slot in 12\u2019o Clock Position, Intake and Exhaust camshaft cam phaser locking pin should be in 12\u2019o clock position. Ensure the Cam locking tool is seated properly on Cam shaft. Position and Refit the timing chain. Ensure Timing mark provided on the crankshaft sprocket match with highlighted chain link (Blue Link) on timing chain. 1st link (Blue Link) of timing chain started on timing mark provided on the crankshaft sprocket. Ensure Timing mark provided on the cam phaser (Intake and Exhaust) match with highlighted chain link (Blue Link) on timing chain. 29th link (Blue Link) of timing chain on timing mark provided on the Intake cam phaser sprocket (Anti-clock wise direction from Crank shaft first chain link). 40th link (Blue Link) of timing chain on timing mark provided on the Exhaust cam phaser sprocket (Anti-clock wise direction from Crank shaft first chain link). Refit the timing chain fixed guide and install the Allen bolts. Torque : 25\u00b13 Nm ",
+ "file": null,
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010607.jpg",
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-24",
+ "content_type": "Description",
+ "content": "Refit the chain tensioner guide and install the mounting Allen bolt. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010612.jpg",
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Compress the chain tensioner and lock it using lock pin. Refit the chain tensioner. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010608.jpg",
+ "display_order": 76
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Refit the timing chain top guide and install the mounting bolts. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010612.jpg",
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Remove the chain tensioner locking pin. Remove the CAM shafts locking MST. Remove the TDC Pin from crankshaft. Apply the Loctite 574 on TDC lock plug and tighten the plug on engine block to specified torque. Torque : 20\u00b12 Nm ",
+ "file": null,
+ "display_order": 87
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010975.jpg",
+ "display_order": 88
+ },
+ {
+ "step_name": "Step-32",
+ "content_type": "Description",
+ "content": "Refit engine mounting LH bracket, torque tighten the mounting bolts to the specified value. Torque : 45\u00b15 Nm ",
+ "file": null,
+ "display_order": 90
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010618.jpg",
+ "display_order": 91
+ },
+ {
+ "step_name": "Step-33",
+ "content_type": "Description",
+ "content": "Remove engine support beam. Install engine bed mounting nuts Both RH & LH, torque tighten the mounting nut to the specified value. Torque : 110 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010617.jpg",
+ "display_order": 97
+ },
+ {
+ "step_name": "Step-35",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner , loosen and remove engine front lifting hook from head. Torque : 35\u00b13 Nm ",
+ "file": null,
+ "display_order": 99
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010971.jpg",
+ "display_order": 100
+ },
+ {
+ "step_name": "Step-36",
+ "content_type": "Description",
+ "content": "Refit Flywheel locking tool (MST\u20130307ABH0001ST) with suitable mounting bolts on crankcase. For additional information refer to Engine Front cover - R&R Section. ",
+ "file": null,
+ "display_order": 102
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 34,
+ "sys_id": "THAR.LX-0009-Engine",
+ "subsys_id": "THAR.LX-0009-Engine-OCFM Oil Cooler",
+ "systems": "Engine",
+ "sub_systems": "OCFM Oil Cooler",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4B010137.jpg",
+ "myid": 1507,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0009-OCFM Oil Cooler-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010137.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/30204.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11477.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Drain the engine coolant. For additional information refer to coolant drain procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Air Cleaner Assembly. For additional information refer to OCFM-Degassing Tank Outlet Pipe - R&R. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove Steering Lower Intermediate Shaft. For additional information refer to Steering Lower Intermediate Shaft - R&R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Link",
+ "content": "THAR.LX-0009,1004,1507",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1513.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using the MST 0306GAM0006ST - Stretch Fit Belt Removal Tool Remove the AC compressor Drive belt. Disconnect the AC compressor electrical connector. Using 12 mm socket spanner, Unscrew AC compressor mounting bolts and keep aside the compressor. Torque : 23 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010140.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew degassing tank coolant outlet pipe OCFM end. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010139.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010138.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using T45 socket spanner, Unscrew Oil cooler mounting bolts. Remove the oil cooler from the engine. Replace New O ring while refitting. Ensure to clean the Engine oil spillages. Install in reverse order of removal. Refill the engine oil and check for the oil leakage. Refill the engine coolant and carry-out de-aeration procedure. Check the oil cooler assembly for any external damage, Replace if required. Remove Air Cleaner Assembly. Remove Steering Lower Intermediate Shaft. Using MST remove AC compressor drive belt. Disconnect AC compressor electrical connector. Using 12 mm socket spanner, Unscrew AC compressor mounting bolts and keep aside the compressor. Disconnect oil pump solenoid electrical connector. Using 8 mm socket spanner, Unscrew oil pump solenoid mounting bolt and remove the solenoid. Install in the reverse order of removal. Inspect the oil pump Solenoid for any physical damage. If found replace. For additional information refer into Flywheel \u2014 R&R Section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010142.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a suitable tool remove the front end oil seal. Remove the seal from the engine. Install in reverse order of removal. The crankshaft oil seals are one time use, should never be reused. Follow the below procedure for front oil seal Installation. Position the front oil seal on the Front Cover. Place the front oil seal installer (MST\u20130311DBH0001ST) over the oil seal and tighten the torsional vibration damper pulley bolt. Tighten the torsional vibration damper pulley bolt till the front oil seal is pushed to the Front Cover. Apply thin layer of oil on the new oil seal lip. Visually inspect the oil seal for proper seating. Check & Top-up the engine oil. Check and clean the oil seal seating area thoroughly for any damage. Hydro lock or hydrostatic lock is an abnormal condition in internal combustion engine. This occurs when a volume of liquid (Coolant/water or fuel) greater than the volume of the cylinder at its minimum (end of the piston stroke) enters the cylinder. Since liquids are nearly incompressible the piston cannot complete its travel; either the engine stop rotating or a mechanical failure occurs. When an engine is suspected to be hydrostatically locked, regardless of what caused the problem, the following steps should be used. DO NOT use starter motor to rotate the engine, severe damage may occur. Inspect air cleaner, air intake system and intake manifold to ensure system is dry and clear of water and foreign material. Disconnect negative battery cable. Place a shop towel around the injectors when removing them from the engine. This will catch any fluid that may possibly be in the cylinder under pressure. With all injectors removed, rotate engine crankshaft. Identify the fluid in the cylinder(s) (i.e., coolant, fuel, oil or other). Make sure all fluid has been removed from the cylinders. Inspect engine for damage (i.e., connecting rods, pistons, valves, etc.). Repair engine or components as necessary to prevent this problem from recurring. Squirt approximately one teaspoon of oil into the cylinders, rotate engine to lubricate the cylinder walls to prevent damage on restart. Drain engine oil and remove oil filter. Install a new oil filter. Fill engine with specified amount of approved oil. Connect negative battery cable. Install all Injectors. Start engine and check for any leaks. The Oil Sump is the reservoir for the oil and also cover for the crank case. Oil sump is bolted to the ladder frame. The oil sump structural type to have better NVH. A liquid sealant is used to provide an leak proof joint. For additional information refer to engine oil draining procedure section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove electric disconnect stone guard. For additional information refer to Electric Disconnect Stone Guard \u2013 R&R Section. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove Water Pump/ AC compressor belt. For additional information refer to Water Pump/ AC compressor belt - R&R section. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010526.jpg",
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, Unscrew water pump idler mounting bolt and remove dealer. Torque : 45 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010623.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the transmission bottom mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010527.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Provide jack to support the front axle assembly. Using 15 mm socket spanner, unscrew front axle mounting bolts and partially detach the axle. Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010918.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Partially down the front axle assembly . Using a 12 mm socket spanner, loosen and remove the AC compressor bottom mounting bolts. Torque : 23 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010529.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using a 14 mm ring and 15 mm socket spanner, Unscrew the front cross member mounting bolts and nuts. Torque : 65 \u00b110 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010916.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Detach the front cross member from the vehicle. For additional information refer to Stabilizer bar with link - R&R section. ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010530.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using a 8 mm socket spanner, loosen and remove the oil sump bottom mounting bolts. Torque : 11 \u00b1 1.0 Nm ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010531.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a 12 mm socket spanner, loosen and remove the oil sump bottom mounting bolts. Torque : 22.5 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010532.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1518.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Detach engine oil sump from the vehicle . Torque : 22.5 \u00b1 2.5 Nm ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010653.jpg",
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010119.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11586.jpg",
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Clean the sump and sump seating area on crankcase . Gently apply sealant for engine oil sump. Apply sealant 5188 as per recommendation and position the sump on crankcase. Please refer Sealant pattern session for sealant apply pattern. Torque tighten the bolts as per sequence below while Installation. Refill the engine oil and check for oil leakage. Check the oil sump for any cracks, damage etc, replace if found any. Remove Timing Chain. For additional information refer to Timing Chain - R&R section. Align the MST \u2013 0310ABG0001ST Camshaft locking tool on the front side of engine in the camshaft slot as shown and fix the camshaft locking tool on cylinder head using appropriate bolts. Using 22 mm socket spanner, Loosen and remove Inlet CAM phaser mounting bolt. Torque : 30 \u00b1 2 Nm + 34\u00b0\u00b1 3\u00b0 ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11655.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. While Installation, Check Exhaust Cam phaser mounting bolt tightening torque first and then torque tightened the Intake Cam phaser mounting bolt. Inspect the CAM Phaser for any physical damage. If found replace. This is a Variable type oil pump uses to supply variable oil pressure to the system. It is chain driven and integral oil strainer. The oil pump circulates the engine oil to lubricate the components such as bearings, piston and valve. The lower chain drives oil pump to lubricate the engine. This oil pump are integrated with the strainer. The oil strainer is the first stage in the filtration of the lubricant. It filters the coarse particles present in the oil before it enters the oil pump. For additional information refer to Engine Oil Sump \u2013 R&R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010472.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew oil strainer bracket mounting bolt. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010473.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010474.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew Oil strainer mounting bolts and remove strainer. Always replace a new metal gasket once it removed. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010521.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 8 mm Allen socket spanner, Loosen and remove oil pump chain tensioner shoulder bolt. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010522.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010523.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Remove the tensioner and detach the chain from oil pump. Using 12 mm socket spanner, Unscrew oil pump mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010525.jpg",
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1519.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Carefully remove engine oil pump. Install in reverse order of removal. Make sure that the retaining key on the rear side of the oil pump is fitted correctly to the retaining key hole on the surface of the cylinder block bed plate. While Installation, Partial attach the Oil Pump tensioner first and insert the tensioner spring lock on position. Then torque tighten the shoulder bolt. Refill the engine oil and check for oil leakage. Inspect the oil pump for any damage. Replace if found. Inspect the oil pump and strainer for any blockage, clean if found. For additional information refer to vacuum pump - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the FIP. For additional information refer to FIP - R&R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the timing chain. For additional information refer to Timing Chain - R&R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010537.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using the MST \u2013 0310ABG0001ST Camshaft locking tool lock the cam shafts. Using 22 mm socket spanner, Loosen and remove exhaust CAM phaser mounting bolt. Torque : 30 \u00b1 2 Nm + 34\u00b0\u00b1 3\u00b0 ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010539.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 22 mm socket spanner, Loosen and remove Inlet CAM phaser mounting bolt Torque : 30 \u00b1 2 Nm + 34\u00b0\u00b1 3\u00b0 ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010537.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010540.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 8 mm socket spanner, Unscrew CAM shafts cap mounting bolts. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010541.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010543.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Remove the camshaft from the cylinder head. Install in reverse order of removal. While Installation, Apply a thin layer of engine oil to the mounting parts of the Cam shafts & on Cam shafts. Sealant (Loctite 5188 - 2mm thickness) to be applied on rear (Vacuum Pump) bearing cap as per below pattern. Extra sealant to be wiped off after assembly of rear bearing cap. Exhaust Cam phaser mounting bolt should be torque tightened first and then torque tightened the Intake Cam phaser mounting bolt. Check the inlet camshaft and the exhaust camshaft for any damage and replace it if necessary. Inspect the camshaft bearing journals for scoring or excessive wear. Inspect the camshaft lobes for scoring or excessive wear. Inspect the threaded bolt holes in the front of the camshaft for damaged threads or debris. For additional information refer into Flywheel - R&R Section .",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010237.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010770.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a screw driver, remove the crankshaft rear end oil seal. Install the rear end oil seal by using MST 0302ABH0001ST - Engine Rear End Oil Seal Installer on the crankshaft. Always use new oil seal while installation. Install in reverse order of removal. Check & Top-up the engine oil. Check and clean the oil seal seating area thoroughly for any damage. For additional information refer into engine coolant draining procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "After installation of water pump, carry out refilling of the coolant. For additional information refer into coolant refilling procedure. For additional information refer into Water Pump Pulley \u2013 R&R Section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010923.jpg",
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Detach the wiring routing clip from the water pump. Using a 13 mm socket spanner, Unscrew water pump mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010633.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Carefully remove the water pump from the engine. Remove the O ring from the water pump. Install in reverse order of removal. Always replace the O ring new one once removal of water pump. Refill the engine coolant and carry-out de-aeration procedure. Check for coolant seepage on the engine. Rectify if any traces found. Inspect the water pump for any damage or leakage or noise. Replace if found. Inspect the impeller for any damage, Replace if found. Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable. Improper tie-up of the lifting rope/chain will cause damage to the vehicle and the persons involved. Torque : 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010045.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the engine top encapsulation cover. Recover AC gas. For additional information refer to AC gas recovery procedure. Using 17 mm open end spanner, Loosen power steering pump outlet pipe mounting nut and Drain power steering fluid. Torque : 22 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove Clean Side Hose Assembly. For additional information refer to Clean Side Hose Assembly - R&R",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B090004.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, loosen starter motor positive cable mounting nut and detach cable from starter motor end. Torque : 12\u00b12 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B090002.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 8 mm socket spanner, Unscrew starter motor solenoid switch electrical connector. Torque : 2.5\u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B090005.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a 14 mm socket spanner, loosen and remove the starter motor mounting bolts and remove starter motor from vehicle. Torque : 44 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1506.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner unscrew exhaust front pipe mounting bolts CATCON end. Torque : 45 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove Radiator Air Guides. For additional information refer to Radiator Air Guides - R&R section. Remove Transmission with Transfer Case. Ensure to close the bypass tubes with dummy caps to avoid dust entry.
Torque : 6.5 \u00b1 0.5 Nm
Using a hose clamp plier, Release coolant vent hose clamps radiator end,engine end and detach the hose both the ends and from routing clips. Using hose clamp plier, Release degassing tank coolant outlet hose clamp and detach hose OCFM end. Using hose clamp plier, Release turbo coolant outlet hose clamp and detach hose turbo end. Using 10 mm socket spanner, Unscrew degassing tank mounting bolts and detach tank with hoses. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010069.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew front top cross member mounting bolts. Torque : 25 \u00b1 4.0 Nm ",
+ "file": null,
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010213.jpg",
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Detach front top cross member and disconnect bonnet latch cable from routing and from lock. Using 10 mm socket spanner, unscrew degassing tank mounting bracket LHS & RHS mounting bolts. Torque : 10 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1509.jpg",
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020285.jpg",
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Disconnect boost pressure sensor, and intercooler fan electrical connectors. Using 7 mm socket spanner, Loosen turbo outlet hose clip and detach hose turbo end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010215.jpg",
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner, Loosen intercooler outlet hose clip and detach hose throttle valve end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010073.jpg",
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew intercooler mounting bolts and remove intercooler with hoses and fan. Torque : 12.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 71
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010216.jpg",
+ "display_order": 72
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner, Loosen radiator outlet hose clip and detach hose OCFM end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010218.jpg",
+ "display_order": 75
+ },
+ {
+ "step_name": "Step-28",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release radiator inlet hose clamp and detach hose cylinder block end. Disconnect heater inlet and outlet hose quick coupler heater end. Press and disconnect the quick coupler carefully to avoid seal damages. Disconnect fuel inlet pipe quick coupler FIP end and detach hose. Press and disconnect the quick coupler carefully to avoid seal damages. Disconnect purge valve vapour hose quick coupler purge valve end and detach hose. Disconnect purge valve electrical connector. Disconnect vapour hose quick coupler and routing clip intake manifold end and detach hose. Press and disconnect the quick coupler carefully to avoid seal damages. Detach purge valve from mounting bracket and remove purge valve with vapour hose assembly. Using hose clamp plier, Release vacuum hose clamp and detach hose vacuum pump end. Open the alternator positive cable cover. Using 12 mm socket spanner, Unscrew alternator positive cable mounting nut and detach cable alternator end. Torque : 15 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 100
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1510.jpg",
+ "display_order": 101
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010130.jpg",
+ "display_order": 102
+ },
+ {
+ "step_name": "Step-38",
+ "content_type": "Description",
+ "content": "Disconnect engine WH inter connector, Holding clip and routing clip fire wall end. Disconnect engine WH connector ECU end and detach harness from routing clips. Using hose clamp plier, Release power steering oil inlet hose clamp and detach hose pump end. Using 12 mm socket spanner, Unscrew AC compressor suction and discharge hose mounting nuts. Torque : 14.0+1.0 Nm ",
+ "file": null,
+ "display_order": 111
+ },
+ {
+ "step_name": "Step-42",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010081.jpg",
+ "display_order": 112
+ },
+ {
+ "step_name": "Step-42",
+ "content_type": "Description",
+ "content": "Support the engine using engine removal support floor crane. Improper tie-up of the lifting rope chain will cause damage to the vehicle and the persons involved. Using 18 mm socket spanner, unscrew engine bed mounting nuts LHS & RHS. Carefully remove the engine from compartment. Improper tie-up of the lifting rope chain will cause damage to the vehicle and the persons involved. Using hose clamp plier, Release heater inlet and outlet hose clamps and detach the hoses. Using 10 mm socket spanner, Unscrew engine WH carrier mounting bolts. Using 12 mm socket spanner, Unscrew ignition coil ground connector mounting nut. Disconnect AC compressor electrical connector Disconnect Variable oil pump solenoid electrical connector. Disconnect upstream Lambda sensor electrical connector and connector holder. Disconnect Engine oil pressure sensor electrical connector and routing clip. Disconnect WGTelectrical connector. Disconnect Dump valve electrical connector and routing clip. Disconnect VVT inlet and exhaust cam phase solenoid connector & routing clip. Disconnect throttle valve electrical connector. Disconnect MAP sensor electrical connector. Disconnect Spark plug (4 nos) electrical connectors. Disconnect Exhaust CAM sensor electrical connector. Disconnect downstream lambda sensor electrical connector and routing clip. Disconnect Inlet CAM phase sensor electrical connector. Disconnect Coolant temperature sensor electrical connector. Disconnect FIP electrical connector. Disconnect Common rail electrical connector. Disconnect Injector (4 nos) electrical connector. Disconnect Knock sensor electrical connector & routing clips(2Nos). Disconnect Alternator connector & routing clip. Detach the WH harness from engine assembly. Using 13 mm socket spanner, Unscrew CATCON mounting bolts and remove CATCON from Turbo end. Using 12 mm socket spanner, Unscrew CATCON brackets mounting bolts and remove CATCON from engine. Using 12 mm socket spanner loosen and remove clutch cover assembly mounting bolts and remove it. Torque : 25 \u00b1 5.0 Nm (Step Torque : 5,15,25) ",
+ "file": null,
+ "display_order": 182
+ },
+ {
+ "step_name": "Step-71",
+ "content_type": "Notice",
+ "content": "Install the MST : 0307ABH0001ST \u2013 Flywheel locking tool and lock the flywheel rotation. Insert MST \u2013 0801BUA0001ST \u2013 Master clutch plate assembly, before loosening the clutch cover bolts to prevent clutch plate falling down and getting damage. While Installation, the projected part of clutch disc should come towards transmission side only, fails may result in clutch disc damage. Using 10 mm socket spanner, Unscrew engine feed cover mounting bolts and remove feed cover. Install in the reverse order of removal. Recharge the AC refrigerant system. For additional information refer to Recharge the AC refrigerant system - R&R section. Refill Engine coolant. For additional information refer to coolant refilling Procedure. Check & Top-up the engine oil. Check for coolant seepage and any oil seepage on the engine and transmission. Rectify if any traces found. Check & Clear DTC if found any. For additional information refer to diagnostic manual. Check the accessory drive belt for any cracks, damage etc, replace if found any Check SMF face-out and run-out. Check SMF Surface thermal cracks condition. Check the flywheel ring gear for worn-out or damage, Refer SMF Inspection procedures for more details. Engine Oil \u2013 \u2013MAHINDRA 'MAXIMILE ULTRA' Gen-NXT Technology Genuine Engine Fluid.Capacity \u2013 6.0 Liters.Position the Vehicle on level ground and turn engine OFF. Open the bonnet and lock it in open position using bonnet stay rod. Wait for about 10 minutes for oil in circulation to drain down. Pull out the dip stick gauge and wipe it clean with a cloth/paper. Insert the dip stick gauge into the dip stick guide fully till the end. Pull out the dip stick slowly and check for the oil level mark between Maximum and Minimum level - if found below minimum level, top up with recommended oil. Insert the dip stick back and fix properly. Start the engine and check for oil leakage/ seepage at: Oil sump & crankcase joint. Oil sump drain plug. Oil filter joint. Always use MAHINDRA 'MAXIMILE ULTRA'Gen-NXT Technology GENUINE ENGINE Fluid. This is specially developed for your engine\u2019s efficiency. In extreme cases of emergency and non-availability of above oil, we suggest to use 'Maximile Feo' engine oil, take the vehicle to nearest Mahindra Authorised Service centre and replace the oil with 'MAXIMILE ULTRA'. No other brand / grade oil recommended. The cylinder head gasket failure can be easy to determine. A large stream of white smoke blowing from the exhaust and an overheating engine are sure signs. However, more suitable cylinder head gasket failure signs may be more difficult to diagnose. The engine may experience mysterious coolant loss, or only lose coolant when the engine is driven under heavy load. You may even experience a rough running engine when you first start the vehicle. An initial inspection of cooling system components and a comprehensive test drive may be necessary to confirm the customer's complaint of coolant loss or overheating. Check for the presence of white steam/smoke coming from the exhaust. Steam coming out of the exhaust may smell slightly sweet as the steam gently dissipates into the surrounding air. Another sign that the head gasket may be leaking is the presence of oil in the cooling system. Check for oil residue in the coolant reservoir. It is important to confirm actual engine running temperature and accuracy of the temperature gauge. This can be verified by using a non-contact infrared heat detection gun. It is a non intrusive method used by most repair shops to verify temperature gauge accuracy and actual engine running temperature. Pressurizing the cooling system (to eliminate coolant leaks as being the source of coolant loss), checking for proper operation of the cooling fan, and checking radiator efficiency are important before jumping to the conclusion that the head gasket is defective. Cylinder to Cylinder Leakage Test ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the cylinder compression pressure as already explained. Leakage between cylinders will be result in drop of compression pressure by nearly 50 to 70% in the affected cylinders. Cylinder to Water jacket Leakage Test ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Remove the degassing pressure cap. Warm up the engine and allow it to warm up until the engine thermostat opens. If large combustion pressure leak exist, bubbles will be visible in coolant. If bubbles are not visible, install a pressure tester and pressurize the cooling circuit. If a cylinder is leaking combustion pressure into the water jackets then the tester\u2019s needle will pulsate with every combustion stroke of the cylinder. Position the vehicle on ground level/ 2 post lift/ 4 post lift and turn engine OFF. Open the bonnet and lock it in open position using bonnet stay rod. Using a 10 mm socket spanner, loosen and remove the engine feed cover mounting bolts. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W376.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the engine feed cover from engine compartment. Using a 24 mm socket spanner, rotate the crank pulley 360\u2070 till belt completes one full rotation to check belt condition and confirm following belt appearances if any. Random Cracking Across the Ribs ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Small yet visible cracks along the length of a rib or ribs. Causes: ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Continuous exposure to high temperatures and the stress of bending around the pulleys leads to cracking. Cracks begin at the rib top and grow to the cord line. As a rule, if cracks appear 1 or 2 cm apart, 80% of the life is gone and the belt should be replaced. Chunk-Out ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Pieces or chunks of rubber material have come off the belt. When chunk-out has occurred, a belt can fail at any moment. Belt should be replaced immediately. Causes: ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Chunk-out can happen when several cracks in one area move parallel to the cord line. Heat, age and stress are the primary contributors. Pilling ",
+ "file": null,
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Belt material wears off from the ribs and builds up in the belts grooves. Causes: ",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "There are a number of causes, including misalignment, new belt on worn pulleys, lack of tension or a combination of these factors. Gravel Penetration ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Small pinholes are visible on the backside of the belt. Bumps may be visible and fabric around the holes can be frayed. Causes: ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Granular gravel or pebble gravel is wedged between the belt groove(s) and pulley ridge(s). Damaged Outermost Ribs ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Sidewalls of the belt may appear glazed or the edge-cord may become frayed and ribs removed. A noticeable noise may result. Causes: ",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Pulley misalignment is a common cause of premature belt failure. Misalignment forces the belt to twist while running, causing premature wear. Oil Contamination ",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "The belt surface is flaky, sticky or swollen. Causes: ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Oil and grease are a rubber compound\u2019s worst enemies, weakening the compound\u2019s bonds and making the belt soft and spongy. Eventually, such a belt will slip, create heat and fail. Abrasion ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "The backside of the belt appears very shiny or glazed. In advance stages, the fabric or even the cord becomes exposed and gets damaged. Causes: ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "When in motion, the belt makes contact with the foreign objects in its path such as a flange or bolt. This may be caused by improper belt tension or by belt flutter (vibrations) on longer span lengths between two pulleys. Rib Separation ",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 56
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "The belt rib shears off or begins to separate from the belt base. Causes: ",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "The belt is not correctly positioned. One of the belt ribs is placed outside the pulley groove, causing a belt rib to run without a supporting or aligning pulley groove. Uneven Rib Wear ",
+ "file": null,
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Wear that is more severe on one rib than on the others or one rib that exhibits a different wear pattern than the others. A thumping or grinding noise may also be heard. Causes: ",
+ "file": null,
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "A foreign object \u2014 such as a pebble \u2014 in the pulley will cause uneven wear and cut into the belt and break the tensile cords. Broken Belt ",
+ "file": null,
+ "display_order": 67
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 68
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "A large foreign object between the belt and pulley can cut into the belt and break the tensile cords. Tensile break may occur but go unnoticed when the belt is forced or pried on during installation. Other possible causes may be severe shock loads or a blocked pulley and/or accessory. Belt Noise ",
+ "file": null,
+ "display_order": 73
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "Inspection: ",
+ "file": null,
+ "display_order": 74
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Run the engine and inspect for Chirping, squealing. tapping, ticking or grinding noise coming from the belt. It is recommended to remove & check the drive belts thoroughly if any abnormality noticed. Check belt tension as per procedure mentioned below: ",
+ "file": null,
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Turn ON belt tension gauge. Select reading mode in hertz (Hz) and hold the probe approximately 5mm distance in front of the belt. Do not touch the probe to the belt, this can damage the probe. Belt tension needs to be checked at the green points shown in illustration. Between Crank pulley & water pump pulley. Between water pump pulley & AC Compressor Pulley. Tap on the belt near the probe. Note the reading, if the reading is within 195 \u2013 228 Hz, belt tension is OK. If the reading is not within the above limit, check & replace the belt if required. Position the vehicle on ground level/ 2 post lift/ 4 post lift and turn engine OFF. Open the bonnet and lock it in open position using bonnet stay rod. Using 10 mm socket spanner, loosen and remove the engine feed cover mounting bolts. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 89
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W384.jpg",
+ "display_order": 90
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the engine feed cover from engine compartment. Using a 24 mm socket spanner, rotate the crank pulley 360\u2070 till belt completes one full rotation to check belt condition and confirm following belt appearances if any. Random Cracking Across the Ribs ",
+ "file": null,
+ "display_order": 95
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 96
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Small yet visible cracks along the length of a rib or ribs. Causes: ",
+ "file": null,
+ "display_order": 98
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Continuous exposure to high temperatures and the stress of bending around the pulleys leads to cracking. Cracks begin at the rib top and grow to the cord line. As a rule, if cracks appear 1 or 2 cm apart, 80% of the life is gone and the belt should be replaced. Chunk-Out ",
+ "file": null,
+ "display_order": 101
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 102
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Pieces or chunks of rubber material have come off the belt. When chunk-out has occurred, a belt can fail at any moment. Belt should be replaced immediately. Causes: ",
+ "file": null,
+ "display_order": 104
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Chunk-out can happen when several cracks in one area move parallel to the cord line. Heat, age and stress are the primary contributors. Pilling ",
+ "file": null,
+ "display_order": 107
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 108
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Belt material wears off from the ribs and builds up in the belts grooves. Causes: ",
+ "file": null,
+ "display_order": 110
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "There are a number of causes, including misalignment, new belt on worn pulleys, lack of tension or a combination of these factors. Gravel Penetration ",
+ "file": null,
+ "display_order": 113
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 114
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Small pinholes are visible on the backside of the belt. Bumps may be visible and fabric around the holes can be frayed. Causes: ",
+ "file": null,
+ "display_order": 116
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Granular gravel or pebble gravel is wedged between the belt groove(s) and pulley ridge(s). Damaged Outermost Ribs ",
+ "file": null,
+ "display_order": 119
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 120
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Sidewalls of the belt may appear glazed or the edge-cord may become frayed and ribs removed. A noticeable noise may result. Causes: ",
+ "file": null,
+ "display_order": 122
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Pulley misalignment is a common cause of premature belt failure. Misalignment forces the belt to twist while running, causing premature wear. Oil Contamination ",
+ "file": null,
+ "display_order": 125
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 126
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "The belt surface is flaky, sticky or swollen. Causes: ",
+ "file": null,
+ "display_order": 128
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Oil and grease are a rubber compound\u2019s worst enemies, weakening the compound\u2019s bonds and making the belt soft and spongy. Eventually, such a belt will slip, create heat and fail. Abrasion ",
+ "file": null,
+ "display_order": 131
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 132
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "The backside of the belt appears very shiny or glazed. In advance stages, the fabric or even the cord becomes exposed and gets damaged. Causes: ",
+ "file": null,
+ "display_order": 134
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "When in motion, the belt makes contact with the foreign objects in its path such as a flange or bolt. This may be caused by improper belt tension or by belt flutter (vibrations) on longer span lengths between two pulleys. Rib Separation ",
+ "file": null,
+ "display_order": 137
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 138
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "The belt rib shears off or begins to separate from the belt base. Causes: ",
+ "file": null,
+ "display_order": 140
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "The belt is not correctly positioned. One of the belt ribs is placed outside the pulley groove, causing a belt rib to run without a supporting or aligning pulley groove. Uneven Rib Wear ",
+ "file": null,
+ "display_order": 143
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 144
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Wear that is more severe on one rib than on the others or one rib that exhibits a different wear pattern than the others. A thumping or grinding noise may also be heard. Causes: ",
+ "file": null,
+ "display_order": 146
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "A foreign object \u2014 such as a pebble \u2014 in the pulley will cause uneven wear and cut into the belt and break the tensile cords. Broken Belt ",
+ "file": null,
+ "display_order": 149
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 150
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 151
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Heading",
+ "content": "Causes: ",
+ "file": null,
+ "display_order": 152
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "A large foreign object between the belt and pulley can cut into the belt and break the tensile cords. Tensile break may occur but go unnoticed when the belt is forced or pried on during installation. Other possible causes may be severe shock loads or a blocked pulley and/or accessory. Belt Noise ",
+ "file": null,
+ "display_order": 155
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Heading",
+ "content": "Inspection: ",
+ "file": null,
+ "display_order": 156
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Run the engine and inspect for Chirping, squealing. tapping, ticking or grinding noise coming from the belt. It is recommended to remove & check the drive belts thoroughly if any abnormality noticed. Inspect the auto-tensioner carefully for symptoms such as cracked arms, excessive vibration during idle speeds, looseness, noise (clatter or rattling) and sticking or seized operation. These all can be signs that roller needs replacement. Rust bleed and cracks ",
+ "file": null,
+ "display_order": 163
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 164
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Rust bleeding between arm and base or dripping from the tensioner. Also, check the tensioner for cracks or damage to arm, housing and bracket. Causes: ",
+ "file": null,
+ "display_order": 166
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Rust bleeding or dripping is a sign of internal component wear. Most common crack damage occurs at tensioner \u201cStops\u201d and mounting bolts. Solution: ",
+ "file": null,
+ "display_order": 168
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Replace the auto-tensioner. Pulley bearing wear ",
+ "file": null,
+ "display_order": 171
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 172
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "If any abnormality noticed, remove the belt and manually rotate the pulley. If you notice, resistance or roughness, the problem is likely to be pulley bearing wear. Causes: ",
+ "file": null,
+ "display_order": 174
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Defective bearing and/or pulley. Solution: ",
+ "file": null,
+ "display_order": 176
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Replace the complete tensioner. Do not attempt to replace a worn pulley in a used tensioner assembly but always replace the entire tensioner assembly, as part failure will inevitably follow quickly. TENSIONER ASSEMBLY MISALIGNMENT ",
+ "file": null,
+ "display_order": 180
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 181
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Abnormal belt tracking on tensioner pulley. Causes: ",
+ "file": null,
+ "display_order": 183
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Bent or misaligned mounting bracket,improper tensioner installation or corrosion/ contamination between tensioner base and mounting surface. A small amount of contamination results in a large amount of at tensioner pulley. Tensioner Noise ",
+ "file": null,
+ "display_order": 185
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Heading",
+ "content": "Appearance: ",
+ "file": null,
+ "display_order": 186
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Squeaks and rattles coming from the tensioner. Causes: ",
+ "file": null,
+ "display_order": 188
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Failure of bearings or pivot are will cause excessive noise. Solution: ",
+ "file": null,
+ "display_order": 190
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Replace the tensioner assembly. The crankshaft speed sensor is an hall effect type sensor. It measures the speed of the trigger wheel mounted on the crankshaft. During engine cranking and running, the EMS ECU receives the output signal from crankshaft speed sensor. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0009,1000,1003",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove Steering Lower Intermediate Shaft.",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.LX-0009,1017,1302",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1520.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Place the MST 0306GAM0006ST \u2013 Drive Belts Removal Tool on damper pulley side as shown in the image. Using a 24 mm socket spanner, rotate the damper pulley to clockwise direction then remove the water pump drive belt and MST 0306GBH0001ST \u2014 Drive Belts Removal Tool separately. Disconnect AC compressor electrical connector. Using 12 mm socket spanner, Unscrew AC compressor mounting bolts and keep aside the compressor. Torque : 23 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010240.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect engine speed sensor electrical connector detach it from holding clip. Using 10 mm socket spanner unscrew engine speed sensor mounting bolt and remove sensor. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Notice",
+ "content": "Take sufficient care not to damage the sensor while removing. Ensure proper torque value is applied to sensor mounting bolt. Else chances of sensor malfunction is high. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Inspect the sensor and connector for any physical damage. Replace if found. EMS (Engine Management System) ECU is an electronic control unit which is used to ensure optimal engine performance. It does this by analyzing values or signals from various sensors and other ECU\u2019s and adjusting the actuators accordingly. EMS ECU is mounted on front left side apron in the engine compartment. ECU electrical connector should be disconnected before carrying out any welding activities in the vehicle. Using 10 mm socket spanner, Loosen battery negative cable mounting nut and disconnect the cable. Torque : 6.0 \u00b1 0.6 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010243.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Open the lock and gently pull-out and disconnect EMS ECU electrical connector. Using 10 mm socket spanner remove EMS ECU mounting bolts. Torque : 6 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. For New EMS ECU replacement carry out Necessary Procedures by using iSMART. For additional information refer Diagnosis Manual. ECU electrical connector should be disconnected before carrying out any welding activities in the vehicle. Check for any external damage, if found replace. Remove the Engine Assembly. Remove the cylinder head assembly. Place the cylinder head on clean flat work table. Using a suitable valve compressor, compress and hold the valve spring and then remove the valve spring lock studs. Remove the upper retainer and valve spring. Incase of reusing the same valves spring, make necessary marking according to the respective cylinder. Remove the valve stem seal. The valve should be identified, so that in case the valves are being reused they can be used. Failure to do so may increase the probability of compression leak through the valve after the engine is rebuilt. Similarly remove the other valves. Check the valve spring lock for any internal and external damage. Check the valve spring height. Check the valve guide bore diameter. Check the valve guide for any damages. Check the valve for any damages. Using a micrometer measures the diameter of the valve stems. If the measurements are not to specification, install a new valve. Check the valves for bend - especially if the engine has suffered water entry into combustion chamber. Clean the cylinder head assembly thoroughly, if any cracks or damages are found replace the cylinder head. Check the Cylinder Head for external damages. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. Check the valve seat area for leakages. Check the Cylinder Head bottom face for distortion. Check the cylinder head flatness, if any misalignment or bend found replace the cylinder head assembly. Check the cylinder head for warpage. Check the length of the Cylinder Head bolts. Using a micrometer measure the diameter at 90\u00b0 intervals to determine if the journals are out-of-round. Measure at two different points on the journal to determine if there is any tapering. Check the camshaft for any damage and replace it if necessary. Inspect the rocker arm for wear or damage. Replace as necessary. Do not dis-assemble the HLLA, as it is not a serviceable component. Incase of a failure of a HLLA, replace the complete assembly. Inspect the camshaft lobes for pitting or damage in the active area. Minor pitting is acceptable outside the active area. Carefully insert the valve from bottom. Apply oil on the valve stem before installation. Incase of reusing the same valves again, make sure the valves used is of respective cylinder. Using suitable tool refit new valve stem seal. Never use old valve stem seal, always use a new one. Always apply oil on the valve stem seal before installation. Insert the respective valve spring and top retainer. Using a suitable tool, compress the valve spring carefully insert the locking pins and lock it properly. Install the cylinder head assembly. Clean the cylinder head assembly thoroughly, if any cracks or damages are found replace the cylinder head. Replace the cylinder head gasket with a new one. Failure to follow this will lead to compression failure. The cylinder head mounting bolts cannot be reused. Always use new bolts during installation Refit the engine assembly. Start the engine. Run at idle for 5 minutes. Observe for leaks. Drive the vehicle at 50% of the maximum speed in each gear for about 10 to 30 kms each (Approx.). Hand over the vehicle to customer to drive with speed limitation for 2000 kms Do not run the engine without load for hours for bedding in. This process only harms the engine. Running the engine without load cause ring fluttering and damage to rings as well as liners. Running the engine at idle for prolonged time has serious consequences on major engine components. Engine Oil \u2013 MAHINDRA 'MAXIMILE ULTRA' Gen-NXT Technology Genuine Engine Fluid.Capacity \u2013 6.0 Liters. Engine should be hot while draining the oil. Position the vehicle on ground level/ 2 post lift/ 4 post lift and turn engine OFF. Open the bonnet and lock it in open position using bonnet stay rod. Remove the engine top encapsulation cover. Remove the engine oil filler cap. Using 22 mm ring/ socket spanner, Unscrew engine oil drain plug located under the oil sump. Allow the entire oil to get drained. Place a tray under the drain plug to collect the oil. Refit the drain plug with a new copper washer and tighten the drain plug to specific torque. Torque : 25\u201330 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "Always replace the copper washer with a new one. Fill fresh recommended oil to specified quantity. Refit the engine oil filler cap. Refit the engine encapsulation cover. Wait for about 10 minutes for oil in circulation to drain down. Pull out the dip stick gauge and wipe it clean with a cloth/paper. Insert the dip stick gauge into the dip stick guide fully till the end. Pull out the dip stick slowly and check for the oil level mark between Maximum and Minimum level - if found below minimum level, top up with recommended oil. Insert the dip stick back and fix properly. Start the engine and check for oil leakage/ seepage at: Oil sump & crankcase joint. Oil sump drain plug. Oil filter joint. Always use MAHINDRA 'MAXIMILE ULTRA'Gen-NXT Technology GENUINE ENGINE Fluid. This is specially developed for your engine\u2019s efficiency. In extreme cases of emergency and non-availability of above oil, we suggest to use 'Maximile Feo' engine oil, take the vehicle to nearest Mahindra Authorised Service centre and replace the oil with 'MAXIMILE ULTRA'. No other brand / grade oil recommended. The knock sensor converts mechanical oscillations of the cylinder block into electrical impulses which can then be processed by the EMS ECU. The Knock sensor consists of piezo-ceramic crystals that generate a voltage when subjected to a mechanical load. Disconnect the knock sensor electrical connector. Using 12 mm socket spanner, Unscrew Knock sensor mounting bolt and remove sensor. Torque : 20 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the knock sensor for any physical damage. If found replace. Oil Pressure sensor operates the low oil pressure indicator in the cluster. This serves as a warning indicator to the driver, indicating a decrease in the oil pressure which might harm the engine if driver continues running the engine. The Oil Pressure Sensor is A Piezo \u2013 Resistive type sensor. It Sends oil pressure values to EMS ECU. Disconnect the oil pressure sensor electrical connector. Using 24 mm socket spanner, Loosen and remove the oil pressure sensor from OCFM. Torque : 20 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Check engine oil level, Top up engine oil and check for oil leakage. Check oil pressure sensor for any cracks, damage etc, replace if found any. For additional information refer to coolant drain procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove CATCON Assembly. For additional information refer to CATCON Assembly - R&R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove Engine Feed Cover. For additional information refer to Engine Feed Cover - R&R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove Air Cleaner Assembly. For additional information refer to Air Cleaner Assembly - R&R section. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1514.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using the MST 0306GAM0006ST - Stretch Fit Belt Removal Tool Remove the Water Pump Drive belt. Using 7 mm socket spanner, Loosen radiator outlet hose clip and detach hose water inlet pipe end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010506.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew degassing tank coolant filling pipe mounting bolt OCFM end. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010507.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew heater outlet pipe routing bracket mounting bolt engine block end. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010508.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew heater outlet pipe routing bracket mounting bolt cylinder head end. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010509.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Using 10 mm combination spanner, Unscrew heater outlet pipe mounting bolt and partially remove pipe. Torque :11\u00b11 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010592.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Disconnect AC compressor electrical connector. Disconnect oil pressure sensor electrical connector. Disconnect crank speed sensor electrical connector. Disconnect engine variable oil pump solenoid electrical connector. Using 12 mm socket spanner, Unscrew engine wiring routing bracket mounting bolt. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010515.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew Turbo wiring routing bracket mounting bolt. Torque : 10\u00b11 Nm ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1515.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew turbo coolant inlet and oil inlet mounting banjo bolts OCFM end. Torque : 18\u00b12 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010517.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Using hose clamp plier, Release oil separator hose clamp clean hose end. Using 7 mm socket spanner, Loosen clean hose clip and detach hose turbo end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010519.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanner, Unscrew OCFM rear mounting bolts. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010520.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew OCFM mounting bolt and strut. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Caution",
+ "content": "Replace New rubber gasket while refitting. Remove OCFM from engine compartment. Using a 10 mm socket spanner, Unscrew water pump pulley mounting bolts and remove pulley from water pump. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Notice",
+ "content": "Using a suitable tool hold the pulley then remove the water pump pulley. Using a 13 mm socket spanner, Unscrew water pump mounting bolts and remove the water pump from the OCFM. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-25",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Refill the engine oil and check for the oil leakage. Refill the engine coolant and carry-out de-aeration procedure. Check the OCFM for any external cracks, replace if found any.
2. If an obvious cause found during the inspection for the reported concern, correct the same before proceeding to the next step.
3. If the cause is not found visually during the inspection, refer to the inspection chart given below.
4. All the components should be inspected for wear. Any components, which are beyond the wear limits, have to be replaced.
5. Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine maintenance. Refer to the Engine trouble shooting chart below, for possible causes and corrections of malfunctions.
",
+ "file": null,
+ "display_order": 3
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 5,
+ "sys_id": "THAR.LX-0009-Engine",
+ "subsys_id": "THAR.LX-0009-Engine-Auto Tensioner & Belts - Replace",
+ "systems": "Engine",
+ "sub_systems": "Auto Tensioner & Belts - Replace",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": "J11-MAT-0060",
+ "cover_image": "/files/W1504.jpg",
+ "myid": 1087,
+ "active_status": true,
+ "Config Kilometer": [
+ {
+ "kilometer_name": "1,000",
+ "kilometer_IDX": 30,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "10,000",
+ "kilometer_IDX": 74,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "20,000",
+ "kilometer_IDX": 116,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "30,000",
+ "kilometer_IDX": 153,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "40,000",
+ "kilometer_IDX": 197,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "50,000",
+ "kilometer_IDX": 239,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "60,000",
+ "kilometer_IDX": 282,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "70,000",
+ "kilometer_IDX": 321,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "80,000",
+ "kilometer_IDX": 364,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "90,000",
+ "kilometer_IDX": 403,
+ "kilometers_applicable": 0
+ },
+ {
+ "kilometer_name": "1,00,000",
+ "kilometer_IDX": 413,
+ "kilometers_applicable": 1
+ }
+ ],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0009-Auto Tensioner & Belts - Replace-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/Auto Tensioner & Belts - Replace.mp4",
+ "display_order": 1
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1504.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A010927.jpg",
+ "display_order": 3
+ },
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "This vehicle is equipped with one autotensioner to maintain the accessory drive belt tension for Alternator and Power steering pump drive belt. It is mandatory to maintain belt tension through out the belt life in-order to have maximum efficiency and life. A tensioner is a device that applies a force to create or maintain recommended belt tension. Position the vehicle on ground level/ 2 post lift/ 4 post lift and turn engine OFF. Open the bonnet and lock it in open position using bonnet stay rod. Using 10 mm socket spanner, loosen and remove the engine feed cover mounting bolts. Torque : 11 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W129.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the engine feed cover from engine compartment. Place the MST 0306GAM0006ST Stretch Fit Belt Removal Tool on dampe pulley side as shown in the image. Using a 24 mm socket spanner, rotate the damper pulley to clockwise direction then remove the water pump drive belt and MST separately. Place the MST 0306GBH0001ST - Stretch Fit Belt Installation Tool on damper pulley as shown in the image. Using a 24 mm socket spanner, rotate the damper pulley in anticlockwise direction. By rotating pulley, belt started getting into pulley groove and once belt installed properly on pulley, then remove the MST and spanner. Ensure proper engagement of belt teeth in all the pulley grooves after Installation. Check the Belt tension. Refer Belt Tension Checking Procedure session below. Refit the engine fead cover on engine compartment, torque tighten the bolts to specified value. Torque : 11\u00b1 1Nm ",
+ "file": null,
+ "display_order": 27
+ }
+ ]
+ },
+ {
+ "procedure_name": "Checking Procedure",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W137.jpg",
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W138.jpg",
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Heading",
+ "content": "Check belt tension as per procedure mentioned below: ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Run the engine for few minutes. Turn ON belt tension gauge. Select reading mode in hertz (Hz) and hold the probe approximately 5mm distance in front of the belt. Do not touch the probe to the belt, this can damage the probe. Belt tension needs to be checked at the green points shown in illustration. Between Crank pulley & water pump pulley. Between water pump pulley & AC Compressor Pulley. Tap on the belt near the probe. Note the reading, if the reading is within 195 \u2013 228 Hz , belt tension is OK. Position the vehicle on ground level/ 2 post lift/ 4 post lift and turn engine OFF. Open the bonnet and lock it in open position using bonnet stay rod. Remove AC Compressor /Water Pump Stretch Fit Belt. Using a 14 mm ring spanner, turn the hexagon knob in the belt tensioner counterclockwise direction to release the tension. Using 14 mm socket spanner, remove the alternator/power steering auto tensioner mounting bolt and remove the tensioner. Refit the new auto-tensioner assembly . Torque tighten the mounting bolt to specified value. Torque : 45 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W144.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1551.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using a 14 mm ring spanner, swing the auto-tensioner in counter-clockwise direction and install the belt. Refit AC Compressor /Water Pump Stretch Fit Belt. Align the MST \u2013 0310ABG0001ST Camshaft locking tool on the front side of engine in the camshaft slot as shown and fix the camshaft locking tool on cylinder head using appropriate bolts. Using 22 mm socket spanner, Loosen and remove Inlet CAM phaser mounting bolt Torque : 30 \u00b1 2 Nm + 34\u00b0\u00b1 3\u00b0 ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11648.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. While Installation, Check Exhaust Cam phaser mounting bolt tightening torque first and then torque tightened the Intake Cam phaser mounting bolt. Inspect the CAM Phaser for any physical damage. If found replace. The cylinder compression test is performed to determine the compression pressure of individual cylinders. The test is performed in two stages. Dry Test. Wet Test. The results of the cylinder compression test can be utilized to diagnose several engine malfunctions. Before carrying out the compression test ensures that the battery is in good working condition. Otherwise the indicated pressures may not be valid for diagnostic purpose. Check engine oil level and add oil if necessary. Drive the vehicle until engine reaches normal operating temperature. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should not be disassembled to determine the cause of low compression unless some malfunction is present. Remove all the spark plug. Fit the appropriate adaptor in one cylinder at a time and connect it with the compression gauge. Disconnect the cam phase sensors electrical connector. Note down the max value the gauge indicates. Repeat the procedure for all the other cylinders. Refer to the specification for the value. The variation between the cylinders should not be more than \u00b1 0.5 Bar. Spray 10 to 20 ml of engine oil inside the bore through the spark plug port with the help of an oil can. Fit the appropriate adaptor in one cylinder at a time and connect it with the compression gauge. Disconnect the cam phase sensors electrical connector. Note down the maximum value displaying in the gauge. Repeat the procedure for all the other cylinders. Refer to the specification for the value. Compare both the dry and the wet values with the specifications. The wet test values should always be higher than the dry test values. If the reading does not change during wet test this can hint towards compression leakage from cylinder head or through the valves. If the wet and dry test values vary considerably between cylinders then the piston rings can be suspected. A gasoline engine cylinder head performs several functions. They provide the top seal for the cylinders bore and the air fuel mixture in this location. They provide structure holding the Valves, ignition coil, camshaft, spark plugs and other components. The cylinder head is construct with cross flow cooling system. It has inclined ignition coil bore and integral intake and exhaust VVT. For additional information refer to the Spark Plug - R&R section. ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Drain the engine coolant. For additional information refer to coolant draining procedure. ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the HLA assembly. For additional information refer to the HLA Assemblies \u2013 R&R section. ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020279.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B020257.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 7 mm socket spanner, Loosen Inter cooler outlet hose clip and detach intercooler end. Torque : 6.5\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010556.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew dipstick guide mounting bolt. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010558.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew intake manifold mounting bolts and remove Intake manifold With Throttle Valve & Inter cooler outlet hose. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1517.jpg",
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Disconnect fuel rail electrical connector. Disconnect injector electrical connector. Using 12 mm socket spanner, Unscrew fuel rail mounting bolts. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B040123.jpg",
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove fuel rail with Injectors. Injectors Combustion Seals should be replaced with new ones when ever removing & refitting the Fuel Rail Assembly from the cylinder head. For more information refer to Fuel Rail Assembly \u2013 R&R section in Fuel System. If Injector/Injectors struck with Cylinder Head and not able to remove from head, Injector can be removed by using Injector removal tool. For more information refer to Injector \u2013 R&R section in Fuel System. For additional information refer to the Turbocharger - R&R section. ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010553.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using hose clip plier release coolant vent hose clip and detach hose engine head end. Using 10 mm socket spanner, Unscrew heater inlet pipe routing bracket mounting bolt cylinder head end. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010555.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew heater inlet pipe mounting bolt cylinder head end and detach pipe. Torque : 11\u00b11 Nm ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010562.jpg",
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew heater outlet pipe routing bracket mounting bolt cylinder head end. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010563.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Disconnect coolant temperature sensor electrical connector. Using 19 mm deep socket spanner, unscrew Coolant temperature sensor. Torque : 20 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010565.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Remove alternator top mounting bolt. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010566.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Loosen alternator top mounting bolt/nut and rotate alternator. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010567.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-20",
+ "content_type": "Description",
+ "content": "Remove CAM shafts front lower bearing cap. Using 15 mm socket spanner, Loosen and remove cylinder head mounting bolts. Torque : 60 \u00b1 6 Nm + (2x95\u00b0) \u00b1 5\u00b0 ",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010569.jpg",
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010570.jpg",
+ "display_order": 59
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010572.jpg",
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Remove the cylinder head from engine. Torque : 25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 62
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010158.jpg",
+ "display_order": 63
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010825.jpg",
+ "display_order": 64
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B010829.jpg",
+ "display_order": 65
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11566.jpg",
+ "display_order": 66
+ },
+ {
+ "step_name": "Step-23",
+ "content_type": "Description",
+ "content": "Install in reverse order of removal. Always replace the cylinder head gasket with a new one when installing. Remove the foreign materials and the gasket residual on the top surface of the cylinder block and cylinder head before installing the cylinder head gasket. Apply fresh engine oil on the head gasket while Installation. Head gasket with the mark of \u201cTC\u201dand gasket part number must be directed towards the cylinder head. When installing the mounting bolts : from the center to the outside diagonally. Do not reuse the mounting bolts for the cylinder head, Always replace the mounting bolts New ones while installing head assembly. Tighten the cylinder head mounting bolts to the specified torque and specified sequence. Check for coolant seepage and any oil seepage on the engine. Rectify if any traces found. Clean the cylinder head assemblies thoroughly, replace it if any cracks or damages are found. Check the Cylinder Head for external damages. Check the cylinder head height and if not meeting the specified value, replace the cylinder head assembly. Check the Cylinder Head bottom face for distortion. Using 10 mm Allen key, loosen and remove rear axle filler plug. Using 10 mm Allen key, remove rear axle drain plug and drain the entire oil. Wait till the entire oil get drained. Place a tray beneath the rear axle for collecting the oil while draining. Using 13 mm and 16 mm ring and open end spanners unscrew rear propeller shaft mounting bolts and nuts rear axle end. Torque : 65 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "By using Special tool MST 203\u2013Companion Flange Holding Tool, hold the companion flange and Using 32 mm deep socket spanner loosen and remove the companion flange mounting nut. Remove the companion flange using mallet. If companion flange shows wear in the area of seal contact, it should be replaced. Remove the pinion oil seal by using screw driver. Ensure not to damage the oil seal mating surface while remove the Oil seal. Inspect t the pinion oil seal for any damage. Replace if found. Inspect t the companion flange for any damage. Replace if found. Using MST 0502AUA0004ST Rear Axle Pinion Oil Seal Installer, Place and Press New oil seal uniformly on banjo gear carrier housing. Apply a light coat of oil to the lip of oil seal before installation. Install the dust cap, companion flange on the banjo housing and Install the new mounting nut with washer. Always use new flange mounting nut once it removed. Hold the companion flange Using MST203 Companion Flange Holding Tool and torque tighten the companion flange mounting nut. Tighten nut to incremental torque from 270 Nm onwards to 330 Nm until specified PTTR ( Pinion torque to rotate) is achieved. Measure the Pinion Rotational Torque (PTTR), It should be within 2.5 - 3.5 Nm. Attach the propeller shaft to the rear axle with mounting nuts, torque tighten it to the specified value. Torque : 65 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit the drain plug and torque tighten to specified value. Clean the drain plug and differential housing with a clean cloth before refitting. Torque : 47 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Refill specified quantity of recommended differential oil into differential assembly. Never reuse drained oil. Always use recommended oil only. Never mix different types of oil and use. Clean filler plug area properly using acloth before filling the oil. Check the oil level and ensure its up to the level. Ensure that the oil level is up to lower most point of the filler plug. Refit the filler plug back and torque tighten to mounting plug specified value. Clean the filler plug with a clean cloth before refitting. Torque : 29 \u00b1 5Nm ",
+ "file": null,
+ "display_order": 55
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 130,
+ "sys_id": "THAR.LX-0009-Rear Axle",
+ "subsys_id": "THAR.LX-0009-Rear Axle-Troubleshoot - Rear Axle",
+ "systems": "Rear Axle",
+ "sub_systems": "Troubleshoot - Rear Axle",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1464,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0009-Troubleshoot - Rear Axle-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Trouble Shooting",
+ "steps": [
+ {
+ "step_name": "Overview",
+ "content_type": "Description",
+ "content": "Certain rear axle and driveline trouble symptoms are also common to the engine, transmission, tyres and other parts of the vehicle. For this reason be sure that the cause of the trouble is in the rear axle before adjusting, repairing or replacing any of the axle parts. Basic characteristics in a rear axle are more difficult to diagnose and repair than mechanical failures. Slight axle noise heard only at certain speed or under particular conditions must be considered normal. Axle noise tend to peak or be more pronounced at particular speeds and the noise is in no way a sign of the trouble in the vehicle. Where noise is present in objectionable form (Loud and/ or at all speeds) the first effort should be to isolate the noise. Isolation of noise in any one unit requires care and experience and an attempt to eliminate a slight noise may baffle even the most experienced mechanic/ technician. The most important characteristic of the gear noise is that it is usually sensitive to accelerator position. E.g. noise audible under drive condition will often disappear under coast condition (i. e. driving in neutral with the clutch released and engine running) at the same vehicle speed and vice versa. Axle gear noise whine will always occur at the same road speed and throttle setting i.e. drive or coast (i. e. driving in neutral with the clutch released and engine running). Gear whine is usually a fairly high pitched pure tone as opposed to a low-pitched rumble caused by a spalled bearing. Some noises, which can be confused with axle gear whine, are: - Whine from an engine component; this will always occur at the same engine speed irrespective of which transmission gear is used. Whine from an indirect transmission gear (e. g. 5th gear on some vehicles produces a whine comparable with axle whine) however this will disappear when the direct transmission ratio is selected. Whine from tyres or wind noise from a rack or aerial. These noise generally occur over a very broad speed range and do not change with driving mode i. e. drive or coast (i. e. driving in neutral with the clutch released and engine running). Before diagnosing the whine as axle gear noise, ensure that the whine:
Occurs in direct transmission ratio (4th gear). Changes with throttle/ accelerator variations (drive and coast) (i.e. driving in neutral with the clutch released and engine running). Always occur at the same road speed and not engine speed. Occurs over a limited vehicle speed. (This can vary over a wide band should the axle be in extremely bad condition.). Bearing noise is inclined to be less throttle sensitive than gear noise and frequently occurs over a wide speed range. Bad cases of faulty bearings can, in fact be detected from walking speed, building up in pitch as speed increases and is not directly affected by changing from drive to coast (i. e., driving in neutral with the clutch released and engine running) and vice versa. Rear wheel bearing noise tends to be low pitched grumble, which can normally be detected and confirmed when driving on a smooth road at constant speed, with the noise most audible while swerving sharply from left to right. If the noise increases or a decrease as the car is swerved, it is probable that a wheel bearing is faulty. Driving close to a wall or a curb at a suitable speed can carry out a further check for wheel bearing noise. Differential bearing noise is usually similar to in pitch to wheel bearing noise but is not affected by the swerve check referred to previously. Pinion bearing noise is normally at a higher pitch than wheel or differential bearings and is often slightly sensitive to throttle position, although not to the same extent as gear noise. A further condition, which can exist, is due to a worn bearing that allows the gear set to move out of its correct mesh cause gear noise. This condition is usually throttle sensitive, with the noise frequently disappearing on a \u201cdrive\u201d condition. Any amount of or end play in either the pinion bearings or differential carrier bearings are detrimental to the gears and bearings and will cause axle noise. A high spot sometimes occur on either the ring gear or the drive pinion; this shows up as a ticking or light knocking noise over a restricted range of throttle position. The frequency of the noise will indicate whether the high spot is on the pinion (drive shaft frequency) or on the ring gear. The severity of the noise indicates the size of the defect. A light \u201ctick\u201d is seldom detrimental and usually occurs in new axle and will normally disappears once the axle has been run in. Louder noise usually indicates a more serious defect and a knock occurring in an axle which was previously free from this type of noise must always be investigated. For additional information refer to Rear Axle Shaft RH - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 0502CAA0012ST \u2014Puller Oil Seal Pinion /Flange Inbord-X ,remove the inboard oil seal. Refit in the reverse order of removal. Use a MST (0502BUA0001ST \u2014 Rear Axle Shaft Inboard Oil Seal Installer, during Installation. Check differential oil level, top up the oil if required. For additional information refer to Parking Brake Adjustment Section. ",
+ "file": null,
+ "display_order": 14
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect t the axle inboard for any damage. Rectify if found. For additional information refer to Rear Axle Shaft RH - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using circlip plier, remove the toner wheel circlip. By using hydraulic press, remove toner wheel along with Rear bearing carrier assembly. Take sufficient care not to damage the toner ring while removing. Remove the bearing from Rear bearing carrier. Replace the toner ring and bearing assembly once removed. Using a suitable tool, Remove the oil seal from Rear bearing carrier. Replace the outboard oil seal once removed. Refit in the reverse order of removal. Check differential oil level, top up the oil if required. For additional information refer to Parking Brake Adjustment Section. ",
+ "file": null,
+ "display_order": 21
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the axle shaft outer oil seal & bearing for any damage, Replace if necessary. For additional information refer to Rear brake drum LH and RH - R&R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Detach the hand brake cable from brake shoe. Remove the hand brake cable lock clip and detach the hand brake cable from back plate. Using 11 mm open end spanner, Loosen brake bundy tube flare nut wheel cylinder end. Torque : 16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 17 mm socket spanner, loosen and remove axle shaft mounting nuts. Torque : 35 \u2013 50 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using MST (0505AAA0001ST puller rear axle shaft banjo) remove rear axle shaft, dust shield with brake liner assembly from vehicle. To avoid the back plate falling down, using a plastic tag tie it with any other fixed member before the shaft is pulled out. Clean sealant on the axle housing flange, Back Plate and apply new sealant on the housing. Apply Locktite Sealant 5060 during Installation and Ensure that sealer bead is on the inside of screw holes as shown above. Bead must be 3 to 6mm high and 3 to 6mm wide. Refit in the reverse order of removal. Check differential oil level, top up the oil if required. For additional information refer to Parking Brake Adjustment Section. ",
+ "file": null,
+ "display_order": 24
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the axle shaft for any damage, crack or bend. Inspect the toner ring for any damage. Inspect the rear wheel bearing for any damage. Inspect the back plate for any damage. Rear Axle Oil \u2013Mahindra 'MAXIMILE ELITE' New Generation Genuine Differential Fluid.Capacity\u20132.0 Litres.Position the vehicle on 2 post lift/ 4 post lift. using 10 mm allen key, loosen and remove rear axle filler plug. Using 10 mm allen key, remove rear axle drain plug and drain the entire oil. Wait till the entire oil get drained. Place a tray beneath the rear axle for collecting the oil while draining. Refit the drain plug and torque tighten to specified value. Clean the drain plug and differential housing with a clean cloth before refitting. Torque:47\u00b17Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Refill specified quantity of recommended differential oil into differential assembly. Never reuse drained oil. Always use recommended oil only. Never mix different types of oil and use. Clean filler plug area properly using a cloth before filling the oil. Check the oil level and ensure its up to the level. Ensure that the oil level is up to lower most point of the filler plug. Refit the filler plug back and torque tighten to mounting plug specified value. Clean the filler plug with a clean cloth before refitting. Torque:29\u00b15Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Recommend to use only Mahindra 'MAXIMILE Elite' new generation genuine differential fluid. In case of non availability of 'Maximile' brand, other brands meeting API GL5, SAE 80W-90 specification can be used as second preference and oil change period should be reduced as 20,000 km. For additional information refer to Rear axle oil draining procedure. ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Rear Axle Carrier Assembly. Mount the Rear Axle carrier assembly on a suitable stand. Liquid sealant is used to seal carrier section with banjo beam. Clean the sealant on the carrier facing. Using a 17 mm socket spanner, loosen and remove the bearing cap mounting bolts and then remove the bearing caps. Using a Mallet, tap and detach the bearing caps. Identification marks are punched on bearing cap; this is to ensure correct bearing cap is installed on correct side. Ensure correct bearing caps used While reassembly. Pry out differential case from carrier with help of (MST 0502AAA0001ST - Tommy Bars) as shown in the illustration. Remove the shims from both the sides of differential case. Backlash shims are not to be interchanged during assembly. If Backlash shims are damaged, replace with new shims during assembly. There is no identification provided on the shim, Needs to be measured by micro meter. Remove the bearing caps from both the ends. Mount the (MST 0502AUA0013ST - R Axle Diff Case Bearing Puller Adapter) and (MST 0502AUA0012ST - Axle Bearing Puller) on side bearing cone as steps shown below. Remove the side bearing cone by tightening the screw rod using 24 mm ring spanner and remove the bearing cone from the differential case. Hold the top plate using 36 mm open end spanner while tightening. It is always preferred to replace side bearings, but one can confirm free rolling of bearings and reuse if they are defect free. Similarly remove ring gear other side bearing cone as steps shown below. Using 14 mm socket spanner remove the ring gear mounting bolts. Ring gear mounting bolts are opposite threaded. Loosen in clock wise direction. Tap ring gear with a mallet to free it from case If required and remove. Follow Steps 15 to 18 to remove Side Gears & Pinion Mate Gears for Open Differential. Using MST 0502AUA0033ST - Front Axle Diff Case Pin Remover&Installer and hammer remove the differential gear locking pin. Using hammer and punch, Remove the differential shaft from differential case as shown in illustration. To remove side gears and pinion mate gears, rotate the side gears, this will allow the pinion mate gears to turn to opening of the case. Remove the pinion and side gears. Check the differential gear condition, any damage replaces it. Inspect cross pin for excessive wear, replace it if necessary. Always replace differential pinion gears and side gear both along with washer as a complete set. Do not mix new gears with old gears, as this may cause uneven wear and short gear life. Position the carrier assembly on the suitable stand to facing the companion flange side. Hold the companion flange using (MST 203\u2013 Companion Flange Holding Tool) and Using 32 mm deep socket spanner loosen and remove the companion flange mounting nut. Using mallet tap and remove the companion flange, washer and dust cup. If companion flange shows wear in the area of seal contact, it should be replaced. Using a mallet, tap the pinion assembly and remove the pinion assembly from the differential housing. Fit a nut of pinion before tapping to avoid thread damage. Hold the pinion with hand to avoid falling. Gear teeth have sharp edges. Handle gears carefully to avoid injury. Remove the collapsible Washer. Discard collapsible spacer. New one is required to be used during assembly Assemble (MST 0502AUA0014ST - R Axle Pinion Inner Bearing Puller Adapter) and (MST 0502AUA0012ST - Axle Bearing Puller) as shown in the illustration. Tighten the screw rod using 24 mm ring spanner to remove the pinion inner bearing. Hold the top plate using 36 mm open end spanner while tightening. Remove the pinion head bearing & remove the shims from the pinion. Collect shims and keep them together. Replace shims if found damaged. Remove the pinion oil seal by using screw driver. Ensure not to damage the oil seal mating surface while remove the Oil seal. Gently pull-out and remove the pinion outer bearing. Using suitable punch and hammer remove the outer bearing cap. Using suitable punch and hammer remove the inner bearing cap. Ring gear and pinion is supplied as a set. They are matched with each other during manufacture. Matching numbers on both pinion and ring gear are etched for verification. Refer Fig. A or Fig. B for more details. If a new gear set is used, verify numbers on pinion and ring for matching before proceeding with assembly. Standard mounting distance from center line of ring gear to back face of pinion is 109.525 mm . This dimension is controlled by selecting shims, which are positioned between the inner pinion bearing and pinion shoulder. Best running position of gear set is achieved by proper shim selection. On the bottom face of pinion, a number is etched. It can be a plus (+) number, a minus (-) number or Zero (0). Required pinion shim selection is achieved with help of this number. Pinion offset always in thou (1 thou = 0.0254 mm). Fig. A shows ring and pinion etched with inch identification.Fig. B shows ring and pinion etched with metric identification.If no offset on pinion face then assume it zero. Shims with different thicknesses are available for selection. Use tables below as a guide for selecting correct thickness of shims either for addition or for subtraction from old shim pack. TABLE \u2014 Pinion Shim Selection (Formula = Old Pinion offset \u2014 New Pinion offset) If Old Shim Not Available then below mentioned gauge method is recommended for Pinion Shim Selection. Position the rear axle housing on a suitable stand. Position the (MST 0502AUA0016ST - Rear Axle Pinion Height Master Block) over the inner bearing cup seating area as shown. Position the (MST 0502AUA0015ST - Rear Axle Pinion Height Setting Gauge) on the differential housing as shown. Using feeler gauge measure the distance between the MST\u2019s as shown and the value assumed as \u2018A\u2019 . For example consider the value obtained as 1.51 mm. Convert the obtained value in \u201cmm\u201d into \u201cThou\u201d (1.51x39 = 59 Thou). Now see the etched value on pinion, the value assumed as \u2018B\u2019 (For example consider the offset value as +4) Now to get the final shim size, the formula is Shim thickness (In Thou) = A \u2013 (+B or \u2013 B). i.e, (59 \u2013 4 = 55 Thau) Convert the Thou value to mm ( 55 x 0.0254 = 1.40 mm) , which is the final shim thickness required. Select shim pack based on Pinion Shim Selection Procedure to position the pinion at correct mounting distance as per value etched on pinion stem for best running position. Mount the pinion positioning shim pack on pinion. Position the pinion inner bearing on pinion & press the bearing by using (MST 0502AUA0017ST - R Axle Pinion Inner Brg Press Dolly). Insert a new collapsible spacer. Collapsible spacer should rest in between pinion inner and outer bearing and it can be fitted in any direction. Always use new collapsible spacer, never use old one. Install the Inner bearing cup by using (MST 0502AUA0018ST - Pinion Inner bearing cup installer) and (MST 0707BBA0003ST - Universal mandrel) on banjo gear carrier housing. Install the Outer bearing cup by using (MST 0502AUA0019ST - Pinion outer bearing cup installer) and (MST 0707BBA0003ST - Universal mandrel) on banjo gear carrier housing. Install the pinion on the axle banjo housing and provide a support for pinion in the bottom. Using (MST 0502AUA0017ST - R Axle Pinion Inner Brg Press Dolly) and hammer press the pinion outer bearing. Place oil slinger on pinion outer bearing cone. Place and Press oil seal on banjo gear carrier housing using (MST 0502AUA0004ST - Rear Axle Pinion Oil Seal Installer). Apply a light coat of oil to the lip of oil seal. Install the dust cap into the companion flange. Install the companion flange on the banjo housing. Install the companion flange mounting nut. Hold the companion flange using (MST203 - Companion Flange Holding Tool) and torque tighten the companion flange mounting nut. Tighten nut to Initial torque as 270 Nm. Measure the Pinion Rotational Torque (PTTR), It should be within 2.5 - 3.5 Nm. If measured Pinion Rotational Torque (PTTR) not within 2.5 - 3.5 Nm, Then tighten nut to incremental torque from 270 Nm onwards to 330 Nm until specified PTTR ( Pinion torque to rotate) is achieved. Measure and ensure the Final Pinion Rotational Torque (PTTR), It should be within 2.5 - 3.5 Nm. (PTTR SPEC : 2.5 to 3.5 Nm) If preload torque is exceeded, a new collapsible spacer must be installed and torquing sequence as above to be repeated. Follow Steps 17 to 20 to Install Side Gears & Pinion Mate Gears for Open Differential. Assemble both side gears and thrust washers, hold them in place with one hand and then assemble the pinion mate gears with thrust washer to hold the side gears in place. An easy way to assemble the side gears and pinion mate gears is to have all parts lubricated before assembly. Rotate the side gears until the holes of the spherical washers and pinion mate gears line up with the holes in the case by the help of engaging the splines of axle shaft to side gears. When both the cross bore hole matched and insert the differential shaft. Use a drift to line holes of the gears up with case. Assemble differential shaft and pull out drift. Be sure vertical lock pin hole is lined up with that of the case, and that pinion mate washers are in place and lined up with gear and case. Align the differential shaft hole, insert the lock pin and fix using (0502AUA0033ST - Differential gear lock pin removal tool) and hammer. Assemble ring gear to the differential case using mounting bolts. Tighten the bolts to specified torque value in recommended sequence. Torque : 90 - 105 Nm
",
+ "file": null,
+ "display_order": 183
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140174.jpg",
+ "display_order": 184
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Notice",
+ "content": "Always use new ring gear bolts. Ring gear mounting bolts have LH threads. While Installation torque in anti-clocking direction. Assemble (MST 0502AUA0020ST - Rear Axle Dummy Bearing) on to differential case. Place differential case assembly into housing. Push the differential case assembly towards the pinion side and insert the shims pack on the LH side (Back to ring gear) and Insert the shims pack on the RH side (Teeth side). Remove the shims (6 Thou) from LH Side and add to RH Side for backlash tolerance. Install dial gauge and locate tip of indicator on the surface of one of the ring gear teeth and measure the backlash at three equally spaced points (Each 120 degree rotation space), confirm the Backlash tolerance is (0.15 to 0.25 mm). Fix the Dial Gauge on Housing, Set the Dial Indicator 0 on Ring gear teeth as shown. Hold the pinion flange at the bottom side. Rotate the ring gear by using ring spanner & measure the backlash. Backlash variation at three points should not more than 30% . These corrections are made by switching shims from one side of differential case to other. High backlash is corrected by moving ring gear closer to pinion (Move Shims from RH to LH). Low backlash is corrected by moving ring gear away from pinion (Move Shims from LH to RH). Remove dial gauge and take out diff case & remove the dummy differential bearings. Press bearing on Differential case assembly by using (MST 0502AUA0021ST - R Axle Diff Case Brgs Pressing tool). Repeat the same procedure for installation of bearing on other side. Install the Differential bearing caps on both the sides. Install differential case assembly into carrier with the help of mallet. Carelessness while installing differential case assembly may result in injury. Install the shims on both the sides of differential case. Backlash shims are not to be interchanged during assembly. If Backlash shims are damaged, replace with new shims during assembly. Assemble bearing caps using mounting bolts. Ensure correct fitment of caps by matching letters on caps and carrier on either side. Tight the bearing cap bolts to specified value. Torque : 90 - 110 Nm
",
+ "file": null,
+ "display_order": 223
+ },
+ {
+ "step_name": "Step-34",
+ "content_type": "Description",
+ "content": "Install dial gauge and locate tip of indicator on the surface of one of the ring gear teeth and measure the ring gear and pinion backlash at three equally spaced points (Each 120 degree rotation space), confirm the Backlash tolerance is (0.15 to 0.25 mm). If backlash is as per specification, check ring gear and pinion tooth contact pattern as below. The TOE of the gear is the portion of the tooth surface at the end towards the center. The HEEL of the gear tooth is the portion of the tooth surface at the outer-end. The TOP LAND of a gear tooth is the surface of the top of the tooth. Every gear has a characteristic pattern. Flat face of the carrier assembly and flat surface of the banjo beam must be free of any oil film or foreign material. Apply Locktite RTV Sealant 5060 to flat surface of banjo beam. Ensure that sealer bead is on the inside of bolt holes. Bead must be 3 to 6 mm high and 3 to 6 mm wide. Refit the Differential Carrier Assembly. For additional information refer to Differential carrier assembly R&R section. Fill the differential fluid. For additional information refer to Differential fluid filling procedure. For additional information refer to rear axle oil draining procedure. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Rear Axle Shaft Assembly LH . For additional information refer to Rear Axle Shaft Assembly LH - R&R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the Rear Axle Shaft Assembly RH . For additional information refer to Rear Axle Shaft Assembly RH - R&R section. ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 14 mm socket spanner, Unscrew rear propeller shaft mounting bolts and detach propeller rear end and properly hang the shaft. Torque : 65 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew gear carrier to banjo housing mounting bolts. Using 17 mm socket spanner, Unscrew rear stabilizer bar bracket mounting bolts and detach the bracket partially. Torque tightening should be done without load and with the tyres on level ground. Ensure to add washer only for bottom mounting of stabilizer bar. Torque : 70 \u00b1 7 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a 5 mm allen key, hold the rear stabilizer bar link bottom mounting then using a 18 ring spanner, loosen and remove the top mounting nut from stabilizer bar. Torque : 90 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140038.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Remove the rear axle gear carrier from vehicle. Clean the sealant on the gear carrier. Refit in the reverse order of removal. Apply Locktite Sealant 5060 during Installation and Ensure that sealer bead is on the inside of screw holes and pattern as shown below. Bead must be 3 to 6 mm high and 3 to 6 mm wide. For additional information refer to Rear Axle Oil Refilling procedure. ",
+ "file": null,
+ "display_order": 30
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the gear carrier, cracks, damage, wear or distortion, replace it if necessary. Check the axle case for yield, deformation or cracks, replace if necessary. Remove the rear axle shaft assembly. Using circlip plier, remove the toner wheel circlip. By using hydraulic press, remove toner wheel along with Rear bearing carrier assembly & dust shield. Take sufficient care not to damage the toner ring while removing. Replace the toner ring and bearing once removed. Refit in the reverse order of removal. Check differential oil level, top up the oil if required. For additional information refer to Parking Brake Adjustment Section. ",
+ "file": null,
+ "display_order": 15
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect t the toner wheel for any damage, Replace if necessary. Inspect the Rear bearing carrier assembly for any damage, Replace if necessary. For additional information refer to Bundy Tube Rear Hose to LH Wheel - R&R section. ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the bundy tube rear hose to RH wheel. For additional information refer to Bundy Tube Rear Hose to LH Wheel - R&R section. ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the flexible hose LH & RH side locking from the axle.",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140013.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140014.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Using a 10mm socket spanner, Unscrew wheel speed sensor mounting bolts and detach the sensors.",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140016.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Torque Value",
+ "content": "Torque:9\u00b11Nm",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140015.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Provide a jack to support the rear axle assembly.",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170013.jpg",
+ "display_order": 25
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the rear propeller shaft. For additional information refer to Rear Propeller Shaft-R&R section. ",
+ "file": null,
+ "display_order": 26
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the stabilizer bar rear. For additional information refer to Stabilizer Bar Rear-R&R section. ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Remove the Pan hard rod.",
+ "file": null,
+ "display_order": 28
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Link",
+ "content": "THAR.LX-0009,1015,1254",
+ "file": null,
+ "display_order": 29
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using a 24 mm socket spanner, loosen and remove the upper link mounting bolt/nut.",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170028.jpg",
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Torque Value",
+ "content": "Torque : 230 \u00b1 20 Nm",
+ "file": null,
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170029.jpg",
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 21mm ring spanner.",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a 24 mm socket spanner, loosen and remove the lower arm mounting bolt/nut.",
+ "file": null,
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170025.jpg",
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 21mm ring spanner.",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Torque Value",
+ "content": "Torque:230\u00b120Nm",
+ "file": null,
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Using a 17 mm socket spanners, loosen and remove the both rear shock absorbers bottom side mounting bolts and nuts.",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170014.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Torque Value",
+ "content": "Torque value: 110\u00b111NmTorque Wrench Type - Open end Torque Wrench",
+ "file": null,
+ "display_order": 43
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 15mm ring spanner",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Remove the rear coil spring and pad securely from vehicle.",
+ "file": null,
+ "display_order": 46
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170016.jpg",
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Caution",
+ "content": "Pay attention while Installation . Locking lug to be matched with hole on Rear Coil spring dome bracket of Chassis.Yellow coloured PU sleeve should be on chassis side while assembling the coil spring ashown in illustration.",
+ "file": null,
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170018.jpg",
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170149.jpg",
+ "display_order": 50
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170113.jpg",
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Carefully remove the rear axle assembly from vehicle.",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A140032.jpg",
+ "display_order": 53
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal.",
+ "file": null,
+ "display_order": 54
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Check differential oil level,top up the oil if required.",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Caution",
+ "content": " All Suspension Torque tightening should be done without load and with the tyres on level ground.",
+ "file": null,
+ "display_order": 56
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the axle shaft for straightness, cracks, damage, wear or distortion, replace it if necessary. Check the axle case for yield, deformation or cracks, replace if necessary. Inspect rear axle for any oil leakage, seepage. ",
+ "file": null,
+ "display_order": 57
+ }
+ ]
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "systemdisplayorder": 44,
+ "sys_id": "THAR.LX-0009-en-SM-Starting System",
+ "system_name": "Starting System",
+ "icon_file": "/files/System_Icon.png",
+ "myid": 1006,
+ "active_status": true,
+ "Assets": [
+ {
+ "systemdisplayorder": 5,
+ "system_asset": "/files/Security.mp4",
+ "active_status": true
+ }
+ ],
+ "Subsystems": [
+ {
+ "subSystemdisplayorder": 46,
+ "sys_id": "THAR.LX-0009-Starting System",
+ "subsys_id": "THAR.LX-0009-Starting System-Ignition Switch",
+ "systems": "Starting System",
+ "sub_systems": "Ignition Switch",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A090001.jpg",
+ "myid": 1126,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0009-Ignition Switch-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Overview",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090001.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11801.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/11802.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using a 10 mm combination spanner,loosen battery negative cable mounting nut and disconnect cable. 6.0\u00b10.6Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the steering column shrouds. Disconnect the ignition switch electrical connection. Using a Small sizzle and hammer, hit and remove the key barrel screws. Use new screw while installing key barrel. Remove the Ignition key with ICU from the vehicle. Using a star screw driver, loosen and remove the ICU mounting screws then remove the ICU from the key barrel. Insert the key and turn the key into AC position. Cut the micro switch routing tag and detach the connector holding clip from the ICU. Install in reverse order of removal. Always use new mounting bolts while installing the Ignition Switch Assembly clamping unit. Inspect ignition key for crack or damage. Replace if found any. Inspect ICU for crack or damage. Replace if found any. This test can only be performed with starter motor removed from vehicle. Remove Starter Motor from vehicle. Disconnect wire from solenoid field coil terminal. Check for continuity between solenoid terminal and solenoid field coil terminal with a continuity tester. There should be continuity. If OK, go to Step 4. If not OK, replace faulty starter motor. Check for continuity between solenoid terminal and solenoid case. There should be continuity. If not OK, replace faulty starter motor. Remove the relay from fuse box. Give 12 volt supply to pin number 86 and earth pin number 85. Once supply is given sound can be noticed which indicated control circuit is perfect. If sound is not noticed, replace the relay. Using multi-meter, check continuity between pin number 30 & 87. (Power given to pin number 86 and earth given to pin number 85). If continuity is there, which indicates that the power circuit is perfect. If Continuity is not there then replace the relay. Using multi-meter, check for continuity between pin numbers 30 and 87 (No power given to pin number 86 and no earth given to pin number 85). If continuity is there which indicates power circuit is NOT OK (Short internally).Replace the relay. If continuity is not there, Relay is OK. The cranking voltage test measures the voltage available for ignition while the starting motor cranks the engine. Turn off the ignition, connect a voltmeter across the battery and crank the engine. Note the voltage reading. If the starting motor cranks normally and the voltmeter reads 9 volts or higher, cranking voltage is normal. Slow cranking with the voltage above 9 volts indicates high resistance in the motor circuit or starting motor Low cranking speed and low voltage may indicate a discharger battery. If the battery is charger, look for trouble in the starter motor or engine Starter Motor Specification ",
+ "file": "/files/11820.jpg",
+ "display_order": 1
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 52,
+ "sys_id": "THAR.LX-0009-Starting System",
+ "subsys_id": "THAR.LX-0009-Starting System-Troubleshoot - Starting System",
+ "systems": "Starting System",
+ "sub_systems": "Troubleshoot - Starting System",
+ "symptom": 1,
+ "component": 0,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": null,
+ "myid": 1457,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0009-Troubleshoot - Starting System-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Troubleshoot",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4729.pdf",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Component Inspection Table",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/4730.pdf",
+ "display_order": 2
+ }
+ ]
+ }
+ ]
+ },
+ {
+ "subSystemdisplayorder": 45,
+ "sys_id": "THAR.LX-0009-Starting System",
+ "subsys_id": "THAR.LX-0009-Starting System-Immobilizer",
+ "systems": "Starting System",
+ "sub_systems": "Immobilizer",
+ "symptom": 0,
+ "component": 1,
+ "estimated_time": 0.0,
+ "rts": null,
+ "mat": null,
+ "cover_image": "/files/W4A090052.jpg",
+ "myid": 1125,
+ "active_status": true,
+ "Config Kilometer": [],
+ "procedure_status": "Publish Ready",
+ "procedure_link": "THAR.LX-0009-Immobilizer-en",
+ "Procedure_details": [
+ {
+ "procedure_name": "Component Location Index",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090052.jpg",
+ "display_order": 1
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25397.jpg",
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25398.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " Using a 10 mm combination spanner loosen battery negative cable mounting nut and disconnect the cable. Remove Combination switch. Disconnect the ignition switch electrical connection. Using a star screw driver, loosen and remove ICU mounting screws then remove ICU from the key barrel. Install in reverse order of removal. Ensure the wheels are straight ahead. Also the steering rack should be in center. Check and ensure both the front wheels for straight ahead position while fitting the steering wheel and also after fitting. Carefully install the clock spring without damaging the locks When installing the DAB, make sure that all electrical connectors are fixed in proper position. When installing the driver airbag into steering wheel, make sure the horn pad buttons are fixed properly and correct position. ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Link",
+ "content": "THAR.LX-0009,1015,1250",
+ "file": null,
+ "display_order": 16
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " Inspect the ICU for any physical damage. Replace if found any. Inspect ICU connector for any damage or loose connection. Rectify if found. The following operation will require a voltmeter accurate to 1/10 (0.10) volt. The battery should be fully-charged. Engage the parking brake. Position the gearshift selector lever in the neutral position and lock the clutch pedal in the fully depressed position. Verify that all lamps and accessories are turned off. In-order to avoid the engine from starting, remove the starter relay. Connect the positive lead of the voltmeter to the battery negative terminal post and then connect the negative lead of the voltmeter to the battery negative cableterminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery negative cable terminal clamp and the battery negative terminal post. Connect the positive lead of the voltmeter to the battery positive terminal post. Connect the negative lead of the voltmeter to the battery positive cable terminal clamp. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor connection between the battery positive cable terminal clamp and the battery positive terminal post. Connect the voltmeter to measure between the battery positive cable terminal clamp and the starter solenoid terminal stud.Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt. Clean and tighten the battery positive cable eyelet terminal connection at the starter solenoid terminal stud. Repeat the test. If the reading is still above 0.2 volt,replace the faulty battery positive cable. Connect the voltmeter to measure between the battery negative cable terminal clamp and ground on the transmission. Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If the reading is above 0.2 volt, clean and tighten the battery negative cable eyelet terminal connection to the engine block. Repeat the test. If the reading is still above 0.2 volt, replace the faulty battery negative cable. The starting motor is a device that converts electric energy into mechanical energy to generate rotational power, and transfers the energy required for starting the engine initially with this power.
The starter motor is composed of three parts, which are:
The solenoid, which moves the starter pinion by means of a fork and at the same time closes the power circuit to feed the electric motor. The direct current electric motor, which cranks the engine. The fork and pinion assembly, which makes the connection between the starter motor and the ring gear on the flywheel.
",
+ "file": null,
+ "display_order": 1
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A090047.jpg",
+ "display_order": 2
+ }
+ ]
+ },
+ {
+ "procedure_name": "Component Location Index",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4B090003.jpg",
+ "display_order": 3
+ }
+ ]
+ },
+ {
+ "procedure_name": "Summary",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25391.jpg",
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/25392.jpg",
+ "display_order": 5
+ }
+ ]
+ },
+ {
+ "procedure_name": "Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": " Using a 10 mm combination spanner, loosen battery negative cable mounting nut and disconnect cable. Using a 13 mm socket spanner, loosen and remove the battery positive cable mounting nut on starter motor end. Using a 8 mm socket spanner, loosen and remove the starter motor solenoid switch mounting nut on starter motor end. Torque : 2.5\u00b1 0.25 Nm Using a 14 mm socket spanner, loosen and remove the starter motor mounting bolts and remove starter motor from vehicle. Install in the reverse order of removal. Inspect battery negative cable for crack or damage. Replace if found any. Check the starter motor external crack or damage. Replace if found any. Check the starter motor internal gear crack or damage. Replace if found any. Using a 10 mm socket spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Glove Box Assembly. Remove the IP grab handle cover. Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts. Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220024.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting screws. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle. Partially detach the door edge beading and using a trim removal tool, remove the IP LH side cover. By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt. Torque : 8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector. Take out the IP LH side top cover with Passenger air bag from the IP. Using a 10 mm ring spanner, loosen and remove the air bag mounting bolt from IP top cover. Torque :4.5\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Expand the PAB module holder both sides using screw driver and detach the PAB separately from IP top cover. Using a star screw driver, Unscrew LH side AC vent mounting screws. Carefully release the vent locking clips from the cover and detach the vent. Check for any external damages or damaged locking clips, Replace if necessary. Inspect the PAB module for any damage. Replace if found any. Inspect the PAB module connector for any damage. Inspect the PAB module trim for any damage. For additional information refer to Combination Switch \u2013 R&R Section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the A Pillar Upper Trim LHS & RHS.",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Link",
+ "content": "THAR.LX-0009,1023,1361",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Remove the Glove Box Assembly.",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Link",
+ "content": "THAR.LX-0009,1020,1341",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the cluster bezel. Partially detach the door edge beading and using a trim Removal tool, Remove the IP side trim RH side. Using star screw driver, Unscrew Driver side top cover mounting screw and remove the cover. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220073.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew the cluster mounting screws. Torque : 2 \u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Partially Detach Cluster and disconnect the electrical connector. Remove the Instrument Cluster. Remove the Floor Console Assembly. Using trim removal tool, Remove IP side vertical trim LHS And RHS. partially detach the switch bang assembly and remove electric connector to take out from the vehicle. Detach the USB Docking station bezel and disconnect the electrical connectors. Disconnect Driver switch bank electrical connector. Remove the IP grab handle cover. Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts. Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting bolts. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-18",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle. Partially detach the door edge beading and using a trim removal tool , remove the IP side trim LH side. By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt. Torque : 8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 55
+ },
+ {
+ "step_name": "Step-22",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector. Remove IP Speaker Grill from LH and RH Sides. Disconnect speaker electrical connectors from both the sides. Using a trim removal tool Detach the infotainment trims. Using a star screw driver, Unscrew the infotainment mounting screws. Torque Value: 1.5 \u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 69
+ },
+ {
+ "step_name": "Step-26",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220085.jpg",
+ "display_order": 70
+ },
+ {
+ "step_name": "Step-27",
+ "content_type": "Description",
+ "content": "Partially detach infotainment and disconnect the electrical connectors. Remove the infotainment from Instrument panel. Using 10 mm socket spanner, Unscrew instrument panel mounting bolts. Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 77
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1004.jpg",
+ "display_order": 78
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1005.jpg",
+ "display_order": 79
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1006.jpg",
+ "display_order": 80
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1007.jpg",
+ "display_order": 81
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W1008.jpg",
+ "display_order": 82
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290094.jpg",
+ "display_order": 83
+ },
+ {
+ "step_name": "Step-29",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A290095.jpg",
+ "display_order": 84
+ },
+ {
+ "step_name": "Step-30",
+ "content_type": "Description",
+ "content": "Carefully remove the instrument panel from vehicle. Install in the reverse order of removal. check for any external damages or damaged locking clips, Replace if necessary. Using trim removal tool remove the cluster bezel. Using a trim removal tool, remove the IP panel assembly driver side. Partially detach the door edge beading and using a trim removal tool, remove the IP RH side cover. Using star screw driver, Unscrew driver side IP cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the driver side IP cover. Using star screw driver, Unscrew AC vent mounting screws. Remove the RH side AC vent. Carefully release the vent locking clips from the cover and detach the vent. Install in the reverse order of removal. check for any external damages or damaged locking clips, Replace if necessary. Remove the Instrument Panel Assembly. Using a star screw driver, Unscrew the Instrument Panel AC & defroster Duct mounting screws and remove the ducts. Using a star screw driver, Unscrew IP driver switch bank mounting screws. Torque : 1.5 \u00b10.5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the Driver Switch bank from Instrument Panel. Using a star screw driver, Unscrew IP centre air vent mounting screws. Remove the Centre Air Vents from Instrument Panel. Install in the reverse order of removal. check for any external damages or damaged locking clips, Replace if necessary. Using trim removal tool remove the cluster bezel. Using a trim removal tool, remove the IP panel assembly driver side. Partially detach the door edge beading and using a trim removal tool, remove the IP RH side cover. Using star screw driver, Unscrew driver side IP cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Detach the driver side IP cover. Using star screw driver, Unscrew AC vent mounting screws. Remove the IP AC Vent RH. Carefully release the vent locking clips from the cover and detach the vent. ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220127.jpg",
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. check for any external damages or damaged locking clips, Replace if necessary. Remove the Instrument Panel Assembly. Using 10 mm socket spanner, Unscrew fuse box mounting bolts. Torque : 5.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect ignition key barrel electrical connector. Detach the bonnet cable from the lever. Using a 12 mm socket spanner, loosen the steering intermediate shaft top bolt and remove bottom mounting bolts and detach the intermediate shaft bottom from the steering column. Torque : 22 \u00b1 4 Nm</nb> ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew steering column mounting bolts and nuts. Torque : 22 \u00b1 4 Nm</nb> ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220108.jpg",
+ "display_order": 19
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "using mm socket spanner, loosen and remove the Ip RH & LH speaker from Cross Car Beam. Torque : 3 \u00b1 1Nm ",
+ "file": null,
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220109.jpg",
+ "display_order": 23
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Disconnect the IP wiring routing clips and HVAC unit electrical connector. Remove the Scuttle Grill. Using 12 mm socket spanner, Unscrew CCB front facing mounting bolts. Using 13 mm socket spanner, Unscrew CCB bottom mounting bolts. Torque : 22\u00b13 Nm ",
+ "file": null,
+ "display_order": 33
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220115.jpg",
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, Unscrew CCB LHS & RHS mounting bolts/nuts. Torque : 22\u00b13 Nm ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220112.jpg",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew CCB LHS & RHS side bottom mounting bolts. Torque : 22\u00b13 Nm ",
+ "file": null,
+ "display_order": 41
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220118.jpg",
+ "display_order": 42
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew CCB to HVAC unit mounting screws. Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-15",
+ "content_type": "Description",
+ "content": "Remove the Cross Car Beam from vehicle. Install in the reverse order of removal. check for any external damages, cracks or bends on the cross car beam, Replace if necessary. Tools Required ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12152.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console RH screvits and detach the panel from vehicle Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 7
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220005.jpg",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using star screw driver unscrew the panel assembly floor console LH screvits and detach the panel from vehicle. Torque Value: 2.5 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220007.jpg",
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Loosen and Remove Gear Knob and Transfer case shifter knobs Remove the gear shifter cover with trim Remove the rummier mat from the cup holder Remove the 4WD selection knob by rotating it in anti-clock wise direction. Pull and fold the gear shifter boot from gear shifter bezel. Partially detach the bezel from the console. Excessive pull may leads to damage of the electrical connector Disconnect the AT gaiter electrical connector from the bezel. Carefully remove the bezel trim from the TGS lever. Handle bezel assembly carefully to prevent it from damage or scratches. Using trim removal tool, carefully remove the floor console top trim with transfer case shifter boot Using 10 mm socket spanner, Unscrew floor console LH and RH side mounting bolts Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220048.jpg",
+ "display_order": 36
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew floor console LH and RH side mounting screws Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 39
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220049.jpg",
+ "display_order": 40
+ },
+ {
+ "step_name": "Step-14",
+ "content_type": "Description",
+ "content": "Remove the bottle holder rubber mat Using 10 mm socket spanner, Unscrew floor console mounting bolts Using 10 mm socket spanner, Unscrew floor console LH and RH side mounting bolts Torque : 4.5\u00b1 0.5 Nm ",
+ "file": null,
+ "display_order": 47
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A220052.jpg",
+ "display_order": 48
+ },
+ {
+ "step_name": "Step-17",
+ "content_type": "Description",
+ "content": "Lift the floor console and disconnect the floor console electrical connector Remove the floor console from vehicle. Remove the power window switch assembly from floor console. Install in the reverse order of removal. Check floor console assembly for any damage, replace if found any. Tools Required ",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Tools Required",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/12182.jpg",
+ "display_order": 4
+ }
+ ]
+ },
+ {
+ "procedure_name": "Removal and Installation",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A200131.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Unlock glove box lock and remove the glove box assembly from IP Using star screw driver, remove the handle mounting screws Remove the glove box handle from the glove box assembly Install in the reverse order of removal. Check the glove box for damage, replace if necessary Using a 10 mm socket spanner, loosen and detach the battery negative cable then wait for atleast 2 mins before starting the work. Torque : 6.0\u00b10.6 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the Glove Box Assembly. Remove the IP grab handle cover. Using 10 mm socket spanner, Unscrew IP grab handle mounting bolts. Torque : 9.5 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using star screw driver, Unscrew IP grab handle mounting screws. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a trim removal tool, Remove the handle. Partially detach the door edge beading and using a trim removal tool, remove the IP LH side cover. By Using 10 mm socket spanner, remove the Passenger Airbag mounting bolt. Torque : 8\u00b11.2 Nm ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-9",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew IP LH side top cover mounting screw. Torque : 2.5\u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 27
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Detach the IP LH top cover and disconnect the PAB electrical Connector. Take out the IP LH side top cover with Passenger air bag from the IP. Using a star screw driver, Unscrew LH side AC vent mounting screws. Remove the IP AC Vent LH. Carefully release the vent locking clips from the cover and detach the vent. Check for any external damages or damaged locking clips, Replace if necessary. The tachometer indicates the real-time engine speed in thousands of RPM(revolutions per minute). Each division is 500 RPM. Operating the engine at very high RPM may lead to excessive engine wear and low fuel economy. Maintain steady engine speed below 2500 RPM and do not accelerate or decelerate abruptly. Do not over-accelerate the engine during idling, this can cause severe engine damage and would be treated as abuse of the engine which is not covered by warranty The speedometer indicates the real time road surface speed of the vehicle in kilometers per hour. The vehicle speedometer is affected by size of the tyres used. If the size of the tyres are changed from those fitted at the factory, the speedometer might not display the correct road surface speed and distance travelled Using trim removal tool, remove the cluster bezel mounting clips and remove the cluster bezel. Using trim removal tool, remove the IP side trim. Using star screw driver, Unscrew IP cover mounting screw and detach the IP cover using trim removal too. Using star screw driver, Unscrew instrument cluster mounting screw. Torque : 2 \u00b1 0.25 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Disconnect cluster electrical connector and remove instrument cluster. Refit in the reverse order of removal Check for any damage or crack, replace if found. Disconnect the TMC electrical connector then detach from the routing clips. Using 13 mm open end spanner, loosen and remove the TMC to EHCU Primary & Secondary bundy tubes from TMC side flare nuts. Torque :16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using hose clip plier, release brake fluid reservoir tank to clutch TMC hose clip then detach the hose. Using 12 mm combination spanner, Unscrew TMC mounting nuts and remove the TMC assembly from the brake booster. Torque : 16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/tmc3.PNG",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Check and top up the brake fluid, If required. Check for master cylinder external damage, if found replace. Using 14 mm socket spanner, loosen and remove the brake hose banjo bolt then detach the brake hose. Torque :24 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Replace the banjo bolt washers with new ones always while installation, else brake fluid leakage may happen. Using 19 mm socket spanner, loosen and remove the caliper assembly mounting bolts. Torque : 95 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the caliper assembly from the vehicle. Install in the reverse order of removal. Check and top up the brake fluid, If required. Inspect the caliper for any physical damage. Replace if found any. Using trim removal tool, remove the IP panel trim driver side. Using Nose plier, remove the R-clip and the clevis pin from the pedal shank. Using 12 mm socket spanner, loosen and remove the pedal box top mounting bolt. Torque :25 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the pedal box mounting nuts then remove the brake pedal box assembly. Torque :25\u00b15.0 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4D180003.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the brake pedal assembly for any physical damage. Replace if found any. Using 13 mm open end spanners, loosen and remove the TMC to primary and secondary bundy tubes flare nuts on EHCU side. Torque :16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using 11 and 13 mm open end spanners,loosen and remove the EHCU to FL,FR,RL, RR output bundy tubes flare nuts on EHCU side. Torque : 16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Caution",
+ "content": "Carefully detach the bundy pipe without any bend. if the bundy tube bends, Constant pressure will not be maintained. Disconnect the EHCU electrical connector. Using 12 mm socket spanner, Unscrew air cleaner housing mounting bolts to partially detach and keep aside. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 13 mm socket spanners, Unscrew EHCU mounting bolts and remove the EHCU assembly with EHCU mounting bracket. Torque : 23 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner , Unscrew EHCU mounting nuts from the bracket. Torque : 8 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130196.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "After removing the bundy tubes from EHCU, seal each port of ECHU with dummy plugs to avoid dust entry. Do not give any impact to hydraulic unit and take at most care not to allow dust to enter the hydraulic unit. Do not place hydraulic unit on its side or upside down. Handling it in inappropriate way will affect its original performance. Take sufficient care while installation and ensure correct bundy is connected to the specified inlet port.Use colour code for identification. Install in the reverse order of removal. Check and top up the brake fluid, If required. For additional information refer to Brake bleeding procedure. ",
+ "file": null,
+ "display_order": 26
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the EHCU for any external damage, if found replace. Disconnect battery negative connector. Disconnect the wheel speed senor electrical connector. Detach the wheel speed sensor cable from the routing clips. Using 10 mm socket spanner, loosen and remove the wheel speed sensor mounting bolt then remove the sensor. Torque :9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130035.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the sensor for any physical damage. Replace if found any. Inspect the sensor for foreign particles segregation. Clean if found. Inspect the sensor connector for any damage. Remove the Floor Console. Using 10 mm open end spanner, loosen and remove the parking brake adjusting nut. Detach the parking brake cable from parking brake lever. Disconnect the parking brake switch electrical connector. Using 12 mm socket spanner, Unscrew parking brake lever assembly mounting nuts. Torque :25 \u00b1 3 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Remove the parking brake switch from parking brake lever assembly. Install in the reverse order of removal. For additional information refer to Parking brake adjustment section. ",
+ "file": null,
+ "display_order": 19
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Inspect the park brake lever for any physical damage. Replace if found any. Remove the front caliper assembly. Blow dry compressed air into the caliper gradually through the inlet port connected to banjo bolt, to gradually move the piston out of the caliper. Remove the piston from the caliper housing. Remove the dust cover from the caliper housing. Remove the rubber seal from the groove in the caliper housing. Piston Outer surface should be free from nicks, score or rust and should feel smooth to touch. Do not use emery paper on piston surface, Replace if found any. Caliper Housing bores should be free from score, pitting, and corrosion, Replace if found any. Carefully refit the rubber seal. Clean all the internal parts thoroughly with fresh brake fluid or alcohol. Do not use mineral oil like kerosene, petrol, diesel etc. If the piston does not move smoothly, remove it and examine the sealing ring for correct seating in its groove. Fit the other end of the piston boot on to the caliper housing. Refit the front caliper assembly. For additional information refer to Caliper assembly \u2013 R&R section. Press the lock and disconnect the electrical connector from the brake switch. Place the brake pedal in release position. Turn the brake switch in anti-clock wise direction to get the brake switch free from adjuster lock. Insert the brake switch (A) in adjuster (B) till the switch plunger get completely pressed against brake pedal (at this point switch body will rest on brake pedal). Ensure no play between adjuster and the mounting bracket . Replace the adjuster if play is observed. While replacing new Switch with adjuster - Adjuster is to be snapped on mounting bracket. Ensure no play between the adjuster and mounting. Rotate the brake switch in clock wise direction till the switch gets locked. After locking the switch, the gap between the switch body and brake pedal will set to 1 \u00b10.15mm. Connect the brake switch electrical connector. Disconnect the brake switch electrical connector. Rotate the brake switch in anti-clockwise direction and remove the brake switch. Install in the reverse order of removal. Carry out brake switch adjustment setting. Inspect the brake switch for any damage. Replace if required. Inspect the connector for any damage. Check proper fitment of connector. Position the vehicle on 2 post lift/ 4 post lift and turn engine OFF. Open the bonnet and lock it in open position using bonnet stay rod. Clutch/Brake Fluid - Mahindra Maximile DOT 4 Genuine Brake fluid.Capacity - 1.75 Liters (Including bleeding quantity).Entire bleeding operation should be done with engine ON condition. In case of fluid reservoir or brake fluid replacement, bleeding of brake circuit is required. Always use recommended fluid and do not mix different brand fluids. Always use fresh and clean fluid from a sealed container. Do not pump the brake pedal at any time while bleeding (i. e. when the bleeding screw is opened). Air in the system will be further compressed into small bubbles and distributed throughout the hydraulic system and will result in additional bleeding operations. Do not reuse the drained fluid. Fluid level in the reservoir must be at MAX level at the start of bleeding and should be checked after bleeding each brake circuit and top up as required. Open brake fluid reservoir cap. Pull-out the bleeding nipple dust cap from both front & Rear (RH and LH) bleeding nipple. Connect a transparent tube into rear LH side bleeding nipple and using a 9 mm ring spanner, loosen the brake fluid nipple then allow the brake fluid to drain. Press the brake pedal gently to drain the fluid completely. Collect the brake fluid in the container and tighten the brake fluid nipple then detach the hose from bleeder nipple. Connect a transparent tube into rear RH side bleeding nipple and using a 9 mm ring spanner, loosen the brake fluid nipple then allow the brake fluid to drain. Press the brake pedal gently to drain the fluid completely. Collect the brake fluid in the container and tighten the brake fluid nipple then detach the hose from bleeder nipple. Connect a transparent tube into front LH side bleeding nipple and using a 8 mm ring spanner, loosen the brake fluid nipple then allow the brake fluid to drain out completely. Press the brake pedal gently to drain the fluid completely. Collect the brake fluid in the container and tighten the brake fluid nipple then detach the hose from bleeder nipple. Connect a transparent tube into front RH side bleeding nipple and using a 8 mm ring spanner, loosen the brake fluid nipple then allow the brake fluid to drain. Press the brake pedal gently to drain the fluid completely. Collect the brake fluid in the container and tighten the brake fluid nipple then detach the hose from bleeder nipple. Hand tighten all the bleeding nipples. Fill recommended brake fluid up to \u201cMAX\u201d mark on the brake fluid reservoir. Press and release brake pedal gently several times, so that brake fluid will get circulated throughout the circuit. For vehicles equipped with ABS/ESP, brake circuit air bleeding needs to be carried out in 3 steps as mentioned below: Manual bleeding. Bleeding the EHCU with the use of diagnostic Tool. Final manual bleeding. During the bleeding process, it has to be ensured that the fluid level in the reservoir does not drop below minimum. Refer the below illustration for the bleeding sequence. Connect a transparent tube into Rear LH side bleeding nipple and insert the other end of tube in a transparent container. Ensure other end of tube is submerged in liquid, else chances for air entry is high. Always use transparent tube for better visibility of air bubbles. Press and release the brake pedal 3 - 4 times gently to the full stroke and hold the pedal in depressed condition. Ensure proper quantity of brake fluid in the reservoir throughout the bleeding procedure. Using a 9 mm ring spanner, loosen the brake fluid nipple and allow the brake fluid to drain. Air bubbles will escape from brake circuit to container through transparent pipe and the bubbles will be clearly visible. Tighten the bleeder screw as soon as there is no air bubbles visible in the transparent tube. Continue procedure steps 2 - 4 till there is no air bubbles visible in the transparent tube. Remove the transparent tube and firmly tighten the brake fluid nipple. Follow steps from 1\u2013 6 for Rear RH side brake. Refit the bleeding nipple dust cap on both REAR RH and LH bleeding nipples. Connect a transparent tube into Front LH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Ensure other end of tube is submerged in liquid, else chances for air entry is high. Always use transparent tube for better visibility of air bubbles. Press and release the brake pedal 3 - 4 times gently to the full stroke and hold the pedal in depressed condition. Ensure proper quantity of brake fluid in the reservoir throughout the bleeding procedure. Using a 8 mm ring spanner, loosen the brake fluid nipple and allow the brake fluid to drain. Air bubbles will escape from brake circuit to container through transparent pipe and the bubbles will be clearly visible. Tighten the bleeder screw as soon as there is no air bubbles visible in the transparent tube. Continue procedure Steps 10 \u2013 12 till there is no air bubbles visible in the transparent tube. Remove the transparent tube and firmly tighten the brake fluid nipple. Follow steps from 9 \u2013 14 for Front RH side brake. Refit the bleeding nipple dust cap on both Front RH and LH brake bleeding nipples. Maintain recommended brake fluid up to MAX mark on the brake fluid reservoir. Refit the brake fluid reservoir cap. During the tool-bleeding process, ensure that the fluid level in the reservoir does not drop below minimum. Connect i-SMART diagnostic tester and turn the ignition \u201cON\u201d . Launch i-SMART Select ABS ECU and Navigate to Write Data. Routine screen will appear. Click on \u201cROUTINE SELECTION\u201d drop down list and select \u201cREPAIR BLEEDING\u201d. Click on \u201cSTART ROUTINE\u201d to initiate the tool bleeding. Ensure the fluid level in brake fluid reservoir is at \u201cMAX\u201d mark. Connect a transparent tube into rear LH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Loosen and open the rear LH bleeding screw and then press \u201cOK\u201d button. Click on \u201cYES\u201d button to proceed for \u201cBleeding phase I\u201d. The following pop up window appears once the \u201cBleeding phase I\u201d ends. Close the rear LH bleeding nipple once the above mentioned pop up window appears. Ensure other end of tube is submerged in liquid, else chances for air entry is high. After pressing \u201cYES\u201d button, Press and hold the brake pedal for 3 seconds and then release for 0.5 seconds. Continue above procedure till \u201cBleeding phase I \u201d ends Connect a transparent tube into front LH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Loosen and open the front LH bleeding screw and then press \u201cOK\u201d button. Click on \u201cYES\u201d button to proceed for \u201cBleeding phase II\u201d. The following pop up window appears once the \u201cBleeding phase II\u201d ends. Ensure other end of tube is submerged in liquid, else chances for air entry is high. After pressing \u201cYES\u201d button, Press and hold the brake pedal for 3 seconds and then release for 0.5 seconds. Continue above procedure till \u201cBleeding phase II \u201d ends. Close the front LH bleeding nipple once the above mentioned pop up window appears. Connect a transparent tube into front RH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Loosen and open the Front RH bleeding screw and then press \u201cOK\u201d button. Ensure other end of tube is submerged in liquid, else chances for air entry is high. Click on \u201cYES\u201d button to proceed for \u201cBleeding phase III\u201d. The following pop up window appears once the \u201cBleeding phase III\u201d ends. After pressing \u201cYES\u201d button, Press and hold the brake pedal for 3 seconds and then release for 0.5 seconds. Continue above procedure till \u201cBleeding phase III\u201d ends. In bleeding phase III, pump motor switches ON and OFF in a pre defined intervals. While pump motor is ON, brake pedal pulsations can be felt along with the motor operating sound. Connect a transparent tube into Rear RH side bleeding nipple and insert the other end of tube in a transparent container with brake fluid. Loosen and open the Rear RH bleeding screw and then press \u201cOK\u201d button. Ensure other end of tube is submerged in liquid, else chances for air entry is high. Click on \u201cYES\u201d button to proceed for \u201cBleeding phase IV\u201d. The following pop up window appears once the \u201cBleeding phase IV\u201d ends. Press \u201cOK\u201d button to complete brake bleeding through i-SMART. After pressing \u201cYES\u201d button, Press and hold the brake pedal for 3 seconds and then release for 0.5 seconds. Continue above procedure till \u201cBleeding phase IV\u201d ends. In bleeding phase IV, pump motor switches ON and OFF in a pre defined intervals. While pump motor is ON, brake pedal pulsations can be felt along with the motor operating sound. Once again carry-out mechanical bleeding. For additional information refer to Manual bleeding section. Check brake/clutch pedal for sponginess. If found spongy, repeat the entire procedure of bleeding. Check and ensure there is no leakage from pipes and joints. Do not spill brake fluid on the vehicle, it may damage the paint, if the brake fluid does contact the paint, wash it off immediately with water. Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid. The fluid reservoir cap/ container should not be opened with dirty hands. Avoid direct water spray on reservoir while washing engine compartment. If Maximile DOT 4 Brake fluid is not used and in emergency conditions, use brake Fluid Meeting SAE J1703 FMVSS NO.116 DOT 4 OR IS 8654 TYPE-2 Specification and change it at 30,000 kms or 2 years whichever is earlier. During the bleeding operation ensure the container and pipe used is of transparent for better visual. Position the vehicle on level ground/ 2 post lift /4 post lift. Open the bonnet and lock it in open position using bonnet stay rod. Brake and Clutch Fluid - Mahindra Maximile DOT 4 Genuine Brake fluid.Brake and Clutch Fluid - 1.75 Liters (Including bleeding quantity). Check Brake fluid reservoir fluid level, if found less than MIN mark, top up to MAX mark. Check the reservoir for leakage and check the level of fluid, if found less top up till MAX mark. Always maintain fluid level at MAX mark on reservoir. Check for brake fluid leakage at master cylinder primary & secondary tubes. Check for brake fluid leakage at EHCU primary, secondary and outlets tubes. Check for brake fluid leakage or seepage at front bundy tube I to front bundy tube II connections (Both LH & RH side). Check for brake fluid leakage or seepage at front bundy tube to flexible hose (Both LH & RH side). Check for brake fluid leakage at front caliper inlet & bleeding nipple (Both LH & RH side). Check for brake fluid leakage or seepage from rear RH & LH bundy tube joints shown in illustration. Check for brake fluid leakage or seepage from rear LH bundy tube II & tube III joints shown in illustration. Check for brake fluid leakage at rear RH/LH flexible hoses. Check for brake fluid leakage at rear wheel cylinder inlet & bleeding nipple (Both LH & RH side). Using trim removal tool, remove the IP panel trim driver side. Using Nose plier, remove the R-clip and the clevis pin from the pedal shank. Using 12 mm socket spanner, loosen and remove the pedal box top mounting bolt. Torque :25 \u00b1 5.0 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using 12 mm socket spanner, loosen and remove the pedal box mounting nuts then remove the brake pedal box assembly. Torque :25\u00b15.0 Nm ",
+ "file": null,
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130330.jpg",
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the brake pedal assembly for any physical damage. Replace if found any. Position the vehicle on 2 post lift. Using a 21 mm wheel spanner, remove wheel mounting nuts and then remove the front wheel. For vehicles with Alloy wheels,measuring can be done without removing the wheels. Insert the Brake pad gauge between caliper housing and edge of brake pad backing plate and contact Tip of tool housing (A) on rotor machined surface as shown. Brake pad gauge should be in perpendicular to rotor surface while measuring. Push the Rear barrel (E) of tool inward and rotate the barrel to rotate Probe tip (B) of the tool as shown. Release the barrel (E) outward upto the probe tip (B) in contact with surface of brake pad back plate as shown. Rotate Knurled ring (D) of rear measuring barrel in same direction to view quick reference color pattern (C) and find actual brake pad thickness (In mm). Refer Brake Pad Thickness Vs Quick reference colors table mentioned below. If Measured pad thickness is 1 mm or less, it has to be replaced. Wear Limits
New pad thickness: 11.35 mm. Useful Pad thickness: 10.35 mm. Follow the Step 2 to 7 for measuring thickness of Inboard Brake Pad. Inspect the disc thickness at different points. Actual thickness of disc: 30 mm. Minimum Useful disc thickness: 28 mm. Refit the front wheel back with the help of mounting nuts and torque tighten it to specified torque value. Follow the above procedure for front other side wheel brake pad and disc inspection. Remove and inspect the brake pads if the vehicle is reported for the following concerns, Brake Shudder Brake Noise Brake Squeal and any other brake related concerns If any one pad is worn out (inboard /outboard) then replace both the pads. If pads on one wheel only are worn, even then replace the other wheels also. Rotate the disc and make sure it is free to rotate. If it is not free to rotate, inspect and rectify. The Pads in the Pad kit should be replace on the respective caliper i.e. assemble < RH > marked pads on RH Caliper and < LH > marked pads on LH Caliper. If the pads are to be reused make sure they are assembled back in the same position as they were when removed i.e., inboard pad on to the piston side and outboard pad to the wheel side. This is possible only when at the time of removal these pads are marked for their positions and kept aside. Never lubricate the pad seating areas as it may lead to jamming. Never polish pad lining with sandpaper. If lining is polished with sandpaper, hard particles of sandpaper will be deposited in lining and may damage disc. When pad lining requires correction, replace it with a new one. After assembly of pads, apply brake pedal 5 - 6 times in static condition in order to make the pads align properly. It is recommended to apply light braking during the road test and avoid heavy and continuous braking during the initial 200kms of run or until the new pads are performing satisfactorily. Never lubricate the pad seating areas as this may lead to jamming. Always ensure that the anti rattle pad clips (small low abutment clip \u2013 sLAC) are replaced whenever the pads are replaced. Always ensure the grease (Wolfracote) between clip & carrier whenever the sLAC clips are removed/replaced. Don\u2019t overload or pull the retraction loop during pad assembling. Don\u2019t use deformed clips & don\u2019t damage the clips during pad insertion. For additional Information refer Primary Bundy Tube - R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Remove the secondary bundy tube. For additional Information refer Secondary Bundy Tube - R&R section. ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Using hose clip plier detach the vacuum hose clip and remove hose from the brake booster. Disconnect the brake booster electrical connector and detach from the routing clips. Using hose clip plier, release the brake fluid reservoir tank to clutch TMC hose hose clip then detach the hose. Using cutting plier, remove the R-clip then remove the clevis pin. Using 12 mm socket spanner, Unscrew brake booster mounting nuts and remove the brake booster with TMC. Torque : 25 \u00b1 5 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130024.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Carry out brake switch adjustment setting. Check and top up the brake fluid, If required. For additional information refer to Brake bleeding procedure. ",
+ "file": null,
+ "display_order": 22
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check for the booster diaphragm if found check & replace the assembly. Disconnect battery negative terminal. Disconnect the wheel speed senor electrical connector. Detach the wheel speed sensor cable from the routing clips. Using 10 mm socket spanner, loosen and remove the wheel speed sensor mounting bolt then remove the sensor. Torque : 9 \u00b1 1 Nm ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A130227.jpg",
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the sensor for any physical damage. Replace if found any. Inspect the sensor for foreign particles segregation. Clean if found. Inspect the sensor connector for any damage. Position the vehicle on 2 post lift. Using a 21 mm wheel spanner, Loosen and remove the rear LH wheel. Using a star screw driver, Loosen and remove drum mounting screw. Clean the brakes by blowing compressed air. Check the wheel cylinder for oil leakage. (It is recommended to check the oil seepage from wheel cylinder by lifting the dust boots.) Check the brake lining for wear/cracks. Measure the brake lining thickness by using Vernier caliper. The minimum usable thickness of the rear brake liner is 4.6 mm. Replace when thickness falls Minimum thickness of lining below 1 mm. The brake shoe must be replaced before the rib starts touching the drum. Measure the wear of the brake lining at the maximum worn out place. Place the drum in its position and install the mounting screw. Refit the LH wheel and torque tighten the nuts to specified value. Whenever the brake shoes are replaced, replace both RH & LH assemblies as a set to prevent car from pulling to one side when braking. If there is significant difference in the thickness of the liner on the left and right sides, check parking brake operation/ wheel cylinders piston for free movement. Position the vehicle on a 2 post lift. Apply and release the parking brake 5 times to condition the cables for normal use and Put the parking brake lever into the released position. Check both the rear wheels for free rotation. Position the parking brake lever at 5th notch position. Check both the rear wheels for free rotation, if the wheels are rotate then tighten the adjusting nut 14 mm till the rear wheels can no longer be rotated using hands. Apply and release the parking brake 5 times. Set the parking brake lever into the released position. The rear wheels must be able to turn freely. If not, loosen the adjusting nut gradually until the wheel can turn freely. Position the vehicle on 2 post lift. Using 21 mm wheel spanner, Loosen and remove the rear LH wheel. Using star screw driver, Loosen and remove drum mounting screw. Using flat screw driver, slide the parking brake retaining lever and Using plier, remove the parking brake cable. Disconnect the parking brake cable connection from the liner assembly. Using plier, remove the liner spring holder. Gently expand and remove the liner assembly carefully. Remove the auto-adjuster and adjuster lever. Using flat end screw driver detach the top shoe return spring and the bottom shoe return spring and remove the liners. Assemble the Liner kit.
Align the shoes and fit bottom return spring. Refit the auto-adjuster and auto-adjuster lever. Refit the top shoe return spring. Refit the liner kit assembly. Refit the liner spring holder. Using plier slide the parking brake retainer lever & fix the parking cable. Refit the brake drum with the help of mounting screw. Refit the LH wheel and torque tighten the nuts to specified value. Whenever the brake shoes are replaced, replace both RH & LH assemblies as a set to prevent car from pulling to one side when braking. If there is significant difference in the thickness of the liner on the left and right sides, check parking brake operation/ wheel cylinders piston for free movement. Brake pads convert the kinetic energy of the car to thermal energy by friction. Two brake pads are contained in the brake caliper with their friction surfaces facing the brake disc which are pressed together against the rotating disc to slow/stop the vehicle. Using 21 mm wheel spanner remove mounting nuts and remove the front RH wheel. Remove front caliper lower mounting bolt using 12 mm socket spanner. Lift the caliper upwards as shown in the illustration. Pull the Brake Pad outwards upto pad contact with clip as shown in the illustration. Twist the pad in anti clock wise direction, lift the pad upwards and remove the pad. Follow Step 4 & 5 for remove another pad. While inserting the pads between the carrier and disc care should be taken that the friction material should be towards the disc. Rotate the disc and make sure it is free to rotate. If it is not free to rotate, inspect and rectify. Before inserting the pads ensure that caliper is returned fully to its position. (Push the caliper inside if necessary.) Never polish pad lining with sandpaper. If lining is polished with sandpaper, hard particles of sandpaper will be deposited in lining and may damage disc. When pad lining requires correction, replace it with a new one. While fitting the guide pin ensure that the straight portion of the pin matches with the ear of the calliper body. The Pads in the Pad kit should be replace on the respective caliper i.e. assemble RH marked pads on RH Caliper and LH marked pads on LH Caliper. If the pads are to be reused make sure they are assembled back in the same position as they were when removed i.e., inboard pad on to the piston side and outboard pad to the wheel side. This is possible only when at the time of removal these pads are marked for their positions and kept aside. Never lubricate the pad seating areas as it may lead to jamming. After assembly of pads, apply brake pedal 5 - 6 times in static condition in order to make the pads align properly. It is recommended to apply light braking during the road test and avoid heavy and continuous braking during the initial 200 kms of run or until the new pads are performing satisfactorily. Never lubricate the pad seating areas as this may lead to jamming. Always ensure that the anti rattle pad clips (small low abutment clip \u2013 sLAC) are replaced whenever the pads are replaced. Always ensure the grease (Wolfracote) between clip & carrier whenever the sLAC clips are removed/replaced. Ensure that the sLAC clips are placed properly and fitted in correct direction in the caliper bracket as shown in the illustration. Ensure that the sLAC clips are replaced/swapped diagonally as shown in the illustration. Ensure that no damage or no deformation of retraction loop in the sLAC clips before fitment. Don\u2019t overload or pull the retraction loop during pad assembling. Don\u2019t use deformed clips & don\u2019t damage the clips during pad insertion. Ensure the proper fitment of all the small low abutment clip (sLAC) . Replace sLAC clips with a new one if found any damage or crack. Refit the brake pad by pushing the pad inside the clips in angled approach as shown in the illustration. Rotate the pad in clockwise direction to vertical position and push the pad inside to caliper. Ensure pad touching the clip retraction. Move the caliper downwards and bring back to its original position. For easy movement, pull the caliper outwards a bit and move it down. Chances for piston seal damage is high, so take adequate precaution while moving the caliper downwards. If the pads are changed with a new one, push both the pistons inside before moving the caliper downwards. Refit the caliper bottom mounting bolt and torque tighten to specified torque value. Ensure the sliding pins are greased well, whenever removed or replaced. Torque : 31 \u2013 38 Nm ",
+ "file": null,
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Refit the front RH wheel back with the help of mounting nuts and torque tighten it to specified torque value. Torque : 140\u00b110 Nm ",
+ "file": null,
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Follow the same procedure for front LH brake pad and caliper inspection. If any one pad is worn out (inboard /outboard) then replace both the pads. If pads on one wheel only are worn, even then replace the other wheels also. Remove Brake Shoes. For additional information refer to brake shoe \u2013 R&R section. Remove the hand brake cable lock clip and detach the hand brake cable from back plate. Using 11 mm open end spanner, Loosen brake bundy tube flare nut wheel cylinder end. Torque : 16 \u00b1 2 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using 10 mm socket spanner, Unscrew Wheel cylinder mounting bolts and remove the cylinder. Using 17 mm socket spanner, loosen and remove axle shaft mounting nuts. Torque : 90 \u2013 100 Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using MST (0505AAA0001ST puller rear axle shaft banjo) remove rear axle shaft, dust shield with brake liner assembly from vehicle. To avoid the back plate falling down,using a plastic tag tie it with any other fixed member before the shaft is pulled out. Clean sealant on the axle housing flange, Back Plate and apply new sealant on the housing. Apply Locktite Sealant 5060 during Installation and Ensure that sealer bead is on the inside of screw holes as shown above. Bead must be 3 to 6 mm high and 3 to 6 mm wide. Remove Back plate from vehicle. Install in the reverse order of removal. Check and top up the brake fluid, If required. For additional Information refer to Brake bleeding procedure. ",
+ "file": null,
+ "display_order": 25
+ }
+ ]
+ },
+ {
+ "procedure_name": "Inspection",
+ "steps": [
+ {
+ "step_name": "Step-1",
+ "content_type": "Description",
+ "content": "Check the brake back plate any external damage & also check the brake back plate usable thickness, if required replace. Remove the front wheel assembly. For additional information refer to Front wheel R&R section. Remove the Front stabilizer bar assembly. For additional information refer to Front Stabilizer Bar \u2013 R&R section. Using 24 mm socket spanner, loosen and remove the front lower control arm mounting nuts on chassis. While loosening the nut, hold the bolt using 24 mm ring spanner. Torque tightening should be done without load and with the tyres on level ground. Torque value: 250 \u00b1 20 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Using a 19 mm socket spanner, loosen and remove strut fork mounting bolt. Torque : 120 \u00b1 12 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Ensure to insert the washer before Install the bolt. Using a cutting plier, remove the cotter pin from the ball joint. Never reuse the split pin, always replace with a new one. Using a 24 mm socket spanner, loosen and remove lower arm ball joint mounting nut. Torque : 130 \u2013 150 Nm ",
+ "file": null,
+ "display_order": 20
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Using a 22 mm socket spanner, loosen and remove knuckle bracket mounting bolts, remove the knuckle lower half. Torque value: 140 \u00b1 10 Nm <n>Torque Wrench Type - Open end Torque Wrench ",
+ "file": null,
+ "display_order": 24
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Using a hammer, tap strut fork and release it from lower arm. Remove the lower control arm mounting bolts from the vehicle frame. Torque value: 250 \u00b1 20 Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the lower control arm from the vehicle. Install in reverse order of removal. Pay attention while Installation. Torque tightening should be done without load and with the tyres on level ground. LH and RH identification sticker available on part for orientation. Camber and caster bolt marking position required at center. Camber and caster bolt should be fitted in the direction of Arrow shown in illustration. Inspect the lower control arm for any external damage or bent, if found replace. Inspect the lower control arm ball joint and bushes for any damage. Place the Pan hard on suitable base block. Place the suitable dolly on the Pan hard bush One end. Using a hydraulic press or hammer remove the Pan hard bush one end. Place the Pan hard other end on base block and place the dolly on Pan hard bush. Using a hydraulic press or hammer remove the Pan hard bush other end. Place the Pan hard one end on base block and place the bush installer (MST:0401BAA0043ST) .on the bush. Using a hydraulic press or hammer,Install the Pan hard bush One end. Panhard bush should be fitted in center of panhard and ensure to maintain equal distance on both side of panhard as shown. Place the Pan hard other end on base block and place the bush installer (MST:0401BAA0043ST) .on the bush. Using a hydraulic press or hammer,Install the Pan hard bush other end. Remove the Front Upper Control Arm. Place the base block (MST: 0401BAA0033ST) and place the collar support (MST: 0401BAA0037ST) . on the base block. Place the upper arm one end on the base block. Place the upper arm bush remover (MST: 0401BAA0040ST) on the bottom bush. Place the Pin cage (MST: 0401BAA0041ST) & the support cage (MST: 0401BAA0013ST) as shown. Using a hydraulic press remove the upper arm one side (bottom) bush. Place the upper arm other end on the base block (MST: 0401BAA0033ST) and collar support (MST: 0401BAA0037ST) . Place the upper arm bush remover (MST: 0401BAA0040ST) on the bush. Place the upper arm dummy bush (MST: 0401BAA0042ST) on the upper side bush seating hole. Place the upper arm pin cage (MST: 0401BAA0041ST) & the support cage (MST: 0401BAA0013ST) as shown. Using a hydraulic press remove the other side bush. Place the Upper arm on the base block (MST: 0401BAA0033ST) & collar support (MST: 0401BAA0037ST) and place the bush over the upper arm. Place the bush installer (MST: 0401BAA0043ST) on the bush. Using a hydraulic press, Install the upper arm one side bush. Place the Upper arm other side on the base block (MST: 0401BAA0033ST) & collar support (MST: 0401BAA0037ST) and place the bush over the upper arm. Place the bush installer (MST:0401BAA0043ST) .on the bush. Using a hydraulic press, Install the upper arm bush. Refit the Front Upper Control Arm. Rear Upper Link is used to compensates the longitudinal load to the vehicle. Using a 24 mm socket spanner, loosen the mounting bolt and nut in the chassis end then remove nut from the link. Torque : 230 \u00b1 20 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt using 21 mm ring spanner. Torque tightening should be done without load and with the tyres on level ground. Torque Wrench Type - Open end Torque Wrench for LH chassis & axle ends Using a 24 mm socket spanner, loosen and remove the link mounting nut from the axle end. Torque : 230 \u00b1 20 Nm Torque Wrench Type - Open end Torque Wrench for LH chassis & axle ends While loosening the nut, hold the bolt using 21 mm ring spanner Torque tightening should be done without load and with the tyres on level ground. Using a appropriate jack support slightly lift the rear axle. Using a 17 mm socket spanners, loosen and remove the both rear shock absorbers bottom side mounting bolts and nuts. Torque value : 110\u00b111 Nm <n>Torque Wrench Type - Open end Torque Wrench ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. While loosening the nut, hold the bolt using 15 mm ring spanner. Remove the respective side coil spring. Jack up the rear axle slightly. Remove the rear upper link chassis end mounting bolt then remove the front and rear upper link from the vehicle. Pay attention while Installation. Bolt should be fitted in the direction of Arrow shown in illustration. Inspect the upper link for any damage, crack or twisting. Replace if found any. Inspect the upper link bushes for any damage, crack or material deterioration. Replace the bushes if found any. Remove the Rear Lower Link. Place the base block (MST:0401BAA0033ST) & place the Rear Lower and Upper Link Coller (MST : 0401BDD0001ST) . Place the Lower link one end on the base block. Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) on the lower link one end bush. Using a hydraulic press, remove the lower link one end bush. Place the Lower link other end on the base block. Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) on the lower link other end bush. Using a hydraulic press, remove the lower link other end bush. Place the Lower link one end on then base block and place the bush over the lower link. Place the Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press While Installation ensure to maintain Bush Void at 45\u00b0 angle as shown. Ensure to Install the Bush with Void end should be fitted in Chassis end on vehicle. Place the Lower link other end on the base block and place the bush over the lower link. Place the Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press. Refit the Rear Lower Link. Remove the front wheel assembly. For additional information refer to Front wheel R&R section. Using a 13 mm socket spanner , loosen and remove the brake hose routing bracket mounting nut. Using a 19 mm socket spanner , loosen and remove the strut fork mounting bolt at lower arm end and detach it. Torque : 120 \u00b1 12 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Using hammer, tap strut fork gradually and release strut fork from lower arm. Using a 17 mm ring spanner, loosen and remove the strut top mounting nuts from chassis. Torque value: 40 \u00b1 5Nm Torque Wrench Type - Open end Torque Wrench Detach Wheel speed sensor routing clips from upper control arm. Using 14 mm socket spanner and 18 mm open end spanner, unscrew upper arm bolt and nut and detach partially. Torque value: 97\u00b1 10 Nm ",
+ "file": null,
+ "display_order": 21
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170137.jpg",
+ "display_order": 22
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Remove front strut assembly from front suspension. LH and RH identification sticker available on part for orientation. Using a 17 mm socket spanner and 19 mm open end spanner, loosen the fork mounting bolt and nut and remove fork from strut assembly. Install in reverse order of removal. Check for the coil spring for any damage, crack etc. Check for oil leakage from the shock absorber. For additional information refer to Rear Upper Link - R&R section. ",
+ "file": null,
+ "display_order": 2
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Link",
+ "content": "THAR.LX-0009,1015,1264",
+ "file": null,
+ "display_order": 3
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Place the base block (MST:0401BAA0033ST) & place the Rear Lower and Upper Link Coller (MST : 0401BDD0001ST) . Place the upper link one end on the base block. Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) over the upper link one end bush and Using a hydraulic press, remove the bush. Place the upper link other end on the base block. Place the Bush Remover-Lower Arm Big End (MST: 0401BAA0038ST) on the upper link other end bush and Using a hydraulic press, remove the bush. Place the upper link one end on then base block and place the bush over the upper link. Place the Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press. While Installation ensure to maintain Bush Void at 45\u00b0 angle as shown. Ensure to Install the Bush with Void end should be fitted in Chassis end on vehicle. Place the upper link other end on the base block and place the bush over the upper link. Place the bush & Installer-Lower Arm Big End Bush (MST: 0401BAA0044ST) over the bush and Refit the bush by loading the hydraulic press. Refit the Rear Upper Link. Using a appropriate jack support and slightly lift the rear axle. Using a 24 mm deep socket spanner, loosen and remove the pan hard rod mounting nut and bolt from chassis side. Torque : 230\u00b1 20 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Notice",
+ "content": "While loosening the nut, hold the bolt with the help of 21 mm deep socket. Torque tightening should be done without load and with the tyres on level ground. Using a 21 mm socket spanner, loosen and remove the pan hard rod mounting bolt from axle side. Torque : 230\u00b1 20 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Remove pan hard rod separately. Yellow color all round marking added on Pan hard rod to identify chassis end. Install in reverse order of removal. After installation of pan hard rod remove the jack support. Pay attention while Installation. Bolt should be fitted in the direction of Arrow shown in illustration. While Installation, ensure to refit the Anti Rotation Bracket in the axle end bold side. Inspect the pan hard rod for any external damage/bend or crack, if found replace. Position the Vehicle on 4 post lift. Check lower control arm front and rear bush condition (both LH & RH) for wear & tear, racks & shift. Replace if necessary. Check upper control arm front and rear bush condition (both LH & RH) for wear & tear, cracks & shift. Replace if necessary. Check the ball joint boots for damage, cracks, replace if necessary. Check shock absorber bushes, shock absorber dust boot, stabilizer bar bushes, stabilizer bar link boots, bump stop for wear & tear, cracks and shift, replace if necessary. Check the lower link, pan hard rod, Upper link, stabilizer bar and stabilizer bar links bushes for any damage/crack or deterioration. Replace the bushes if found any. Check shock absorber bushes, dust boot & bump stop for wear, crack and shift. Inspect front suspension lower control arm for any bend, damage or crack. Inspect front suspension upper control arm for any bend, damage or crack. Inspect front suspension stabilizer bar for any bend, twisting, damage or crack. Inspect rear suspension stabilizer bar for any bend, twisting, damage or crack. Inspect rear suspension lower link for any bend, damage or crack. Inspect rear suspension upper link for any bend, twisting, damage or crack. Inspect rear suspension panhard rod for any bend, twisting, damage or crack. Inspect front & rear suspension stabilizer bar link for any bend, twisting, damage or crack. While tightening the link & torquing ensure that wheels are resting on the ground/ 4 post lift. If it is not done, the ride quality will get adversely affected. Remove the Front Lower Control Arm. Place the base block (MST:0401BAA0033ST) & place the Front Lower Arm Big End Bush Collar (MST : 0401BBB0001ST) on the base block. Place the Lower arm big bush end over the fixture. Place the LCA big bush remover (MST: 0401BAA0038ST) and Front Lower Arm Bushs Support tool (MST: 0401BBB0002ST) on the big end bush. Place the Pin cage (MST:0401BAA0019ST) & the support cage (MST:0401BAA0013ST) as shown. Using a hydraulic press, remove the lower arm big end bush. Place the LCA small bush end on the base block (MST: 0401BAA0033ST) and LCA small bush collar support (MST : 0401BAA0036ST) . Place the Lower arm small bush end over the fixture. Place the LCA small bush remover (MST: 0401BAA0039ST) & Front Lower Arm Bushs Support tool (MST : 0401BBB0002ST) over the lower arm bush. Place the dummy bush (MST: 0401BAA0016ST) on the big end bush seating hole. Place the Pin cage (MST: 0401BAA0019ST) & support cage (MST: 0401BAA0013ST) as shown. Using a hydraulic press, remove the LCA small bush. Place the lower arm on the base block (MST: 0401BAA0033ST). Place the bigger end bush on the lower arm & place the bush installer (MST: 0401BAA0044ST)on the bush. Lower arm big end bush has Void profile and While Installation ensure to maintain Bush Void at appropriate angle as shown. Using a hydraulic press, Install the lower arm big end bush. Place the lower arm small end on the base block (MST: 0401BAA0033ST) Place the lower arm small end bush & the installer (MST: 0401BAA0045ST). Using a hydraulic press, Install the lower arm small end bush. Refit the Front Lower Control Arm. Support the rear axle using the appropriate hydraulic jack. Using a 17 mm socket spanners, loosen and remove the both rear shock absorbers bottom side mounting bolts and nuts. Torque value : 110\u00b111 Nm Torque Wrench Type - Open end Torque Wrench Torque tightening should be done without load and with the tyres on level ground. While loosening the nut, hold the bolt using 15 mm ring spanner Remove the rear coil spring and pad securely from vehicle. Install in reverse order of removal. Pay attention while Installation. Locking lug to be matched with hole on Rear Coil spring dome bracket of Chassis. Yellow coloured PU sleeve should be on chassis side while assembling the coil spring ashown in illustration. Inspect the coil spring for any damage, crack. Replace if found. Inspect the coil spring pad for any damage. Replace if found. Remove the Front strut assembly. Using a spring compressor compress the strut coil spring. Ensure that the spring compressor is tightened with the spring, else expansion of the spring cause severe injury Using a 6 mm open end spanner hold the shock absorber & using a 16 mm ring spanner remove the mounting nut. Remove the shock absorber washer & bush. Remove the bracket coil spring guide assembly. Remove the coil spring seat. Remove the compressed coil spring. Remove the shock absorber bush. Remove the bump stopper cap. Remove the shock absorber dust seal. Remove the front bump stopper. Remove the shock absorber. Inspect shock absorber for oil leak. Inspect the dust seal for damage, if found replace. Check the bush condition, if worn out please replace. Install the front bump stopper on the shock absorber. Install the shock absorber dust seal. Install the bump stopper cap. Install the shock absorber bush. Install the compressed spring. Install the coil spring seat. Install the coil spring bracket. Install the shock absorber washer & bush. Install the mounting nut. Install the top mounting nut. Torque tighten the nut to specified value. Torque : 40 \u2013 45 Nm <n>Torque Wrench Type - Open end Torque wrench ",
+ "file": null,
+ "display_order": 49
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "Remove the spring compressor tool. Remove front wheel. For additional information refer to Front wheel \u2013 R&R section. Using a cutting plier, remove the cotter pin from the ball joint. Never reuse the split pin, always replace with a new one. Using a 24 mm socket spanner, loosen and remove the upper control arm ball joint nut. Torque : 90 \u2013 110 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Detach the wheel speed sensor routing clips from the upper control arm. Using a 18 mm ring spanner, hold the mounting nut & using an 14 mm socket spanner loosen the bolt, remove the bolts & nuts. Torque : 97 \u00b1 10 Nm ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Detach and remove the upper control arm. Install in reverse order of removal. Pay attention while Installation. Bolt should be fitted in the direction of Arrow marks shown in illustration. Inspect the upper control arm for any external damage or bent, if found replace. Remove the Rear Shock Absorber. Place the rear shock absorber one end on the suitable base block. Place the suitable dolly on the rear shock absorber bush. Using a hydraulic press or hammer remove the rear shock absorber bush. Place the rear shock absorber one end on then base block and place the bush over the rear shock absorber. Place the bush & suitable dolly over the bush and Refit the bush by loading the hydraulic press. Refit the Rear Shock Absorber. Shock absorber is a tubular hydraulic device placed near each wheel to dampen the spring oscillations. One end of the shock absorber is attached to the frame and the other end on rear axle. The hydraulic shock absorber only dampens oscillations due to road irregularities. It does not support the weight of the vehicle. Shock absorber is Double Acting hydraulic telescopic Shock Absorber type. Support the rear axle using the appropriate hydraulic jack and lift the vehicle to compress the coil springs. Using a 17 mm socket spanners, loosen and remove the bottom mounting bolts and nuts of rear shock absorbers from the rear axle. Torque value : 110\u00b111 Nm Torque Wrench Type - Open end Torque Wrench Torque tightening should be done without load and with the tyres on level ground. While loosening the nut, hold the bolt using 15 mm ring spanner. Using a 14 mm socket spanner, loosen and remove the top mounting bolts of both rear shock absorbers from the chassis. Torque value : 65\u00b110Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Caution",
+ "content": "Torque tightening should be done without load and with the tyres on level ground. Remove the shock absorber from the vehicle. Install in reverse order of removal. Pay attention while Installation. Bolt should be fitted in the direction of Arrow shown in illustration. Ensure the arrow on Rear Shock absorber should be on rear side of vehicle. Inspect the shock absorber for any damage or oil leakage, replace if found any. Inspect the shock absorber bushes for any damage. Wheel alignment (adjustment of Camber, Caster and Toe) is part of standard automobile maintenance that consists of adjusting the angles of the wheels so that they are set to the specification. The purpose of these adjustments is to reduce tyre wear, and to ensure that vehicle travel is straight and true (without pulling to one side). Wheel alignment consists of adjusting the angles of the wheels so that they are perpendicular to the ground and parallel to each other. The purpose of these adjustments is maximum tyre life and a vehicle that tracks straight and true when driving along a straight and level road. The symptoms of a vehicle that is out of alignment are: Uneven or rapid tyre wear, Pulling or drifting away from a straight line, Wandering on a straight level road, Spokes of the steering wheel off to one side while driving on a straight and level road. Wheel Alignment Sequence ",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/U3A130002.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-1",
+ "content_type": "Caution",
+ "content": "If above sequence is not followed, it will lead to incorrect wheel alignment even though individual adjustments are done correctly. Run Out Compensation ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Park the vehicle on 4 post wheel alignment equipment to do the run-out compensation. Refer wheel alignment equipment manufacturer's guide lines while doing run-out compensation. Refer the procedure given below for SAP setting ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Keep the wheels on turntables of the wheel alignment machine. Rotate the steering wheel to LHS lock position. From LHS lock position, rotate steering wheel to RHS Lock position. Count the number of turns of steering wheel from LHS to RHS lock position. From RHS lock position, rotate steering wheel exactly half the number of turns towards LHS. Lock the steering wheel. If the steering straight ahead does not match the wheel straight ahead, then adjust the OBJ of the desired side. Ensure that the silent bushes in the front suspension are in satisfactory condition. Ensure that the front suspension fasteners are tightened to specified torque. Ensure that there is no play in steering linkages and suspension ball joints. Follow instruction manual of wheel aligning system manufacturer. Wheel Alignment - Check & Adjust ",
+ "file": null,
+ "display_order": 12
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Wheel alignment consists of adjusting the angles of the wheels so that they are parallel to each other and perpendicular to the ground, thus maximizing tyre life and ensures straight and true tracking along a straight and level road. Specification for Wheel Alignment <n>Front Suspension ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21715.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Heading",
+ "content": "Front Suspension Steering Angle Parameters ",
+ "file": null,
+ "display_order": 16
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21716.jpg",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Caution",
+ "content": "Wheel alignment procedure to be done in vehicle unladen condition only. Do wheel alignment only according to manufacturer's specifications. Front tyre should have uniform wear and inflated to recommended pressure. Ensure that hub play is correct. Ensure that the front suspension fasteners are tightened to specified torque. Ensure that there is no play in steering linkages and suspension ball joints. Camber is defined as the inward or outward tilt of the top of the wheel as viewed from the front. While adjusting camber angle vehicle should be unladen and nobody should sit inside. The camber values should be within: 0\u2070 \u00b1 0.2\u2070 The difference between two wheels should be within: 0\u2070\u00b1 0.4\u2070. Using a 24 mm socket spanner, loosen the camber bolt locking nut. While loosening hold the bolt with the help of a 24 mm ring spanner. To adjust camber angle, rotate the camber bolt using 24 mm ring/socket , to clockwise or anti clockwise direction. Clockwise rotation will reduce the camber angle and anti-clockwise rotation will increase the camber angle. After adjusting camber angle tighten the camber bolt locking nut and recheck the camber angle. The angle between the vertical line and king pin, which fixes the steering knuckle and front axle, (steering column which connects the top and bottom ball joints in the independent axle type) when viewed the tyres from the side is called caster angle. While adjusting caster angle vehicle should be unladen. The values should be within: 4.2\u00b0 \u00b10.4\u00b0. The difference between two wheels should be within: 0\u00b0 \u00b1 0.4\u00b0. Adjust caster bolt until red zone becomes green. (Only if wheel alignment is out of specs). Using a 24 mm socket spanner, loosen the caster bolt locking nut. While loosening the nut, hold the bolt using 24 mm ring spanner. To adjust castor angle, rotate the caster bolt to clockwise or anti clockwise direction using 24 mm socket spanner. Clockwise rotation will decrease the caster angle and anti-clockwise rotation will increase the caster angle. Toe is the difference of measured distances between the front ends of the tyres (A) and the rear ends of the tyres (B) along the same axle when viewed the wheels from the top. Front Toe In to be adjusted individually on LH and RH side tie rod ends. Front Total toe between two wheels should be within: 0.23\u2070 \u00b1 0.1\u2070. The difference between two wheels should be within: 0\u00b0 \u00b1 0.4\u00b0. Using a 19 mm open end spanner, hold tie rod end first and then loosen tie rod end lock nut with the help of 19 mm open end spanner. Using a 14 mm open end spanner, Toe-in is adjusted by varying the length of tie rods. While adjusting toe-in, adjust the length of both the tie rods by rotating them in the same direction such that their lengths remain equal at all times. Perform steering angle sensor (SAS) calibration if steering wheel is removed and adjusted during straight ahead position setting and procedure as below. After adjusting the length of tie rods, recheck toe in and then hold tie rod end with 19 mm open end spanner and then tightening locknut with 19 mm open end spanner. Ensure the Steering Wheel is at center and the front wheels are straight. Connect the i-SMART diagnostic tester and turn the ignition ON . Launch i-SMART Select ABS ECU and Navigate to Write Data . Select the WRITE DATA tab. Click on \u201cROUTINE SELECTION\u201d drop down list and select \u201cSteering Angle Sensor Calibration\u201d . Click on \u201cSTART ROUTINE\u201d to initiate the SAS Calibration. Ensure the Steering Wheel is at center and the front wheels are straight. The following pop up window appears once the SAS Calibration completed. Press \u201cOK\u201d button to complete SAS Calibration through i-SMART. Refer wheel alignment equipment manufacturer's guide lines for wheel turning angle check. Ride height is to be measured from wheel arch center (Bottom Surface) to ground for both front and rear in unladen condition. Front ride height : Front wheel arch center (Bottom Surface) to ground.Rear ride height : Rear wheel arch center (Bottom Surface) to ground.Ride Heights of different variants ",
+ "file": null,
+ "display_order": 60
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/21732.jpg",
+ "display_order": 61
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "R16 SF 6S - Rim Size 16, Side Facing 6 Seater.R16 FF 4S - Rim Size 16, Front Facing 4 Seater.R18 FF 4S - Rim Size 18, Front Facing 4 SeaterEnsure below before Checking Ride height Correct Wheel alignment values. Recommended Tyre pressure. Fuel tank filled 90%. Spare Wheel mounted If ride height is not within limits, then check (Measure ride heights only when the vehicle is on plain ground.) Correct tyre pressure. Coil spring damage. Loosened suspension mounting bolts. Rubber bushes of UCA and LCA. Prior to inspect the ball joint, inspect the wheel bearings for any play. Check 1 (On Vehicle)
Position the vehicle on a 2 post lift and Raise the vehicle. Inspect the ball joint for relative movement by, grasp the top and bottom of the wheel and rock it in and out along the wheel\u2019s vertical axis.Observe any relative movement between the wheel knuckle and ball joints. Ensure wheel nuts/bolts are not in loosen condition while checking, as that may cause movement when rocking the wheel. If relative movement play is little or no play then the ball joint is in good condition. If relative movement play that seems excessive or noises, then Visual check the ball joints. Any noises or play heard towards the top are most likely indicative of a problem with the upper ball joint, while, any play or noise coming from the bottom of the wheel are probably indicative of a problem with the lower ball joint. Check 2 (On Vehicle) ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Take a pry bar and place it between the lower control arm and the steering knuckle, the two parts that are connected together by the ball joint and attempt to pry them apart. Loose ball joints will have an excessive amount of play and movement when you pry on them, may even make knocking or clicking sounds. Check 3 (On Vehicle) \u2013 Visual Inspection ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A170172.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-8",
+ "content_type": "Description",
+ "content": "Inspect the ball joints for any signs of rust, damage to the dust boot, grease leakage, or other potential problems that may indicate a need for replacement. Check the looseness of ball joints in Control arms. Check 4 (Off Vehicle) ",
+ "file": null,
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Description",
+ "content": "Remove the Ball joints from Vehicle. Refer Respective Ball Joints R&R Section. Check the ball joint for free rotational torque by rotate the ball pin through the periphery of ball joint cup for checking the movement. Replace the ball joint only if movement is found jerky during rotation. Check the Axial lift by holding the ball Joint and lifting the ball pin in upward direction. If the play was observed more than 0.5 mm replace the ball joint. Lift the ball pin by one hand & hold the lower end of ball joint grounded by other hand. Rear Lower Link is used to provide articulation for rear suspension in vertical direction. It also supports the lower end of the axle. Using a 24 mm socket spanner loosen and remove the rear lower link front and rear mounting nuts and bolts. Torque value: 230 \u00b1 20 Nm Torque Wrench Type - Open end Torque Wrench for LH chassis side While loosening the nut, hold the bolt using 21 mm ring spanner. Torque tightening should be done without load and with the tyres on level ground. Detach the rear wheel speed sensor routing from the lower link. Remove the rear lower link from the vehicle. Install in reverse order of removal. Pay attention while Installation. Bolt should be fitted in the direction of Arrow shown in illustration. Inspect the rear lower link for any damage. Replace if found. Inspect the rear lower link bushes for any damage. If found replace. Using 10 mm socket spanner, unscrew glass channel mounting nuts and detach the run channel beading from the channel and take out the channel from door. Torque :5\u00b11 Nm ",
+ "file": "",
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect the door latch electrical connector. Detach the mounting link from latch to exterior door handle. Detach link from the handle lever. Using a 5 mm Allen key, Unscrew the latch to door mounting Allen screws. Torque : 7 Nm ",
+ "file": "",
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-7",
+ "content_type": "Description",
+ "content": "Remove the front door latch assembly separately. Install in the reverse order of removal. Inspect the latch assembly for any damage, replace if found. Inspect the linkages for any damage or bend. Open the bonnet and lock it using bonnet stay rod. . Using a star screw driver, loosen and remove both side front splash shield mounting screw rivets. Remove both front splash shields from vehicle . Using a 10 mm socket spanner, loosen and remove the front stone guard front mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250064.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Using a 13 mm socket spanner, loosen and remove the rear stone guard rear mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 17
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250033.jpg",
+ "display_order": 18
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the stone guard mounting screw rivets. Remove the stone guard from the vehicle. Disconnect the fog lamp electrical connectors LH & RH sides. Pull and remove the front bumper top panel trim clips and remove the panel. Using a 10 mm socket spanner, Unscrew front bumper mounting nuts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 30
+ },
+ {
+ "step_name": "Step-10",
+ "content_type": "Torque Value",
+ "content": "Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 31
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/hood5.PNG",
+ "display_order": 32
+ },
+ {
+ "step_name": "Step-11",
+ "content_type": "Description",
+ "content": "using a 13 mm socket spanner, Unscrew front bumper bottom mounting bolts. Torque : 4.0\u00b10.5Nm ",
+ "file": null,
+ "display_order": 34
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/hood2.PNG",
+ "display_order": 35
+ },
+ {
+ "step_name": "Step-12",
+ "content_type": "Description",
+ "content": "Using a 10 mm socket spanner, Unscrew front bumper top side mounting bolts. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 37
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/hood3.PNG",
+ "display_order": 38
+ },
+ {
+ "step_name": "Step-13",
+ "content_type": "Description",
+ "content": "Using a star screw driver, Unscrew front bumper top centre mounting screw rivets. Remove the front bumper assembly from the vehicle. Using a 13 mm socket spanner, Unscrew front bumper center bracket mounting bolts and remove the front bumper center mounting bracket. Torque : 10.0\u00b11 Nm ",
+ "file": null,
+ "display_order": 44
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250060.jpg",
+ "display_order": 45
+ },
+ {
+ "step_name": "Step-16",
+ "content_type": "Description",
+ "content": "Using a star screw driver, loosen and remove the front grill mounting screw rivets. Using a star screw driver, loosen and remove the bottom side front grill mounting screw rivets. Using a 10 mm socket spanner, loosen and remove the front grill mounting bolts. Torque : 4.0\u00b10.5 Nm ",
+ "file": null,
+ "display_order": 51
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A250062.jpg",
+ "display_order": 52
+ },
+ {
+ "step_name": "Step-19",
+ "content_type": "Description",
+ "content": "Remove the front grill assembly from the vehicle. Using a 10 mm socket spanner, Unscrew hood catcher mounting nuts both the sides. Torque : 7 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 57
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380104.jpg",
+ "display_order": 58
+ },
+ {
+ "step_name": "Step-21",
+ "content_type": "Description",
+ "content": "Remove the hood catchers from the vehicle. Install in the reverse order of removal. Inspect the hood catcher for any damages. Replace if found any For additional information refer to Front Door Window Glass R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380033.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Disconnect the front door window glass motor electrical connector. Using a 10 mm socket spanner, loosen and remove the front door window glass mechanism to door mounting nuts. Torque : 10.50 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 9
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380035.jpg",
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380036.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the front door window glass mechanism separately. Install in the reverse order of removal. Inspect the glass for any damage. Replace if found. Inspect the regulator for any damages, Replace if found any For additional information refer to Tail Door Trim R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380063.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380064.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a star screw drive, unscrew tail door handle top mounting screw and remove the cover. Carefully pull and detach the outer door handle from tail door. Using a star screw driver, unscrew handle inside support mounting screw from the tail gate. Torque : 1.3 \u00b1 0.2 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-5",
+ "content_type": "Description",
+ "content": "Refit in the reverse order of removal. Inspect the rear door exterior handle for any damages. Replace if found any. Pull out the bonnet latch cable and open the bonnet. Lock it using bonnet stay rod. Disconnect cable guide and link from latch. Detach cable from routing clips. Press the lock and pull lever to detach bonnet cable lever with cable and take out the cable from the vehicle. Install in the reverse order of removal. Inspect the latch assembly for any damage, replace if found. For additional information refer to Tail Door Trim \u2013 R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "For Softtop Variants,
Remove the Tail Door Inner Handle. For additional information refer to Tail Door Inner Handle - R&R Section.
",
+ "file": null,
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380052.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Disconnect tail door latch electrical connector. Disconnect latch lever from the key lock and handle. Using a 5mm allen key, unscrew the tail door latch mounting screw. Torque : 7 Nm ",
+ "file": null,
+ "display_order": 13
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380055.jpg",
+ "display_order": 14
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380056.jpg",
+ "display_order": 15
+ },
+ {
+ "step_name": "Step-6",
+ "content_type": "Description",
+ "content": "Carefully detach tail door latch. Install in the reverse order of removal. Inspect the latch assembly for any damage, replace if found. For additional information refer to Front Door Window Glass regulator LH R&R section. ",
+ "file": null,
+ "display_order": 4
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380110.jpg",
+ "display_order": 5
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380081.jpg",
+ "display_order": 6
+ },
+ {
+ "step_name": "Step-2",
+ "content_type": "Description",
+ "content": "Using a T20 torx socket spanner, unscrew the regulator motor mounting screws. Torque : 2.5 to 3 Nm ",
+ "file": null,
+ "display_order": 8
+ },
+ {
+ "step_name": "Step-3",
+ "content_type": "Description",
+ "content": "Install in the reverse order of removal. Inspect the glass for any damage. Replace if found. Inspect the regulator for any damages, Replace if found any. Remove the Intercooler Assembly. Disconnect cable guide and link from latch. Using a 10 mm socket spanner, unscrew bonnet latch mounting nuts. Torque : 10.5 \u00b1 1.5 Nm ",
+ "file": null,
+ "display_order": 10
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "File",
+ "content": null,
+ "file": "/files/W4A380073.jpg",
+ "display_order": 11
+ },
+ {
+ "step_name": "Step-4",
+ "content_type": "Description",
+ "content": "Remove the bonnet latch from hood. Install in the reverse order of removal. While Installation, hand tighten the latch mounting nuts first and align the latch in appropriate position And ensure smooth locking of latch in holding bracket , finally torque tighten the mounting nuts. Inspect the bonnet latch for any damage, replace if found. ' + result[r] + ' '
+ FLAG = 1
+ else:
+ sts += result[r]
+ FLAG = 0
+ frappe.db.sql(
+ f'''update tabProcedure_Details set content = "{sts}" where name = '{v['name']}'; ''')
+ v['new_content'] = sts
+ except Exception as e:
+ error_list.append({v['name']: e})
+ updated_list.append(v)
+
+ content_file = base_path + "/files/json_files/content_update.json"
+ error_file = base_path + "/files/json_files/content_error.json"
+
+ with open(error_file, 'w') as outfile:
+ try:
+ outfile.write(json.dumps(error_list))
+ except:
+ pass
+ with open(content_file, 'w') as outfile:
+ try:
+ outfile.write(json.dumps(updated_list))
+ except:
+ pass
+ return content_file
+
+
+def change_file_type():
+ folder_path = base_url
+ count = 0
+ for root, dirs, files in os.walk(folder_path):
+ for file in files:
+ if file.split('.')[-1] == 'PNG':
+ count += 1
+ f1 = os.path.join(root, file)
+ f2 = f1[:-3] + 'png'
+ os.rename(f1, f2)
+
+ if file.split('.')[-1] == 'JPG':
+ count += 1
+ f1 = os.path.join(root, file)
+ f2 = f1[:-3] + 'jpg'
+ os.rename(f1, f2)
+
+ return count
+
+
+def change_procedure_ext():
+ try:
+ frappe.db.sql('''
+ update tabProcedure_Details set file = concat(substring(file,1,length(file)-3),lower(substring(file,length(file)-2)))
+ where substring(file,length(file)-2) REGEXP BINARY '[A-Z]';
+ ''')
+ frappe.db.commit()
+ return True
+ except:
+ return False
+
+
+def change_file_ext():
+ try:
+ """ File URL Change """
+ frappe.db.sql('''
+ update tabFile set file_url = concat(substring(file_url,1,length(file_url)-3),lower(substring(file_url,length(file_url)-2)))
+ where substring(file_url,length(file_url)-2) REGEXP BINARY '[A-Z]';
+ ''')
+ frappe.db.commit()
+
+ """ File Name """
+ frappe.db.sql('''
+ update tabFile set file_name = concat(substring(file_name,1,length(file_name)-3),lower(substring(file_name,length(file_name)-2)))
+ where substring(file_name,length(file_name)-2) REGEXP BINARY '[A-Z]';
+ ''')
+ frappe.db.commit()
+ except:
+ return False
+ return True
+
+
+def delete_file_ext():
+ try:
+ frappe.db.sql('''
+ Delete from tabFile where substring(file_url,length(file_url)-2) REGEXP BINARY '[A-Z]';
+ ''')
+ frappe.db.commit()
+ except:
+ return False
+ return True
+
+@frappe.whitelist()
+def append_size_file():
+ try:
+ data = frappe.db.sql(
+ """ SELECT * FROM `tabFile` where file_size = 0 and is_folder!=1; """, as_dict=1)
+ for d in data:
+ try:
+ file_path = base_url1 + d.get("file_url")
+ isExist=os.path.exists(file_path)
+ if isExist:
+ file_size = os.path.getsize(file_path)
+ frappe.db.sql(
+ f'''UPDATE `tabFile` SET file_size = '{file_size}' WHERE name = '{d['name']}'; ''', as_dict=1)
+ frappe.db.commit()
+ else:
+ pass
+
+ except Exception as e:
+ return str(e)
+ return data
+ except Exception as e:
+ frappe.log_error("FIle size ", str(e))
+ return e
+
+
+def asset_to_files_path():
+ try:
+ count = frappe.db.sql('''
+ select count(*) from tabProcedure_Details where content_type = 'File' and file like '%Asset/%';''')
+ frappe.db.sql('''
+ update tabProcedure_Details set file =concat('/files/',SUBSTRING_INDEX(file,'/',-1)) where content_type = 'File' and file like '%Asset/%';
+ ''')
+ frappe.db.commit()
+ return count
+ except:
+ return False
+
+
+def change_file_dir():
+ base_path = os.path.expanduser(
+ "~") + "/frappe-bench/sites/" + site_name + "/public"
+ file_data = frappe.db.sql('''
+ select name,file from tabProcedure_Details where content_type = 'File' ;''', as_dict=1)
+ changed_file_list = []
+ for d in file_data:
+ path = d['file']
+ isExist = os.path.exists(base_path + path)
+ if not isExist:
+ ext = path[-3:]
+ path = path[:-3]
+
+ extension = ''
+ if ext == 'png':
+ extension = 'jpg'
+
+ if ext == 'jpg':
+ extension = 'png'
+
+ new_full_path = path + extension
+
+ new_file_dir = base_path + new_full_path
+ if os.path.exists(new_file_dir):
+ changed_file_list.append(str(new_full_path))
+ frappe.db.sql(f'''
+ update tabProcedure_Details set file = '{new_full_path}' where content_type = 'File' and name = '{d['name']}';
+ ''')
+ frappe.db.commit()
+
+ frappe.log_error("ALL updated files", str(changed_file_list))
+ if file_data:
+ return file_data
+ else:
+ return "Done"
+
+@frappe.whitelist(allow_guest=1)
+def file_not_exists():
+ # file_data = frappe.db.sql(
+ # '''select parent,step_name,file,name from tabProcedure_Details where content_type = 'File' order by parent;''', as_dict=1)
+ """ Cover Images """
+ file_data = frappe.db.sql(
+ '''selectparent,systems,sub_systems,cover_image from `tabSystem Mapping_Sub System` where order by parent;''', as_dict=1)
+
+ changed_file_list = []
+ count = 1
+ for d in file_data:
+
+ path = d['file']
+ is_exist = os.path.exists(base_path + path)
+
+ if not is_exist:
+ print(d)
+ d['id'] = count
+ changed_file_list.append(d)
+ count += 1
+
+ file_path_not_exists = base_path + "/files/json_files/cover_missing.json"
+ with open(file_path_not_exists, 'w') as outfile:
+ try:
+ outfile.write(json.dumps(changed_file_list))
+ except Exception as e:
+ pass
+
+
+@frappe.whitelist(allow_guest=1)
+def get_mp4_cover():
+ file_data = frappe.db.sql(
+ '''select parent,systems,sub_systems,cover_image from `tabSystem Mapping_Sub System` where cover_image like '.mp4' order by parent;''', as_dict=1)
+
+ file_path_not_exists = base_path + "/files/json_files/cover_mp4.json"
+ with open(file_path_not_exists, 'w') as outfile:
+ try:
+ outfile.write(json.dumps(file_data))
+ except Exception as e:
+ pass
+
+
+def remove_extra_spaces_in_file_path():
+ import re
+ file_path_not_exists = base_path + "/files/json_files/1.json"
+ with open(file_path_not_exists, 'r') as outfile:
+ data = json.load(outfile)
+
+ for d in data:
+ print(d['file'])
+ res_str = re.sub("/files/ ", "/files/", d['file'])
+ # res_str = re.sub("/files/ ", "/files/", res_str)
+ print(res_str)
+
+ frappe.db.sql(f'''
+ update tabProcedure_Details set file = '{res_str}' where name = '{d['name']}';
+ ''')
+ frappe.db.commit()
+
+
+def return_star_data():
+ data = frappe.db.sql('''
+ select content_type,content,name,parent,replace(content,'*','abcxyz ') as new_content from tabProcedure_Details where content like "%*%";
+ ''', as_dict=1)
+ return data
+
+
+def change_star_data():
+ count = frappe.db.sql('''
+ select count(*) from tabProcedure_Details where content like '%**%';
+ ''', as_dict=1)
+ print(count)
+ updated_list = []
+ error_list = []
+ data = frappe.db.sql('''
+ select step_name,content_type,content,name,parent,replace(content,'**','abcxyz ') as new_content from tabProcedure_Details where content like '%**%';
+ ''', as_dict=1)
+ for v in data:
+ try:
+ result = re.split(r"abcxyz ", v['new_content'], flags=0)
+ FLAG = 0
+ sts = ''
+ if len(result) > 1:
+ sts += result[0]
+ for r in range(1, len(result)):
+ if FLAG == 0:
+ sts += '' + result[r] + ' '
+ FLAG = 1
+ else:
+ sts += result[r]
+ FLAG = 0
+ frappe.db.sql(
+ f'''update tabProcedure_Details set content = "{sts}" where name = '{v['name']}'; ''')
+ v['new_content'] = sts
+ except Exception as e:
+ error_list.append({v['name']: e})
+ updated_list.append(v)
+
+ content_file = base_path + "/files/json_files/content_update.json"
+ error_file = base_path + "/files/json_files/content_error.json"
+
+ with open(error_file, 'w') as outfile:
+ try:
+ outfile.write(json.dumps(error_list))
+ except:
+ pass
+ with open(content_file, 'w') as outfile:
+ try:
+ outfile.write(json.dumps(updated_list))
+ except:
+ pass
+ return content_file
+
+
+def change_single_star_data():
+ count = frappe.db.sql('''
+ select count(*) from tabProcedure_Details where content like "%* %";''', as_dict=1)
+ print(count)
+ updated_list = []
+ error_list = []
+ data = frappe.db.sql('''
+ select name,parent,step_name,content_type,content,replace(content,'* ','abcxyz ') as new_content from tabProcedure_Details where content like "%* %";
+ ''', as_dict=1)
+ for v in data:
+ try:
+ result = re.split(r"abcxyz ", v['new_content'], flags=0)
+ sts = ''
+ if len(result) > 1:
+ for a in range(1, len(result)):
+ sts += '' + result[a] + ' '
+ sts += ' '
+ frappe.db.sql(
+ f'''update tabProcedure_Details set content = "{sts}" where name = '{v['name']}'; ''')
+ frappe.db.commit()
+ v['new_content'] = sts
+ updated_list.append(v)
+
+ except Exception as e:
+ error_list.append({v['name']: e})
+
+ content_file = base_path + "/files/json_files/content_single_star_update.json"
+ error_file = base_path + "/files/json_files/content_error_single_star.json"
+
+ with open(error_file, 'w') as outfile:
+ try:
+ outfile.write(json.dumps(error_list))
+ except:
+ pass
+ with open(content_file, 'w') as outfile:
+ try:
+ outfile.write(json.dumps(updated_list))
+ except:
+ pass
+ return content_file
+
+
+def get_single_star_data():
+ count = frappe.db.sql('''
+ select count(*) from tabProcedure_Details where content like "%*%";''', as_dict=1)
+
+@frappe.whitelist(allow_guest=1)
+def procedure_do(variant,language,system):
+ data = frappe.db.sql(f'''SELECT min(tmss.idx) as systemdisplayorder,ts.system_name,ts.icon_file,ts.myid,ts.active_status,concat(variant,'-',ts.system_name) FROM
+ `tabSystem Mapping_Sub System` as tmss inner join `tabSystems` as ts on tmss.systems = ts.system_name
+ where tmss.parent LIKE "{variant}" and substring(tmss.parent,-5,2) = "{language}" and tmss.systems ="{system}";''',as_dict=1)
+ return data
+
+@frappe.whitelist()
+def set_procedure_false():
+ try:
+ frappe.db.sql('''update `tabSystem Mapping_Sub System` set procedure_is_published=0;
+ ''')
+ frappe.db.commit()
+ return True
+ except Exception as e:
+ return False
+
+
+# @frappe.whitelist(allow_guest=1)
+# def clear_procedures():
+# try:
+# set_procedure_false()
+# frappe.db.sql('''delete FROM `tabPublish`;''')
+# frappe.db.sql('''delete FROM `tabPublish_Docs`;''')
+# frappe.db.sql('''update `tabVariant Mapping_Assets` set published=0;''')
+# frappe.db.sql('''update `tabSystem Mapping_Sub System` set procedure_is_published=0;''')
+# frappe.db.sql('''update `tabSystem Mapping_System Assets` set published=0;''')
+# frappe.db.commit()
+# except Exception as e:
+# return e
+
+@frappe.whitelist(allow_guest=1)
+def circular_api():
+ api = frappe.db.sql(
+ '''SELECT creation,name,title,status,description,circular_image as FileUrl,valid_till from `tabCircular` WHERE valid_till >='{}' '''.format(
+ frappe.utils.today()), as_dict=True)
+ for i in api:
+ if i["status"] == "Active":
+ i["status"] = True
+ else:
+ i["status"] = False
+ return api
+
+@frappe.whitelist(allow_guest=1)
+def get_kms_mapping(sub_system,variant,language):
+ try:
+ varKMS = variant + "-" + language + "%"
+ data = frappe.db.sql(f'''SELECT kilometer as kilometer_name, idx as kilometer_IDX, applicable as kilometers_applicable
+ FROM `tabKilometer Mapping_Items` where sub_systems="{sub_system}" and parent LIKE "{varKMS}" order by kilometer_IDX;''',as_dict=1)
+ return data
+ except Exception as e:
+ return e
+
+@frappe.whitelist(allow_guest=1)
+def remove_html_tags():
+ try:
+ frappe.db.sql('''update tabProcedure_Details set content= replace(content,'>','>'); ''')
+ frappe.db.sql('''update tabProcedure_Details set content= replace(content,'<','<'); ''')
+ frappe.db.sql('''update tabProcedure_Details set content= replace(content,'',''); ''')
+ frappe.db.sql('''update tabProcedure_Details set content= replace(content,'
English Label : Only 50 characters allowed")
validated = false;
}
@@ -36,10 +36,10 @@ frappe.ui.form.on('App Labels', {
frappe.throw(__("Just a . is not prescribed!"));
frappe.validated = false;
}
- var regex = /[!@#$%^&*()_+\=\[\]{};`~':"\\|.<>\/?]+/;
+ var regex = /[!@#$%^&*()+\=\[\]{};`~':"\\|.<>\/]+/;
if (frm.doc.english_label) {
if (regex.test(frm.doc.english_label) === true) {
- frappe.throw(__("English Label : Only letters, numbers and -, are allowed."));
+ frappe.throw(__("English Label : Only letters, numbers and - , are allowed."));
frappe.validated = false;
} else if (frm.doc.english_label) {
if (frm.doc.english_label.includes("'")) {
@@ -50,7 +50,7 @@ frappe.ui.form.on('App Labels', {
}
if (frm.doc.page_name) {
- if (frm.doc.page_name.length > 50) {
+ if (frm.doc.page_name.length > 100) {
frappe.msgprint("Page Name : Only 50 characters allowed")
validated = false;
}
@@ -63,7 +63,7 @@ frappe.ui.form.on('App Labels', {
frappe.throw(__("Just a . is not prescribed!"));
frappe.validated = false;
}
- var regex = /[!@#$%^&*()_+\=\[\]{};`~':"\\|.<>\/?]+/;
+ var regex = /[!@#$%^&*()+\=\[\]{};`~':"\\|.<>\/?]+/;
if (frm.doc.page_name) {
if (regex.test(frm.doc.page_name) === true) {
frappe.throw(__("Page Name : Only letters, numbers and -, are allowed."));
@@ -77,7 +77,7 @@ frappe.ui.form.on('App Labels', {
}
if (frm.doc.label) {
- if (frm.doc.label.length > 50) {
+ if (frm.doc.label.length > 100) {
frappe.msgprint("Translated Label : Only 50 characters allowed")
validated = false;
}
@@ -90,7 +90,7 @@ frappe.ui.form.on('App Labels', {
frappe.throw(__("Just a . is not prescribed!"));
frappe.validated = false;
}
- var regex = /[!@#$%^&*()_+\=\[\]{};`~':"\\|.<>\/?]+/;
+ var regex = /[!@#$%^&*()+\=\[\]{};`~':"\\|.<>\/]+/;
if (frm.doc.label) {
if (regex.test(frm.doc.label) === true) {
frappe.throw(__("Translated Label : Only letters, numbers and -, are allowed."));
diff --git a/smart_service/masters/doctype/custom_languages/custom_languages.json b/smart_service/masters/doctype/custom_languages/custom_languages.json
index 89a7cd3..42e1fd5 100644
--- a/smart_service/masters/doctype/custom_languages/custom_languages.json
+++ b/smart_service/masters/doctype/custom_languages/custom_languages.json
@@ -6,6 +6,10 @@
"editable_grid": 1,
"engine": "InnoDB",
"field_order": [
+ "internal_publish",
+ "column_break_10",
+ "global_publish",
+ "section_break_3",
"lang_code",
"active_status",
"column_break_2",
@@ -60,11 +64,33 @@
"label": "myID",
"read_only": 1,
"set_only_once": 1
+ },
+ {
+ "default": "0",
+ "fieldname": "internal_publish",
+ "fieldtype": "Check",
+ "label": "Internal Publish",
+ "read_only": 1
+ },
+ {
+ "default": "0",
+ "fieldname": "global_publish",
+ "fieldtype": "Check",
+ "label": "Global Publish",
+ "read_only": 1
+ },
+ {
+ "fieldname": "section_break_3",
+ "fieldtype": "Section Break"
+ },
+ {
+ "fieldname": "column_break_10",
+ "fieldtype": "Column Break"
}
],
"index_web_pages_for_search": 1,
"links": [],
- "modified": "2022-02-11 12:41:29.369497",
+ "modified": "2023-07-11 15:55:25.503377",
"modified_by": "Administrator",
"module": "Masters",
"name": "Custom Languages",
diff --git a/smart_service/masters/doctype/drive/drive.js b/smart_service/masters/doctype/drive/drive.js
index 07feb07..0da8456 100644
--- a/smart_service/masters/doctype/drive/drive.js
+++ b/smart_service/masters/doctype/drive/drive.js
@@ -20,7 +20,7 @@ frappe.ui.form.on('Drive', {
}
var regex = /[!@#$%^&*()_+\=\[\]{};'`~:"\\|.<>\/?]+/;
if (regex.test(frm.doc.drive) === true) {
- frappe.msgprint(__("Variant: Only letters, numbers and -, are allowed."));
+ frappe.msgprint(__("Variant: Only letters, numbers and - , are allowed."));
frappe.validated = false;
} else if (frm.doc.drive) {
if (frm.doc.drive.includes("'")) {
diff --git a/smart_service/masters/doctype/fuel/fuel.js b/smart_service/masters/doctype/fuel/fuel.js
index 382f492..6eddad9 100644
--- a/smart_service/masters/doctype/fuel/fuel.js
+++ b/smart_service/masters/doctype/fuel/fuel.js
@@ -21,7 +21,7 @@ frappe.ui.form.on('Fuel', {
var regex = /[!@#$%^&*()_+\=\[\]{};`~':"\\|.<>\/?]+/;
if (frm.doc.fuel) {
if (regex.test(frm.doc.fuel) === true) {
- frappe.msgprint(__("Fuel: Only letters, numbers and -, are allowed."));
+ frappe.msgprint(__("Fuel: Only letters, numbers and - , are allowed."));
frappe.validated = false;
} else if (frm.doc.fuel) {
if (frm.doc.fuel.includes("'")) {
diff --git a/smart_service/masters/doctype/procedure_name/procedure_name.js b/smart_service/masters/doctype/procedure_name/procedure_name.js
index a679ead..0ed3c54 100644
--- a/smart_service/masters/doctype/procedure_name/procedure_name.js
+++ b/smart_service/masters/doctype/procedure_name/procedure_name.js
@@ -20,7 +20,7 @@ frappe.ui.form.on('Procedure Name', {
var regex = /[!@#$%^&*()_+\=\[\]{};`~':"\\|.<>\/?]+/;
if (frm.doc.procedure_name) {
if (regex.test(frm.doc.procedure_name) === true) {
- frappe.msgprint(__("Procedure Name: Only letters, numbers and -, are allowed."));
+ frappe.msgprint(__("Procedure Name: Only letters, numbers and - , are allowed."));
frappe.validated = false;
} else if (frm.doc.procedure_name) {
if (frm.doc.procedure_name.includes("'")) {
diff --git a/smart_service/masters/doctype/service_kilometers/service_kilometers.js b/smart_service/masters/doctype/service_kilometers/service_kilometers.js
index d17712d..e627c9f 100644
--- a/smart_service/masters/doctype/service_kilometers/service_kilometers.js
+++ b/smart_service/masters/doctype/service_kilometers/service_kilometers.js
@@ -31,7 +31,7 @@ frappe.ui.form.on('Service Kilometers', {
var regex = /[!@#$%^&*()_+\=\[\]{};~`':"\\|.<>\/?]+/;
if (frm.doc.kilometer) {
if (regex.test(frm.doc.kilometer) === true) {
- frappe.throw(__("Service Kilometer: Only letters, numbers and , are allowed."));
+ frappe.throw(__("Service Kilometer: Only letters, numbers and - , are allowed."));
frappe.validated = false;
} else if ((frm.doc.kilometer.includes("'"))) {
frappe.throw(__("Service Kilometer: Only letters, numbers and , are allowed."));
diff --git a/smart_service/masters/doctype/sub_systems/sub_systems.js b/smart_service/masters/doctype/sub_systems/sub_systems.js
index 4ee5a95..e55625c 100644
--- a/smart_service/masters/doctype/sub_systems/sub_systems.js
+++ b/smart_service/masters/doctype/sub_systems/sub_systems.js
@@ -17,7 +17,7 @@ frappe.ui.form.on('Sub Systems', {
var regex = /[!@#$%^&*()_+\=\[\]{};`~:"\\|.<>\/?]+/;
if (frm.doc.sub_system_name) {
if (regex.test(frm.doc.sub_system_name) === true) {
- frappe.msgprint(__("Sub System Name: Only letters, numbers and -,' are allowed."));
+ frappe.msgprint(__("Sub System Name: Only letters, numbers and - , ' are allowed."));
frappe.validated = false;
}
}
diff --git a/smart_service/masters/doctype/systems/systems.js b/smart_service/masters/doctype/systems/systems.js
index 12731da..18d0a2f 100644
--- a/smart_service/masters/doctype/systems/systems.js
+++ b/smart_service/masters/doctype/systems/systems.js
@@ -47,7 +47,7 @@ frappe.ui.form.on('Systems', {
var regex = /[!@#$%^&*()_+\=\[\]{};`~:"\\|.<>\/?]+/;
if (frm.doc.system_name) {
if (regex.test(frm.doc.system_name) === true) {
- frappe.msgprint(__("system Name: Only letters, numbers and -,' are allowed."));
+ frappe.msgprint(__("system Name: Only letters, numbers and - ,' are allowed."));
frappe.validated = false;
}
}
diff --git a/smart_service/masters/doctype/transmission/transmission.js b/smart_service/masters/doctype/transmission/transmission.js
index e8cd205..2b92f8f 100644
--- a/smart_service/masters/doctype/transmission/transmission.js
+++ b/smart_service/masters/doctype/transmission/transmission.js
@@ -21,7 +21,7 @@ frappe.ui.form.on('Transmission', {
var regex = /[!@#$%^&*()_+\=\[\]{};`~':"\\|.<>\/?]+/;
if (frm.doc.transmission) {
if (regex.test(frm.doc.transmission) === true) {
- frappe.msgprint(__("Transmission: Only letters, numbers and -, are allowed."));
+ frappe.msgprint(__("Transmission: Only letters, numbers and - , are allowed."));
frappe.validated = false;
} else if (frm.doc.transmission) {
if (frm.doc.transmission.includes("'")) {
diff --git a/smart_service/masters/doctype/variant/__pycache__/__init__.cpython-38.pyc b/smart_service/masters/doctype/variant/__pycache__/__init__.cpython-38.pyc
index 81f4b64..4dcda72 100644
Binary files a/smart_service/masters/doctype/variant/__pycache__/__init__.cpython-38.pyc and b/smart_service/masters/doctype/variant/__pycache__/__init__.cpython-38.pyc differ
diff --git a/smart_service/masters/doctype/variant/__pycache__/variant.cpython-38.pyc b/smart_service/masters/doctype/variant/__pycache__/variant.cpython-38.pyc
index 3ea54e1..df0ad7e 100644
Binary files a/smart_service/masters/doctype/variant/__pycache__/variant.cpython-38.pyc and b/smart_service/masters/doctype/variant/__pycache__/variant.cpython-38.pyc differ
diff --git a/smart_service/masters/doctype/variant/variant.js b/smart_service/masters/doctype/variant/variant.js
index 51d76a6..83f2dcd 100644
--- a/smart_service/masters/doctype/variant/variant.js
+++ b/smart_service/masters/doctype/variant/variant.js
@@ -27,7 +27,7 @@ frappe.ui.form.on('Variant', {
var regex = /[!@#$%^&*()_+\=\[\]{};'`~:"\\|.<>\/?]+/;
if(frm.doc.variant){
if (regex.test(frm.doc.variant) === true){
- frappe.msgprint(__("Variant: Only letters, numbers and -, are allowed."));
+ frappe.msgprint(__("Variant: Only letters, numbers and - , are allowed."));
frappe.validated = false;
} else if(frm.doc.variant) {
if(frm.doc.variant.includes("'")) {
diff --git a/smart_service/masters/doctype/vehicle/__pycache__/__init__.cpython-38.pyc b/smart_service/masters/doctype/vehicle/__pycache__/__init__.cpython-38.pyc
index 800af7a..616f642 100644
Binary files a/smart_service/masters/doctype/vehicle/__pycache__/__init__.cpython-38.pyc and b/smart_service/masters/doctype/vehicle/__pycache__/__init__.cpython-38.pyc differ
diff --git a/smart_service/masters/doctype/vehicle/__pycache__/vehicle.cpython-38.pyc b/smart_service/masters/doctype/vehicle/__pycache__/vehicle.cpython-38.pyc
index 925ef7b..b9d8e38 100644
Binary files a/smart_service/masters/doctype/vehicle/__pycache__/vehicle.cpython-38.pyc and b/smart_service/masters/doctype/vehicle/__pycache__/vehicle.cpython-38.pyc differ
diff --git a/smart_service/masters/doctype/vehicle/vehicle.js b/smart_service/masters/doctype/vehicle/vehicle.js
index 21e1e2b..98bd452 100644
--- a/smart_service/masters/doctype/vehicle/vehicle.js
+++ b/smart_service/masters/doctype/vehicle/vehicle.js
@@ -88,7 +88,7 @@ frappe.ui.form.on('Vehicle', {
frappe.msgprint(__("Just a . is not prescribed!"));
frappe.validated = false;
}
- var regex = /[!@#$%^&*()_+\=\[\]{};'`~:"\\|.<>\/?]+/;
+ var regex = /[!@#$%^&*()_+\=\[\]{};'`~:"\\|.<>\/?]+/;
if (frm.doc.vehicle) {
if (regex.test(frm.doc.vehicle) === true) {
frappe.msgprint(__("Vehicle: Only letters, numbers and -, are allowed."));
diff --git a/smart_service/masters/doctype/vehicle/vehicle.json b/smart_service/masters/doctype/vehicle/vehicle.json
index 03f0065..a7c6c7d 100644
--- a/smart_service/masters/doctype/vehicle/vehicle.json
+++ b/smart_service/masters/doctype/vehicle/vehicle.json
@@ -9,6 +9,10 @@
"editable_grid": 1,
"engine": "InnoDB",
"field_order": [
+ "internal_publish",
+ "column_break_2",
+ "global_publish",
+ "section_break_4",
"vehicle",
"image",
"preview",
@@ -18,9 +22,7 @@
"active_status",
"myid",
"display_order",
- "service_kilometers",
- "global_publish_flag",
- "internal_publish_flag"
+ "service_kilometers"
],
"fields": [
{
@@ -103,24 +105,27 @@
},
{
"default": "0",
- "fieldname": "global_publish_flag",
+ "fieldname": "internal_publish",
"fieldtype": "Check",
- "hidden": 1,
- "label": "Global Publish Flag",
- "read_only": 1
+ "label": "Internal Publish"
},
{
- "default": "0",
- "fieldname": "internal_publish_flag",
- "fieldtype": "Check",
- "hidden": 1,
- "label": "Internal Publish Flag",
- "read_only": 1
+ "fieldname": "global_publish",
+ "fieldtype": "Data",
+ "label": "Global Publish"
+ },
+ {
+ "fieldname": "column_break_2",
+ "fieldtype": "Column Break"
+ },
+ {
+ "fieldname": "section_break_4",
+ "fieldtype": "Section Break"
}
],
"index_web_pages_for_search": 1,
"links": [],
- "modified": "2022-04-01 17:41:13.606316",
+ "modified": "2023-07-11 15:51:55.396348",
"modified_by": "Administrator",
"module": "Masters",
"name": "Vehicle",
diff --git a/smart_service/masters/doctype/vehicle_segment/vehicle_segment.js b/smart_service/masters/doctype/vehicle_segment/vehicle_segment.js
index 344d4b9..e47b5e2 100644
--- a/smart_service/masters/doctype/vehicle_segment/vehicle_segment.js
+++ b/smart_service/masters/doctype/vehicle_segment/vehicle_segment.js
@@ -58,7 +58,7 @@ frappe.ui.form.on('Vehicle Segment', {
var regex = /[!@#$%^&*()_+\-=\[\]{};'`~:"\\|,.<>\/?]+/;
if (frm.doc.vehicle_segment) {
if (regex.test(frm.doc.vehicle_segment) === true) {
- frappe.msgprint(__("Vehicle Segment: Only letters and numbers are allowed"));
+ frappe.msgprint(__("Vehicle Segment: Only letters , numbers and - , are allowed"));
frappe.validated = false;
} else if (frm.doc.vehicle_segment) {
if (frm.doc.vehicle_segment.includes("'")) {
diff --git a/smart_service/masters/report/_fuel_translation/_fuel_translation.py b/smart_service/masters/report/_fuel_translation/_fuel_translation.py
index 2ba6ec2..636eae9 100644
--- a/smart_service/masters/report/_fuel_translation/_fuel_translation.py
+++ b/smart_service/masters/report/_fuel_translation/_fuel_translation.py
@@ -1,7 +1,7 @@
# Copyright (c) 2013, Hard n Soft Technologies Pvt Ltd and contributors
# For license information, please see license.txt
-# import frappe
+import frappe
def execute(filters=None):
columns, data = [], []
diff --git a/smart_service/public/css/smart_service.css b/smart_service/public/css/smart_service.css
index b2e8cf9..9183ba7 100644
--- a/smart_service/public/css/smart_service.css
+++ b/smart_service/public/css/smart_service.css
@@ -26,8 +26,8 @@
}
.app-logo {
- width: 400px !important;
- height: 50px !important;
+ /* width: 400px !important;
+ height: 50px !important; */
image-rendering: -webkit-optimize-contrast !important;
filter: none !important;
}
diff --git a/smart_service/public/images/Mahindra Rise2.png b/smart_service/public/images/Mahindra Rise2.png
new file mode 100644
index 0000000..e545f83
Binary files /dev/null and b/smart_service/public/images/Mahindra Rise2.png differ
diff --git a/smart_service/public/images/Mahindra Rise2_test.png b/smart_service/public/images/Mahindra Rise2_test.png
new file mode 100644
index 0000000..ef8689b
Binary files /dev/null and b/smart_service/public/images/Mahindra Rise2_test.png differ
diff --git a/smart_service/reports/__pycache__/__init__.cpython-38.pyc b/smart_service/reports/__pycache__/__init__.cpython-38.pyc
index ddcb831..40a965b 100644
Binary files a/smart_service/reports/__pycache__/__init__.cpython-38.pyc and b/smart_service/reports/__pycache__/__init__.cpython-38.pyc differ
diff --git a/smart_service/transactions/__pycache__/__init__.cpython-38.pyc b/smart_service/transactions/__pycache__/__init__.cpython-38.pyc
deleted file mode 100644
index 904a8fb..0000000
Binary files a/smart_service/transactions/__pycache__/__init__.cpython-38.pyc and /dev/null differ
diff --git a/smart_service/transactions/doctype/__pycache__/__init__.cpython-38.pyc b/smart_service/transactions/doctype/__pycache__/__init__.cpython-38.pyc
deleted file mode 100644
index c5bdddd..0000000
Binary files a/smart_service/transactions/doctype/__pycache__/__init__.cpython-38.pyc and /dev/null differ
diff --git a/smart_service/transactions/doctype/fish/__pycache__/__init__.cpython-38.pyc b/smart_service/transactions/doctype/fish/__pycache__/__init__.cpython-38.pyc
deleted file mode 100644
index f45a6de..0000000
Binary files a/smart_service/transactions/doctype/fish/__pycache__/__init__.cpython-38.pyc and /dev/null differ
diff --git a/smart_service/transactions/doctype/fish/__pycache__/fish.cpython-38.pyc b/smart_service/transactions/doctype/fish/__pycache__/fish.cpython-38.pyc
deleted file mode 100644
index 1c1b97a..0000000
Binary files a/smart_service/transactions/doctype/fish/__pycache__/fish.cpython-38.pyc and /dev/null differ
diff --git a/smart_service/transactions/doctype/kilometer_mapping/__pycache__/__init__.cpython-38.pyc b/smart_service/transactions/doctype/kilometer_mapping/__pycache__/__init__.cpython-38.pyc
index b65ae46..119635c 100644
Binary files a/smart_service/transactions/doctype/kilometer_mapping/__pycache__/__init__.cpython-38.pyc and b/smart_service/transactions/doctype/kilometer_mapping/__pycache__/__init__.cpython-38.pyc differ
diff --git a/smart_service/transactions/doctype/kilometer_mapping/__pycache__/kilometer_mapping.cpython-38.pyc b/smart_service/transactions/doctype/kilometer_mapping/__pycache__/kilometer_mapping.cpython-38.pyc
index 6dde310..9a8bfa1 100644
Binary files a/smart_service/transactions/doctype/kilometer_mapping/__pycache__/kilometer_mapping.cpython-38.pyc and b/smart_service/transactions/doctype/kilometer_mapping/__pycache__/kilometer_mapping.cpython-38.pyc differ
diff --git a/smart_service/transactions/doctype/kilometer_mapping_items/__pycache__/__init__.cpython-38.pyc b/smart_service/transactions/doctype/kilometer_mapping_items/__pycache__/__init__.cpython-38.pyc
index bba4461..1045222 100644
Binary files a/smart_service/transactions/doctype/kilometer_mapping_items/__pycache__/__init__.cpython-38.pyc and b/smart_service/transactions/doctype/kilometer_mapping_items/__pycache__/__init__.cpython-38.pyc differ
diff --git a/smart_service/transactions/doctype/kilometer_mapping_items/__pycache__/kilometer_mapping_items.cpython-38.pyc b/smart_service/transactions/doctype/kilometer_mapping_items/__pycache__/kilometer_mapping_items.cpython-38.pyc
index 9339623..5cf7b9d 100644
Binary files a/smart_service/transactions/doctype/kilometer_mapping_items/__pycache__/kilometer_mapping_items.cpython-38.pyc and b/smart_service/transactions/doctype/kilometer_mapping_items/__pycache__/kilometer_mapping_items.cpython-38.pyc differ
diff --git a/smart_service/transactions/doctype/procedure/__pycache__/__init__.cpython-38.pyc b/smart_service/transactions/doctype/procedure/__pycache__/__init__.cpython-38.pyc
deleted file mode 100644
index 397813c..0000000
Binary files a/smart_service/transactions/doctype/procedure/__pycache__/__init__.cpython-38.pyc and /dev/null differ
diff --git a/smart_service/transactions/doctype/procedure/__pycache__/procedure.cpython-38.pyc b/smart_service/transactions/doctype/procedure/__pycache__/procedure.cpython-38.pyc
deleted file mode 100644
index f0c9414..0000000
Binary files a/smart_service/transactions/doctype/procedure/__pycache__/procedure.cpython-38.pyc and /dev/null differ
diff --git a/smart_service/transactions/doctype/procedure/procedure.js b/smart_service/transactions/doctype/procedure/procedure.js
index 3aa3386..d42a733 100644
--- a/smart_service/transactions/doctype/procedure/procedure.js
+++ b/smart_service/transactions/doctype/procedure/procedure.js
@@ -35,14 +35,15 @@ frappe.ui.form.on('Procedure', {
},
validate: function (frm) {
- var regex = /[@#$%^*+\\[\]{}`~:\\|\?]+/;
+ // var regex = /[@#$%^*\\[\]{}`~\\|\?]/;
+ var regex = /[@#$^\\[\]{}`\\|\?]/;
if (frm.doc.procedure_details) {
for (var i = 0; i < frm.doc.procedure_details.length; i++) {
if (regex.test(frm.doc.procedure_details[i].content) === true) {
if (frm.doc.procedure_details[i].content_type != "Link") {
frm.doc.procedure_details[i].content_type = ''
frm.refresh_fields();
- frappe.msgprint(__("Content: Only letters, numbers and - ,'<>_()!=/; are allowed."));
+ frappe.msgprint(__("Content: Only letters, numbers and - ,'<>_()!=/:+; are allowed."));
}
}
}
@@ -68,19 +69,28 @@ frappe.ui.form.on('Procedure', {
callback: function (r) {
}
})
-
-
- var url = window.location.host;
- var regex = /[://]+/;
- frappe.db.get_value('Fish', { name: "Fish" }, 'path', (r) => {
- for (var i = 0; i < frm.doc.procedure_details.length; i++) {
- if (frm.doc.procedure_details[i].content && r.path && frm.doc.procedure_details[i].content_type == "Link"){// && !(frm.doc.procedure_details[i].content).includes('')){
- var x = "' + frm.doc.procedure_details[i].temp_cnt + ' ';
- frm.doc.procedure_details[i].content = x
- }
+ if(frm.doc.procedure_details){
+ frappe.call({
+ "method": "smart_service.transactions.doctype.procedure.procedure.get_path",
+ "args": {
+ "name": frm.doc.name,
+ },
+ callback: function (r) {
+
+ var url = window.location.host;
+ var regex = /[://]+/;
+ // frappe.db.get_value('Fish', { name: "Fish" }, 'path', (r) => {
+ for (var i = 0; i < frm.doc.procedure_details.length; i++) {
+ if (frm.doc.procedure_details[i].content && r.message && frm.doc.procedure_details[i].content_type == "Link"){// && !(frm.doc.procedure_details[i].content).includes('')){
+ var x = "' + frm.doc.procedure_details[i].temp_cnt + ' ';
+ frm.doc.procedure_details[i].content = x
+ }
+ }
+ cur_frm.refresh_fields('procedure_details');
+ // })
}
- cur_frm.refresh_fields('procedure_details');
- })
+ })
+ }
}
// select_row(frm);
// if (frm.doc.procedure_filter == "All") {
diff --git a/smart_service/transactions/doctype/procedure/procedure.py b/smart_service/transactions/doctype/procedure/procedure.py
index 1d296f2..3403977 100644
--- a/smart_service/transactions/doctype/procedure/procedure.py
+++ b/smart_service/transactions/doctype/procedure/procedure.py
@@ -1,195 +1,252 @@
# Copyright (c) 2021, Hard n Soft Technologies Pvt Ltd and contributors
# For license information, please see license.txt
+import re
+import sys
import frappe
from frappe.model.document import Document
-import frappe,json
+import frappe
+import json
current_db_name = frappe.conf.get("db_name")
-import sys
-sys.tracebacklimit=0
+sys.tracebacklimit = 0
+
class Procedure(Document):
- def validate(self):
- if self.procedure_details:
- for x in self.get("procedure_details"):
- if x.content_type == "File":
- if not x.file:
- frappe.throw("Please choose the file in row no " + str(x.idx))
- if x.content_type != "File":
- if not x.content:
- frappe.throw("Please enter the content in row no " + str(x.idx))
+ def validate(self):
+ if self.procedure_details:
+ for x in self.get("procedure_details"):
+ if x.content:
+
+ res_str = re.sub("–", "—", x.content)
+ res_str = re.sub("—", "–", res_str)
+ res_str = re.sub("‘", "‘", res_str)
+ res_str = re.sub("’", "’", res_str)
+ res_str = re.sub("“", "“", res_str)
+ res_str = re.sub("â€", "”", res_str)
+ res_str = re.sub("Â", "", res_str)
+ x.content = res_str
+
+ if x.content_type == "File":
+ if not x.file:
+ frappe.throw(
+ "Please choose the file in row no " + str(x.idx))
+ if x.content_type != "File":
+ if not x.content:
+ frappe.throw(
+ "Please enter the content in row no " + str(x.idx))
+
+ if not self.is_new():
+ frappe.db.sql(
+ f"""UPDATE `tabSystem Mapping_Sub System` set procedure_is_published=0,procedure_status='{self.workflow_state}',active_status='{self.active_status}' where `procedure`='{self.name}';""")
+ frappe.db.commit()
+
+
@frappe.whitelist()
def get_doc_status(docname):
- self = frappe.get_doc("Procedure",docname)
- return self.workflow_state
+ self = frappe.get_doc("Procedure", docname)
+ return self.workflow_state
+
@frappe.whitelist()
-def get_publish_details(procedure_name,status):
- data=frappe.db.sql('''select pd.parent from {0}.`tabPublish_Docs` pd, {0}.`tabPublish` p where pd.procedure_link='{1}' and p.publish_status != '{2}' and pd.parent=p.name'''.format(current_db_name,procedure_name,status), as_list=True)
- return data
+def get_publish_details(procedure_name, status):
+ data = frappe.db.sql('''select pd.parent from {0}.`tabPublish_Docs` pd, {0}.`tabPublish` p where pd.procedure_link='{1}' and p.publish_status != '{2}' and pd.parent=p.name'''.format(
+ current_db_name, procedure_name, status), as_list=True)
+ return data
+
@frappe.whitelist()
def sub_systems(doctype, txt, searchfield, start, page_len, filters):
- return frappe.db.sql(""" select name
+ return frappe.db.sql(""" select name
FROM {0}.`tabSub Systems` where
- (name like "%%%(txt)s%%") order by creation desc limit %(start)s, %(page_len)s """.format(current_db_name)%{'txt': txt, 'start': start, 'page_len': page_len})
+ (name like "%%%(txt)s%%") order by creation desc limit %(start)s, %(page_len)s """.format(current_db_name) % {'txt': txt, 'start': start, 'page_len': page_len})
+
@frappe.whitelist()
def variant(doctype, txt, searchfield, start, page_len, filters):
- return frappe.db.sql(""" select name,family_code,fuel,transmission,vehicle_segment,active_status
+ return frappe.db.sql(""" select name,family_code,fuel,transmission,vehicle_segment,active_status
FROM {0}.`tabVariant Mapping` where
- (active_status like "%%%(txt)s%%" or vehicle_segment like "%%%(txt)s%%" or name like "%%%(txt)s%%" or variant like "%%%(txt)s%%" or family_code like "%%%(txt)s%%" or fuel like "%%%(txt)s%%" or transmission like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name)%{'txt': txt, 'start': start, 'page_len': page_len})
+ (active_status like "%%%(txt)s%%" or vehicle_segment like "%%%(txt)s%%" or name like "%%%(txt)s%%" or variant like "%%%(txt)s%%" or family_code like "%%%(txt)s%%" or fuel like "%%%(txt)s%%" or transmission like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name) % {'txt': txt, 'start': start, 'page_len': page_len})
+
@frappe.whitelist()
def fuel(doctype, txt, searchfield, start, page_len, filters):
- return frappe.db.sql(""" select name FROM {0}.tabFuel where
- (name like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name)%{'txt': txt, 'start': start, 'page_len': page_len})
+ return frappe.db.sql(""" select name FROM {0}.tabFuel where
+ (name like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name) % {'txt': txt, 'start': start, 'page_len': page_len})
+
@frappe.whitelist()
def transmission(doctype, txt, searchfield, start, page_len, filters):
- return frappe.db.sql(""" select name FROM {0}.tabTransmission where
- (name like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name)%{'txt': txt, 'start': start, 'page_len': page_len})
+ return frappe.db.sql(""" select name FROM {0}.tabTransmission where
+ (name like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name) % {'txt': txt, 'start': start, 'page_len': page_len})
+
@frappe.whitelist()
def drive(doctype, txt, searchfield, start, page_len, filters):
- return frappe.db.sql(""" select name FROM {0}.tabDrive where
- (name like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name)%{'txt': txt, 'start': start, 'page_len': page_len})
+ return frappe.db.sql(""" select name FROM {0}.tabDrive where
+ (name like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name) % {'txt': txt, 'start': start, 'page_len': page_len})
+
@frappe.whitelist()
def get_variant(doctype, txt, searchfield, start, page_len, filters):
- if not filters:
- return []
- filters = frappe._dict(filters)
- vm = filters.get('variant_mapping')
- lang = filters.get('language')
- if vm:
- vehicle = frappe.db.get_value('Variant Mapping', vm, 'vehicle')
- variant = frappe.db.sql("""select name,family_code,fuel,transmission,drive,active_status FROM {0}.`tabVariant Mapping` where vehicle = '{1}' and
- (name like "%%%(txt)s%%" or active_status like "%%%(txt)s%%" or drive like "%%%(txt)s%%" or family_code like "%%%(txt)s%%" or fuel like "%%%(txt)s%%" or transmission like "%%%(txt)s%%") group by name limit %(start)s, %(page_len)s """.format(current_db_name,vehicle)%{'txt': txt, 'start': start, 'page_len': page_len})
- if variant:
- return variant
- else:
- return []
- else:
- return []
+ if not filters:
+ return []
+ filters = frappe._dict(filters)
+ vm = filters.get('variant_mapping')
+ lang = filters.get('language')
+ if vm:
+ vehicle = frappe.db.get_value('Variant Mapping', vm, 'vehicle')
+ variant = frappe.db.sql("""select name,family_code,fuel,transmission,drive,active_status FROM {0}.`tabVariant Mapping` where vehicle = '{1}' and
+ (name like "%%%(txt)s%%" or active_status like "%%%(txt)s%%" or drive like "%%%(txt)s%%" or family_code like "%%%(txt)s%%" or fuel like "%%%(txt)s%%" or transmission like "%%%(txt)s%%") group by name limit %(start)s, %(page_len)s """.format(current_db_name, vehicle) % {'txt': txt, 'start': start, 'page_len': page_len})
+ if variant:
+ return variant
+ else:
+ return []
+ else:
+ return []
+
@frappe.whitelist()
def get_systems(doctype, txt, searchfield, start, page_len, filters):
- if not filters:
- return []
- filters = frappe._dict(filters)
- vm = filters.get('variant_mapping')
- lang = filters.get('language')
- if vm:
- sys_mapping = frappe.db.sql("""select name from {0}.`tabSystem Mapping` where variant_mapping = '{1}' and language ='{2}'""".format(current_db_name,vm,lang),as_dict=True)
- if sys_mapping:
- for x in sys_mapping:
- doc = frappe.get_doc('System Mapping', x.name)
- systems = frappe.db.sql(""" select systems FROM {0}.`tabSystem Mapping_Sub System` where parent = '{1}' and
- (systems like "%%%(txt)s%%") group by systems limit %(start)s, %(page_len)s """.format(current_db_name,doc.name)%{'txt': txt, 'start': start, 'page_len': page_len},as_list=True)
- if systems:
- return systems
- else:
- return []
- else:
- return []
- else:
- return []
+ if not filters:
+ return []
+ filters = frappe._dict(filters)
+ vm = filters.get('variant_mapping')
+ lang = filters.get('language')
+ if vm:
+ sys_mapping = frappe.db.sql("""select name from {0}.`tabSystem Mapping` where variant_mapping = '{1}' and language ='{2}'""".format(
+ current_db_name, vm, lang), as_dict=True)
+ if sys_mapping:
+ for x in sys_mapping:
+ doc = frappe.get_doc('System Mapping', x.name)
+ systems = frappe.db.sql(""" select systems FROM {0}.`tabSystem Mapping_Sub System` where parent = '{1}' and
+ (systems like "%%%(txt)s%%") group by systems limit %(start)s, %(page_len)s """.format(current_db_name, doc.name) % {'txt': txt, 'start': start, 'page_len': page_len}, as_list=True)
+ if systems:
+ return systems
+ else:
+ return []
+ else:
+ return []
+ else:
+ return []
+
@frappe.whitelist()
def get_subsystems(doctype, txt, searchfield, start, page_len, filters):
- if not filters:
- return []
- filters = frappe._dict(filters)
- vm = filters.get('variant_mapping')
- systems = filters.get('systems')
- lang = filters.get('language')
- if vm:
- sys_mapping = frappe.db.sql("""select name from {0}.`tabSystem Mapping` where variant_mapping = '{1}' and language = '{2}'""".format(current_db_name,vm,lang),as_dict=True)
- if sys_mapping:
- for x in sys_mapping:
- doc = frappe.get_doc('System Mapping', x.name)
- systems = frappe.db.sql(""" select sub_systems FROM {0}.`tabSystem Mapping_Sub System` where parent = '{1}' and systems = '{2}' and
- (sub_systems like "%%%(txt)s%%") group by sub_systems limit %(start)s, %(page_len)s """.format(current_db_name,doc.name,systems)%{'txt': txt, 'start': start, 'page_len': page_len})
- if systems:
- return systems
- else:
- return []
- else:
- return []
- else:
- return []
+ if not filters:
+ return []
+ filters = frappe._dict(filters)
+ vm = filters.get('variant_mapping')
+ systems = filters.get('systems')
+ lang = filters.get('language')
+ if vm:
+ sys_mapping = frappe.db.sql("""select name from {0}.`tabSystem Mapping` where variant_mapping = '{1}' and language = '{2}'""".format(
+ current_db_name, vm, lang), as_dict=True)
+ if sys_mapping:
+ for x in sys_mapping:
+ doc = frappe.get_doc('System Mapping', x.name)
+ systems = frappe.db.sql(""" select sub_systems FROM {0}.`tabSystem Mapping_Sub System` where parent = '{1}' and systems = '{2}' and
+ (sub_systems like "%%%(txt)s%%") group by sub_systems limit %(start)s, %(page_len)s """.format(current_db_name, doc.name, systems) % {'txt': txt, 'start': start, 'page_len': page_len})
+ if systems:
+ return systems
+ else:
+ return []
+ else:
+ return []
+ else:
+ return []
+
@frappe.whitelist()
def get_procedure(doctype, txt, searchfield, start, page_len, filters):
- if not filters:
- return []
- filters = frappe._dict(filters)
- vm = filters.get('variant_mapping')
- systems = filters.get('systems')
- sub_systems = filters.get('sub_systems')
- lang = filters.get('language')
- if vm:
- sys_mapping = frappe.db.sql("""select name from {0}.`tabSystem Mapping` where variant_mapping = '{1}' and language = '{2}'""".format(current_db_name,vm,lang),as_dict=True)
- if sys_mapping:
- for x in sys_mapping:
- doc = frappe.get_doc('System Mapping', x.name)
- procedure = frappe.db.sql(""" select `procedure` FROM {0}.`tabSystem Mapping_Sub System` where parent = '{1}' and systems = '{2}' and sub_systems = '{3}' and
- (`procedure` like "%%%(txt)s%%") group by `procedure` limit %(start)s, %(page_len)s """.format(current_db_name,doc.name,systems,sub_systems)%{'txt': txt, 'start': start, 'page_len': page_len})
- if procedure:
- return procedure
- else:
- return []
- else:
- return []
- else:
- return []
-
-@frappe.whitelist()
-def get_procedures(variant_mapping,systems,sub_systems,language):
- sys_mapping = frappe.db.sql("""select name from {0}.`tabSystem Mapping` where variant_mapping = '{1}' and language = '{2}'""".format(current_db_name,variant_mapping,language),as_dict=True)
- if sys_mapping:
- for x in sys_mapping:
- doc = frappe.get_doc('System Mapping', x.name)
- procedure = frappe.db.sql(""" select `procedure` FROM {0}.`tabSystem Mapping_Sub System` where parent = '{1}' and systems = '{2}' and sub_systems = '{3}'""".format(current_db_name,doc.name,systems,sub_systems))
- return procedure
+ if not filters:
+ return []
+ filters = frappe._dict(filters)
+ vm = filters.get('variant_mapping')
+ systems = filters.get('systems')
+ sub_systems = filters.get('sub_systems')
+ lang = filters.get('language')
+ if vm:
+ sys_mapping = frappe.db.sql("""select name from {0}.`tabSystem Mapping` where variant_mapping = '{1}' and language = '{2}'""".format(
+ current_db_name, vm, lang), as_dict=True)
+ if sys_mapping:
+ for x in sys_mapping:
+ doc = frappe.get_doc('System Mapping', x.name)
+ procedure = frappe.db.sql(""" select `procedure` FROM {0}.`tabSystem Mapping_Sub System` where parent = '{1}' and systems = '{2}' and sub_systems = '{3}' and
+ (`procedure` like "%%%(txt)s%%") group by `procedure` limit %(start)s, %(page_len)s """.format(current_db_name, doc.name, systems, sub_systems) % {'txt': txt, 'start': start, 'page_len': page_len})
+ if procedure:
+ return procedure
+ else:
+ return []
+ else:
+ return []
+ else:
+ return []
+
+
+@frappe.whitelist()
+def get_procedures(variant_mapping, systems, sub_systems, language):
+ sys_mapping = frappe.db.sql("""select name from {0}.`tabSystem Mapping` where variant_mapping = '{1}' and language = '{2}'""".format(
+ current_db_name, variant_mapping, language), as_dict=True)
+ if sys_mapping:
+ for x in sys_mapping:
+ doc = frappe.get_doc('System Mapping', x.name)
+ procedure = frappe.db.sql(""" select `procedure` FROM {0}.`tabSystem Mapping_Sub System` where parent = '{1}' and systems = '{2}' and sub_systems = '{3}'""".format(
+ current_db_name, doc.name, systems, sub_systems))
+ return procedure
+
@frappe.whitelist()
def get_systemid(systems):
- system = frappe.db.sql(""" select myid FROM {0}.`tabSystems` where name = '{1}'""".format(current_db_name,systems))
- if system:
- return system
+ system = frappe.db.sql(""" select myid FROM {0}.`tabSystems` where name = '{1}'""".format(
+ current_db_name, systems))
+ if system:
+ return system
+
@frappe.whitelist()
def get_subsystemid(systems):
- system = frappe.db.sql(""" select myid FROM {0}.`tabSub Systems` where name = '{1}'""".format(current_db_name,systems))
- if system:
- return system
+ system = frappe.db.sql(""" select myid FROM {0}.`tabSub Systems` where name = '{1}'""".format(
+ current_db_name, systems))
+ if system:
+ return system
+
@frappe.whitelist()
def procedure_name(doctype, txt, searchfield, start, page_len, filters):
- return frappe.db.sql(""" select name FROM {0}.`tabProcedure Name` where
- (name like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name)%{'txt': txt, 'start': start, 'page_len': page_len})
-
+ return frappe.db.sql(""" select name FROM {0}.`tabProcedure Name` where
+ (name like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name) % {'txt': txt, 'start': start, 'page_len': page_len})
+
+
@frappe.whitelist()
def procedure_step_name(doctype, txt, searchfield, start, page_len, filters):
- return frappe.db.sql(""" select name FROM {0}.`tabProcedure Step Name` where
- (name like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name)%{'txt': txt, 'start': start, 'page_len': page_len})
+ return frappe.db.sql(""" select name FROM {0}.`tabProcedure Step Name` where
+ (name like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name) % {'txt': txt, 'start': start, 'page_len': page_len})
+
@frappe.whitelist()
def update_system_id(name):
- doc = frappe.get_doc("Procedure",name)
- for table in doc.get("procedure_details"):
- if table.content_type == "Link":
- procedure = table.temp_cnt
- system_mapping = frappe.db.sql("""select name from {0}.`tabSystem Mapping` where variant_mapping = '{1}' and language = '{2}'""".format(current_db_name,doc.variant_mapping,doc.language),as_dict=True)
- if system_mapping:
- sm = system_mapping[0]['name']
- sys_procedure = frappe.db.sql("""select systems,sub_systems,system_id,sub_system_id,`procedure` from {0}.`tabSystem Mapping_Sub System` where parent = '{1}' and `procedure` = '{2}'""".format(current_db_name,sm,table.temp_cnt),as_dict=True)
- if sys_procedure:
- if table.temp_cnt == sys_procedure[0]['procedure']:
- sys_id = doc.variant_mapping + ',' + str(sys_procedure[0]['system_id']) + ',' + str(sys_procedure[0]['sub_system_id'])
- table.system_id = sys_id
- frappe.db.sql("""update {0}.`tabProcedure_Details` set system_id = '{1}' where parent = '{2}' and temp_cnt = '{3}'""".format(current_db_name,sys_id,doc.name,table.temp_cnt) )
- frappe.db.commit()
-
+ doc = frappe.get_doc("Procedure", name)
+ for table in doc.get("procedure_details"):
+ if table.content_type == "Link":
+ procedure = table.temp_cnt
+ system_mapping = frappe.db.sql("""select name from {0}.`tabSystem Mapping` where variant_mapping = '{1}' and language = '{2}'""".format(
+ current_db_name, doc.variant_mapping, doc.language), as_dict=True)
+ if system_mapping:
+ sm = system_mapping[0]['name']
+ sys_procedure = frappe.db.sql("""select systems,sub_systems,system_id,sub_system_id,`procedure` from {0}.`tabSystem Mapping_Sub System` where parent = '{1}' and `procedure` = '{2}'""".format(
+ current_db_name, sm, table.temp_cnt), as_dict=True)
+ if sys_procedure:
+ if str(table.temp_cnt) == str(sys_procedure[0]['procedure']):
+
+ sys_id = doc.variant_mapping + ',' + \
+ str(sys_procedure[0]['system_id']) + ',' + \
+ str(sys_procedure[0]['sub_system_id'])
+ table.system_id = sys_id
+ frappe.db.sql("""update {0}.`tabProcedure_Details` set system_id = '{1}' where parent = '{2}' and temp_cnt = '{3}'""".format(
+ current_db_name, sys_id, doc.name, table.temp_cnt))
+ frappe.db.commit()
+@frappe.whitelist()
+def get_path(name):
+ path = frappe.db.get_single_value("Fish", "path")
+ if path:
+ return path
\ No newline at end of file
diff --git a/smart_service/transactions/doctype/procedure_details/__pycache__/__init__.cpython-38.pyc b/smart_service/transactions/doctype/procedure_details/__pycache__/__init__.cpython-38.pyc
deleted file mode 100644
index c39c900..0000000
Binary files a/smart_service/transactions/doctype/procedure_details/__pycache__/__init__.cpython-38.pyc and /dev/null differ
diff --git a/smart_service/transactions/doctype/procedure_details/__pycache__/procedure_details.cpython-38.pyc b/smart_service/transactions/doctype/procedure_details/__pycache__/procedure_details.cpython-38.pyc
deleted file mode 100644
index 151583b..0000000
Binary files a/smart_service/transactions/doctype/procedure_details/__pycache__/procedure_details.cpython-38.pyc and /dev/null differ
diff --git a/smart_service/transactions/doctype/procedure_details/procedure_details.json b/smart_service/transactions/doctype/procedure_details/procedure_details.json
index 179927b..410bf13 100644
--- a/smart_service/transactions/doctype/procedure_details/procedure_details.json
+++ b/smart_service/transactions/doctype/procedure_details/procedure_details.json
@@ -74,14 +74,13 @@
{
"fieldname": "system_id",
"fieldtype": "Data",
- "hidden": 1,
"label": "System ID"
}
],
"index_web_pages_for_search": 1,
"istable": 1,
"links": [],
- "modified": "2022-04-08 22:21:10.666175",
+ "modified": "2023-06-08 14:41:02.141600",
"modified_by": "Administrator",
"module": "Transactions",
"name": "Procedure_Details",
diff --git a/smart_service/transactions/doctype/publish/__pycache__/__init__.cpython-38.pyc b/smart_service/transactions/doctype/publish/__pycache__/__init__.cpython-38.pyc
index a767963..810d807 100644
Binary files a/smart_service/transactions/doctype/publish/__pycache__/__init__.cpython-38.pyc and b/smart_service/transactions/doctype/publish/__pycache__/__init__.cpython-38.pyc differ
diff --git a/smart_service/transactions/doctype/publish/__pycache__/publish.cpython-38.pyc b/smart_service/transactions/doctype/publish/__pycache__/publish.cpython-38.pyc
index e58073b..4aae2c6 100644
Binary files a/smart_service/transactions/doctype/publish/__pycache__/publish.cpython-38.pyc and b/smart_service/transactions/doctype/publish/__pycache__/publish.cpython-38.pyc differ
diff --git a/smart_service/transactions/doctype/publish/publish.js b/smart_service/transactions/doctype/publish/publish.js
index a876861..e0753ba 100644
--- a/smart_service/transactions/doctype/publish/publish.js
+++ b/smart_service/transactions/doctype/publish/publish.js
@@ -15,7 +15,7 @@ cur_frm.fields_dict['vehicle'].get_query = function (doc, cdt, cdn) {
return { query: "smart_service.masters.doctype.vehicle.vehicle.vehicle_filter", };
};
-var lang_set_first_time = true;
+let lang_set_first_time = true;
frappe.ui.form.on('Publish', {
onload: function (frm) {
$(document).on('mouseover', function (events) {
@@ -28,7 +28,7 @@ frappe.ui.form.on('Publish', {
},
planned_publish_date: function (frm) {
- var date = (frappe.datetime.nowdate())
+ let date = (frappe.datetime.nowdate())
if (frm.doc.planned_publish_date < date) {
frm.doc.planned_publish_date = '';
cur_frm.refresh_fields();
@@ -113,8 +113,8 @@ frappe.ui.form.on('Publish', {
cur_frm.refresh_field('version')
if (frm.doc.docstatus === 1 && frm.doc.publish_status == 'To Publish') {
frappe.call({
- // method: "smart_service.apis.publish_api.api_procedure",
- method: "smart_service.apis.publish_api.new_publish",
+ // method: "smart_service.apis.publish_api.api_procedure",
+ method: "smart_service.apis.publish_api.new_publish",
args: {
"args": frm.doc.name,
"publish_type": frm.doc.publish_type,
@@ -123,30 +123,74 @@ frappe.ui.form.on('Publish', {
"version": frm.doc.version
},
callback: function (r) {
- if (r.message != "Failed to save file") {
- frm.set_value('publish_status', 'Published');
- frm.set_value('actual_published_date', frappe.datetime.nowdate());
- frappe.msgprint({
- title: __('Notification'),
- message: __('Successfully Published' + r.message),
- primary_action: {
- action(values) {
- frm.save('Update');
-
- }
+ // if (r.message[0]) {
+ frm.set_value('publish_status', 'Published');
+ frm.page.clear_primary_action("Publish");
+ frm.set_value('actual_published_date', frappe.datetime.nowdate());
+ frappe.call({
+ method: "smart_service.transactions.doctype.publish.publish.update_procedure_value",
+ args: {
+ "name": frm.doc.name,
+ "file_path": r.message[1],
+ },
+ callback: (r) => {
+ // frm.save('Update');
+ }
+ })
+ frappe.msgprint({
+ title: __('Notification'),
+ message: __('Successfully Published: ' + r.message[1]),
+ primary_action: {
+ action(values) {
+ frm.save('Update');
}
- });
- } else {
- frappe.msgprint('Publish Failed')
- }
+ }
+ });
+ // }
+ // else {
+ // frappe.msgprint({
+ // title: __('Notification'),
+ // message: __('Not Successfully Published: ' + r.message[1]),
+ // // primary_action: {
+ // // action(values) {
+ // // frm.save('Update');
+ // // }
+ // // }
+ // });
+ // }
+
+
+ // if (r.message != "Failed to save file") {
+ // frm.set_value('publish_status', 'Published');
+ // frm.set_value('actual_published_date', frappe.datetime.nowdate());
+ // frappe.call({
+ // method: "smart_service.transactions.doctype.publish.publish.update_procedure_value",
+ // args: {
+ // "name": frm.doc.name,
+ // "file_path": r.message,
+ // },
+ // callback: (r) => {
+ // // frm.save('Update');
+ // }
+ // })
+ // frappe.msgprint({
+ // title: __('Notification'),
+ // message: __('Successfully Published: ' + r.message),
+ // primary_action: {
+ // action(values) {
+ // frm.save('Update');
+ // }
+ // }
+ // });
+ // } else {
+ // frappe.msgprint('Publish Failed')
+ // }
}
});
}
-
},
})
}
-
}, () => {
// action to perform if No is selected
});
@@ -158,12 +202,12 @@ frappe.ui.form.on('Publish', {
if (frm.doc.docstatus === 0 && frm.doc.publish_status == 'To Publish') {
frm.get_field('system_mapping').grid.add_custom_button(__('Add to Publish'), function () {
- var added = 0;
- var topublish = [];
+ let added = 0;
+ let topublish = [];
if (frm.doc.publish_type == 'Global') { topublish = ['Publish Ready']; } else { topublish = ['Review Pending', 'Publish Ready', 'Approval Pending']; }
frm.doc.system_mapping.forEach(row => {
if (topublish.indexOf(row.procedure_status) > -1) {
- var dulicate = false;
+ let dulicate = false;
if (frm.doc.publish_documents) {
frm.doc.publish_documents.forEach(publishrow => {
if (frm.doc.variant_mapping == publishrow.variant_mapping &&
@@ -174,7 +218,7 @@ frappe.ui.form.on('Publish', {
});
}
if (dulicate === false) {
- var child = cur_frm.add_child("publish_documents");
+ let child = cur_frm.add_child("publish_documents");
child.variant_mapping = frm.doc.variant_mapping;
child.system = row.systems;
child.sub_system = row.sub_systems;
@@ -197,11 +241,10 @@ frappe.ui.form.on('Publish', {
}
if (frm.doc.docstatus === 0 && frm.doc.publish_status == 'To Publish') {
frm.get_field('variant_mapping_assets').grid.add_custom_button(__('Add to Publish'), function () {
- var added = 0;
- var topublish = [];
+ let added = 0;
frm.doc.variant_mapping_assets.forEach(row => {
if (row.active_status == "Active" || row.active_status == "Inactive") {
- var dulicate = false;
+ let dulicate = false;
if (frm.doc.publish_documents) {
frm.doc.publish_documents.forEach(publishrow => {
if (frm.doc.variant_mapping == publishrow.variant_mapping &&
@@ -211,7 +254,7 @@ frappe.ui.form.on('Publish', {
});
}
if (dulicate === false) {
- var child = cur_frm.add_child("publish_documents");
+ let child = cur_frm.add_child("publish_documents");
child.variant_mapping = frm.doc.variant_mapping;
child.asset_category = row.category;
child.item_category = "Variant Mapping Assets";
@@ -230,15 +273,16 @@ frappe.ui.form.on('Publish', {
}
if (frm.doc.docstatus == 1) {
$(".grid-buttons").hide();
+
}
},
validate: function (frm) {
- var regex = /[!@#$%^*_+\=\[\]{};'`~\\|.<>\?]+/;
- if (regex.test(frm.doc.release_description) === true) {
+ let regex = /[!@#$%^*_+\=\[\]{};'`~\\|.<>\?]+/;
+ if (regex.test(frm.doc.release_description) === true) {
frm.doc.release_description = '';
frm.refresh_fields();
- frappe.msgprint(__("Publish Description: Only letters, numbers and / - () & , ' : are allowed."));
- }
+ frappe.msgprint(__("Publish Description: Only letters, numbers and / - () & , ' : are allowed."));
+ }
if (frm.doc.vehicle && frm.doc.release_description && frm.fields_dict.publish_documents.grid.grid_rows.length === 0) {
frappe.msgprint(__("No item selected to Publish"));
@@ -255,7 +299,7 @@ frappe.ui.form.on('Publish', {
cur_frm.refresh_field('variant');
})
- var km_name = frm.doc.variant_mapping + "-" + frm.doc.language + "-KM";
+ let km_name = frm.doc.variant_mapping + "-" + frm.doc.language + "-KM";
frappe.db.get_value('Kilometer Mapping', { name: km_name }, 'workflow_state', (r) => {
if (r.workflow_state == "Draft") {
frm.doc.kilometer_mapping = '';
@@ -294,17 +338,18 @@ frappe.ui.form.on('Publish', {
}, 5);
}
if (frm.doc.km_active_status === "" || frm.doc.km_active_status === null) { return; }
- var filter = frm.doc.variant_mapping + "-" + frm.doc.language + "-SM";
+ let filter = frm.doc.variant_mapping + "-" + frm.doc.language + "-SM";
if (frm.doc.variant_mapping_status == "Active" && frm.doc.km_active_status == "Active") {
frappe.call({
"method": "smart_service.transactions.doctype.publish.publish.get_system",
"args": {
"doc": frm.doc.variant_mapping,
- "name": filter
+ "name": filter,
+ "lang": frm.doc.language
},
callback: function (r) {
$.each(r.message, function (index, row) {
- var child;
+ let child;
child = cur_frm.add_child("system_mapping");
child.systems = row.systems;
child.sub_systems = row.sub_systems;
@@ -327,10 +372,11 @@ frappe.ui.form.on('Publish', {
"method": "smart_service.transactions.doctype.publish.publish.get_vm_asset",
"args": {
"doc": frm.doc.variant_mapping,
+ "lang": frm.doc.language
},
callback: function (r) {
$.each(r.message, function (index, row) {
- var child;
+ let child;
child = cur_frm.add_child("variant_mapping_assets");
child.category = row.category;
child.language = row.language;
@@ -347,11 +393,12 @@ frappe.ui.form.on('Publish', {
"method": "smart_service.transactions.doctype.publish.publish.get_sm_asset",
"args": {
"doc": frm.doc.variant_mapping,
- "name": filter
+ "name": filter,
+ "lang": frm.doc.language
},
callback: function (r) {
$.each(r.message, function (index, row) {
- var child_row;
+ let child_row;
child_row = cur_frm.add_child("variant_mapping_assets");
child_row.category = row.systems;
child_row.language = row.language;
@@ -375,7 +422,7 @@ frappe.ui.form.on('Publish', {
}
},
add_variant_mapping_to_publish: function (frm) {
- var dulicate = false;
+ let dulicate = false;
if (frm.doc.publish_documents) {
frm.doc.publish_documents.forEach(publishrow => {
if (frm.doc.variant_mapping == publishrow.variant_mapping && publishrow.systems === undefined && publishrow.sub_systems === undefined && publishrow.procedure === undefined) {
@@ -385,7 +432,7 @@ frappe.ui.form.on('Publish', {
frappe.msgprint("Variant Mapping already added");
}
if (dulicate === false) {
- var child = cur_frm.add_child("publish_documents");
+ let child = cur_frm.add_child("publish_documents");
child.variant_mapping = frm.doc.variant_mapping;
child.item_category = "Variant Mapping";
refresh_field("publish_documents");
@@ -406,7 +453,7 @@ frappe.ui.form.on('Publish', {
},
callback: function (r) {
if (r.message) {
- var vehicle = frm.doc.vehicle;
+ let vehicle = frm.doc.vehicle;
cur_frm.doc.vehicle = '';
cur_frm.doc.vehicle_status = '';
cur_frm.refresh_field('vehicle');
@@ -449,6 +496,7 @@ frappe.ui.form.on('Publish', {
doc: frm.doc.name
},
callback: (r) => {
+ frm.doc.version = r
cur_frm.refresh_field('version')
},
error: (r) => {
diff --git a/smart_service/transactions/doctype/publish/publish.json b/smart_service/transactions/doctype/publish/publish.json
index b9eb4e1..ccceb10 100644
--- a/smart_service/transactions/doctype/publish/publish.json
+++ b/smart_service/transactions/doctype/publish/publish.json
@@ -11,6 +11,7 @@
"actual_published_date",
"publish_type",
"publish_status",
+ "file_path",
"column_break_3",
"release_description",
"version",
@@ -89,6 +90,7 @@
{
"fieldname": "vehicle",
"fieldtype": "Link",
+ "in_standard_filter": 1,
"label": "Vehicle",
"options": "Vehicle",
"reqd": 1,
@@ -128,6 +130,9 @@
{
"fieldname": "language",
"fieldtype": "Link",
+ "in_filter": 1,
+ "in_list_view": 1,
+ "in_standard_filter": 1,
"label": "Language",
"options": "Custom Languages",
"read_only_depends_on": "eval:doc.publish_documents",
@@ -221,7 +226,7 @@
{
"allow_on_submit": 1,
"fieldname": "version",
- "fieldtype": "Data",
+ "fieldtype": "Float",
"in_standard_filter": 1,
"label": "Version",
"read_only": 1
@@ -295,12 +300,19 @@
"fieldtype": "Small Text",
"label": "Kilometer Mapping List",
"read_only": 1
+ },
+ {
+ "allow_on_submit": 1,
+ "fieldname": "file_path",
+ "fieldtype": "Data",
+ "label": "File Path",
+ "read_only": 1
}
],
"index_web_pages_for_search": 1,
"is_submittable": 1,
"links": [],
- "modified": "2022-08-19 20:36:03.516687",
+ "modified": "2023-06-15 11:30:29.844592",
"modified_by": "Administrator",
"module": "Transactions",
"name": "Publish",
diff --git a/smart_service/transactions/doctype/publish/publish.py b/smart_service/transactions/doctype/publish/publish.py
index e931577..8a9771d 100644
--- a/smart_service/transactions/doctype/publish/publish.py
+++ b/smart_service/transactions/doctype/publish/publish.py
@@ -1,270 +1,383 @@
# Copyright (c) 2021, Hard n Soft Technologies Pvt Ltd and contributors
# For license information, please see license.txt
+import sys
+from html import unescape
import frappe
from frappe.model.document import Document
-import json
+import json
current_db_name = frappe.conf.get("db_name")
-from html import unescape
-import sys
-sys.tracebacklimit=0
+sys.tracebacklimit = 0
+
class Publish(Document):
- def validate(self):
- ###Selected variant and kilometer mapping details list
- variant = []
- for vm in self.get('publish_documents'):
- if vm.variant_mapping in variant:
- pass
- else:
- variant.append(vm.variant_mapping)
-
- self.variant_mapping_details = ''
- self.kilometer_mapping_details = ''
- for v in variant:
- self.variant_mapping_details = self.variant_mapping_details + str(v) + '\n'
- km_mapping_record = frappe.db.sql("""select name from {0}.`tabKilometer Mapping` where variant_mapping = '{1}' and language = '{2}'""".format(current_db_name,str(v),self.language),as_dict=True)
- for km_mapping in km_mapping_record:
- self.kilometer_mapping_details = self.kilometer_mapping_details + str(km_mapping.name) + '\n'
-
- def onload(self):
- current_db_name = frappe.conf.get("db_name")
- ###To validate updated procedure status
- procedure_status = frappe.db.sql("""select p.name,p.update_procedure_status,pro.name,p.variant_mapping,p.system,p.sub_system,p.asset_category,p.item_category,p.variant,p.procedure_link,p.procedure_status,pro.name,pro.workflow_state
- from {0}.`tabPublish_Docs` as p,{0}.`tabProcedure` as pro
- where p.parent = '{1}' and p.procedure_link = pro.name and p.procedure_link is not null""".format(current_db_name,self.name),as_dict=True)
- l = len(procedure_status)
- if procedure_status and self.publish_status == "Published":
- for x in procedure_status:
- for y in self.get("publish_documents"):
- if y.procedure_link:
- if x.procedure_link == y.procedure_link and y.update_procedure_status != y.procedure_status:
- y.update_procedure_status = x.workflow_state
- frappe.db.sql("""update `tabPublish_Docs` set update_procedure_status = %s where procedure_link = %s""",(x.workflow_state,x.procedure_link))
- frappe.db.commit()
- if x.procedure_link == y.procedure_link and x.workflow_state != y.procedure_status:
- y.update_procedure_status = x.workflow_state
- frappe.db.sql("""update `tabPublish_Docs` set update_procedure_status = %s where procedure_link = %s""",(x.workflow_state,x.procedure_link))
- frappe.db.commit()
- if y.procedure_status == "Publish Ready":
- if x.procedure_link == y.procedure_link and x.workflow_state != y.procedure_status and not y.excluded_global:
- y.excluded_global = "1"
- if x.procedure_link == y.procedure_link and x.workflow_state != y.procedure_status and x.workflow_state == "Draft" and y.procedure_status != "Publish Ready":
- y.excluded_internal = "1"
- y.save()
- frappe.db.commit()
-
- ###Update system and variant mapping ststus
- if self.publish_status == "Published" and self.publish_type == "Global":
- global_publish = frappe.db.sql("""select name from {0}.`tabPublish` where global_publish = '{1}'""".format(current_db_name,self.name),as_dict=True)
- for global_name in global_publish:
- update_mapping(self.variant_mapping,global_name.name)
-
- u_id = frappe.get_all("User",filters={"name":frappe.session.user},fields=["username"])
- if u_id:
- for i in u_id:
- name = i.username
- if not self.published_by and self.publish_status == "Published":
- self.published_by = str(name)
- frappe.db.set_value("Publish",self.name,"published_by",str(name))
- frappe.db.commit()
-
- def on_cancel(self):
- ###Published document should not allow to cancel
- if self.publish_status == "Published":
- frappe.throw('You can not cancel a Published Document!')
-
-def update_procedure(vehicle,lang,publish_type,doc):
- ###To validate updated procedure status
- doc = frappe.get_doc("Publish",doc)
- current_db_name = frappe.conf.get("db_name")
- procedure_status = frappe.db.sql("""select p.name,p.update_procedure_status,pro.name,p.variant_mapping,p.system,p.sub_system,p.asset_category,p.item_category,p.variant,p.procedure_link,p.procedure_status,pro.name,pro.workflow_state
- from {0}.`tabPublish_Docs` as p,{0}.`tabProcedure` as pro
- where p.parent = '{1}' and p.procedure_link = pro.name and pro.workflow_state != p.update_procedure_status and p.procedure_link is not null""".format(current_db_name,doc.name),as_dict=True)
- l = len(procedure_status)
- if procedure_status:
- for x in procedure_status:
- for y in doc.get("publish_documents"):
- if y.procedure_link:
- if x.procedure_link == y.procedure_link and x.workflow_state != y.update_procedure_status:
- y.update_procedure_status = x.workflow_state
- frappe.db.sql("""update `tabPublish_Docs` set update_procedure_status = %s where procedure_link = %s""",(x.workflow_state,x.procedure_link))
- frappe.db.commit()
- if y.procedure_status == "Publish Ready":
- if x.procedure_link == y.procedure_link and x.workflow_state != y.procedure_status and not y.excluded_global:
- y.excluded_global = "1"
- if x.procedure_link == y.procedure_link and x.workflow_state != y.procedure_status and x.workflow_state == "Draft" and y.procedure_status != "Publish Ready":
- y.excluded_internal = "1"
-
- y.save()
- frappe.db.commit()
- if l > 0:
- frappe.msgprint(str(l) + ' Procedure Status to be updated, Please check the Publish Documents table.')
- draft_procedure_status = frappe.db.sql("""select name from {0}.`tabPublish_Docs` where parent = '{1}' and update_procedure_status = 'Draft' and procedure_link is not null""".format(current_db_name,doc.name),as_dict=True)
- publish_table = doc.publish_documents
- table_len = len(publish_table)
- l1 = len(draft_procedure_status)
- if str(l1) == str(table_len):
- frappe.throw("There is no item for internal publish")
-
- if doc.publish_type == "Global":
- publish_table = doc.publish_documents
- table_len = len(publish_table)
- publish_record = frappe.db.sql("""select name from {0}.`tabPublish_Docs` where update_procedure_status != procedure_status and update_procedure_status != 'Publish Ready' and parent = '{1}'""".format(current_db_name,doc.name),as_dict=True)
- if publish_record:
- len_publish = len(publish_record)
- if str(table_len) == str(len_publish):
- frappe.throw("There is no item for global publish")
-
-###Generate Publish versions
+ def validate(self):
+ # Selected variant and kilometer mapping details list
+ variant = []
+ for vm in self.get('publish_documents'):
+ # if vm.variant_mapping in variant:
+ # pass
+ # else:
+ # variant.append(vm.variant_mapping)
+ if vm.variant_mapping not in variant:
+ variant.append(vm.variant_mapping)
+
+ self.variant_mapping_details = ''
+ self.kilometer_mapping_details = ''
+ for v in variant:
+ self.variant_mapping_details = self.variant_mapping_details + \
+ str(v) + '\n'
+ km_mapping_record = frappe.db.sql("""select name from {0}.`tabKilometer Mapping` where variant_mapping = "{1}" and
+ language = '{2}'""".format(current_db_name, str(v), self.language), as_dict=1)
+ for km_mapping in km_mapping_record:
+ self.kilometer_mapping_details = self.kilometer_mapping_details + \
+ str(km_mapping.name) + '\n'
+
+ def onload1(self):
+ current_db_name = frappe.conf.get("db_name")
+ # To validate updated procedure status
+ procedure_status = frappe.db.sql("""select p.name,p.update_procedure_status,pro.name,p.variant_mapping,p.system,p.sub_system,p.asset_category,
+ p.item_category,p.variant,p.procedure_link,p.procedure_status,pro.name,pro.workflow_state
+ from {0}.`tabPublish_Docs` as p,{0}.`tabProcedure` as pro where p.parent = '{1}' and
+ p.procedure_link = pro.name and p.procedure_link is not null""".format(current_db_name, self.name), as_dict=1)
+ l = len(procedure_status)
+
+ if procedure_status and self.publish_status == "Published":
+ for x in procedure_status:
+ for y in self.get("publish_documents"):
+ if y.procedure_link:
+ if x.procedure_link == y.procedure_link and y.update_procedure_status != y.procedure_status:
+ y.update_procedure_status = x.workflow_state
+ frappe.db.sql("""update `tabPublish_Docs` set update_procedure_status = %s where parent = %s and procedure_link = %s ; """, (
+ x.workflow_state, self.name, x.procedure_link))
+ frappe.db.commit()
+ if x.procedure_link == y.procedure_link and x.workflow_state != y.procedure_status:
+ y.update_procedure_status = x.workflow_state
+ frappe.db.sql("""update `tabPublish_Docs` set update_procedure_status = %s where parent = %s and procedure_link = %s""", (
+ x.workflow_state, self.name, x.procedure_link))
+ frappe.db.commit()
+ if y.procedure_status == "Publish Ready":
+ if x.procedure_link == y.procedure_link and x.workflow_state != y.procedure_status and not y.excluded_global:
+ y.excluded_global = "1"
+ if x.procedure_link == y.procedure_link and x.workflow_state != y.procedure_status and x.workflow_state == "Draft" and y.procedure_status != "Publish Ready":
+ y.excluded_internal = "1"
+ y.save()
+ frappe.db.commit()
+
+ # Update system and variant mapping ststus
+ if self.publish_status == "Published" and self.publish_type == "Global":
+ current_db_name = frappe.conf.get("db_name")
+ global_publish = frappe.db.sql("""select name from {0}.`tabPublish` where global_publish = "{1}"; """.format(
+ current_db_name, self.name), as_dict=True)
+ for global_name in global_publish:
+ update_mapping(self.variant_mapping, global_name.name)
+
+ u_id = frappe.get_all(
+ "User", filters={"name": frappe.session.user}, fields=["username"])
+ if u_id:
+ for i in u_id:
+ name = i.username
+ if not self.published_by and self.publish_status == "Published":
+ self.published_by = str(name)
+ frappe.db.set_value(
+ "Publish", self.name, "published_by", str(name))
+ frappe.db.commit()
+
+ def on_cancel(self):
+ # Published document should not allow to cancel
+ if self.publish_status == "Published":
+ frappe.throw('You can not cancel a Published Document!')
+
+
+def update_procedure(vehicle, lang, publish_type, doc):
+ # To validate updated procedure status
+ doc = frappe.get_doc("Publish", doc)
+ current_db_name = frappe.conf.get("db_name")
+ procedure_status = frappe.db.sql("""select p.name,p.update_procedure_status,pro.name,p.variant_mapping,p.system,p.sub_system,p.asset_category,
+ p.item_category,p.variant,p.procedure_link,p.procedure_status,pro.name,pro.workflow_state
+ from {0}.`tabPublish_Docs` as p,{0}.`tabProcedure` as pro
+ where p.parent = "{1}" and p.procedure_link = pro.name and pro.workflow_state != p.update_procedure_status
+ and p.procedure_link is not null""".format(current_db_name, doc.name), as_dict=1)
+ l = len(procedure_status)
+ if procedure_status:
+ for x in procedure_status:
+ for y in doc.get("publish_documents"):
+ if y.procedure_link:
+ if x.procedure_link == y.procedure_link and x.workflow_state != y.update_procedure_status:
+ y.update_procedure_status = x.workflow_state
+ frappe.db.sql("""update `tabPublish_Docs` set update_procedure_status = %s where procedure_link = %s""", (
+ x.workflow_state, x.procedure_link))
+ frappe.db.commit()
+ if y.procedure_status == "Publish Ready":
+ if x.procedure_link == y.procedure_link and x.workflow_state != y.procedure_status and not y.excluded_global:
+ y.excluded_global = "1"
+ if x.procedure_link == y.procedure_link and x.workflow_state != y.procedure_status and x.workflow_state == "Draft" and y.procedure_status != "Publish Ready":
+ y.excluded_internal = "1"
+
+ y.save()
+ frappe.db.commit()
+ if l > 0:
+ frappe.msgprint(str(
+ l) + ' Procedure Status to be updated, Please check the Publish Documents table.')
+ draft_procedure_status = frappe.db.sql(
+ """select name from {0}.`tabPublish_Docs` where parent = "{1}" and update_procedure_status = 'Draft' and
+ procedure_link is not null""".format(current_db_name, doc.name), as_dict=1)
+ publish_table = doc.publish_documents
+ table_len = len(publish_table)
+ l1 = len(draft_procedure_status)
+ if str(l1) == str(table_len):
+ frappe.throw("There is no item for internal publish")
+
+ if doc.publish_type == "Global":
+ publish_table = doc.publish_documents
+ table_len = len(publish_table)
+ publish_record = frappe.db.sql("""select name from {0}.`tabPublish_Docs` where update_procedure_status != procedure_status and
+ update_procedure_status != 'Publish Ready' and parent = "{1}";
+ """.format(current_db_name, doc.name), as_dict=1)
+ if publish_record:
+ len_publish = len(publish_record)
+ if str(table_len) == str(len_publish):
+ frappe.throw("There is no item for global publish")
+
+# Generate Publish versions
+
+
@frappe.whitelist()
-def cal_ver(vehicle,lang,publish_type,doc):
- update_procedure(vehicle,lang,publish_type,doc)
- current_db_name = frappe.conf.get("db_name")
- doc = frappe.get_doc("Publish",doc)
- ver = frappe.db.sql("""select max(version),publish_type from {current_db_name}.tabPublish where vehicle = '{vehi}' and language = '{lang}';"""
- .format(current_db_name=current_db_name,vehi=vehicle,lang=lang))
- v = 0.0
- if publish_type == 'Global':
- if ver[0][0] == None:
- v = 1.0
- else:
- v= int(float(ver[0][0])) + 1.0
-
- elif publish_type == 'Internal':
- if ver[0][0] == None:
- v = 0.01
- else:
- v= float(ver[0][0]) + 0.01
- v = "{:.2f}".format(v)
- doc.version = v
- frappe.db.sql("""update {0}.`tabPublish` set version = '{1}' where name = '{2}'""".format(current_db_name,v,doc.name))
- frappe.db.commit()
- return v
-
-###Create global publish document for publish ready procedures
+def cal_ver(vehicle, lang, publish_type, doc):
+ update_procedure(vehicle, lang, publish_type, doc)
+ current_db_name = frappe.conf.get("db_name")
+ doc = frappe.get_doc("Publish", doc)
+ ver = frappe.db.sql("""select max(version) from `tabPublish` where vehicle = "{vehi}" and language = "{lang}";"""
+ .format(vehi=vehicle, lang=lang))
+ v = 0.0
+ if publish_type == 'Global':
+ if ver[0][0] == None:
+ v = 1.0
+ else:
+ v = int(float(ver[0][0])) + 1.0
+
+ elif publish_type == 'Internal':
+ if ver[0][0] == None:
+ v = 0.01
+ else:
+ v = float(ver[0][0]) + 0.01
+ v = "{:.2f}".format(v)
+ doc.version = v
+ frappe.db.sql("""update {0}.`tabPublish` set version = "{1}" where name = "{2}";""".format(
+ current_db_name, v, doc.name))
+ frappe.db.commit()
+ return v
+
+# Create global publish document for publish ready procedures
+
+
@frappe.whitelist()
def global_publish(doc):
- doc = frappe.get_doc("Publish",doc)
- current_db_name = frappe.conf.get("db_name")
- procedure = frappe.db.sql("""select parent,name from {0}.`tabPublish_Docs` where parent = '{1}' and update_procedure_status='Publish Ready' and procedure_link is not null""".format(current_db_name,doc.name))
- asset = frappe.db.sql("""select parent,name from {0}.`tabPublish_Docs` where parent = '{1}' and variant_mapping is not null and procedure_link is null""".format(current_db_name,doc.name))
- if not procedure and not asset:
- frappe.throw("There is no item for global publish")
-
- publish_type = "Global"
- publish_record = frappe.new_doc("Publish")
- publish_record.language = doc.language
- publish_record.publish_type = "Global"
- publish_record.release_description = doc.release_description
- publish_record.vehicle = doc.vehicle
- publish_record.vehicle_id = doc.vehicle_id
- publish_record.variant_mapping = doc.variant_mapping
- publish_record.variant_mapping_status = doc.variant_mapping_status
- publish_record.kilometer_mapping = doc.kilometer_mapping
- publish_record.km_active_status = doc.km_active_status
- publish_record.variant = doc.variant
- for table in doc.get('publish_documents'):
- if table.update_procedure_status == "Publish Ready":
- publish_table = publish_record.append('publish_documents',{})
- publish_table.variant_mapping = table.variant_mapping
- publish_table.system = table.system
- publish_table.sub_system = table.sub_system
- publish_table.procedure_link = table.procedure_link
- publish_table.procedure_status = table.procedure_status
- publish_table.update_procedure_status = table.procedure_status
- publish_table.asset_category = table.asset_category
- publish_table.item_category = table.item_category
- publish_table.variant = table.variant
- if table.variant_mapping and not table.procedure_link:
- publish_table = publish_record.append('publish_documents',{})
- publish_table.variant_mapping = table.variant_mapping
- publish_table.asset_category = table.asset_category
- publish_table.item_category = table.item_category
- publish_table.variant = table.variant
-
- publish_record.save()
- doc.global_publish = publish_record.name
- doc.save()
- frappe.msgprint('Global Publish Created for ' + publish_record.name)
+ doc = frappe.get_doc("Publish", doc)
+ current_db_name = frappe.conf.get("db_name")
+ procedure = frappe.db.sql(
+ """select parent,name from {0}.`tabPublish_Docs` where parent = "{1}" and update_procedure_status='Publish Ready' and
+ procedure_link is not null; """.format(current_db_name, doc.name))
+ asset = frappe.db.sql("""select parent,name from {0}.`tabPublish_Docs` where parent = "{1}" and variant_mapping is not null
+ and procedure_link is null""".format(current_db_name, doc.name))
+
+ if not procedure and not asset:
+ frappe.throw("There is no item for global publish")
+
+ publish_record = frappe.new_doc("Publish")
+ publish_record.language = doc.language
+ publish_record.publish_type = "Global"
+ publish_record.release_description = doc.release_description
+ publish_record.vehicle = doc.vehicle
+ publish_record.vehicle_id = doc.vehicle_id
+ publish_record.variant_mapping = doc.variant_mapping
+ publish_record.variant_mapping_status = doc.variant_mapping_status
+ publish_record.kilometer_mapping = doc.kilometer_mapping
+ publish_record.km_active_status = doc.km_active_status
+ publish_record.variant = doc.variant
+ for table in doc.get('publish_documents'):
+ if table.update_procedure_status == "Publish Ready":
+ publish_table = publish_record.append('publish_documents', {})
+ publish_table.variant_mapping = table.variant_mapping
+ publish_table.system = table.system
+ publish_table.sub_system = table.sub_system
+ publish_table.procedure_link = table.procedure_link
+ publish_table.procedure_status = table.procedure_status
+ publish_table.update_procedure_status = table.procedure_status
+ publish_table.asset_category = table.asset_category
+ publish_table.item_category = table.item_category
+ publish_table.variant = table.variant
+ if table.variant_mapping and not table.procedure_link:
+ publish_table = publish_record.append('publish_documents', {})
+ publish_table.variant_mapping = table.variant_mapping
+ publish_table.asset_category = table.asset_category
+ publish_table.item_category = table.item_category
+ publish_table.variant = table.variant
+
+ publish_record.save()
+ doc.global_publish = publish_record.name
+ doc.save()
+ frappe.msgprint('Global Publish Created for ' + publish_record.name)
+
@frappe.whitelist()
-def old_publish(vehicle,language):
- current_db_name = frappe.conf.get("db_name")
- publish_record = frappe.db.sql("""select name,publish_type from {0}.`tabPublish` where vehicle = '{1}' and language = '{2}' and publish_status='To Publish' and publish_type = 'Internal' and docstatus != '2'""".format(current_db_name,vehicle,language),as_dict=True)
- if publish_record:
- return publish_record
- global_publish_record = frappe.db.sql("""select name,publish_type from {0}.`tabPublish` where vehicle = '{1}' and language = '{2}' and publish_status='To Publish' and publish_type = 'Global' and docstatus != '2'""".format(current_db_name,vehicle,language),as_dict=True)
- if global_publish_record:
- return global_publish_record
-
-###Update System and Variant Mapping and its called from publish client script
+def old_publish(vehicle, language):
+ current_db_name = frappe.conf.get("db_name")
+ publish_record = frappe.db.sql("""select name,publish_type from {0}.`tabPublish` where vehicle = "{1}" and language = "{2}"
+ and publish_status='To Publish' and publish_type = 'Internal' and docstatus != '2'""".format(
+ current_db_name, vehicle, language), as_dict=1)
+ if publish_record:
+ return publish_record
+ global_publish_record = frappe.db.sql("""select name,publish_type from {0}.`tabPublish` where vehicle = "{1}" and language = "{2}"
+ and publish_status='To Publish' and publish_type = 'Global' and docstatus != '2'""".format(
+ current_db_name, vehicle, language), as_dict=1)
+ if global_publish_record:
+ return global_publish_record
+
+# Update System and Variant Mapping and its called from publish client script
+
+
@frappe.whitelist()
-def update_mapping(variant_mapping,doc):
- doc = frappe.get_doc("Publish",doc)
- current_db_name = frappe.conf.get("db_name")
- if doc.publish_documents:
- for variant in doc.get('publish_documents'):
- if variant.item_category == "Variant Mapping Assets":
- vm = frappe.get_doc("Variant Mapping",variant.variant_mapping)
- for v in vm.get('assets'):
- if v.category == variant.asset_category:
- v.published = '1'
- frappe.db.sql("""update {0}.`tabVariant Mapping_Assets` set published = '1' where parent = '{1}' and category = '{2}'""".format(current_db_name,variant.variant_mapping,variant.asset_category))
- frappe.db.commit()
-
- if variant.item_category == "System Mapping":
- system_mapping = frappe.db.sql("""select name from {0}.`tabSystem Mapping` where variant_mapping = '{1}' and language = '{2}'""".format(current_db_name,variant.variant_mapping,doc.language),as_dict=True)
- if system_mapping:
- for system_map in system_mapping:
- sm = frappe.get_doc("System Mapping",system_map.name)
- for sys_asset in sm.get('systems_assets'):
- if sys_asset.systems == variant.system:
- sys_asset.published = '1'
- frappe.db.sql("""update {0}.`tabSystem Mapping_System Assets` set published = '1' where parent = '{1}' and systems = '{2}'""".format(current_db_name,sm.name,variant.system))
- frappe.db.commit()
-
- for sm_item in sm.get("system_sub_systems"):
- if sm_item.systems == variant.system and sm_item.sub_systems == variant.sub_system and sm_item.procedure == variant.procedure_link:
- sm_item.procedure_is_published = '1'
- frappe.db.sql("""update {0}.`tabSystem Mapping_Sub System` set procedure_is_published = '1' where parent = '{1}' and systems = '{2}' and sub_systems = '{3}'""".format(current_db_name,sm.name,variant.system,variant.sub_system))
- frappe.db.commit()
-
-###Set filter for latest modified document
+def update_mapping(variant_mapping, doc):
+ doc = frappe.get_doc("Publish", doc)
+ current_db_name = frappe.conf.get("db_name")
+ if doc.publish_documents:
+ for variant in doc.get('publish_documents'):
+ if variant.item_category == "Variant Mapping Assets":
+ vm = frappe.get_doc("Variant Mapping", variant.variant_mapping)
+ for v in vm.get('assets'):
+ if v.category == variant.asset_category:
+ v.published = '1'
+ frappe.db.sql("""update {0}.`tabVariant Mapping_Assets` set published = '1' where parent = "{1}" and category = "{2}";""".format(
+ current_db_name, variant.variant_mapping, variant.asset_category))
+ frappe.db.commit()
+
+ if variant.item_category == "System Mapping":
+ system_mapping = frappe.db.sql("""select name from {0}.`tabSystem Mapping` where variant_mapping = "{1}" and language = "{2}";""".format(
+ current_db_name, variant.variant_mapping, doc.language), as_dict=1)
+ if system_mapping:
+ for system_map in system_mapping:
+ sm = frappe.get_doc("System Mapping", system_map.name)
+ for sys_asset in sm.get('systems_assets'):
+ if sys_asset.systems == variant.system:
+ sys_asset.published = '1'
+ frappe.db.sql("""update {0}.`tabSystem Mapping_System Assets` set published = '1' where parent = "{1}" and systems = "{2}";""".format(
+ current_db_name, sm.name, variant.system))
+ frappe.db.commit()
+
+ for sm_item in sm.get("system_sub_systems"):
+ if sm_item.systems == variant.system and sm_item.sub_systems == variant.sub_system and sm_item.procedure == variant.procedure_link:
+ sm_item.procedure_is_published = '1'
+ frappe.db.sql("""update {0}.`tabSystem Mapping_Sub System` set procedure_is_published = '1' where parent = "{1}"
+ and systems = "{2}" and sub_systems = "{3}";""".format(
+ current_db_name, sm.name, variant.system, variant.sub_system))
+ frappe.db.commit()
+
+# Set filter for latest modified document
+
+
@frappe.whitelist()
-def get_vm_asset(doc):
- doc = frappe.get_doc("Variant Mapping",doc)
- vm_assets = frappe.db.sql("""select category,language,attach_file,active_status from {0}.`tabVariant Mapping_Assets` where parent = '{1}' and published = '0'""".format(current_db_name,doc.name),as_dict=True)
- return vm_assets
+def get_vm_asset(doc,lang):
+ doc = frappe.get_doc("Variant Mapping", doc)
+ vm_assets = frappe.db.sql("""select category,language,attach_file,active_status from {0}.`tabVariant Mapping_Assets`
+ where parent = "{1}" and language '{2}' and published = '0'; """.format(current_db_name, doc.name,lang), as_dict=1)
+ return vm_assets
+
@frappe.whitelist()
-def get_sm_asset(doc,name):
- system_map = frappe.db.sql("""select name from {0}.`tabSystem Mapping` where variant_mapping='{1}' and name = '{2}'""".format(current_db_name,doc,name),as_dict=True)
- if system_map:
- for s in system_map:
- doc = frappe.get_doc("System Mapping",s.name)
- system_asset = frappe.db.sql("""select systems,language,active_status,system_asset from {0}.`tabSystem Mapping_System Assets` where parent = '{1}' and published = '0'""".format(current_db_name,s.name),as_dict=True)
- return system_asset
-
+def get_sm_asset(doc, name,lang):
+ system_map = frappe.db.sql("""select name from {0}.`tabSystem Mapping` where variant_mapping="{1}" and name = "{2}" and language = '{3}'; """.format(
+ current_db_name, doc, name,lang), as_dict=1)
+ if system_map:
+ for s in system_map:
+ doc = frappe.get_doc("System Mapping", s.name)
+ system_asset = frappe.db.sql("""select systems,language,active_status,system_asset from {0}.`tabSystem Mapping_System Assets`
+ where parent = "{1}" and language = "{2}" and published = '0'; """.format(current_db_name, s.name,lang), as_dict=1)
+ return system_asset
+
+
@frappe.whitelist()
-def get_system(doc,name):
- system_map = frappe.db.sql("""select name from {0}.`tabSystem Mapping` where variant_mapping='{1}' and name = '{2}'""".format(current_db_name,doc,name),as_dict=True)
- if system_map:
- for s in system_map:
- doc = frappe.get_doc("System Mapping",s.name)
- system = frappe.db.sql("""select systems,sub_systems,active_status,symptom,component,estimate_time,rts,component,mat,procedure_status,`procedure` from {0}.`tabSystem Mapping_Sub System` where parent = '{1}' and procedure_is_published = '0'""".format(current_db_name,s.name),as_dict=True)
- return system
+def get_system(doc, name,lang):
+ system_map = frappe.db.sql("""select name from {0}.`tabSystem Mapping` where variant_mapping="{1}" and name = "{2}" and language = "{3}";""".format(
+ current_db_name, doc, name,lang), as_dict=1)
+ if system_map:
+ for s in system_map:
+ doc = frappe.get_doc("System Mapping", s.name)
+ system = frappe.db.sql("""select systems,sub_systems,active_status,symptom,component,estimate_time,rts,component,mat,
+ procedure_status,`procedure` from {0}.`tabSystem Mapping_Sub System` where parent = "{1}" and procedure_status != "Draft" and
+ procedure_is_published = "0";""".format(current_db_name, s.name), as_dict=1)
+ return system
@frappe.whitelist()
def max_publish(doc):
- doc = frappe.get_doc("Publish",doc)
- ver = frappe.db.sql("""select max(version) from {0}.tabPublish where vehicle = '{1}' and language = '{2}';""".format(current_db_name,doc.vehicle,doc.language))
- if ver:
- return ver
+ doc = frappe.get_doc("Publish", doc)
+ ver = frappe.db.sql("""select max(version) from {0}.tabPublish where vehicle = "{1}" and language = "{2}";""".format(
+ current_db_name, doc.vehicle, doc.language))
+ if ver:
+ return ver
+
@frappe.whitelist()
def variant(doctype, txt, searchfield, start, page_len, filters):
- vehicle = filters.get('vehicle')
- return frappe.db.sql(""" select name,family_code,fuel,transmission,vehicle_segment,active_status
- FROM {0}.`tabVariant Mapping` where vehicle = '{1}' and
- (active_status like "%%%(txt)s%%" or vehicle_segment like "%%%(txt)s%%" or name like "%%%(txt)s%%" or variant like "%%%(txt)s%%" or family_code like "%%%(txt)s%%" or fuel like "%%%(txt)s%%" or transmission like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name,vehicle)%{'txt': txt, 'start': start, 'page_len': page_len})
+ vehicle = filters.get('vehicle')
+ return frappe.db.sql(""" select name,family_code,fuel,transmission,vehicle_segment,active_status
+ FROM {0}.`tabVariant Mapping` where vehicle = "{1}" and
+ (active_status like "%%%(txt)s%%" or vehicle_segment like "%%%(txt)s%%" or name like "%%%(txt)s%%" or variant like "%%%(txt)s%%" or
+ family_code like "%%%(txt)s%%" or fuel like "%%%(txt)s%%" or transmission like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name, vehicle) % {'txt': txt, 'start': start, 'page_len': page_len})
+
+
+@frappe.whitelist()
+def update_procedure_value(name, file_path):
+ self = frappe.get_doc("Publish", name)
+
+ frappe.db.sql(
+ f'''update `tabPublish` set file_path = "{file_path}" where name = "{name}";''')
+ frappe.db.commit()
+ current_db_name = frappe.conf.get("db_name")
+ # To validate updated procedure status
+ procedure_status = frappe.db.sql("""select p.name,p.update_procedure_status,pro.name,p.variant_mapping,p.system,p.sub_system,
+ p.asset_category,p.item_category,p.variant,p.procedure_link,p.procedure_status,pro.name,pro.workflow_state
+ from {0}.`tabPublish_Docs` as p,{0}.`tabProcedure` as pro where p.parent = "{1}" and
+ p.procedure_link = pro.name and p.procedure_link is not null""".format(current_db_name, self.name), as_dict=1)
+ # l = len(procedure_status)
+
+ if procedure_status:
+ for x in procedure_status:
+ for y in self.get("publish_documents"):
+ if y.procedure_link:
+ if x.procedure_link == y.procedure_link and y.update_procedure_status != y.procedure_status:
+ y.update_procedure_status = x.workflow_state
+ frappe.db.sql("""update `tabPublish_Docs` set update_procedure_status = %s where parent = %s and procedure_link = %s ; """, (
+ x.workflow_state, self.name, x.procedure_link))
+ frappe.db.commit()
+ if x.procedure_link == y.procedure_link and x.workflow_state != y.procedure_status:
+ y.update_procedure_status = x.workflow_state
+ frappe.db.sql("""update `tabPublish_Docs` set update_procedure_status = %s where parent = %s and procedure_link = %s""", (
+ x.workflow_state, self.name, x.procedure_link))
+ frappe.db.commit()
+ if y.procedure_status == "Publish Ready":
+ if x.procedure_link == y.procedure_link and x.workflow_state != y.procedure_status and not y.excluded_global:
+ y.excluded_global = "1"
+ if x.procedure_link == y.procedure_link and x.workflow_state != y.procedure_status and x.workflow_state == "Draft" and y.procedure_status != "Publish Ready":
+ y.excluded_internal = "1"
+ y.save()
+ frappe.db.commit()
+
+ # Update system and variant mapping ststus
+ if self.publish_type == "Global":
+ current_db_name = frappe.conf.get("db_name")
+ global_publish = frappe.db.sql("""select name from {0}.`tabPublish` where global_publish = "{1}";""".format(
+ current_db_name, self.name), as_dict=True)
+ for global_name in global_publish:
+ update_mapping(self.variant_mapping, global_name.name)
+
+ u_id = frappe.get_all(
+ "User", filters={"name": frappe.session.user}, fields=["username"])
+ if u_id:
+ for i in u_id:
+ name = i.username
+ if not self.published_by:
+ self.published_by = str(name)
+ frappe.db.set_value(
+ "Publish", self.name, "published_by", str(name))
+ frappe.db.commit()
diff --git a/smart_service/transactions/doctype/publish_docs/__pycache__/__init__.cpython-38.pyc b/smart_service/transactions/doctype/publish_docs/__pycache__/__init__.cpython-38.pyc
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diff --git a/smart_service/transactions/doctype/publish_temp_doc/__pycache__/__init__.cpython-38.pyc b/smart_service/transactions/doctype/publish_temp_doc/__pycache__/__init__.cpython-38.pyc
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diff --git a/smart_service/transactions/doctype/system_mapping/__pycache__/__init__.cpython-38.pyc b/smart_service/transactions/doctype/system_mapping/__pycache__/__init__.cpython-38.pyc
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diff --git a/smart_service/transactions/doctype/system_mapping/__pycache__/system_mapping.cpython-38.pyc b/smart_service/transactions/doctype/system_mapping/__pycache__/system_mapping.cpython-38.pyc
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diff --git a/smart_service/transactions/doctype/system_mapping/system_mapping.py b/smart_service/transactions/doctype/system_mapping/system_mapping.py
index 8be2972..50ab0e0 100644
--- a/smart_service/transactions/doctype/system_mapping/system_mapping.py
+++ b/smart_service/transactions/doctype/system_mapping/system_mapping.py
@@ -6,7 +6,7 @@ from frappe.model.document import Document
current_db_name = frappe.conf.get("db_name")
import sys
sys.tracebacklimit=0
-
+import re
class SystemMapping(Document):
@@ -14,35 +14,77 @@ class SystemMapping(Document):
###Set Procedure Status and Active status in DB level
for x in self.get("system_sub_systems"):
- procedure = frappe.db.sql("""select name,workflow_state from {0}.`tabProcedure` where name = '{1}'""".format(current_db_name,x.procedure),as_dict=True)
- procedure = frappe.db.get_value('Procedure', x.procedure, 'workflow_state')
- x.procedure_status = str(procedure)
- frappe.flags.mute_messages = True
- frappe.msgprint(str(procedure))
- x.save()
- frappe.flags.mute_messages = True
+ procedure = frappe.db.sql("""select name,workflow_state from {0}.`tabProcedure` where name = "{1}";""".format(
+ current_db_name,x.procedure),as_dict=1)
+ procedure = frappe.db.get_value("Procedure", x.procedure, "workflow_state")
+ frappe.db.sql("""update `tabSystem Mapping_Sub System` set procedure_status = %s where parent = %s and `procedure` = %s ; """, (
+ str(procedure), self.name, x.procedure))
+ frappe.db.commit()
+ # x.procedure_status = str(procedure)
+ # frappe.flags.mute_messages = True
+ # frappe.msgprint(str(procedure))
+ # x.save()
+ # frappe.flags.mute_messages = True
- po = frappe.db.sql("""select procedure_status from {0}.`tabSystem Mapping_Sub System` where parent = '{1}'""".format(current_db_name,self.name))
+ # po = frappe.db.sql("""select procedure_status from {0}.`tabSystem Mapping_Sub System` where parent = "{1}";""".format(current_db_name,self.name))
frappe.db.commit()
- km = frappe.db.sql("""select name,active_status from {0}.`tabKilometer Mapping` where variant_mapping = '{1}'""".format(current_db_name,self.variant_mapping),as_dict=True)
+ km = frappe.db.sql("""select name,active_status from {0}.`tabKilometer Mapping` where variant_mapping = "{1}";""".format(
+ current_db_name,self.variant_mapping),as_dict=True)
if km:
for status in km:
- self.km_active_status = status.active_status
+ frappe.db.sql("""update `tabSystem Mapping` set km_active_status = "{0}" where name = "{1}"
+ """.format(status.active_status,self.name))
+ frappe.db.commit()
+ # self.km_active_status = status.active_status
+
+ def validate(self):
+ if self.system_sub_systems:
+ for x in self.get("system_sub_systems"):
+ if x.procedure:
+ res_str = re.sub("–", "–", x.procedure)
+ res_str = re.sub("–", "—", x.procedure)
+ res_str = re.sub("—", "–", res_str)
+ res_str = re.sub("‘", "‘", res_str)
+ res_str = re.sub("’", "’", res_str)
+ res_str = re.sub("“", "“", res_str)
+ res_str = re.sub("â€", "”", res_str)
+ res_str = re.sub("Â", "", res_str)
+ x.procedure = res_str
- def validate(self):
+ if x.systems:
+ res_str = re.sub("–", "—", x.systems)
+ res_str = re.sub("—", "–", res_str)
+ res_str = re.sub("‘", "‘", res_str)
+ res_str = re.sub("’", "’", res_str)
+ res_str = re.sub("“", "“", res_str)
+ res_str = re.sub("â€", "”", res_str)
+ res_str = re.sub("Â", "", res_str)
+ x.systems = res_str
+
+ if x.sub_systems:
+ res_str = re.sub("–", "—", x.sub_systems)
+ res_str = re.sub("—", "–", res_str)
+ res_str = re.sub("‘", "‘", res_str)
+ res_str = re.sub("’", "’", res_str)
+ res_str = re.sub("“", "“", res_str)
+ res_str = re.sub("â€", "”", res_str)
+ res_str = re.sub("Â", "", res_str)
+ x.sub_systems = res_str
+
###On creation of System Mapping to create Kilometer Mapping record
- km = frappe.db.sql("""select name from {0}.`tabKilometer Mapping` where variant_mapping = '{1}' and language = '{2}'""".format(current_db_name,self.variant_mapping,self.language),as_list=True)
+ km = frappe.db.sql("""select name from {0}.`tabKilometer Mapping` where variant_mapping = "{1}" and language = "{2}";""".format(current_db_name,self.variant_mapping,self.language),as_list=True)
if not km:
mat = []
km_record = frappe.new_doc("Kilometer Mapping")
km_record.variant_mapping = self.variant_mapping
km_record.language = self.language
- vehicle_sk = frappe.db.sql("""select service_kilometers from {0}.`tabVehicle_SK` where parent = '{1}' order by service_kilometers""".format(current_db_name,self.vehicle),as_dict=True)
+ vehicle_sk = frappe.db.sql("""select service_kilometers from {0}.`tabVehicle_SK` where parent = "{1}"
+ order by service_kilometers""".format(current_db_name,self.vehicle),as_dict=1)
for service_km in vehicle_sk:
- for sys in self.get('system_sub_systems'):
+ for sys in self.get("system_sub_systems"):
if sys.mat:
- sub_system = km_record.append('config_kilometer', {})
+ sub_system = km_record.append("config_kilometer", {})
sub_system.kilometer = str(service_km.service_kilometers)
sub_system.mat = sys.mat
sub_system.systems = sys.systems
@@ -55,16 +97,16 @@ class SystemMapping(Document):
###Should not allow duplicate mat code value
mat_code = []
- for sm in self.get('system_sub_systems'):
+ for sm in self.get("system_sub_systems"):
if str(sm.mat):
if str(sm.mat) in mat_code:
- frappe.throw('You Cannot Select Same MAT ' + str(sm.mat) + ' Multiple Times' + ' in Row no ' + str(sm.idx))
+ frappe.throw("You Cannot Select Same MAT " + str(sm.mat) + " Multiple Times" + " in Row no " + str(sm.idx))
else:
mat_code.append(sm.mat)
###If anything change system and subsystem table to be set Published flag as 0
systems = frappe.db.sql("""select systems,sub_systems,active_status,estimate_time,idx,rts,mat,cover_image,`procedure`
- from {0}.`tabSystem Mapping_Sub System` where parent = '{1}'""".format(current_db_name,self.name),as_dict=True)
+ from {0}.`tabSystem Mapping_Sub System` where parent = "{1}";""".format(current_db_name,self.name),as_dict=1)
if systems:
for prev_system in systems:
for cur_system in self.get("system_sub_systems"):
@@ -94,29 +136,30 @@ class SystemMapping(Document):
cur_system.procedure_is_published = "0"
update_procedure(current_db_name,self.name,str(cur_system.idx))
- assets = frappe.db.sql("""select systems,idx,active_status,system_asset,remarks from {0}.`tabSystem Mapping_System Assets` where parent = '{1}'""".format(current_db_name,self.name),as_dict=True)
+ assets = frappe.db.sql("""select systems,idx,active_status,system_asset,remarks from {0}.`tabSystem Mapping_System Assets`
+ where parent = "{1}";""".format(current_db_name,self.name),as_dict=1)
if assets:
for x in assets:
for y in self.get("systems_assets"):
if x.idx == y.idx and y.systems == x.systems:
if y.active_status != x.active_status:
y.published = "0"
- frappe.db.sql("""update {0}.`tabSystem Mapping_System Assets` set published = '0' where parent = '{1}' and idx = '{2}'""".format(current_db_name,self.name,str(y.idx)))
+ frappe.db.sql("""update {0}.`tabSystem Mapping_System Assets` set published = "0" where parent = "{1}" and idx = "{2}";""".format(current_db_name,self.name,str(y.idx)))
frappe.db.commit()
if y.system_asset != x.system_asset:
y.published = "0"
- frappe.db.sql("""update {0}.`tabSystem Mapping_System Assets` set published = '0' where parent = '{1}' and idx = '{2}'""".format(current_db_name,self.name,str(y.idx)))
+ frappe.db.sql("""update {0}.`tabSystem Mapping_System Assets` set published = "0" where parent = "{1}" and idx = "{2}";""".format(current_db_name,self.name,str(y.idx)))
frappe.db.commit()
if y.remarks != x.remarks:
y.published = "0"
- frappe.db.sql("""update {0}.`tabSystem Mapping_System Assets` set published = '0' where parent = '{1}' and idx = '{2}'""".format(current_db_name,self.name,str(y.idx)))
+ frappe.db.sql("""update {0}.`tabSystem Mapping_System Assets` set published = "0" where parent = "{1}" and idx = "{2}";""".format(current_db_name,self.name,str(y.idx)))
frappe.db.commit()
###Mandatory fields for system mapping table
for system in self.get("system_sub_systems"):
if not system.procedure:
- frappe.throw('Procedure to be added in row no ' + str(system.idx))
- values = self.get('system_sub_systems')
+ frappe.throw("Procedure to be added in row no " + str(system.idx))
+ values = self.get("system_sub_systems")
for i in range(0, len(values)):
if values[i].systems:
for x in range(i + 1, len(values)):
@@ -136,7 +179,7 @@ class SystemMapping(Document):
###Method called from validation fucntion
def update_procedure(current_db_name,name,idx):
- frappe.db.sql("""update {0}.`tabSystem Mapping_Sub System` set procedure_is_published = '0' where parent = '{1}' and idx = '{2}'""".format(current_db_name,name,idx))
+ frappe.db.sql("""update {0}.`tabSystem Mapping_Sub System` set procedure_is_published = "0" where parent = "{1}" and idx = "{2}";""".format(current_db_name,name,idx))
frappe.db.commit()
###Method called from system mapping js file
@@ -150,7 +193,7 @@ def update_mat(doc,km,vehicle,type,idx,systems,sub_systems,mat_initial,mat_updat
###Updating MAT in kilometer mapping for edited mat
if type == "Edited":
- subsystem_record = frappe.db.sql("""select systems,sub_systems,mat,idx from {0}.`tabSystem Mapping_Sub System` where parent = '{1}'""".format(current_db_name,doc.name),as_dict=True)
+ subsystem_record = frappe.db.sql("""select systems,sub_systems,mat,idx from {0}.`tabSystem Mapping_Sub System` where parent = "{1}";""".format(current_db_name,doc.name),as_dict=True)
for km in kilometer_mapping.get("config_kilometer"):
for sys in subsystem_record:
if str(sub_systems) == str(km.sub_systems) and str(idx) == str(km.row_name):
@@ -166,53 +209,61 @@ def update_mat(doc,km,vehicle,type,idx,systems,sub_systems,mat_initial,mat_updat
###Insert MAT in kilometer mappnig for added mat
if mat:
if type == "Added" or type == "New":
- vehicle_sk = frappe.db.sql("""select service_kilometers from {0}.`tabVehicle_SK` where parent = '{1}' order by service_kilometers""".format(current_db_name,vehicle),as_dict=True)
+ vehicle_sk = frappe.db.sql("""select service_kilometers from {0}.`tabVehicle_SK` where parent = "{1}" order by service_kilometers""".format(current_db_name,vehicle),as_dict=True)
for service_km in vehicle_sk:
- sub_system = kilometer_mapping.append('config_kilometer', {})
- sub_system.kilometer = str(service_km.service_kilometers)
- sub_system.mat = str(mat)
- sub_system.systems = str(systems)
- sub_system.row_name = str(idx)
- sub_system.sub_systems = str(sub_systems)
- sub_system.applicable = km_applicable
+
+ data = frappe.db.sql("""select name from {0}.`tabKilometer Mapping_Items` where parent = "{1}" and kilometer = "{2}" and sub_systems = "{3}" and
+ mat = '{4}'""".format(current_db_name,kilometer_mapping.name,service_km.service_kilometers,str(sub_systems),str(mat)),as_dict=True)
+ if data:
+ pass
+ else:
+ # if service_km.service_kilometers != km.kilometer and str(sub_systems) != km.sub_systems:
+ sub_system = kilometer_mapping.append("config_kilometer", {})
+ sub_system.kilometer = str(service_km.service_kilometers)
+ sub_system.mat = str(mat)
+ sub_system.systems = str(systems)
+ sub_system.row_name = str(idx)
+ sub_system.sub_systems = str(sub_systems)
+ sub_system.applicable = km_applicable
+
kilometer_mapping.save()
###Delete kilometer mapping item depends on System and Sub system
if type == "Deleted":
for km in kilometer_mapping.get("config_kilometer"):
if km.row_name == str(idx):
- frappe.db.sql("""delete from {0}.`tabKilometer Mapping_Items` where parent = '{1}' and row_name = '{2}'""".format(current_db_name,kilometer_mapping.name,str(idx)))
+ frappe.db.sql("""delete from {0}.`tabKilometer Mapping_Items` where parent = "{1}" and row_name = "{2}";""".format(current_db_name,kilometer_mapping.name,str(idx)))
###Filter applied depends on last modified records and its called from system mapping js file
def variant(doctype, txt, searchfield, start, page_len, filters):
return frappe.db.sql(""" select name,variant,vehicle,vehicle_segment,active_status
FROM {0}.tabVariant where
- (active_status like "%%%(txt)s%%" or vehicle_segment like "%%%(txt)s%%" or name like "%%%(txt)s%%" or variant like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name)%{'txt': txt, 'start': start, 'page_len': page_len})
+ (active_status like "%%%(txt)s%%" or vehicle_segment like "%%%(txt)s%%" or name like "%%%(txt)s%%" or variant like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name)%{"txt": txt, "start": start, "page_len": page_len})
@frappe.whitelist()
def systems(doctype, txt, searchfield, start, page_len, filters):
return frappe.db.sql(""" select name FROM {0}.tabSystems where
- (name like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name)%{'txt': txt, 'start': start, 'page_len': page_len})
+ (name like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name)%{"txt": txt, "start": start, "page_len": page_len})
@frappe.whitelist()
def sub_systems(doctype, txt, searchfield, start, page_len, filters):
return frappe.db.sql(""" select name FROM {0}.`tabSub Systems` where
- (name like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name)%{'txt': txt, 'start': start, 'page_len': page_len})
+ (name like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name)%{"txt": txt, "start": start, "page_len": page_len})
@frappe.whitelist()
def procedure(doctype, txt, searchfield, start, page_len, filters):
return frappe.db.sql(""" select name FROM {0}.`tabProcedure` where
- (name like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name)%{'txt': txt, 'start': start, 'page_len': page_len})
+ (name like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name)%{"txt": txt, "start": start, "page_len": page_len})
@frappe.whitelist()
def system_filter(doctype, txt, searchfield, start, page_len, filters):
- name = filters.get('system_filter')
- system = frappe.db.sql("""select name FROM {0}.`tabSystems` where name LIKE '{1}' and
- (name like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name,name)%{'txt': txt, 'start': start, 'page_len': page_len})
+ name = filters.get("system_filter")
+ system = frappe.db.sql("""select name FROM {0}.`tabSystems` where name LIKE "{1}" and
+ (name like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name,name)%{"txt": txt, "start": start, "page_len": page_len})
if system:
return system
else:
return frappe.db.sql(""" select name FROM {0}.`tabSystems` where
- (name like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name)%{'txt': txt, 'start': start, 'page_len': page_len})
+ (name like "%%%(txt)s%%") order by modified desc limit %(start)s, %(page_len)s """.format(current_db_name)%{"txt": txt, "start": start, "page_len": page_len})
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diff --git a/smart_service/transactions/doctype/variant_mapping/__pycache__/__init__.cpython-38.pyc b/smart_service/transactions/doctype/variant_mapping/__pycache__/__init__.cpython-38.pyc
index 08e9139..affbedd 100644
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diff --git a/smart_service/transactions/doctype/variant_mapping/__pycache__/variant_mapping.cpython-38.pyc b/smart_service/transactions/doctype/variant_mapping/__pycache__/variant_mapping.cpython-38.pyc
index f32f2f3..60f95e5 100644
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diff --git a/smart_service/transactions/doctype/variant_mapping_assets/__pycache__/__init__.cpython-38.pyc b/smart_service/transactions/doctype/variant_mapping_assets/__pycache__/__init__.cpython-38.pyc
index 6235cdf..c62598e 100644
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diff --git a/smart_service/transactions/doctype/variant_mapping_assets/__pycache__/variant_mapping_assets.cpython-38.pyc b/smart_service/transactions/doctype/variant_mapping_assets/__pycache__/variant_mapping_assets.cpython-38.pyc
index d5449ce..192f76d 100644
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diff --git a/smart_service/transactions/report/__pycache__/__init__.cpython-38.pyc b/smart_service/transactions/report/__pycache__/__init__.cpython-38.pyc
deleted file mode 100644
index a50f4db..0000000
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diff --git a/smart_service/transactions/report/audit_report/audit_report.py b/smart_service/transactions/report/audit_report/audit_report.py
index 4a461ae..6957396 100644
--- a/smart_service/transactions/report/audit_report/audit_report.py
+++ b/smart_service/transactions/report/audit_report/audit_report.py
@@ -16,7 +16,10 @@ activeStatusQuerycase= "case when active_status = 'Active' then 'A' else 'IA' en
def execute(filters=None):
+
data = getData(filters)
+ if not data:
+ data = []
columns = getColumns()
return columns, data
diff --git a/smart_service/transactions/report/kilometer_mapping/__pycache__/__init__.cpython-38.pyc b/smart_service/transactions/report/kilometer_mapping/__pycache__/__init__.cpython-38.pyc
index 2945143..57033b6 100644
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diff --git a/smart_service/transactions/report/kilometer_mapping/__pycache__/kilometer_mapping.cpython-38.pyc b/smart_service/transactions/report/kilometer_mapping/__pycache__/kilometer_mapping.cpython-38.pyc
index 5ad891f..7b3d6db 100644
Binary files a/smart_service/transactions/report/kilometer_mapping/__pycache__/kilometer_mapping.cpython-38.pyc and b/smart_service/transactions/report/kilometer_mapping/__pycache__/kilometer_mapping.cpython-38.pyc differ
diff --git a/smart_service/transactions/report/procedure_report/procedure_report.js b/smart_service/transactions/report/procedure_report/procedure_report.js
index 5caca7b..8b52c4d 100644
--- a/smart_service/transactions/report/procedure_report/procedure_report.js
+++ b/smart_service/transactions/report/procedure_report/procedure_report.js
@@ -126,21 +126,21 @@ frappe.query_reports["Procedure Report"] = {
}
- if(data && String(column.fieldname).slice(3)=='workflow_state'){
- if (value !== undefined){
+ if (data && String(column.fieldname).slice(3) == 'workflow_state') {
+ if (value !== undefined) {
value = `
`
- var langCode = String(column.fieldname).slice(0,2)
- var proc = String(data.procedure).slice(0,-2)
- column.link_onclick = "frappe.query_reports['_Procedure Report'].set_route(" + JSON.stringify(proc+langCode) + ")"
+ var langCode = String(column.fieldname).slice(0, 2)
+ var proc = String(data.procedure).slice(0, -2)
+ column.link_onclick = "frappe.query_reports['_Procedure Report'].set_route(" + JSON.stringify(proc + langCode) + ")"
}
}
- if(data && String(column.fieldname).slice(2) == '_active_status'){
- switch(data.indent){
- case 2:
- if(value !== undefined){
+ if (data && String(column.fieldname).slice(2) == '_active_status') {
+ switch (data.indent) {
+ case 2:
+ if (value !== undefined) {
newValue = ""
val = String(value).split(' / ');
switch (val[0]) {
@@ -151,12 +151,12 @@ frappe.query_reports["Procedure Report"] = {
newValue = ` ${val[0]} `
break;
}
- value = newValue +" / "+ ` ${val[1]} `
+ value = newValue + " / " + ` ${val[1]} `
}
break;
case 3:
- column.align= 'center'
- if (value !==undefined){
+ column.align = 'center'
+ if (value !== undefined) {
value = ` ${value} `
}
break;
diff --git a/smart_service/www/__init__.py b/smart_service/www/__init__.py
new file mode 100644
index 0000000..e69de29
diff --git a/smart_service/www/__pycache__/login.cpython-38.pyc b/smart_service/www/__pycache__/login.cpython-38.pyc
deleted file mode 100644
index 0075bab..0000000
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