Volume 1
Precautions ........................................................ 00-i
Precautions ......................................................... 00-1
General Information ............................................ 0-i
General Information ........................................... 0A-1
Maintenance and Lubrication ............................. 0B-1
Engine ................................................................... 1-i
Precautions .......................................................... 1-1
Engine General Information and Diagnosis ....... 1A-1
Aux. Emission Control Devices .......................... 1B-1
Engine Electrical ................................................ 1C-1
Engine Mechanical ............................................ 1D-1
Engine Lubrication System ................................ 1E-1
Engine Cooling System ...................................... 1F-1
Fuel System ....................................................... 1G-1
Ignition System .................................................. 1H-1
Starting System ................................................... 1I-1
Charging System ................................................ 1J-1
Exhaust System .................................................. 1K-1
Suspension .......................................................... 2-i
Precautions ........................................................... 2-1
Suspension General Diagnosis .......................... 2A-2
Front Suspension ............................................... 2B-1
Rear Suspension ............................................... 2C-1
Wheels and Tires ............................................... 2D-1
Front Drive Shaft ................................................. 3-i
Front Drive Shaft ................................................ 3A-1
Brakes ................................................................... 4-i
Brakes ................................................................... 4-1
Brakes (With ABS) .............................................. 4A-1
ABS ..................................................................... 4B-1
Transmission ....................................................... 5-i
Manual Transmission .......................................... 5B-1
Clutch ................................................................. 5C-1
Volume 2
ecautions ........................................................ 00-i
Precautions ........................................................ 00-1
Steering ................................................................ 6-i
Steering General Diagnosis ............................... 6A-1
Steering Wheel and Column .............................. 6B-1
Electrical Power Steering System ..................... 6C-1
HVAC ...................................................................... 7-i
Precautions ........................................................... 7-1
Heater and Ventilation ........................................ 7A-1
Air Conditioning System ..................................... 7B-1
Restraint ............................................................... 8-i
Seat Belts ............................................................ 8A-1
Air Bag System ................................................... 8B-1
Body, Cab and Accessories ............................... 9-i
Precautions ........................................................... 9-1
Wiring Systems .................................................. 9A-**
(Refer wiring Diagram manual Part
No.99512M59K00-74E)
Lighting Systems ................................................ 9B-1
Instrumentation / Driver Info. / Horn .................. 9C-1
Wipers / Washers ............................................... 9D-1
Glass / Windows / Mirrors ................................... 9E-1
Security and Locks ............................................. 9F-1
Seats .................................................................. 9G-1
Interior Trim ........................................................ 9H-1
Hood / Fenders / Doors ...................................... 9J-1
Body Structure .................................................... 9K-1
Paint / Coatings ................................................... 9L-1
TABLE OF CONTENTS
Summary of Contents for Zen Estilo 2018
Page 5: ......
Page 21: ......
Page 24: ...GENERAL INFORMATION 0A 3 ...
Page 47: ......
Page 51: ......
Page 57: ...1A 6 ENGINE GENERAL INFORMATION AND DIAGNOSIS ...
Page 58: ...ENGINE GENERAL INFORMATION AND DIAGNOSIS 1A 7 ...
Page 181: ...1D 50 ENGINE MECHANICAL Main Bearings Crankshaft and Cylinder Block Components ...
Page 192: ...ENGINE MECHANICAL 1D 61 REQUIRED SERVICE MATERIALS ...
Page 193: ...1D 62 ENGINE MECHANICAL ...
Page 239: ...1H 2 IGNITION SYSTEM Schematic and Routing Diagram Ignition System Wiring Circuit Diagram ...
Page 248: ...IGNITION SYSTEM 1H 11 Special Tools ...
Page 249: ......
Page 265: ...1J 4 CHARGING SYSTEM ...
Page 272: ...CHARGING SYSTEM 1J 11 Generator Component ...
Page 281: ......
Page 287: ......
Page 289: ......
Page 297: ...2B 2 FRONT SUSPENSION ...
Page 298: ...FRONT SUSPENSION 2B 3 ...
Page 315: ......
Page 335: ......
Page 347: ......
Page 348: ...FRONT DRIVE SHAFT 3A 1 Front Drive Shaft General Description Removal Installation ...
Page 349: ...3A 2 FRONT DRIVE SHAFT Disassembly Reassembly ...
Page 418: ...BRAKES WITH ABS 4A 11 f a b c d e a b a b c e f d 1 2 6 5 4 7 8 3 ...
Page 420: ...BRAKES WITH ABS 4A 13 ...
Page 447: ......
Page 450: ...ANTILOCK BRAKE SYSTEM 4B 3 System Schematic ...
Page 452: ...ANTILOCK BRAKE SYSTEM 4B 5 System Circuit ...
Page 485: ......
Page 487: ...2 5B MANUAL TRANSMISSION ...
Page 494: ...MANUAL TRANSMISSION 5B 9 Gear Shift Control Lever and Rod ...
Page 521: ...36 5B MANUAL TRANSMISSION Special Tools ...
Page 522: ...MANUAL TRANSMISSION 5B 37 ...
Page 523: ......
Page 536: ...ii 6 TABLE OF CONTENTS ...
Page 556: ......
Page 558: ...6C 2 ELECTRICAL POWER STERRING EPS SYSTEM ...
Page 578: ......
Page 594: ......
Page 596: ......
Page 608: ......
Page 613: ...AIR CONDITIONING SYSTEM 7B 5 A C System Wiring Diagram ...
Page 648: ......
Page 650: ......
Page 657: ...AIR BAG SYSTEM 8B 3 System Components and Wiring Location View and Connectors ...
Page 718: ......
Page 728: ......
Page 734: ......
Page 760: ......
Page 766: ......
Page 773: ...BODY STRUCTURE 9K 1 Front Bumper Rear Bumper Body Structure ...
Page 774: ...9K 2 BODY STRUCTURE Body Dimensions Unit in mm ...
Page 775: ...BODY STRUCTURE 9K 3 Unit in mm Unit in mm ...
Page 776: ...9K 4 BODY STRUCTURE Unit in mm Unit in mm ...
Page 777: ...BODY STRUCTURE 9K 5 Unit in mm Under Body Dimensions ...
Page 778: ...9K 6 BODY STRUCTURE Unit in mm ...
Page 780: ......
Page 783: ...PAINT COATINGS 9L 3 Sealant Application Area ...
Page 784: ...9L 4 PAINT COATINGS ...
Page 785: ...PAINT COATINGS 9L 5 ...
Page 786: ...9L 6 PAINT COATINGS ...
Page 788: ......