Background Image
Table of Contents Table of Contents
TIGOR AMT Next Page
Information
Show Menu
TIGOR AMT Next Page

 


1. TRANSAXLE 		5
1. PRECAUTION 		8
2. TRANSAXLE GENERAL INFORMATION 		9
3. TECHNICAL SPECIFCICATIONS 		10
4. TIGHTENING TORQUES 		11
5. SPECIAL TOOLS 		12
A. CLUTCH 		12
B. TRANSAXLE 		12
6. DIAGNOSIS OF TRANSAXLE 		17
7. SERVICE SCHEDULE OF TRANSAXLE 		17
8. CUT SECTION OF TRANSAXLE 		18
9. EXPLODED VIEWS OF TRANSAXLE 		19
10. REMOVAL OF TRANSAXLE FROM VEHICLE 		28
11. TRANSAXLE TA65 STAR AMT DISASSEMBLY (ON BENCH) 		31
12. SUB ASSEMBLIES 		37
13. TRANSAXLE TA65 STAR AMT ASSEMBLY 		49
2. CLUTCH 		52
1. GENERAL INFORMATION 		55
2. TEHCNICAL SPECIFCICATIONS & TIGHTENING TORQUES 		55
3. DIAGNOSIS 		58
4. CLUTCH 		60
A. THEORY OF DIAPHRAGM SPRING CLUTCH 		60
B. CONSTRUCTIONAL DETAILS 		61
C. FACTOR AFFECTING CLUTCH WEAR 		63
D. REMOVAL OF CLUTCH FROM THE CAR 		63
E. INSTALLATION OF CLUTCH ON THE CAR 		63
5. MAINTENANCE, ADJUSTMENT AND TESTS TRANSAXLE 		64
3. DRIVESHAFT 		65
1. GENERAL INFORMATION 		68
2 GENERAL GUIDELINES FOR TESTING DRIVE SHAFT NOISE 		69
3. TESTING FOR NOISE 		69
4. DRIVE SHAFT PARTS 		70
5. DISASSEMBLY PROCEDURE FOR TRIPOT JOINT 		71
6. DISASSEMBLY AND ASSEMBLY OF CV JOINT ASSEMBLY (OUTER) 		74
4. AMT KIT 		78
1. AMT-KIT LOCATION ON VEHICLE(LAYTOUT) 		81
2 NOMENCLATURE FOR AMT KIT 		82
3. TIGHTENING TORQUES AND CONSTRUCTIONAL DETAILS 		83
4. SPECIAL TOOLS 		86
5. PRECAUTIONS 		89
6. ON VEHICLE PROCEDURES 		90
A. DEPRESSURIZATION OF AMT KIT 		90
B. AMT KIT REMOVAL (FROM TOP) 		93
7. ON BENCH PROCEDURES 		96
A. OIL TANK REMOVAL AND RE-FITMENT 		96
B. MECHATRONIC GEAR ACTUATOR UNIT (MGA) REMOVAL AND RE-FITMENT 		98
C. TRANSMISSION CONTROL UNIT (TCU) REMOVAL AND RE-FITMENT 		101
D. DC MOTOR REMOVAL AND RE-FITMENT 		104
E. HYDRAULIC OIL ACCUMLATOR REMOVAL AND RE-FITMENT 		105
F. CLUTCH POSITION SENSOR REMOVAL AND RE-FITMENT 		105
G. POWER UNIT (PWU) BASE PLATE REMOVAL AND RE-FITMENT ON BENCH 		106
5. CONSOLE 		107
1. AMT GEARBOX SHIFTER AND SHIFTING MECHANISM 		110
2 DRIVING MODES 		111
3. GEAR SHIFTER CENTER CONSOLE REMOVAL AND RE-FITMENT ON VEHICLE 		112
4. GEAR SHIFTER PIN CONFIGURATION 		114
6. COMPONENT REPLACEMENT MANUAL 		115
1. DOCUMENT SCOPE 		118
2. INTENDED AUDIENCE 		118
3. TERMINOLOGIES 		118
4. CONFIDENTIALITY 		118
5. CONTACTS AT TATA MOTORS 		118
6. ROUTINE PROCEDURE FOR COMPONENT REPLACEMENT 		119
6.1 MATRIX OF ROUTINE PROCEDURE FOR COMPONENT REPLACEMENT 		119
6.2 ROUTINE PROCEDURE FOR TCU REPLACEMENT 		120
6.3 ROUTINE PROCEDURE FOR ACTUATION SYSTEM REPLACEMENT 		121
6.4 ROUTINE PROCEDURE FOR GEAR BOX REPLACEMENT 		122
6.5 ROUTINE PROCEDURE FOR PUMP/ACCUMULATOR/CLUTCH ACTUATOR REPLACEMENT 		123
6.6 ROUTINE PROCEDURE FOR VALVE BOCK AND TCU REPLACEMENT 		124
6.7 ROUTINE PROCEDURE FOR CLUTCH SENSOR REPLACEMENT 		125
6.8 ROUTINE PROCEDURE FOR CLUTCH REPLACEMENT 		126
6.9 ROUTINE PROCEDURE FOR PRIMARY SHAFT SPEED SENSOR REPLACEMENT 		127
6.10 ROUTINE PROCEDURE FOR RUBBER BELLOW REPLACEMENT 		128
6.11 ROUTINE PROCEDURE FOR RESERVOIR REPLACEMENT 		128
6.12 ROUTINE PROCEDURE FOR GEAR SHIFT LEVER OR SPORTS/ECO REPLACEMENT 		129
6.13 ROUTINE PROCEDURE FOR ELECTRIC MOTOR REPLACEMENT 		129
6.14 TCU PROGRAMMING (FLASHING) 		130
6.15 ROUTINE PROCEDURE FOR AMT KIT REPLACEMENT 		131
7. DTC MANUAL 		134
1. P0914-02: GEAR POSITION SENSOR CIRCUIT– FIXED SIGNAL HIGH LEVEL 		142
2. P0914-01: GEAR POSITION SENSOR CIRCUIT– FIXED SIGNAL LOW LEVEL 		145
3. P0914-03: GEAR POSITION SENSOR CIRCUIT– PERIOD ERROR 		148
4. P0914-05: GEAR POSITION SENSOR CIRCUIT– PWM DUTY HIGH 		151
5. P0914-04: GEAR POSITION SENSOR CIRCUIT– PWM DUTY LOW 		154
6. P1853-02: GEAR/SHIFT POSITION SENSOR– WRONG SUPPLY VOLTAGE VBATT ERROR 		157
7. P1853-01: GEAR/SHIFT POSITION SENSOR– WRONG SUPPLY VOLTAGE GND ERROR 		160
8. P0904-02: SHIFT POSITION SENSOR CIRCUIT– FIXED SIGNAL HIGH LEVEL 		163
9. P0904-01: SHIFT POSITION SENSOR CIRCUIT– FIXED SIGNAL LOW LEVEL 		166
10. P0904-03: SHIFT POSITION SENSOR CIRCUIT– PERIOD ERROR 		169
11. P0904-05: SHIFT POSITION SENSOR CIRCUIT– PWM DUTY HIGH 		172
12. P0904-04: SHIFT POSITION SENSOR CIRCUIT– PWM DUTY LOW 		175
13. P0805-02: CLUTCH POSITION SENSOR CIRCUIT– FIXED SIGNAL HIGH LEVEL 		178
14. P0805-01: CLUTCH POSITION SENSOR CIRCUIT– FIXED SIGNAL LOW LEVEL 		181
15. P0805-03: CLUTCH POSITION SENSOR CIRCUIT– PERIOD ERROR 		184
16. P0805-05: CLUTCH POSITION SENSOR CIRCUIT– PWM DUTY HIGH 		187
17. P0805-04: CLUTCH POSITION SENSOR CIRCUIT– PWM DUTY LOW 		190
18. P1852-02: CLUTCH POSITION/HYD PRESS SENSOR – WRONG SUPPLY VOLTAGE VBATT ERROR 		193
19. P1852-01: CLUTCH POSITION/HYD PRESS SENSOR – WRONG SUPPLY VOLTAGE GND ERROR 		196
20. P0932-02: HYDRAULIC PRESSURE SENSOR CIRCUIT– SIGNAL OVER MAX THRESHOLD 		199
21. P0932-01: HYDRAULIC PRESSURE SENSOR CIRCUIT– SIGNAL UNDER MIN THRESHOLD 		203
22. P0932-07: HYDRAULIC PRESSURE SENSOR CIRCUIT– WRONG VALUE SENSOR 		206
23. P0932-03: HYDRAULIC PRESSURE SENSOR CIRCUIT– WRONG SIGNAL SPIKES 		209
24. P0820/P0821/P0822/P0823-02: GEAR LEVER SENSOR CIRCUIT– OVER MAX THRESHOLD 		212
25. P0820/P0821/P0822/P0823-01: GEAR LEVER SENSOR CIRCUIT– UNDER MIN. THRESHOLD 		216
26. P0825 -02: GEAR LEVER SENSOR CIRCUIT– SIGNAL NOT VALID 		220
27. P0825 -01: GEAR LEVER SENSOR CIRCUIT– MISUSE 		224
28. P0715 -03: CLUTCH SPEED SENSOR CIRCUIT– SIGNAL ABSENT 		229
29. P0715 -01: CLUTCH SPEED SENSOR CIRCUIT– SIGNAL WRONG 		232
30. P0715 -02: CLUTCH SPEED SENSOR CIRCUIT– SIGNAL WRONG SPIKES 		235
31. P2900 -01: SPORT SWITCH INPUT CIRCUIT – SWITCH STUCK 		238
32. P0725-02: ENGINE SPEED INPUT CIRCUIT– SIGNAL NOT VALID 		241
33. P0725-03: ENGINE SPEED INPUT CIRCUIT– SIGNAL ABSENT 		244
34. P0725-01: ENGINE SPEED INPUT CIRCUIT– SIGNAL WRONG 		247
35. P0505 -02: IDLE ENGINE SPEED INPUT– SIGNAL IMPLAUSIBLE / SIGNAL WRONG 		250
36. P2903 -02: ACCELERATOR PEDAL POSITION– SIGNAL NOT VALID 		253
37. P2906 -02: GENERATED ENGINE TORQUE– SIGNAL NOT VALID 		256
38. P2906 -03: ENGINE LOSS TORQUE– SIGNAL NOT VALID 		259
39. P1981 -02: DRIVER ENGINE TORQUE– SIGNAL NOT VALID 		262
40. P2906 -04: ENGINE WISH TORQUE– SIGNAL NOT VALID 		265
41. P2907 -02: ENGINE MAXIMUM TORQUE– SIGNAL NOT VALID 		268
42. P0703 -02: BRAKE SWITCH INPUT CIRCUIT – SIGNAL NOT VALID 		271
43. P0710 -02: ENGINE WATER TEMPERATURE – SIGNAL NOT VALID 		274
44. P0716 -02: VEHICLE SPEED INPUT – SIGNAL NOT VALID 		277
45. P0716 -03: VEHICLE SPEED INPUT – SIGNAL ABSENT 		280
46. P0716 -01: VEHICLE SPEED INPUT – SIGNAL WRONG 		283
47. P0710 -03: EXTERNAL TEMPERATURE – SIGNAL NOT VALID 		286
48. P0900-04: CLUTCH ELECTROVALVE – OPEN CIRCUIT 		289
49. P0900-02: CLUTCH ELECTROVALVE – SHORT TO SUPPLY 		292
50. P0900-01: CLUTCH ELECTROVALVE – SHORT TO GROUND 		295
51. P0900-05: CLUTCH ELECTROVALVE – SHORT TO SUPPLY/OPEN CIRCUIT 		298
52. P0750-04: GEAR 1 ELECTROVALVE – OPEN CIRCUIT 		301
53. P0750-02: GEAR 1 ELECTRO VALVE – SHORT TO SUPPLY 		304
54. P0750-01: GEAR 1 ELECTROVALVE – SHORT TO GROUND 		307
55. P0750-05: GEAR 1 ELECTROVALVE – SHORT TO SUPPLY/OPEN CIRCUIT 		310
56. P0755-04: GEAR 2 ELECTROVALVE – OPEN CIRCUIT 		313
57. P0755-02: GEAR 2 ELECTROVALVE – SHORT TO SUPPLY 		316
58. P0755-01: GEAR 2 ELECTROVALVE – SHORT TO GROUND 		319
59. P0755-05: GEAR 2 ELECTROVALVE – SHORT TO SUPPLY/OPEN CIRCUIT 		322
60. P1889-04: SHIFT ELECTROVALVE – OPEN CIRCUIT 		325
61. P1889-02: SHIFT ELECTROVALVE – SHORT TO SUPPLY 		328
62. P1889-01: SHIFT ELECTROVALVE – SHORT TO GROUND 		331
63. P1889-05: SHIFT ELECTROVALVE – SHORT TO SUPPLY/OPEN CIRCUIT 		334
64. P185C-05: HYDRAULIC PUMP SUPPLY – OPEN CIRCUIT /SHORT TO SUPPLY 		337
65. P185C-01: HYDRAULIC PUMP SUPPLY –SHORT TO GROUND 		340
66. P185C-03: HYDRAULIC PUMP SUPPLY –DEVICE CLOSED 		343
67. P185C-07: HYDRAULIC PUMP SUPPLY –SHORT TO SUPPLY 		347
68. P081A-03: CRANKING ENABLE –SHORT TO GROUND/OPEN CIRCUIT 		350
69. P081A-02: CRANKING ENABLE –SHORT TO SUPPLY 		352
70. P1884-04: REVERSE LAMP RELAY –OPEN CIRCUIT 		355
71. P1884-02: REVERSE LAMP RELAY –SHORT TO SUPPLY 		358
72. P1884-01: REVERSE LAMP RELAY –SHORT TO GROUND 		361
73. P2904-01: CLUTCH SYSTEM – NOT OPENING BEFORE SHIFT 		364
74. P2904-02: CLUTCH SYSTEM – CLOSING DURING ENGAGE 		367
75. P2904-03: CLUTCH SYSTEM – OVERHEAT 		370
76. P2908-01: CLUTCH SYSTEM – CONTROL ERROR 		374
77. P1905-02: CLUTCH SYSTEM – CLUTCH LOCKED 		376
78. P2905-01: GEARBOX SYSTEM – DISENGAGE FAILED 		379
79. P2909-01: GEARBOX SYSTEM – SHIFT FAILED 		383
80. P2905-02: GEARBOX SYSTEM –ENGAGE FAILED 		387
81. P2905-03: GEARBOX SYSTEM –UNINTENDED DISENGAGE 		391
82. P2909-02: GEARBOX SYSTEM –SHIFT LOCKED 		395
83. P190B-01: GEARBOX SYSTEM –UNINTENDED ENGAGE 		399
84. P190C-07: GEARBOX SYSTEM –CONTROL ERROR 		402
85. P190D-01: GEARBOX SYSTEM –CLUTCH OVER SPEED 		405
86. P0942- 01: HYDRAULIC CIRCUIT – PRESSURE LOW 		408
87. P0942- 07: HYDRAULIC CIRCUIT – PUMP OVERHEATING 		412
88. P2712- 07: HYDRAULIC CIRCUIT – LEAKAGE TOO HIGH 		416
89. P2901- 01: HYDRAULIC CIRCUIT – ACCUMULATOR DISCHARGED 		419
90. P0780- 07: HYDRAULIC CIRCUIT – SYSTEM MISUSE 		422
91. P184A- 01: HYDRAULIC CIRCUIT – PUMP TIMEOUT 		425
92. P0562-04: BATTERY SUPPLY 1 –OPEN CIRCUIT 		428
93. P0560-01: BATTERY SUPPLY 1 –WRONG VALUE 		431
94. P0560-02: IGNITION KEY VOLTAGE –WRONG VALUE 		434
95. P0945-04: BATTERY SUPPLY 2 –OPEN CIRCUIT 		437
96. P1711-01: BATTERY SUPPLY –UNDER SHIFT THRESHOLD 		440
97. P1711-02: BATTERY SUPPLY –OVER THRESHOLD 		442
98. P1711-07: BATTERY SUPPLY –UNDER LOW THRESHOLD 		444
99. P0604- 08: TCU ROM– CHECKSUM ERROR 		446
100. P0604- 07: TCU RAM– INTEGRITY ERROR 		448
101. P062F- 07: TCU EEPROM– TUNING DATA ALTERATION ERROR 		450
102. P062F- 08: TCU EEPROM– GRID DATA ALTERATION ERROR 		452
103. P1704- 07: TCU EEPROM– SYSTEM DATA ALTERATION ERROR 		454
104. P060A- 07: SAFETY MICROPROCESSOR– INTEGRITY FAILURE 		455
105. P060A- 08: SAFETY MICROPROCESSOR– OUTPUT FAILURE 		456
106. P0701- 02: ELECTRO VALVES DRIVER 1– SPI DEVICE FAULT 		457
107. P0701- 01: ELECTRO VALVES DRIVER 1– THERMAL WARNING 		459
108. P0701- 03: ELECTRO VALVES DRIVER 1– DEVICE CLOSED 		461
109. P0701- 04: ELECTRO VALVES DRIVER 1– DEVICE OPEN 		463
110. P184D- 02: ELECTRO VALVES DRIVER 2– SPI DEVICE FAULT 		465
111. P184D- 01: ELECTRO VALVES DRIVER 2– THERMAL WARNING 		467
112. P0881- 02: TCU 12V INTERNAL SUPPLY – DEVICE OPEN 		469
113. P0881- 03: TCU 12V INTERNAL SUPPLY – DEVICE CLOSED* 		471
114. P0880- 04: SMP 5V POWER SUPPLY – UNDER LOW THRESHOLD 		473
115. P0880- 06: SMP 5V POWER SUPPLY – UNDER MEDIUM THRESHOLD 		475
116. P0880- 02: SMP 5V POWER SUPPLY – UNDER LOW THRESHOLD 		477
117. P0880- 03: TCU 5V POWER SUPPLY – DEVICE CLOSED 		479
118. P1401- 07: LEVEL 2 INTERVENTION-SAFETY INPUT FAILURE 		481
119. P1401- 08: LEVEL 2 INTERVENTION-SYSTEM PROBLEM 		483
120. P060C-07: LEVEL 3 INTERVENTION-SYSTEM PROBLEM 		485
121. P1844 -07: GRID SELF TUNING PROCEDURE – ERROR 		487
122. P080A -07: KISS POINT SELFTUNING PROCEDURE – ERROR 		490
123. P185B -07: CLUTCH STROKE SELFTUNING – ERROR 		492
124. P1886-07:- DUAL PORT RAM CHECK 		494
125. U0001-01:- CAN EMS ERROR 		495
126. C0082-00:- ABS STATUS CAN SIGNAL INVALID 		496
PRELIMINARY CHECK FOR IVN RELATED DTC’S 		497
127. U0001-88 - VEHICLE COMMUNICATION BUS A- BUS OFF 		498
128. U0121 -08:- LOST COMMUNICATION WITH ANTILOCK BRAKING SYSTEM MODULE- ABS/ESP BUS SIGNAL/ MESSAGE FAILURE 		500
129. U0155-08:- LOST COMMUNICATION WITH INSTRUMENT PANEL CLUSTER MODULE- BUS SIGNAL/ MESSAGE FAILURE 372 		506
130. U0100-08 LOSS OF COMMUNICATION WITH ENGINE CONTROL MODULE- BUS SIGNAL/ MESSAGE FAILURE 		512
131. P1C10-01:- INVALID DATA RECEIVED FROM ECM (106 FRAME)-CYCLIC REDUNDANCY CHECK ERROR 		522
132. P1C11-02:- INVALID DATA RECEIVED FROM ECM (106 FRAME) -MESSAGE ROLLING COUNTER ERROR 		525
133. P1C12-01:- INVALID DATA RECEIVED FROM ECM (108 FRAME)-CYCLIC REDUNDANCY CHECK ERROR 		527
134. P1C13-02:- INVALID DATA RECEIVED FROM ECM (108 FRAME)-MESSAGE ROLLING COUNTER ERROR 		530
135. P1C14-01:- INVALID DATA RECEIVED FROM IPC (197 FRAME)-CYCLIC REDUNDANCY CHECK ERROR 		532
136. P1C15-02:- INVALID DATA RECEIVED FROM IPC (197 FRAME)-MESSAGE ROLLING COUNTER ERROR 		534
137. P1986-07 VARIANT CODE PROCEDURE NOT COMPLETED 		536
138. U0001-02 ENGINE LIMP HOME SIGNAL-SIGNAL NOT VALID 		538
139. P0820/P0821/P0822/P0823-03: GEAR LEVER SENSOR CIRCUIT– SIGNAL IN MEDIUM RANGE 		539
GENERIC TROUBLESHOOTING GUIDELINES 		542
CAN BUS ARCHITECTURE & NETWORK TOPOLOGY 		543
IVN PRELIMINARY CHECK 		544
ABBREVIATIONS 		545
APPENDIX 		546
DIAGNOSTIC TROUBLE CODES LIST 		550
 FlippingBook