TIAGO TIGOR BSVI - SERVICE MANUAL
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TIAGO TIGOR BSVI - SERVICE MANUAL |
1 |
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INDEX |
5 |
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ENGINE |
6 |
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CONTENTS |
7 |
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1.1. GENERAL INFORMATION |
7 |
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A. ENGINE INTRODUCTION |
12 |
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B. ELECTRONIC CONTROL |
13 |
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C. TECHNICAL SPECIFICATION |
14 |
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D. SPECIAL TOOLS |
15 |
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E. ASSEMBLY CLEARANCES |
18 |
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F. SEALANTS |
18 |
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G. LEAKAGE RATES |
18 |
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H. RECOMMENDED LUBRICANTS & COOLANTS |
18 |
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1.2. TROUBLESHOOTING |
19 |
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1.3. CONSTRUCTIONAL AND SERVICE DETAILS |
26 |
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A. ENGINE LIFTING |
26 |
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B. INTAKE MANIFOLD |
27 |
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C. CYLINDER HEAD COVER |
29 |
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D. CYLINDER HEAD-A |
31 |
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E. CYLINDER HEAD-B |
33 |
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F. CYLINDER BLOCK |
34 |
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G. OIL SUMP |
36 |
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H. MOVING PARTS |
38 |
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I. ENGINE TIMING |
40 |
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J. EXHAUST MANIFOLD |
42 |
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K. FUEL INJECTION EQUIPMENT |
43 |
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L. LUBRICATION PUMP AND COMPONENTS |
44 |
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M. AIR INTAKE SYSTEM |
46 |
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N. SPECIAL INSTALLATION |
48 |
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O. ENGINE SUSPENSION |
51 |
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1.4. ENGINE TESTS AND MAINTENANCE |
54 |
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A. PRELIMINARY INSPECTION |
54 |
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B. ENGINE TESTS |
55 |
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C. REGULAR MAINTENANCE |
58 |
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1.5. REPAIR AND INSPECTION DETAILS |
66 |
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A. ACCESSORY DRIVING BELT |
66 |
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B. TIMING CHAIN |
66 |
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C. CYLINDER HEAD |
66 |
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D. VALVES |
67 |
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E. CYLINDER HEAD VALVE SEATS |
69 |
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F. ROLLER FINGER FOLLOWER |
70 |
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G. HYDRAULIC LASH ADJUSTER |
70 |
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H. CAMSHAFT (INTAKE AND EXHAUST) |
70 |
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I. PISTON AND PISTON RINGS |
72 |
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J. CONNECTING RODS |
73 |
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K.CRANKSHAFT |
75 |
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L. CRANK CASE |
77 |
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M. FUEL TANK |
78 |
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N. CANISTER PURGE VALVE |
78 |
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O. CANISTER |
79 |
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1.6. ENGINE SYSTEM |
80 |
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A. AIR INTAKE SYSTEM |
80 |
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B. BLOW BY SYSTEM |
82 |
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C. LUBRICATION SYSTEM |
83 |
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D. EXHAUST SYSTEM |
87 |
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E. COOLING SYSTEM |
90 |
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F. FUEL SYSTEM |
93 |
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1.7. ENGINE ON VEHICLE SERVICE PROCEDURE |
96 |
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A. ENGINE REMOVAL AND INSTALLATION FOR MT VEHICLE |
96 |
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B. ENGINE REMOVAL AND INSTALLATION FOR AMT VEHICLE |
101 |
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C. AIR FILTER ASSY |
106 |
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D. INJECTION SYSTEM |
106 |
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E. SPARK PLUG |
107 |
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F. EXHAUST SYSTEM |
107 |
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G. FUEL SYSTEM |
110 |
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H. COOLING SYSTEM |
116 |
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I. REMOVAL OF ACCESSORIES |
119 |
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1.8. ENGINE OVEHAULING (ON OVERHAUL STAND) |
121 |
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A. ENGINE DIS-ASSEMBLY |
121 |
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I. REMOVAL OF INTAKE MANIFOLD |
121 |
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II. REMOVAL OF EXHAUST MANIFOLD |
122 |
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III. REMOVAL OF OIL SUMP |
123 |
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IV. REMOVAL OF SENSORS |
123 |
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V. REMOVAL OF ACCESSORIES |
124 |
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VI. REMOVAL OF TIMING CHAIN |
127 |
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VII. REMOVAL OF CYLINDER HEAD AND CAMSHAFT |
128 |
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VIII. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES |
129 |
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IX. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES |
131 |
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B. ENGINE ASSEMBLY |
134 |
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I. ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES |
134 |
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II. ASSEMBLY OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES |
136 |
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III. ASSEMBLY OF CYLINDER HEAD SUB-ASSEMBLIES |
138 |
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IV. ASSEMBLY OF CYLINDER HEAD |
139 |
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V. ASSEMBLY OF TIMING CHAIN |
141 |
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VI. ASSEMBLY OF ACCESSORIES DRIVING BELT |
144 |
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VII. ASSEMBLY OF ENGINE SENSORS AND PERIPHERALS |
145 |
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VIII. ASSEMBLY OF OIL SUMP |
146 |
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IX. ASSEMBLY OF EXHAUST MANIFOLD |
146 |
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X. ASSEMBLY OF INTAKE MANIFOLD |
147 |
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1.9. ENGINE MANAGEMENT SYSTEM |
148 |
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A. ABBREVIATIONS |
148 |
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B. AN OVERVIEW |
149 |
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C. ELECTRONIC CONTROL UNIT |
150 |
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D. SENSORS |
155 |
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E. ACTUATORS |
164 |
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F. SWITCH |
171 |
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GEARBOX |
177 |
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A. MT GEARBOX REMOVAL |
179 |
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B. AMT GEARBOX REMOVAL |
183 |
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MANDO STEERING |
186 |
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1 GENERAL INFORMATION |
188 |
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1.1 SPECIFICATIONS |
188 |
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1.2 SYSTEM LAYOUT |
188 |
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1.3 GENERAL DESCRIPTION |
189 |
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1.4 TIGHTENING TORQUES |
190 |
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1.5 SPECIAL TOOLS |
192 |
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2. MAINTENANCE, INSPECTION AND TEST |
193 |
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2.1 PRELIMINARY INSPECTION |
193 |
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2.2 REGULAR MAINTENANCE |
194 |
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2.3 ON VEHICLE REPAIRS |
195 |
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2.3.1 STEERING WHEEL REMOVAL |
195 |
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2.3.2 STEERING COLUMN REMOVAL |
197 |
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2.3.3 INTERMEDIATE SHAFT REMOVAL |
199 |
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2.3.4 ECU REMOVAL |
199 |
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2.3.5 MOTOR REMOVAL |
200 |
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2.3.6 RACK & PINION ASSEMBLY REMOVAL |
201 |
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3. OVERHAULING |
203 |
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3.1. OVERHAULING OF STEERING RACK AND PINION ASSEMBLY |
203 |
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3.2 PRECAUTIONS |
204 |
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3.3 DISMANTLING, INSPECTION AND ASSEMBLY |
204 |
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3.3.1 DISASSEMBLY OF RACK & PINON |
204 |
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3.3.2 INSPECTION OF DISMANTLED PARTS |
205 |
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3.3.3 ASSEMBLY OF RACK & PINON |
205 |
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3.3.4 OBJ ON-VEHICLE REMOVAL |
206 |
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3.3.5 DO’S & DON’TS |
206 |
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3.3.6 WHEEL ALIGNMENT |
210 |
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4. TROUBLESHOOTING AND DIAGNOSIS |
212 |
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5. STEERING ANGLE CALIBRATION PROCESS |
216 |
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6. EPAS ECU REPLACEMENT AND SOFTWARE UPDATE PROCEDURE IN FIELD |
223 |
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BRAKES |
227 |
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1. PRECAUTIONS |
230 |
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2. TECHNICAL SPECIFICATIONS |
231 |
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3. TIGHTENING TORQUES |
233 |
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4. DIAGNOSIS |
234 |
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5. NESSECITY OF ABS with EBD |
237 |
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6. BRAKE HYDRAULIC LINES |
238 |
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7. VACUUM BRAKE BOOSTER |
240 |
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8. WORKING OF ANTI-LOCK BRAKINGSYSTEM (ABS) |
241 |
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9. ABS COMPONENTS |
245 |
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9.1. ABS 9 ELECTRONIC CONTROL UNIT/ HYDRAULIC CONTROL UNIT (ECU / HCU) |
245 |
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9.2. HYDRAULIC CONTROL UNIT |
247 |
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9.3. WHEEL SPEED SENSOR: (MONITORSWHEEL SPEED) |
248 |
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9.4. ABS SYSTEM FAILURE WARNING LIGHT |
249 |
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10. MAINTENANCE, ADJUSTMENTS & TEST |
250 |
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10.1. FRONT BRAKE MAINTENANCE |
250 |
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10.2. REAR BRAKE MAINTENANCE |
252 |
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10.3. BRAKE TROUBLE SHOOTING |
257 |
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10.4. CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO |
258 |
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10.5. STOP LIGHT SWITCH ADJUSTMENT |
259 |
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11. ACCELERATOR PEDAL ASSEMBLY |
260 |
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12. BRAKE/CLUTCH PEDAL ASSEMBLY |
260 |
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13. SNAP TYPE BRAKE LIGHT SWITCHINSTALLATION PROCEDURE |
262 |
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14. REPAIRS |
263 |
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14.1. FRONT BRAKE ADJUSTMENT,REMOVAL AND REFITMENT |
264 |
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14.2. REMOVAL OF FRONT BRAKE DISC |
270 |
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14.3. REMOVAL AND REFITMENT OF TMC &BOOSTER ASSEMBLY |
271 |
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14.4. REAR BRAKE ASSEMBLY |
273 |
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14.5. REMOVAL AND REFITMENT OF REARBRAKE ASSEMBLY |
275 |
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14.6. REMOVAL OF PARKING BRAKELEVER |
281 |
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14.7. REMOVAL AND INSTALLATION OFPARKING BRAKE CABLE |
282 |
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14.8A. PARKING BRAKE CABLEADJUSTMENT |
283 |
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14.8B. PARKING BRAKE LEVER PRIMARYCABLE GREASING |
283 |
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14.9. REMOVAL AND REFITMENT OF ABSECU / HCU |
284 |
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14.10. REMOVAL AND REFITMENT OF FRONTWHEEL SPEED SENSOR |
285 |
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14.11. REMOVAL AND REFITMENT OF REARWHEEL SPEED SENSOR |
286 |
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15. TROUBLE SHOOTING & DIAGNOSIS |
288 |
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16. ABS ECU CONNECTOR (K2) |
290 |
|
FRONT & REAR BUMPER |
292 |
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A. FRONT BUMPER REMOVAL (TIGOR |
294 |
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B. REAR BUMPER REMOVAL (TIGOR |
295 |
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C. FRONT BUMPER REMOVAL (TIAGO) |
296 |
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D. REAR BUMPER REMOVAL (TIAGO) |
298 |
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E. BONNET |
299 |
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ELECTRICAL |
300 |
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3. ALTERNATOR |
308 |
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4. LIGHTING SYSTEM |
311 |
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4.1. A BULB SPECIFICATIONS (TIGOR ) |
311 |
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4.1. B BULB SPECIFICATIONS (TIAGO ) |
312 |
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4.2 HEAD LAMP (TIAGO) |
313 |
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4.3 TAIL LAMP (TIAGO) |
318 |
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4.4A. INFOTAINMENT SYSTEM: ( If f itted) ( 7” Di s p l a y) |
321 |
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4.4B. INFOTAINMENT SYSTEM: ( If f itted) (Level A) |
324 |
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4.5. HEAD LAMP (TIGOR ) |
329 |
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4.6 HIGH MOUNTED STOP LAMP |
336 |
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4.7 TAIL LAMP (TIGOR) |
337 |
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4.8 REMOVAL & REFITMENT OF REVERSELAMP |
339 |
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4.9 DRL |
340 |
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4.10A INFOTAINMENT SYSTEM (TIGOR) : ( If f itted) ( 7”Di sp l a y) |
341 |
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4.10B. INFOTAINMENT SYSTEM (TIGOR) : (If fitted) (Level A) |
344 |
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5.ANTENNA |
349 |
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6. INSTRUMENT CLUSTER |
350 |
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6.1. BASIC FUNCTIONAL MATRIX |
353 |
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6.2. TELL TALES MATRIX |
354 |
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6.3. DRIVER INFORMATION SYSTEM |
360 |
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6.4 REMINDER FEATURES |
367 |
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6.5 MAIN CONNECTOR PIN-OUTS |
368 |
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6.6. FUEL GAUGE DETAILS |
369 |
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6.7 TEMPERATURE BAR GRAPH DETAILS |
369 |
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6.8. CHIME TABLE |
370 |
|
6.9. DISPLAY SCREEN FLOW AND SETTINGS |
371 |
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6.10 REMOVAL OF INSTRUMENT CLUSTER |
372 |
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7. FUSE AND RELAY BOX DETAILS |
374 |
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7.1 BATTERY MOUNTED FUSE BOX (BDU) |
377 |
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7.2 ENGINE FUSE AND RELAY BOX |
378 |
|
7.3 CABIN FUSE AND RELAY BOX |
383 |
|
8. WIPER & WASHER SYSTEM |
387 |
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8.1 FRONT WIPER AND WAHSER SYSTEM LAYOUT |
388 |
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8.2 FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY |
389 |
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8.3 WIPER AND WIPER CARE |
393 |
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8.4 DIAGNOSTIC INFORMATION AND PROCEDURES |
394 |
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8.5 REMOVAL AND FITMENT OF FRONT ANDREAR WIPER |
395 |
|
9. REVERSE PARK ASSIST SYSTEM |
397 |
|
9.1 REAR PARK ASSIST SYSTEM ARCHITECTURE WITHOUT CONTROLLER (THROUGH BCM |
399 |
|
9.2 ECU to Sensor Electrical Interface |
400 |
|
9.3 REAR VIEW CAMERA |
405 |
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9.4 "Rear Park Assist System Architecture Without Controller (Through BCM) (Applicable For TIGOR) |
406 |
|
9.5 Connector Details of Rear View Camera |
406 |
|
9.6 REAR VIEW CAMERA REMOVAL (TIGOR &TIAGO) |
407 |
|
9.7 TROUBLESHOOTING |
408 |
|
10. PASSIVE ENTRY PASSIVE START (PEPS) |
409 |
|
10.1 PEPS ECU |
410 |
|
10.2 START STOP SWITCH |
412 |
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10.3 ELECTRONIC STEERING COLUMN LOCK(ESCL) |
413 |
|
10.4 LF ANTENNAS |
415 |