Table of Contents 1 561

TIGOR AMT

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

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