TIGOR EV_ZIPTRON_SERVICE MANUAL

HV ELECTRICALSYSTEM	6
1. GENERAL INFORMATION	9
A. TOOLS	9
B. HAND GLOVES	9
C. PPES FOR HV	10
D. MEASURING TOOLS	13
E. SAFETY INSTRUCTIONS	14
F. DO’S AND DON’TS	15
G. SAFETY WHILE SERVICING	18
H. WASHING INSTRUCTIONS	22
I. ELECTRICAL COMPONENT INFORMATION	23
J. MOTOR COMPARTMENT	24
2. TYPES OF CHARGING	25
A. NORMAL CHARGING	25
B. FAST CHARGING	31
3. TIGHTENING TORQUES	33
4. SPECIAL TOOLS	38
5. INSTRUCTION FOR WORKING ON HV COMPONENTS ON VEHICLE	40
6. HV CONNECTOR CONNECTION & LOCKING PROCESS	42
7. ON VEHICLE REMOVAL	50
A. POWER DISTRIBUTION UNIT (PDU) REMOVAL	50
B. VEHICLE CONTROL UNIT	52
C. DC – DC CONVERTOR REMOVAL	53
D. ON BOARD CHARGER (OBC) REMOVAL	55
E. VACCUM PUMP REMOVAL	58
F. E - DRIVE REMOVAL	58
G. REDUCER OIL LEVEL CHECKING / DRAIN / FILLING DO & DONTS	62
8. TRACTION COOLING SYSTEM (TCS	63
A. SYSTEM LAYOUT	63
B. CIRCUIT SCHEMATICS	63
C. TCS COOLANT DRAINING PROCEDURE	64
D. TCS COOLANT FILLING PROCEDURE	64
E. TCS COOLANT PUMP REMOVAL	65
F. RADIATOR FAN REMOVAL	65
G. RADIATOR REMOVAL	66
H. CONDENSOR REMOVAL	67
I. AUX TANK RESERVIOR REMOVAL	69
9. HV BATTERY	70
A. SYSTEM LAYOUT	70
B. BATTERY PACK REPLACEMENT GUIDELINE	70
C. HV BATTERY REMOVAL	71
10. BATTERY COOLING SYSTEM (BCS)	74
A. SYSTEM LAYOUT	74
B. CIRCUIT SCHEMATICS	74
C. BCS COOLANT DRAINING PROCEDURE	75
D. BCS COOLANT FILLING PROCEDURE	75
E. COMPRESSOR	76
F. BATTERY COOLING PUMP REMOVAL	77
G. AUX TANK RESERVIOR REMOVAL	78
H. CHILLER UNIT (HEAT EXCHANGER) REMOVAL	79
I. HV / LV CHARGER PORT & CABLE REMOVAL	80
11. CRADLE	83
A. CRADLE EXPLODED VIEW	83
B. CRADLE REMOVAL	84
C. CRADLE FITMENT	85
D. A, B, & C MOUNT FITMENT SEQUENCE	87
LV ELECTRICALSYSTEM	91
1 GENERAL PRECAUTIONS	92
2 BATTERY	95
3 LIGHTING SYSTEM	98
4 WIPER & WASHER SYSTEM	118
5 SWITCHES	123
6 HORN	147
7 POWER SOCKETS	149
8 INFOTAINMENT SYSTEM	150
9 INSTRUMENT CLUSTER	159
10 IMMOBILIZER	177
11 IGNITION KEY	181
12 BODY CONTROL MODULE (BCM)	189
13 FUSE AND RELAY BOX DETAILS	205
14 REVERSE PARK ASSIST SYSTEM	217
15 PASSIVE ENTRY PASSIVE START (PEPS)	232
16 TELEMATICS	240
DRIVE SHAFT	243
1. INTRODUCTION	245
2. DRIVE SHAFT PARTS	246
3. GENERAL GUIDELINES FOR TESTING DRIVE SHAFT NOISE	246
4. TESTING FOR NOISE	247
5. TIGHTENING TORQUES	248
6. SPECIAL TOOLS	248
7. ON VEHICLE DRIVE SHAFT REMOVAL	249
8. ON VEHICLE DRIVE SHAFT ASSEMBLY	250
9. DISASSEMBLY PROCEDURE FOR DRIVE SHAFT	251
10. ASSEMBLY PROCEDURE FOR DRIVE SHAFT	253
11. PRECAUTIONS TO AVOID THE DAMAGE TO THE DRIVE SHAFT	254
12. DO’S AND DON’T’S FOR DRIVE SHAFT	255
SUSPENSION	256
1. TECHINICAL SPECIFICATIONS	258
2. TIGHTENING TORQUES	259
3. SPECIAL TOOLS	266
4. DIAGNOSIS	272
5. PRECAUTIONS	273
6. SUSPENSION SYSTEM	274
7. EXPLODED VIEWS FRONT SUSPENSION SYSTEM	277
8. ON VEHICLE PROCEDURE FRONT SUSPENSION	281
9. EXPLODED VIEWS REAR SUSPENSION SYSTEM	297
10. ON VEHICLE PROCEDURE REAR SUSPENSION	300
11. SUSPESION PRE LOADING CONDITION	308
WHEELS AND TYRES	309
1. GENERAL INFORMATION	311
A. SPECIFICATIONS	311
B. TYRE PRESSURE DETAILS	311
C. CONSTRUCTION	312
D. TIGHTENING TORQUES	315
2 GENERAL SYMPTOMS DIAGNOSIS	316
A. DIAGNOSIS CHART	316
B. TYRE WEAR PATTERN	318
C. WEAR CAUSES	319
D. TYRE VIBRATION DIAGNOSIS	320
3 MAINTENANCE, INSPECTION AND TESTS	321
A. PRELIMINARY INSPECTION	321
B. REGULAR MAINTENANCE	322
I. INFLATION	322
II. WHEEL BALANCING	322
III. TYRE ROTATION	323
IV. WHEEL RUN OUT	324
V. DO'S AND DON’TS	324
4 WHEEL AND TYRE REPLACEMENT	325
A. PRECAUTIONS DURING TYRE REPLACEMENT	325
B. TYRE REPLACEMENT	326
C. WHEEL ASSEMBLY REPLACEMENT	326
D. WHEEL REMOVAL	327
E. TYRE CARE	329
STEERING_MANDO (ELECTRICAL POWER ASSIST SYSTEM-EPAS)	330
1. TECHNICAL SPECIFICATIONS	332
2. SYSTEM LAYOUT	333
3. TIGHTENING TORQUES	334
4. SPECIAL TOOLS	336
5. MAINTENANCE, INSPECTION AND TEST	337
A. PRELIMINARY INSPECTION	337
B. REGULAR MAINTENANCE	338
6. ON VEHICLE REPAIRS	340
A. STEERING WHEEL REMOVAL	340
B. STEERING COLUMN REMOVAL	341
C. INTERMEDIATE SHAFT REMOVAL	343
D. ECU REMOVAL	343
E. MOTOR REMOVAL	344
F. RACK & PINION ASSEMBLY REMOVAL	345
7. EXPLODED VIEW OF STEERING RACK AND PINION ASSEMBLY	346
8. OVERHAULING OF STEERING RACK & PINION ASSEMBLY	347
9. DO'S & DON’T'S	349
10. WHEEL ALIGNMENT	352
11. TROUBLESHOOTING AND DIAGNOSIS	354
12. STEERING ANGLE CALIBRATION PROCESS	358
13. TUNING DATA SELECTION	363
14. EPAS ECU REPLACEMENT AND SOFTWARE UPDATE PROCEDURE IN FIELD	364
BRAKES	368
1. TECHNICAL SPECIFICATIONS	371
2. TIGHTENING TORQUES	373
3. SPECIAL TOOLS	379
4. PRECAUTIONS	379
5. DIAGNOSIS	380
6. NESSECITY OF ABS WITH EBD	383
7. BRAKE HYDRAULIC LINES	384
8. VACUUM BRAKE BOOSTER	385
9. WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS)	386
10. ABS COMPONENTS	390
10.1. ABS 9 ELECTRONIC CONTROL UNIT CIRCUIT	390
10.2. ABS 9 ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU / HCU	391
10.3. WHEEL SPEED SENSOR	392
10.4. ABS SYSTEMFAILUREWARNING LIGHT	393
11. MAINTAINANCE, ADJUSTMENTS & TEST	394
11.1. FRONT BRAKE MAINTENANCE	394
11.2. REAR BRAKE MAINTENANCE	396
11.3. BLEEDING OF HYDRAULIC SYSTEM	398
11.4. BRAKE TROUBLE SHOOTING	402
11.5. CHECKLIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO	403
11.6. STOP LIGHT SWITCH ADJUSTMENT	404
12. SNAP TYPE BRAKE LIGHT SWITCH INSTALLATION PROCEDURE	405
13. REGENERATION SENSOR REMOVAL	406
14. ACCELERATOR PEDAL ASSEMBLY REMOVAL	406
15. BRAKE PEDAL ASSEMBLY REMOVAL	407
16. REPAIRS	409
16.1. FRONT BRAKE ADJUSTMENT, REMOVAL AND REFITMENT	410
16.2. REMOVAL OF FRONT BRAKE DISC	418
16.3. REMOVAL & REFITMENT OF TMC & BOOSTER ASSEMBLY	419
16.4. REAR BRAKE ASSEMBLY	421
16.5. REMOVAL AND REFITMENT REAR BRAKE ASSEMBLY	422
16.6. EXPLODED VIEW OF WHEEL CYLINDER	424
16.7. REMOVAL OF WHEEL CYLINDER	425
16.8. PARKING BRAKE ASSEMBLY	427
16.9. REMOVAL OF PARKING BRAKE LEVER	428
16.10. REMOVAL AND INSTALLATION OF PARKING BRAKE CABLE	429
16.11. PARKING BRAKE CABLE ADJUSTMENT	430
16.12. REMOVAL & REFITMENT OF ABS ECU / HCU	431
16.13. REMOVAL & REFITMENT OF FRONT WHEEL SPEED SENSOR	432
16.14. REMOVAL & REFITMENT OF REAR WHEEL SPEED SENSOR	433
16.15. REMOVAL & REFITMENT OF VACUUM PUMP	434
17. TROUBLE SHOOTING & DIAGNOSIS	435
18. ABS ECU CONNECTOR	437
FATC	438
1. TECHNICAL SPECIFICATION	441
2. FATC SYSTEM & LAYOUT	442
3. FATC UNIT AIR FLOW LAYOUT	442
4. BATTERY COOLING SYSTEM LAYOUT	443
5. SCHEMATICS OF HVAC & BATTERY COOLING SYSTEM (BCS)	444
6. HVAC UNIT ELECTRICAL CIRCUIT DIAGRAM	445
7. TIGHTENING TORQUES	446
8. PRECAUTIONS	449
9. FATC CONTROL PANEL	450
10. CONTROL PANEL CONNECTOR DETAILS	455
11. FATC UNIT	456
12. COMPRESSOR	458
13. CHILLER UNIT	460
14. COOLANT PUMP	460
15. BLOWER	461
16. AC FILTER	461
17. TXV	462
18. HVAC UNIT	462
19. FATC SENSORS AND ACTUATORS	463
A. LINEAR PRESSURE SENSOR (LPS)	463
B. CONDENSER AND RECEIVER DRIER	463
C. SOLAR LOAD SENSOR	464
D. OAT SENSOR	465
E. THERMISTER OR THERMO SENSOR	467
F. AIR INLET ACTUATOR	468
G. LINEAR POWER MODULE	469
H. PTC HEATER	470
20. REFRIGERANT HOSES / PIPES	471
21. DO’S AND DONT’S	472
22. TROUBLESHOOTING	473
23. MAINTAINANCE	486
23.1. PRELIMINARY INSPECTION	486
A. AC SYSTEM PERFORMANCE TEST	486
B. LEAK DETECTION	488
23.2. REGULAR MAINTAINANCE	488
A. REFRIGERANT RECOVERY, RECYCLING AND RECHARGING	488
B. FLUSHING OF AC SYSTEM	489
C. REPLENISHING COMPRESSOR OIL	490
D. PRESSURE TEST USING MANIFOLD GAUGES	491
BODY	492
1. GENERAL LAYOUT	495
2. TIGHTENING TORQUES	496
3. SPECIAL TOOLS	502
4. ON VEHICLE REMOVAL	503
4.1. BONNET	503
4.2. FLOOR CONSOLE	505
4.3. DASHBOARD SKIN	507
4.4. CROSS CAR BEAM WITH COCKPIT ASSEMBLY	510
4.5. GLOVE BOX	514
4.6. SIDE AIR VENTS	514
4.7. FRONT BUMPER	515
4.8. REAR BUMPER	516
4.9. FRONT DOOR	517
4.10. FRONT DOOR TRIMS	518
4.11. DOOR INNER LOCK HANDLE	519
4.12. FRONT OUTER DOOR LOCK	520
4.13. FRONT DOOR LATCH	521
4.14. FRONT DOOR GLASS AND WINDOW WINDING MECHANISM	523
4.15. REAR DOOR	524
4.16. REAR DOOR TRIM	525
4.17. REAR OUTER DOOR LOCK	526
4.18. DOOR LATCH REAR	527
4.19. TRUNK LID REMOVAL	529
4.20. ORVM	531
4.22. INNER REAR VIEW MIRROR	532
4.23. FRONT ROW SEAT	532
4.24. REAR ROW SEAT	533
4.25. REAR ROW SEAT ARMREST	534
4.26. FRONT SEAT BELT	535
4.27. REAR SEAT BELT	537
4.28. “A” PILLAR TRIM	538
4.29. FRONT SCUFF PLATE	540
4.30. “B” PILLAR TRIMS	540
4.31. “C” PILLAR TRIMS	541
4.32. GRAB HANDLE	542
4.33. SUNVISOR	543
4.34. ROOF LINER	543
4.35. PLENUM COVER	544
4.36. BONNET INSULATION	544
4.37. GLASS	545
4.38. REAR QUARTER GLASS	546
4.39. FAST CHARGER ASSEMBLY	546
4.40. FRONT WHEEL ARCH LINER	549
4.41. REAR WHEEL ARCH LINER	550
4.42. FRONT FENDER	550
4.43. REAR WIPER MOTOR	552
4.41. REAR DOOR CHEATER COVER	553
SUPPLEMENTARY RESTRAINT SYSTEM (SRS)	554
1. WORKING OF RESTRAINTS	556
2. SYSTEM LAYOUT	558
3. SAFETY PRECAUTIONS	559
4. DISPOSAL OF FAULTY AIR BAG UNIT	561
5. SRS POST ACCIDENT PROCEDURE	562
6. TIGHTENING TORQUES	563
7. COMPONENTS	565
7.1. RESTRAINT WITHOUT AIRBAGS	565
7.2. RESTRAINT WITH AIRBAGS	565
A. ECU	565
B. FRONT IMPACT SENSORS	569
C. AIRBAGS	570
D. FRONT SEAT (DRIVER) BELT BUCKLE	572
E. RPLL BELTS	573
F. CLOCK SPRING	575

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