TIAGO TIGOR CNG - SERVICE MANUAL

1.2L REVOTRON Bi-FUEL CNG ENGINE	6
1.1. GENERAL INFORMATION	12
A ENGINE INTRODUCTION	12
B ELECTRONIC CONTROL	13
C TECHNICAL SPECIFICATION	14
D SPECIAL TOOLS	15
E ASSEMBLY CLEARANCES	19
F SEALANTS	19
G LEAKAGE RATES	19
1.2. TROUBLESHOOTING	20
1.3. CONSTRUCTIONAL AND SERVICE DETAILS	29
A ENGINE LIFTING	29
B INTAKE MANIFOLD	30
C CYLINDER HEAD COVER	31
D CYLINDER HEAD-A	33
E CYLINDER HEAD-B	35
F CYLINDER BLOCK	36
G OIL SUMP	38
H MOVING PARTS	39
I ENGINE TIMING	41
J EXHAUST MANIFOLD	43
K FUEL INJECTION EQUIPMENT	44
L LUBRICATION PUMP AND COMPONENTS	45
M AIR INTAKE SYSTEM	47
N SPECIAL INSTALLATION	48
O ENGINE SUSPENSION	51
P CNG SYSTEM	54
1.2L REVOTRON Bi FUEL CNG ENGINE	55
1.4. ENGINE TESTS AND MAINTENANCE	56
A PRELIMINARY INSPECTION	56
B ENGINE TESTS	57
I ENGINE COMPRESSION TEST	57
II ENGINE OIL CONSUMPTION TEST	58
III ENGINE OIL PRESSURE TEST	59
C REGULAR MAINTENANCE	60
I ENGINE OIL AND FILTER CHANGE	60
II ENGINE COOLANT REPLACEMENT	61
III AIR FILTER ELEMENT REPLACEMENT	65
IV SPARK PLUG REPLACEMENT	66
V AIR CONDITIONER COMPRESSOR BELT REPLACEMENT	67
VI RECEPTACLE VALVE O-RING REPLACEMENT	68
VII CNG FILTER REPLACEMENT	69
1.5. REPAIR AND INSPECTION DETAILS	72
A ACCESSORY DRIVING BELT	72
B TIMING CHAIN	72
C CYLINDER HEAD	72
D VALVES	73
E CYLINDER HEAD VALVE SEATS	74
F ROLLER FINGER FOLLOWER	75
G HYDRAULIC LASH ADJUSTER	75
H CAMSHAFT (INTAKE AND EXHAUST)	75
I PISTON AND PISTON RINGS	77
J CONNECTING RODS	78
K CRANKSHAFT	80
L CRANK CASE	82
M FUEL TANK	83
N CANISTER PURGE VALVE	83
O CANISTER	84
1.6. ENGINE SYSTEM	85
A AIR INTAKE SYSTEM	85
B BLOW BY SYSTEM	87
C LUBRICATION SYSTEM	88
D EXHAUST SYSTEM	92
E COOLING SYSTEM	94
F FUEL SYSTEM	97
1.7. ENGINE ON VEHICLE SERVICE PROCEDURE	108
A ENGINE REMOVAL AND INSTALLATION FOR MT VEHICLE	108
B AIR FILTER ASSY	114
C INJECTION SYSTEM	114
D SPARK PLUG	117
E EXHAUST SYSTEM	117
F FUEL SYSTEM	120
G CNG FUEL SYSTEM	125
H COOLING SYSTEM	133
I REMOVAL OF ACCESSORIES	135
1.8. ENGINE OVEHAULING (ON OVERHAUL STAND)	136
A ENGINE DIS-ASSEMBLY	136
I REMOVAL OF INTAKE MANIFOLD	136
II REMOVAL OF EXHAUST MANIFOLD	138
III REMOVAL OF OIL SUMP	139
IV REMOVAL OF SENSORS	140
V REMOVAL OF ACCESSORIES	141
VI REMOVAL OF TIMING CHAIN	142
VII REMOVAL OF CYLINDER HEAD AND CAMSHAFT	144
VIII REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES	145
IX REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES	147
1.2L REVOTRON Bi FUEL CNG ENGINE	150
B ENGINE ASSEMBLY	150
I ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES	150
II ASSEMBLY OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES	152
III ASSEMBLY OF CYLINDER HEAD SUB-ASSEMBLIES	154
IV ASSEMBLY OF CYLINDER HEAD	156
V ASSEMBLY OF TIMING CHAIN	157
VI ASSEMBLY OF ACCESSORIES DRIVING BELT	160
VII ASSEMBLY OF ENGINE SENSORS AND PERIPHERALS	162
VIII ASSEMBLY OF OIL SUMP	163
IX ASSEMBLY OF EXHAUST MANIFOLD	164
X ASSEMBLY OF INTAKE MANIFOLD	165
1.9. ENGINE MANAGEMENT SYSTEM	167
A ABBREVIATIONS	167
B AN OVERVIEW	167
C ELECTRONIC CONTROL UNIT	168
D SENSORS	173
I T-MAP SENSOR	174
II LAMBDA SENSOR	175
III CAMSHAFT POSITION SENSOR (INTAKE / EXHAUST)	177
IV KNOCK SENSOR	178
V CRANKSHAFT POSITION SENSOR	179
VI COOLANT TEMPERATURE SENSOR	180
VII OIL PRESSURE SWITCH	181
VIII PRESSURE / TEMPERATURE SENSOR	182
IX CNG HIGH PRESSURE SENSOR (NON SERVICEABLE)	183
E ACTUATORS	184
I IGNITION COIL	185
II PURGE CONTROL VALVE	186
III SOLENOID VALVE (OCV)	187
IV GASOLINE FUEL INJECTOR	188
V CNG FUEL INJECTOR	189
VI ELECTRONIC THROTTLE BODY	189
F SWITCH	191
I THROTTLE PEDAL SENSOR	191
II CLUTCH SWITCH	192
III BRAKE SWITCH	193
IV VEHICLE SPEED SENSOR	194
V WHEEL SPEED SENSOR	195
TRANSAXLE	199
1. TECHNICAL SPECIFCICATIONS	199
2. PRECAUTIONS	199
3. GENERAL DESCRIPTION	200
4. TIGHTENING TORQUES	201
5. SPECIAL TOOLS LIST	207
6. DIAGNOSIS OF TRANSAXLE	212
7. CUT SECTION OF TRANSAXLE TA 65 STAR	213
8. CUT SECTION OF TOP COVER ASSEMBLY	214
9. EXPLODED VIEWS OF TRANSAXLE	215
A. TRANSAXLE HOUSING	215
B. TOP COVER ASSEMBLY	216
C. DIFFERENTIAL	218
D. SHIFTER FORK	219
E. GEAR SHIFT LINKAGE ASSEMBLY	220
F. LAY SHAFT AND INPUT SHAFT	221
10. REMOVAL OF TRANSAXLE FROM VEHICLE	223
11. TRANSAXLE TA65 STAR (ON BENCH) DISASSEMBLY	227
12. INPUT SHAFT SUB ASSEMBLY	232
13. DISASSEMBLY OF LAY SHAFT	233
14. IDENTIFICATION OF COMPONENTS	235
A. ENGAGING GEARS	235
B. SHIFTER SHAFT SUB ASSEMBLY	236
C. SHIFTER FORKS	236
D. SHIFTER SHAFT	237
E. SHIFTER SLEEVE	237
F. SYNCHROCONE	237
G. SUB ASSEMBLIES	237
15. LAY SHAFT ASSEMBLY	239
16. DIFFERENTIAL ASSEMBLY	242
17. ASSEMBLY OF TRANSAXLE	244
18. TOP COVER DISASSEMBLY & ASSEMBLY	247
19. INSTRUCTION FOR ASSEMBLY / DISASSEMBLY OF CABLE AT GEAR BOX	250
20. INSTALLATION OF TRANSAXLE ON THE VEHICLE	251
21. REMOVAL OF GEAR SHIFTER AND SELECTOR CABLE	252
CLUTCH_CNG	254
1 GENERAL INFORMATION	256
2 PRECAUTIONS	256
3 TECHNICAL SPECIFICATIONS	257
A. CLUTCH DISC	257
B. CLUTCH PRESSURE PLATE	259
C. FLYWHEEL	260
4 TIGHTENING TORQUES	261
5 SPECIAL TOOLS	262
6 DIAGNOSIS OF CLUTCH	263
7 MAINTENANCE, TESTS AND FACTOR AFFECTING CLUTCH	266
8 CONSTRUCTIONAL DETAILS	267
9 CLUTCH CABLE	268
10 REMOVAL & INSTALLATION OF CLUTCH	270
11 FLYWHEEL	270
12 CLUTCH ADJUSTMENT PROCEDURE	271
DRIVESHAFT_CNG	272
1. INTRODUCTION	274
2. DRIVESHAFT	275
3. DRIVE SHAFT PARTS	276
4. GENERAL GUIDELINES FOR TESTING DRIVE SHAFT NOISE	277
5. TESTING FOR NOISE	277
6. TIGHTENING TORQUES	278
7. SPECIAL TOOLS	278
8. ON VEHICLE REMOVAL OF DRIVE SHAFT (LH & RH SIDE)	279
9. DISASSEMBLY PROCEDURE FOR DRIVE SHAFT	281
10. ASSEMBLY PROCEDURE FOR DRIVESHAFT	283
11. DISASSEMBLY AND ASSEMBLY OF CV JOINT ASSEMBLY (OUTER)	284
12. DO’S AND DON’T’S FOR DRIVE SHAFT	288
SUSPENSION	289
1. TECHNICAL SPECIFICATION	291
2. TIGHTENING TORQUES	292
3. ECIE / PRELOAD CONDITION	297
4. SPECIAL TOOLS	299
5. DIAGNOSIS	305
6. PRECAUTIONS	306
7. SUSPENSION SYSTEM LAYOUT	307
8. FRONT SUSPENSION EXPLODED VIEWS	310
9. ON VEHICLE FRONT SUSPENSION REMOVAL PROCEDURES	314
A. REMOVAL AND INSTALLATION OF FRONT STRUT ASSEMBLY	314
B. DISASSEMBLY AND ASSEMBLY OF FRONT STRUT	316
C REMOVAL AND INSTALLATION OF WHEEL HUB	318
D REMOVAL AND INSTALLATION OF ANTI ROLL BAR	321
E REMOVAL AND INSTALLATION OF LOWER CONTROL ARM (LCA)	323
F REMOVAL AND INSTALLATION LOWER ARM BALL JOINT	325
G REMOVAL AND INSTALLATION OF LOWER ARM RUBBER BUSHES	326
10. PROCEDURE FOR CHECKING THE BALL JOINT PLAY LOWER ARM	328
11. REAR SUSPENSION EXPLODED VIEWS	329
12. ON VEHICLE REAR SUSPENSION REMOVAL PROCEDURES	332
A. REMOVAL AND INSTALLATION OF REAR SHOCK ABSORBER	332
B. DISASSEMBLY AND ASSEMBLY OF REAR SHOCK ABSORBER	332
C REMOVAL AND INSTALLATION OF TORSION BEAM	335
D REAR BRAKE DRUM BEARING REMOVAL & FITMENT	340
13. SUSPENSION ECIE / PRE LOADING CONDITION	341
WHEELS AND TYRES	342
1. GENERAL INFORMATION	345
A. SPECIFICATIONS	345
B. TYRE PRESSURE DETAILS	345
C. CONSTRUCTION (XM CNG TIAGO)	346
D. CONSTRUCTION (XT CNG TIAGO)	347
E. CONSTRUCTION (XZ CNG TIAGO)	348
F. CONSTRUCTION (XE CNG TIGOR)	349
G. CONSTRUCTION (XM CNG TIGOR)	350
H. CONSTRUCTION (XZ CNG TIGOR)	351
2 TIGHTENING TORQUES	352
3 GENERAL SYMPTOMS DIAGNOSIS	353
A. DIAGNOSIS CHART	353
B. TYRE WEAR PATTERN	355
C. WEAR CAUSE	356
D. TYRE VIBRATION DIAGNOSIS	357
4 MAINTENANCE, INSPECTION AND TESTS	358
A. PRELIMINARY INSPECTION	358
B. REGULAR MAINTENANCE	359
I. INFLATION	359
II. WHEEL BALANCING	360
III. TYRE ROTATION	360
IV. WHEEL RUN OUT	361
V. DO'S AND DON’TS	361
4 WHEEL AND TYRE REPLACEMENT	362
A. PRECAUTIONS DURING TYRE REPLACEMENT	362
B. TYRE REPLACEMENT	362
C. DEFECTIVE WHEEL ASSEMBLY REPLACEMENT	363
D. SPARE WHEEL REMOVAL PROCEDURE	363
E. WHEEL REMOVAL	364
F. TYRE CARE	366
BRAKES	367
1 TECHNICAL SPECIFICATIONS	370
2 TIGHTENING TORQUES	372
3 SPECIAL TOOLS	376
4 PRECAUTIONS	376
5 DIAGNOSIS	377
6 NESSECITY OF ABS WITH EBD	380
7 BRAKE HYDRAULIC LINES	381
8 VACUUM BRAKE BOOSTER	382
9 WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS)	383
10 ABS COMPONENTS	387
A ABS 9 ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU / HCU)	387
B WHEEL SPEED SENSOR	389
C ABS SYSTEM FAILURE WARNING LIGHT	390
11 MAINTENANCE, ADJUSTMENTS & TEST	391
A FRONT BRAKE MAINTENANCE	391
B REAR BRAKE MAINTENANCE	393
C BLEEDING OF HYDRAULIC SYSTEM	395
D BRAKE TROUBLE SHOOTING	399
E ROAD TESTING	399
12 CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO	400
13 STOP LIGHT SWITCH ADJUSTMENT	401
14 SNAP TYPE BRAKE LIGHT SWITCH INSTALLATION PROCEDURE	402
15 ACCELERATOR PEDAL ASSEMBLY REMOVAL	403
16 BRAKE / CLUTCH PEDAL ASSEMBLY REMOVAL	403
17 FRONT BRAKE ASSEMBLY	405
A CALIPER BRAKE ASSSEMBLY EXPLODED VIEW	405
B FRONT BRAKE DISC	406
C FRONT BRAKE ADJUSTMENT, REMOVAL AND REFITMENT	406
D REMOVAL AND REFITMENT OF TMC & BOOSTER ASSEMBLY	413
18 REAR BRAKE ASSEMBLY	415
A REAR BRAKE ASSEMBLY EXPLODED VIEW	415
B REMOVAL AND REFITMENT OF REAR BRAKE ASSEMBLY REMOVAL	416
C WHEEL CYLINDER ASSEMBLY EXPLODED VIEW	418
D REMOVAL & ASSEMBLY OF WHEEL CYLINDER	419
E ASSEMBLING NEW AUTO ADJUSTER	419
F INSTALLATION OF BRAKE BACK PLATE	420
19 PARKING BRAKE ASSEMBLY	421
A LAYOUT	421
B REMOVAL OF PARKING BRAKE LEVER	422
C REMOVAL OF PARKING BRAKE CABLE	423
D INSTALLATION OF PARKING BRAKE CABLE	423
E INSTALLATION OF PARKING BRAKE LEVER	423
F PARKING BRAKE CABLE ADJUSTMENT	424
G PARKING BRAKE LEVER PRIMARY CABLE GREASING	424
20 REMOVAL AND REFITMENT OF ABS ECU / HCU	425
21 REMOVAL AND REFITMENT OF FRONT WHEEL SPEED SENSOR	426
22 REMOVAL AND REFITMENT OF REAR WHEEL SPEED SENSOR	427
23 TROUBLE SHOOTING & DIAGNOSIS	428
24 ABS ECU CONNECTOR	430
25 WHEEL SPEED SENSOR CONNECTOR	430
STEERING_MANDO	431
1. GENERAL INGOTMATION	433
A. TECHNICAL SPECIFICATION	433
B. INTRODUCTION	433
C. SYSTEM LAYOUT	434
2. TIGHTENING TORQUES	435
3. SPECIAL TOOLS	437
4. MAINTENANCE, INSPECTION AND TEST	438
A. PRELIMINARY INSPECTION	438
B. REGULAR MAINTENANCE	439
5. ON VEHICLE REPAIRS	441
A. STEERING WHEEL REMOVAL	441
B. STEERING COLUMN REMOVAL	442
C. INTERMEDIATE SHAFT REMOVAL	444
D. ECU REMOVAL	444
E. MOTOR REMOVAL	445
F. RACK & PINION ASSEMBLY REMOVAL	446
6. STEERING RACK AND PINION ASSEMBLY EXPLODED VIEW	447
7. OVERHAULING OF STEERING RACK & PINION ASSEMBLY	448
8. DO'S & DON’T'S	450
9. WHEEL ALIGNMENT	453
10. TROUBLESHOOTING AND DIAGNOSIS	455
11. STEERING ANGLE CALIBRATION PROCESS	459
12. TUNING DATA SELECTION	464
13. EPAS ECU REPLACEMENT AND SOFTWARE UPDATE PROCEDURE IN FIELD	465
BODY	469
1. LAYOUT	472
2. TIGHTENING TORQUES	473
3. SPECIAL TOOLS	475
4. ON VEHICLE REPAIRS	476
4.1. BONNET REMOVAL	476
4.2. FLOOR CONSOLE REMOVAL	478
4.3. DASHBOARD REMOVAL	480
4.4. GLOVE BOX REMOVAL	487
4.5. SIDE AIR VENTS REMOVAL	488
4.6. FRONT BUMPER REMOVAL	488
4.7. REAR BUMPER REMOVAL (TIAGO)	490
4.8. REAR BUMPER REMOVAL (TIGOR)	491
4.9. FRONT DOOR REMOVAL	492
4.10. FRONT DOOR TRIMS REMOVAL	493
4.11. DOOR INNER LOCK HANDLE REMOVAL	495
4.12. FRONT OUTER DOOR LOCK REMOVAL	496
4.13. FRONT DOOR LATCH REMOVAL	498
4.14. FRONT DOOR GLASS AND WINDOW WINDING MECHANISM REMOVAL	499
4.15. REAR DOOR REMOVAL	500
4.16. REAR DOOR TRIM REMOVAL	501
4.17. REAR OUTER DOOR LOCK REMOVAL	502
4.18. DOOR LATCH REAR REMOVAL	503
4.19. TAIL GATE REMOVAL	504
4.20. TAIL GATE LATCH CABLE REMOVAL	506
4.21. TAIL GATE TRIM REMOVAL	507
4.22. OUTER REAR VIEW MIRROR REMOVAL	507
4.23. INNER REAR VIEW MIRROR REMOVAL	508
4.24. FRONT ROW SEAT REMOVAL	508
4.25. REAR ROW SEAT REMOVAL (TIAGO)	509
4.26. REAR ROW SEAT REMOVAL (TIGOR)	511
4.27. REAR ROW SEAT ARMREST REMOVAL	512
4.28. FRONT SEAT BELT REMOVAL	513
4.29. REAR SEAT BELT REMOVAL (TIAGO)	515
4.30. REAR SEAT BELT REMOVAL (TIGOR)	516
4.31. “A” PILLAR TRIM REMOVAL	517
4.32. FRONT SCUFF PLATE REMOVAL	519
4.33. “B" PILLAR TRIMS REMOVAL	519
4.34. “C” PILLAR TRIM REMOVAL	520
4.35. GRAB HANDLES REMOVAL	521
4.36. SUNVISOR REMOVAL	521
4.37. ROOF LINER REMOVAL	522
4.38. PLENUM COVER REMOVAL	522
4.39. GEAR LEVEL BOOT REMOVAL	523
4.40. BONNET INSULATION REMOVAL	523
4.41. GLASS REMOVAL	524
4.42. FUEL FILLER ASSEMBLY REMOVAL	525
4.43. FRONT WHEEL ARCH LINER REMOVAL	526
4.44. REAR WHEEL ARCH LINER REMOVAL	527
4.45. FRONT FENDER REMOVAL	527
4.46. REAR WIPER MOTOR REMOVAL	529
4.47. FRONT WIPER REMOVAL	530
HVAC	531
1 TECHNICAL SPECIFICATIONS	533
2 TIGHTENING TORQUES	534
3 PRECAUTIONS	537
4 HVAC UNIT EXPLODED VIEW	538
5 HVAC SYSTEM LAYOUT AND WORKING	539
6 COMPONENTS OF HVAC SYSTEM	541
A. CONTROL PANEL	541
B. HVAC UNIT	544
C. BLOWER RESISTER	547
D. CONDENSOR AND RECEIVER DRIER	548
E. CONDENSER SEALING DUCTS	548
F. PRESSURE SENSOR	548
7 TROUBLESHOOTING	550
8 MAINTENANCE	564
9 ON VEHICLE REMOVAL	571
A. CONTROL PANEL ASSEMBLY	571
B. COMPRESSOR	575
C. BLOWER	575
D. BLOWER RESISTER	576
E. AIR FILTER	576
F. TXV	577
G. PRESSURE SENSOR	578
H. HVAC UNIT	578
I. CONDENSOR SEALING DUCT	579
J. CONDENSOR	579
10 REFRIGERANT HOSES/PIPES LAYOUT	580
11 DO’S & DONT’S	581
FATC	582
1 TECHNICAL SPECIFICATIONS	584
2 TIGHTENING TORQUES	586
3 FATC LAYOUT	589
4 FATC CONTROL PANEL DETAILS	590
4 FATC CONTROL PANEL REMOVAL	593
6 CONTROL PANEL CONNECTOR DETAILS	594
7 FATC SENSOR	596
A. SOLAR LOAD SENSOR (FOR TIAGO ONLY)	596
B. OAT SENSOR	597
C. THERMISTOR OR THERMO SENSOR	598
D. AIR INLET ACTUATOR	599
E. LINEAR POWER MODULE	601
ELECTRICAL	602
1 TECHNICAL SPECIFICATION	607
A. BATTERY	607
B. STARTER MOTOR	609
C. ALTERNATOR	617
2 LIGHTING SYSTEM	620
A. BULB SPECIFICATIONS (TIGOR)	620
B. BULB SPECIFICATIONS (TIAGO)	621
C. FASTENERS TORQUE VALUE TABLE	621
D. GENERAL SYMPTOMS AND DIAGNOSTICS	622
E. HEAD LAMP (SINGLE CHAMBER)	625
F. HEAD LAMP (DUAL CHAMBER) (IF APPLICABLE)	629
G. ROOF LAMP	633
H. HIGH MOUNTED STOP LAMP (FOR TIGOR)	634
I. HIGH MOUNTED STOP LAMP (FOR TIAGO)	635
J. TAIL LAMP (FOR TIAGO)	636
K. TAIL LAMP (FOR TIGOR)	638
L. FRONT FOG LAMP	640
M. REGISTRATION PLATE LAMP	641
N. REVERSE LAMP (FOR TIGOR)	642
O. TAIL GATE SWITCH LAMP (FOR TIGOR)	642
P. DRL (IF APPLICABLE)	643
3 WIPER & WASHER SYSTEM	644
4 SWITCHES	650
A. COMBI SWITCH	650
B. STEERING LOCK CUM IGNITION SWITCH	657
C. FASCIA SWITCHES	659
D. HAZARD SWITCH	661
E. MIRROR SWITCH	662
F. WINDOW WINDING MODULE	663
G. POWER WINDOW SWITCHES & INHIBIT SWITCH	665
H. STEERING WHEEL SWITCHS	668
I. FUEL FLAP SWITCH	670
J. CNG CUTOFF SWITCH	671
K. ENGINE START-STOP (ESS) OFF SWITCH (IF EQUIPPED)	672
L. DOOR HANDLE SWITCH REMOVAL	673
M. TAILGATE HANDLE SWITCH	674
5 HORN	676
6 POWER SOCKETS	678
7 INFOTAINMENT	679
A. INFOTAINMENT SYSTEM DISPLAY DETAILS (LEVEL B)	680
B. INFOTAINMENT SYSTEM DISPLAY DETAILS (LEVEL A)	682
C. USB/AUX PORT	684
D. SPEAKERS	685
E. TWEETER	686
F. ANTENNA	687
G.MICROPHONE	688
8 INSTRUMENT CLUSTER	689
A. CNG INSTRUMENT CLUSTER VARIANTS	689
B. FEATURES	690
C. BASIC FUNCTIONAL MATRIX	693
D. TELL TALES MATRIX	694
E. TELL TALES DISCRIPTION	696
F. DRIVER INFORMATION SYSTEM	700
G. REMINDER FEATURES	707
H. MAIN CONNECTOR PIN-OUTS	708
I. FUEL GAUGE DETAILS	709
J. CHIME TABLE	709
K. DISPLAY SCREEN FLOW AND SETTINGS	710
L. REMOVAL OF INSTRUMENT CLUSTER	711
9 IMMOBILIZER SYSTEM	712
A. IMMOBILIZER SYSTEM DESCRIPTION	712
B. TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB	714
C. IMMOBILIZER SYSTEM STATUS IN EMS ECU	715
D. IGNITION REMOTE KEY (IF APPLICABLE)	716
E. IGNITION E-KEY (IF APPLICABLE)	719
F. IGNITION E-KEY LEARNING PROCEDURE	721
G. PAIRING OF VCU-ECU & LIN BASED BCM IMMOBILIZER	721
H. MAINTENANCE AND TROUBLE SHOOTING	722
I. TWO SMART KEYS SCENARIO	723
10 BODY CONTROL MODULE	724
A. REMOVAL OF BCM	724
B. CONNECTION DETAILS	725
C. BCM SPECIFICATION	729
D. BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIXS	730
E. BCM FEATURES	736
F. BCM REPLACEMENT STRATEGY	738
G. BCM FUNCTIONS	739
11 FUSE AND RELAY BOX	740
A. FUSE AND RELAY BOX LAYOUT	742
B. BATTERY MOUNTED FUSE BOX (BDU):	743
C. ENGINE FUSE AND RELAY BOX	744
D. CABIN FUSE AND RELAY BOX	748
E. FUSE AND RELAY REPLACEMENT	750
12 REVERSE PARK ASSIST SYSTEM	751
A. PARK ASSIST	751
B. PARK ASSIST FUNCTIONALITY OVERVIEW	751
C. PARK ASSIST INDICATIONS	751
D. PARK ASSIST ACTIVATION / DEACTIVATION PROCEDURE	751
E. PARK ASSIST DELAY TIMER	751
F. PARK ASSIST LIMITATIONS	752
G. PARK ASSIST SYSTEM MAINTENANCE	752
H. RPAS ARCHITECTURE WITHOUT CONTROLLER (THROUGH BCM)	753
I. SENSOR CONNECTOR DETAILS	754
J. ECU TO SENSOR ELECTRICAL INTERFACE	755
K. REMOVAL OF SENSOR	756
13 REVERSE PARK ASSIST WITH CAMERA (IF APPLICABLE)	759
A. REAR VIEW CAMERA (IF APPLICABLE)	760
B. REAR VIEW CAMERA REMOVAL (IF APPLICABLE)	761
C. TROUBLESHOOTING	762
14 PASSIVE ENTRY PASSIVE START (PEPS) (IF APPLICABLE)	763
A. PEPS ECU	764
B. START STOP SWITCH (IF APPLICABLE)	766
C. ELCTRONIC STEERING COLUMN LOCK (ESCL)	767
D. LF ANTENNAS	769
15 RAIN LIGHT SENSOR SYSTEM (IF APPLICABLE)	772
A. RAIN LIGHT SENSOR	772
B. FUNCTIONAL DETAILS	775
C. FAIL SAFE MODES OF RLS & BCM	776
SUPPLEMENTARYRESTRAINT SYSTEM	777
1. WORKING OF RESTRAINTS	779
2. SRS SYSTEM COMPONENTS LAYOUT	780
3. SYSTEM LAYOUT	782
4. SAFETY PRECAUTIONS	783
5. DISPOSAL OF FAULTY AIR BAG UNIT	785
6. SRS POST ACCIDENT PROCEDURE	786
7. TIGHTENING TORQUES	787
8. COMPONENTS	790
8.1. RESTRAINT WITHOUT AIRBAGS	790
8.2. RESTRAINT WITH AIRBAGS	790
A. ECU	790
B. FRONT IMPACT SENSORS	794
C. AIRBAGS	795
D. FRONT SEAT (DRIVER) BELT BUCKLE	797
E. RPLL BELTS	797
F. CLOCK SPRING	800

Made with FlippingBook

RkJQdWJsaXNoZXIy MTIwNTUz