TIAGO TIGOR BSVI - SERVICE MANUAL

TIAGO TIGOR BSVI - SERVICE MANUAL	1
INDEX	5
ENGINE	6
CONTENTS	7
1.1. GENERAL INFORMATION	7
A. ENGINE INTRODUCTION	12
B. ELECTRONIC CONTROL	13
C. TECHNICAL SPECIFICATION	14
D. SPECIAL TOOLS	15
E. ASSEMBLY CLEARANCES	18
F. SEALANTS	18
G. LEAKAGE RATES	18
H. RECOMMENDED LUBRICANTS & COOLANTS	18
1.2. TROUBLESHOOTING	19
1.3. CONSTRUCTIONAL AND SERVICE DETAILS	26
A. ENGINE LIFTING	26
B. INTAKE MANIFOLD	27
C. CYLINDER HEAD COVER	29
D. CYLINDER HEAD-A	31
E. CYLINDER HEAD-B	33
F. CYLINDER BLOCK	34
G. OIL SUMP	36
H. MOVING PARTS	38
I. ENGINE TIMING	40
J. EXHAUST MANIFOLD	42
K. FUEL INJECTION EQUIPMENT	43
L. LUBRICATION PUMP AND COMPONENTS	44
M. AIR INTAKE SYSTEM	46
N. SPECIAL INSTALLATION	48
O. ENGINE SUSPENSION	51
1.4. ENGINE TESTS AND MAINTENANCE	54
A. PRELIMINARY INSPECTION	54
B. ENGINE TESTS	55
C. REGULAR MAINTENANCE	58
1.5. REPAIR AND INSPECTION DETAILS	66
A. ACCESSORY DRIVING BELT	66
B. TIMING CHAIN	66
C. CYLINDER HEAD	66
D. VALVES	67
E. CYLINDER HEAD VALVE SEATS	69
F. ROLLER FINGER FOLLOWER	70
G. HYDRAULIC LASH ADJUSTER	70
H. CAMSHAFT (INTAKE AND EXHAUST)	70
I. PISTON AND PISTON RINGS	72
J. CONNECTING RODS	73
K.CRANKSHAFT	75
L. CRANK CASE	77
M. FUEL TANK	78
N. CANISTER PURGE VALVE	78
O. CANISTER	79
1.6. ENGINE SYSTEM	80
A. AIR INTAKE SYSTEM	80
B. BLOW BY SYSTEM	82
C. LUBRICATION SYSTEM	83
D. EXHAUST SYSTEM	87
E. COOLING SYSTEM	90
F. FUEL SYSTEM	93
1.7. ENGINE ON VEHICLE SERVICE PROCEDURE	96
A. ENGINE REMOVAL AND INSTALLATION FOR MT VEHICLE	96
B. ENGINE REMOVAL AND INSTALLATION FOR AMT VEHICLE	101
C. AIR FILTER ASSY	106
D. INJECTION SYSTEM	106
E. SPARK PLUG	107
F. EXHAUST SYSTEM	107
G. FUEL SYSTEM	110
H. COOLING SYSTEM	116
I. REMOVAL OF ACCESSORIES	119
1.8. ENGINE OVEHAULING (ON OVERHAUL STAND)	121
A. ENGINE DIS-ASSEMBLY	121
I. REMOVAL OF INTAKE MANIFOLD	121
II. REMOVAL OF EXHAUST MANIFOLD	122
III. REMOVAL OF OIL SUMP	123
IV. REMOVAL OF SENSORS	123
V. REMOVAL OF ACCESSORIES	124
VI. REMOVAL OF TIMING CHAIN	127
VII. REMOVAL OF CYLINDER HEAD AND CAMSHAFT	128
VIII. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES	129
IX. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES	131
B. ENGINE ASSEMBLY	134
I. ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES	134
II. ASSEMBLY OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES	136
III. ASSEMBLY OF CYLINDER HEAD SUB-ASSEMBLIES	138
IV. ASSEMBLY OF CYLINDER HEAD	139
V. ASSEMBLY OF TIMING CHAIN	141
VI. ASSEMBLY OF ACCESSORIES DRIVING BELT	144
VII. ASSEMBLY OF ENGINE SENSORS AND PERIPHERALS	145
VIII. ASSEMBLY OF OIL SUMP	146
IX. ASSEMBLY OF EXHAUST MANIFOLD	146
X. ASSEMBLY OF INTAKE MANIFOLD	147
1.9. ENGINE MANAGEMENT SYSTEM	148
A. ABBREVIATIONS	148
B. AN OVERVIEW	149
C. ELECTRONIC CONTROL UNIT	150
D. SENSORS	155
E. ACTUATORS	164
F. SWITCH	171
GEARBOX	177
A. MT GEARBOX REMOVAL	179
B. AMT GEARBOX REMOVAL	183
MANDO STEERING	186
1 GENERAL INFORMATION	188
1.1 SPECIFICATIONS	188
1.2 SYSTEM LAYOUT	188
1.3 GENERAL DESCRIPTION	189
1.4 TIGHTENING TORQUES	190
1.5 SPECIAL TOOLS	192
2. MAINTENANCE, INSPECTION AND TEST	193
2.1 PRELIMINARY INSPECTION	193
2.2 REGULAR MAINTENANCE	194
2.3 ON VEHICLE REPAIRS	195
2.3.1 STEERING WHEEL REMOVAL	195
2.3.2 STEERING COLUMN REMOVAL	197
2.3.3 INTERMEDIATE SHAFT REMOVAL	199
2.3.4 ECU REMOVAL	199
2.3.5 MOTOR REMOVAL	200
2.3.6 RACK & PINION ASSEMBLY REMOVAL	201
3. OVERHAULING	203
3.1. OVERHAULING OF STEERING RACK AND PINION ASSEMBLY	203
3.2 PRECAUTIONS	204
3.3 DISMANTLING, INSPECTION AND ASSEMBLY	204
3.3.1 DISASSEMBLY OF RACK & PINON	204
3.3.2 INSPECTION OF DISMANTLED PARTS	205
3.3.3 ASSEMBLY OF RACK & PINON	205
3.3.4 OBJ ON-VEHICLE REMOVAL	206
3.3.5 DO’S & DON’TS	206
3.3.6 WHEEL ALIGNMENT	210
4. TROUBLESHOOTING AND DIAGNOSIS	212
5. STEERING ANGLE CALIBRATION PROCESS	216
6. EPAS ECU REPLACEMENT AND SOFTWARE UPDATE PROCEDURE IN FIELD	223
BRAKES	227
1. PRECAUTIONS	230
2. TECHNICAL SPECIFICATIONS	231
3. TIGHTENING TORQUES	233
4. DIAGNOSIS	234
5. NESSECITY OF ABS with EBD	237
6. BRAKE HYDRAULIC LINES	238
7. VACUUM BRAKE BOOSTER	240
8. WORKING OF ANTI-LOCK BRAKINGSYSTEM (ABS)	241
9. ABS COMPONENTS	245
9.1. ABS 9 ELECTRONIC CONTROL UNIT/ HYDRAULIC CONTROL UNIT (ECU / HCU)	245
9.2. HYDRAULIC CONTROL UNIT	247
9.3. WHEEL SPEED SENSOR: (MONITORSWHEEL SPEED)	248
9.4. ABS SYSTEM FAILURE WARNING LIGHT	249
10. MAINTENANCE, ADJUSTMENTS & TEST	250
10.1. FRONT BRAKE MAINTENANCE	250
10.2. REAR BRAKE MAINTENANCE	252
10.3. BRAKE TROUBLE SHOOTING	257
10.4. CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO	258
10.5. STOP LIGHT SWITCH ADJUSTMENT	259
11. ACCELERATOR PEDAL ASSEMBLY	260
12. BRAKE/CLUTCH PEDAL ASSEMBLY	260
13. SNAP TYPE BRAKE LIGHT SWITCHINSTALLATION PROCEDURE	262
14. REPAIRS	263
14.1. FRONT BRAKE ADJUSTMENT,REMOVAL AND REFITMENT	264
14.2. REMOVAL OF FRONT BRAKE DISC	270
14.3. REMOVAL AND REFITMENT OF TMC &BOOSTER ASSEMBLY	271
14.4. REAR BRAKE ASSEMBLY	273
14.5. REMOVAL AND REFITMENT OF REARBRAKE ASSEMBLY	275
14.6. REMOVAL OF PARKING BRAKELEVER	281
14.7. REMOVAL AND INSTALLATION OFPARKING BRAKE CABLE	282
14.8A. PARKING BRAKE CABLEADJUSTMENT	283
14.8B. PARKING BRAKE LEVER PRIMARYCABLE GREASING	283
14.9. REMOVAL AND REFITMENT OF ABSECU / HCU	284
14.10. REMOVAL AND REFITMENT OF FRONTWHEEL SPEED SENSOR	285
14.11. REMOVAL AND REFITMENT OF REARWHEEL SPEED SENSOR	286
15. TROUBLE SHOOTING & DIAGNOSIS	288
16. ABS ECU CONNECTOR (K2)	290
FRONT & REAR BUMPER	292
A. FRONT BUMPER REMOVAL (TIGOR	294
B. REAR BUMPER REMOVAL (TIGOR	295
C. FRONT BUMPER REMOVAL (TIAGO)	296
D. REAR BUMPER REMOVAL (TIAGO)	298
E. BONNET	299
ELECTRICAL	300
TABLE OF CONTENTS	301
1. BATTERY	303
2. STARTER MOTOR	305
3. ALTERNATOR	313
4. LIGHTING SYSTEM	316
4.1. A BULB SPECIFICATIONS (TIGOR )	316
4.1. B BULB SPECIFICATIONS (TIAGO )	317
4.2 HEAD LAMP (TIAGO)	318
4.3 TAIL LAMP (TIAGO)	323
4.4A. INFOTAINMENT SYSTEM: ( If f itted) ( 7” Di s p l a y)	326
4.4B. INFOTAINMENT SYSTEM: ( If f itted) (Level A)	329
4.5. HEAD LAMP (TIGOR )	334
4.6 HIGH MOUNTED STOP LAMP	341
4.7 TAIL LAMP (TIGOR)	342
4.8 REMOVAL & REFITMENT OF REVERSELAMP	344
4.9 DRL	345
4.10A INFOTAINMENT SYSTEM (TIGOR) : ( If f itted) ( 7”Di sp l a y)	346
4.10B. INFOTAINMENT SYSTEM (TIGOR) : (If fitted) (Level A)	349
5.ANTENNA	354
6. INSTRUMENT CLUSTER	355
6.1. BASIC FUNCTIONAL MATRIX	358
6.2. TELL TALES MATRIX	359
6.3. DRIVER INFORMATION SYSTEM	365
6.4 REMINDER FEATURES	372
6.5 MAIN CONNECTOR PIN-OUTS	373
6.6. FUEL GAUGE DETAILS	374
6.7 TEMPERATURE BAR GRAPH DETAILS	374
6.8. CHIME TABLE	375
6.9. DISPLAY SCREEN FLOW AND SETTINGS	376
6.10 REMOVAL OF INSTRUMENT CLUSTER	377
7. FUSE AND RELAY BOX DETAILS	379
7.1 BATTERY MOUNTED FUSE BOX (BDU)	382
7.2 ENGINE FUSE AND RELAY BOX	383
7.3 CABIN FUSE AND RELAY BOX	388
8. WIPER & WASHER SYSTEM	392
8.1 FRONT WIPER AND WAHSER SYSTEM LAYOUT	393
8.2 FRONT AND REAR WASH/WIPE SWITCH FUNCTIONALITY	394
8.3 WIPER AND WIPER CARE	398
8.4 DIAGNOSTIC INFORMATION AND PROCEDURES	399
8.5 REMOVAL AND FITMENT OF FRONT ANDREAR WIPER	400
9. REVERSE PARK ASSIST SYSTEM	402
9.1 REAR PARK ASSIST SYSTEM ARCHITECTURE WITHOUT CONTROLLER (THROUGH BCM	404
9.2 ECU to Sensor Electrical Interface	405
9.3 REAR VIEW CAMERA	410
9.4 "Rear Park Assist System Architecture Without Controller (Through BCM) (Applicable For TIGOR)	411
9.5 Connector Details of Rear View Camera	411
9.6 REAR VIEW CAMERA REMOVAL (TIGOR &TIAGO)	412
9.7 TROUBLESHOOTING	413
10. PASSIVE ENTRY PASSIVE START (PEPS)	414
10.1 PEPS ECU	415
10.2 START STOP SWITCH	417
10.3 ELECTRONIC STEERING COLUMN LOCK(ESCL)	418
10.4 LF ANTENNAS	420
11 IMMOBILIZER	423
12 IGNITION KEY	427
SUPPLEMENTARYRESTRAINT SYSTEM(SRS) AB12	435
CONTENTS	436
1. WORKING OF RESTRAINTS	437
2. SRS SYSTEM COMPONENTS LAYOUT	438
3. SYSTEM LAYOUT	440
4. SAFETY PRECAUTIONS	441
5. DISPOSAL OF FAULTY AIR BAG UNIT	443
6. SRS POST ACCIDENT PROCEDURE	444
7. TIGHTENING TORQUES	445
8. COMPONENTS	448
8.1. RESTRAINT WITHOUT AIRBAGS	448
8.2. RESTRAINT WITH AIRBAGS	448
A. ECU	448
B. FRONT IMPACT SENSORS	452
C. AIRBAGS	453
D. FRONT SEAT (DRIVER) BELT BUCKLE	455
E. RPLL BELTS	455
F. CLOCK SPRING	458

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