TIGOR EV SERVICE MANUAL

TIGOR EV	1
HV ELECTRICAL	6
1 GENERAL INFORMATION	8
A. TOOLS	8
B. HAND GLOVES	8
C. WASHING INSTRUCTIONS	9
D. HV ELECTRICAL COMPONENT INFORMATION	10
E. MOTOR COMPARTMENT	12
F. TYPES OF CHARGING	16
2 TORQUE DETAILS	24
3 SPECIAL TOOLS	34
4 INSTRUCTION FOR WORKING ON HV COMPONENTS ON VEHICLE	36
5 HV COMPONENT IN UNDER BONNET COMPONENTS	37
6 REMOVAL & REFITMENT PROCEDURE	38
A. VCU REMOVAL	38
B. ON- BOARD CHARGER REMOVAL	39
C. PRU (PRE CHARGE RELAY UNIT) REMOVAL	40
D. SIU (SIGNAL ISOLATION UNIT) REMOVAL	41
E. MAIN CONTACTOR UNIT REMOVAL	41
F. MCU (MOTOR CONTROL UNIT) REMOVAL	42
G. PTC HEATER CONTACTOR REMOVAL	44
H. VACUUM PUMP	45
I. E BOX REMOVAL PROCESS	46
J. TRACTION COOLING SYSTEM	51
K. HV BATTERY	53
L. HV BATTERY REMOVAL	55
M. HV BATTERY REMOVAL	59
N. BATTERY COOLING SYSTEM	61
P. CRADLE	63
Q. FAST CHARGER ASSEMBLY REMOVAL	68
R. SLOW CHARGER REMOVAL	70
LV ELECTRICAL	72
1 GENERAL PRECAUTIONS TECHNICAL SPECIFICATION	74
2 BATTERY	77
3 LIGHTING SYSTEM	79
4 WIPER & WASHER SYSTEM	98
5 SWITCHES	103
6 HORN	126
7 POWER SOCKETS	128
8 IGNITION KEY	129
9 INFOTAINMENT SYSTEM	131
10 INSTRUMENT CLUSTER	142
11 IMMOBILIZER SYSTEM	158
12 BODY CONTROL MODULE (BCM)	167
13 CLUTCH PEDAL SENSOR	183
14 FUSE AND RELAY BOX DETAILS	186
15 REVERSE PARK ASSIST SYSTEM	198
DRIVE SHAFT	212
1. INTRODUCTION	214
2. DRIVE SHAFT PARTS	215
3. GENERAL GUIDELINES FOR TESTING DRIVE SHAFT NOISE	215
4. TESTING FOR NOISE	216
5. TIGHTENING TORQUES	217
6. SPECIAL TOOLS	218
7. ON VEHICLE DRIVE SHAFT REMOVAL	219
8. ON VEHICLE DRIVE SHAFT ASSEMBLY	220
9. DISASSEMBLY PROCEDURE FOR DRIVE SHAFT	221
10. ASSEMBLY PROCEDURE FOR DRIVE SHAFT	223
11. PRECAUTIONS TO AVOID THE DAMAGE TO THE DRIVE SHAFT	224
12. DO’S AND DON’T’S FOR DRIVE SHAFT	225
SUSPENSION	226
1 GENERAL INFORMATION	228
A. FRONT SUSPENSION	228
B. REAR SUSPENSION	229
C. SHOCK ABSORBER	230
2 TECHNICAL SPECIFICATIONS	231
3 TIGHTENING TORQUES	233
4 SPECIAL TOOLS	238
5 DIAGNOSIS	244
6 PRECAUTION	245
7 EXPLODED VIEWS FRONT SUSPENSION SYSTEM	246
A. ASSEMBLY FRONT STRUT EXPLODED VIEW	246
B. LOWER ARM LINK EXPLODED VIEW	247
C. ANTI ROLL BAR MOUNTING EXPLODED VIEW	248
D. FRONT AXLE ASSEMBLY EXPLODED VIEW	249
8 EXPLODED VIEWS REAR SUSPENSION SYSTEM	250
A. REAR SHOCK ABSORBER EXPLODED VIEW	250
B. REAR HUB ASSEMBLY EXPLODED VIEW	251
C. PIVOT MOUNTING BRACKET AND BUSH EXPLODED VIEW	252
9 ON VEHICLE REPAIRS FRONT SUSPENSION	253
9.1 REMOVAL AND INSTALLATION OF STRUT ASSEMBLY	253
9.2 DISASSEMBLY AND ASSEMBLY OF FRONT STRUT	254
9.3 REMOVAL AND INSTALLATION OF WHEEL HUB	256
9.4 REMOVAL AND INSTALLATION OF ANTI ROLL BAR	259
9.5 REMOVAL AND INSTALLATION OF LOWER ARM ASSEMBLY	261
9.6 REMOVAL AND INSTALLATION OF LOWER ARM BALL JOINT	262
9.7 REMOVAL AND INSTALLATION OF LOWER ARM RUBBER BUSHES	264
9.8 PROCEDURE FOR CHECKING BALL JOINT PLAY ON LOWER ARM	265
10 ON VEHICLE REPAIRS REAR SUSPENSION	266
10.1. DISASSEMBLY AND ASSEMBLY OF REAR SHOCK ABSORBER FROM VEHICLE	266
10.2. DISASSEMBLY AND ASSEMBLY OF REAR SHOCK ABSORBER	267
10.3. REMOVAL AND INSTALLATION OF TORSION BEAM	269
10.4. TWIST BEAM BUSH REMOVAL	272
11 SUSPENSION ECIE / PRE-LOADING CONDITION	273
WHEELS AND TYRES	274
1. GENERAL INFORMATION	276
A. SPECIFICATIONS	276
B. TYRE PRESSURE DETAILS	276
C. CONSTRUCTION (FOR TIGOR EESL XT)	277
D. CONSTRUCTION (FOR TIGOR EESL XM)	278
E. CONSTRUCTION (FOR TIGOR ER XT)	279
F. CONSTRUCTION (FOR TIGOR ER XM)	280
G. CONSTRUCTION (FOR TIGOR ER XE)	281
2 TIGHTENING TORQUES	282
3 GENERAL SYMPTOMS DIAGNOSIS	283
A. DIAGNOSIS CHART	283
B. TYRE WEAR PATTERN	285
C. WEAR CAUSES	286
D. TYRE VIBRATION DIAGNOSIS	287
4 MAINTENANCE, INSPECTION AND TESTS	288
A. PRELIMINARY INSPECTION	288
B. REGULAR MAINTENANCE	289
I. INFLATION	289
II. WHEEL BALANCING	289
III. TYRE ROTATION	290
IV. WHEEL RUN OUT	291
V. DO'S AND DON’TS	291
5 WHEEL AND TYRE REPLACEMENT	292
A. PRECAUTIONS DURING TYRE REPLACEMENT	292
B. TYRE REPLACEMENT	293
C. WHEEL ASSEMBLY REPLACEMENT	293
D. WHEEL REMOVAL	294
STEERING_BOSCH (ELECTRICAL POWER ASSIST SYSTEM-EPAS)	295
1. GENERAL INFORMATION	297
1.1. SPECIFICATIONS	297
1.2. SYSTEM LAYOUT	297
1.3. GENERAL DISCRIPTION	298
1.4. TIGHTENING TORQUES	299
1.5. SPECIAL TOOLS	301
2. MAINTENANCE, INSPECTION AND TEST	302
2.1. PRELIMINARY INSPECTION	302
2.2. REGULAR MAINTENANCE	303
2.3. ON VEHICLE REPAIRS	304
2.3.1. STEERING WHEEL REMOVAL	304
2.3.2. STEERING COLUMN REMOVAL	305
2.3.3. INTERMEDIATE SHAFT REMOVAL	307
2.3.4. ECU REMOVAL	307
2.3.5. RACK & PINION ASSEMBLY REMOVAL	309
3. OVERHAULING	311
3.1. OVERHAULING OF STEERING RACK & PINION ASSEMBLY	311
3.2. PRECAUTIONS	312
3.3. DISMANTLING, INSPECTION & ASSEMBLY	312
3.3.1. DISASSEMBLY OF RACK & PINOIN	312
3.3.2. INSPECTION OF DISMANTLED PARTS	313
3.3.3. ASSEMBLY OF RACK & PINOIN	313
3.3.4. OBJ ON VEHICLE REMOVAL	314
3.3.5. DO'S & DON’T'S	314
3.3.6. WHEEL ALIGNMENT	315
4. TROUBLESHOOTING AND DIAGNOSIS	318
5. STEERING ANGLE CALIBRATION AND INITIALIZATION PROCESS	322
6. EPAS ECU REPLACEMENT AND SOFTWARE UPDATE PROCEDURE IN FIELD	324
STEERING_MANDO (ELECTRICAL POWER ASSIST SYSTEM-EPAS)	329
1. GENERAL INFORMATION	331
1.1. SPECIFICATIONS	331
1.2. SYSTEM LAYOUT	331
1.3. GENERAL DISCRIPTION	332
1.4. TIGHTENING TORQUES	333
1.5. SPECIAL TOOLS	335
2. MAINTENANCE, INSPECTION AND TEST	336
2.1. PRELIMINARY INSPECTION	336
2.2. REGULAR MAINTENANCE	337
2.3. ON VEHICLE REPAIRS	338
2.3.1. STEERING WHEEL REMOVAL	338
2.3.2. STEERING COLUMN REMOVAL	340
2.3.3. INTERMEDIATE SHAFT REMOVAL	342
2.3.4. ECU REMOVAL	342
2.3.5. MOTOR REMOVAL	343
2.3.6. RACK & PINION ASSEMBLY REMOVAL	344
3. OVERHAULING	346
3.1. OVERHAULING OF STEERING RACK & PINION ASSEMBLY	346
3.2. PRECAUTIONS	347
3.3. DISMANTLING, INSPECTION & ASSEMBLY	347
3.3.1. DISASSEMBLY OF RACK & PINOIN	347
3.3.2. INSPECTION OF DISMANTLED PARTS	348
3.3.3. ASSEMBLY OF RACK & PINOIN	348
3.3.4. OBJ ON VEHICLE REMOVAL	349
3.3.5. DO'S & DON’T'S	349
3.3.6. WHEEL ALIGNMENT	353
4. TROUBLESHOOTING AND DIAGNOSIS	355
5. STEERING ANGLE CALIBRATION PROCESS	359
6. EPAS ECU REPLACEMENT AND SOFTWARE UPDATE PROCEDURE IN FIELD	366
BRAKES	370
1 TECHNICAL SPECIFICATIONS	373
2 TIGHTENING TORQUES	375
3 SPECIAL TOOLS	380
4 PRECAUTIONS	380
5 DIAGNOSIS	381
6 NESSECITY OF ABS WITH EBD	384
7 BRAKE HYDRAULIC LINES	385
8 VACUUM BRAKE BOOSTER	386
9 WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS)	387
10 ABS COMPONENTS	391
10.1 ABS 9 ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU / HCU)	392
10.2 HYDRAULIC CONTROL UNIT	393
10.3 WHEEL SPEED SENSOR: (MONITORSWHEEL SPEED)	393
10.4 ABS SYSTEM FAILUREWARNING LIGHT	394
11 MAINTENANCE, ADJUSTMENTS & TEST	395
11.1 FRONT BRAKE MAINTENANCE	395
11.2 REAR BRAKE MAINTENANCE	397
11.3 BLEEDING OF HYDRAULIC SYSTEM	399
11.4 BRAKE TROUBLE SHOOTING	403
11.5 CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO	404
11.6 STOP LIGHT SWITCH ADJUSTMENT	405
12 SNAP TYPE BRAKE LIGHT SWITCH INSTALLATION PROCEDURE	406
13 REGENERATION SENSOR REMOVAL	407
14 ACCELERATOR PEDAL ASSEMBLY	407
15 BRAKE/CLUTCH PEDAL ASSEMBLY	408
16 REPAIRS	410
16.1 FRONT BRAKE ADJUSTMENT, REMOVAL AND REFITMENT	411
16.2 REMOVAL OF FRONT BRAKE DISC	419
16.3 REMOVAL AND REFITMENT OF TMC & BOOSTER ASSEMBLY	420
16.4 REAR BRAKE ASSEMBLY	422
16.5 REMOVAL AND REFITMENT OF REAR BRAKE ASSEMBLY	423
16.6 REMOVAL OF PARKING BRAKE LEVER	429
16.7 REMOVAL AND INSTALLATION OF PARKING BRAKE CABLE	430
16.8 PARKING BRAKE CABLE ADJUSTMENT	431
16.9 PARKING BRAKE LEVER PRIMARY CABLE GREASING	431
16.10 REMOVAL AND REFITMENT OF ABS ECU / HCU	432
16.11 REMOVAL AND REFITMENT OF FRONTWHEEL SPEED SENSOR	433
16.12 REMOVAL AND REFITMENT OF REARWHEEL SPEED SENSOR	434
16.13 REMOVAL AND REFITMENT VACUUM PUMP	435
16.14 VACUUM SENSOR REMOVAL	436
17 TROUBLE SHOOTING & DIAGNOSIS	436
18 ABS ECU CONNECTOR	438
FATC	439
1. TECHNICAL SPECIFICATION	441
2. FATC SYSTEM & LAYOUT	443
3. FATC UNIT WORKING	444
4. BATTERY COOLING UNIT	444
5. SCHEMATICS OF HVAC & BCS	445
6. HVAC ELECTRICAL CIRCUIT DIAGRAM	446
7. TIGHTENING TORQUES	447
8. PRECAUTIONS	452
9. FATC CONTROL PANEL	453
10. CONTROL PANEL CONNECTOR DETAILS	457
11. FATC UNIT	459
12. COMPRESSOR	460
13. BLOWER	462
14. FILTER	462
15. TXV	463
16. HVAC UNIT REMOVAL	463
17. PRESSURE SENSOR / SWITCH	464
18. CONDENSER	464
19. SOLAR LOAD SENSOR	465
20. OAT SENSOR	466
21. THERMISTOR OR THERMO SENSOR	467
22. AIR INLET ACTUATOR	468
23. TEMPERATURE ACTUATOR	469
24. FRESH / RECIRCULATION ACTUATOR	469
25. LINEAR POWER MODULE	469
26. PTC HEATER	470
27. REFRIGERANT HOSES/PIPES	470
28. DO’S & DON’T’S	471
29. TROUBLESHOOTING	472
30. MAINTAINANCE	483
30.1. PRELIMINARY INSPECTION	483
30.2. REGULAR MAINTENANCE	486
BODY	490
1. GENERAL INFORMATION	493
1.1. LAYOUT	493
1.2. TIGHTENING TORQUES	494
1.3. SPECIAL TOOLS	500
2. ON VEHICLE REPAIRS	501
2.1. BONNET	501
2.2. FLOOR CONSOLE	503
2.3. DASHBOARD SKIN REMOVAL PROCEDURE	505
2.4. CROSS CAR BEAM WITH COCKPIT ASSEMBLY REMOVAL	508
2.5. GLOVE BOX	512
2.6. SIDE AIR VENTS	512
2.7. FRONT BUMPER	513
2.8. REAR BUMPER	514
2.9. FRONT DOOR	515
2.10. FRONT DOOR TRIMS	516
2.11. DOOR INNER LOCK HANDLE	517
2.12. FRONT OUTER DOOR LOCK	518
2.13. FRONT DOOR LATCH	519
2.14. FRONT DOOR GLASS AND WINDOW WINDING MECHANISM	520
2.15. REAR DOOR	521
2.16. REAR DOOR TRIM	522
2.17. REAR OUTER DOOR LOCK	524
2.18. DOOR LATCH REAR	525
2.19. TRUNK LID	526
2.20. TRUNK LID TRIM	527
2.21. OUTER REAR VIEW MIRROR	529
2.22. INNER REAR VIEW MIRROR	529
2.23. FRONT ROW SEAT	530
2.24. REAR ROW SEAT	531
2.25. REAR ROW SEAT ARMREST	532
2.26. FRONT SEAT BELTS	532
2.27. REAR SEAT BELT	534
2.28. “A” PILLAR TRIM	536
2.29. FRONT SCUFF PLATE	537
2.30. “B" PILLAR TRIMS	538
2.31. “C” PILLAR TRIM	539
2.32. GRAB HANDLES	540
2.33. SUNVISOR	540
2.34. ROOF LINER	541
2.35. PLENUM COVER	541
2.36. BONNET INSULATION	542
2.37. GLASS	543
2.38. REAR QUARTER GLASS	544
2.39. FUEL FILLER ASSEMBLY	544
2.40. FRONT WHEEL ARCH LINER	547
2.41. REAR WHEEL ARCH LINER	548
2.42. FRONT FENDER	548
2.43. FRONT WIPER	550
2.44. REAR DOOR CHEATER	551
2.45. BATTERY TOP COVER	552
2.46. SLOW CHARGER REMOVAL	553
SUPPLEMENTARYRESTRAINT 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	566
7.1. RESTRAINT WITHOUT AIRBAGS	566
7.2. RESTRAINT WITH AIRBAGS	566
A. ECU	566
B. SENSORS	570
C. AIRBAGS	571
D. FRONT SEAT (DRIVER) BELT BUCKLE	573
E. RPLL BELTS	574
E. CLOCK SPRING	576

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