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TIAGO TIGOR iCNG - 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
1.4. 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
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
1.10. MOON VALVE REMOVAL / REPLACEMENT PROCEDURE 196
A. TOOLS REQUIRE 196
B. MOON VALVE LOCATION 196
C. MOON VALVE REMOVAL / REPLACEMENT 197
TRANSAXLE 207
1. TECHNICAL SPECIFCICATIONS 207
2. PRECAUTIONS 207
3. GENERAL DESCRIPTION 208
4. TIGHTENING TORQUES 209
5. SPECIAL TOOLS LIST 215
6. DIAGNOSIS OF TRANSAXLE 220
7. CUT SECTION OF TRANSAXLE TA 65 STAR 221
8. CUT SECTION OF TOP COVER ASSEMBLY 222
9. EXPLODED VIEWS OF TRANSAXLE 223
A. TRANSAXLE HOUSING 223
B. TOP COVER ASSEMBLY 224
C. DIFFERENTIAL 226
D. SHIFTER FORK 227
E. GEAR SHIFT LINKAGE ASSEMBLY 228
F. LAY SHAFT AND INPUT SHAFT 229
10. REMOVAL OF TRANSAXLE FROM VEHICLE 231
11. TRANSAXLE TA65 STAR (ON BENCH) DISASSEMBLY 235
12. INPUT SHAFT SUB ASSEMBLY 240
13. DISASSEMBLY OF LAY SHAFT 241
14. IDENTIFICATION OF COMPONENTS 243
A. ENGAGING GEARS 243
B. SHIFTER SHAFT SUB ASSEMBLY 244
C. SHIFTER FORKS 244
D. SHIFTER SHAFT 245
E. SHIFTER SLEEVE 245
F. SYNCHROCONE 245
G. SUB ASSEMBLIES 245
15. LAY SHAFT ASSEMBLY 247
16. DIFFERENTIAL ASSEMBLY 250
17. ASSEMBLY OF TRANSAXLE 252
18. TOP COVER DISASSEMBLY & ASSEMBLY 255
19. INSTRUCTION FOR ASSEMBLY / DISASSEMBLY OF CABLE AT GEAR BOX 258
20. INSTALLATION OF TRANSAXLE ON THE VEHICLE 259
21. REMOVAL OF GEAR SHIFTER AND SELECTOR CABLE 260
CLUTCH_CNG 262
1 GENERAL INFORMATION 264
2 PRECAUTIONS 264
3 TECHNICAL SPECIFICATIONS 265
A. CLUTCH DISC 265
B. CLUTCH PRESSURE PLATE 267
C. FLYWHEEL 268
4 TIGHTENING TORQUES 269
5 SPECIAL TOOLS 270
6 DIAGNOSIS OF CLUTCH 271
7 MAINTENANCE, TESTS AND FACTOR AFFECTING CLUTCH 274
8 CONSTRUCTIONAL DETAILS 275
9 CLUTCH CABLE 276
10 REMOVAL & INSTALLATION OF CLUTCH 278
11 FLYWHEEL 278
12 CLUTCH ADJUSTMENT PROCEDURE 279
DRIVESHAFT_CNG 280
1. INTRODUCTION 282
2. DRIVESHAFT 283
3. DRIVE SHAFT PARTS 284
4. GENERAL GUIDELINES FOR TESTING DRIVE SHAFT NOISE 285
5. TESTING FOR NOISE 285
6. TIGHTENING TORQUES 286
7. SPECIAL TOOLS 286
8. ON VEHICLE REMOVAL OF DRIVE SHAFT (LH & RH SIDE) 287
9. DISASSEMBLY PROCEDURE FOR DRIVE SHAFT 289
10. ASSEMBLY PROCEDURE FOR DRIVESHAFT 291
11. DISASSEMBLY AND ASSEMBLY OF CV JOINT ASSEMBLY (OUTER) 292
12. DO’S AND DON’T’S FOR DRIVE SHAFT 296
SUSPENSION 297
1. TECHNICAL SPECIFICATION 299
2. TIGHTENING TORQUES 300
3. ECIE / PRELOAD CONDITION 305
4. SPECIAL TOOLS 307
5. DIAGNOSIS 313
6. PRECAUTIONS 314
7. SUSPENSION SYSTEM LAYOUT 315
8. FRONT SUSPENSION EXPLODED VIEWS 318
9. ON VEHICLE FRONT SUSPENSION REMOVAL PROCEDURES 322
A. REMOVAL AND INSTALLATION OF FRONT STRUT ASSEMBLY 322
B. DISASSEMBLY AND ASSEMBLY OF FRONT STRUT 324
C REMOVAL AND INSTALLATION OF WHEEL HUB 326
D REMOVAL AND INSTALLATION OF ANTI ROLL BAR 329
E REMOVAL AND INSTALLATION OF LOWER CONTROL ARM (LCA) 331
F REMOVAL AND INSTALLATION LOWER ARM BALL JOINT 333
G REMOVAL AND INSTALLATION OF LOWER ARM RUBBER BUSHES 334
10. PROCEDURE FOR CHECKING THE BALL JOINT PLAY LOWER ARM 336
11. REAR SUSPENSION EXPLODED VIEWS 337
12. ON VEHICLE REAR SUSPENSION REMOVAL PROCEDURES 340
A. REMOVAL AND INSTALLATION OF REAR SHOCK ABSORBER 340
B. DISASSEMBLY AND ASSEMBLY OF REAR SHOCK ABSORBER 340
C REMOVAL AND INSTALLATION OF TORSION BEAM 343
D REAR BRAKE DRUM BEARING REMOVAL & FITMENT 348
13. SUSPENSION ECIE / PRE LOADING CONDITION 349
WHEELS AND TYRES 350
1. GENERAL INFORMATION 353
A. SPECIFICATIONS 353
B. TYRE PRESSURE DETAILS 353
C. CONSTRUCTION (XM CNG TIAGO) 354
D. CONSTRUCTION (XT CNG TIAGO) 355
E. CONSTRUCTION (XZ CNG TIAGO) 356
F. CONSTRUCTION (XE CNG TIGOR) 357
G. CONSTRUCTION (XM CNG TIGOR) 358
H. CONSTRUCTION (XZ CNG TIGOR) 359
2 TIGHTENING TORQUES 360
3 GENERAL SYMPTOMS DIAGNOSIS 361
A. DIAGNOSIS CHART 361
B. TYRE WEAR PATTERN 363
C. WEAR CAUSE 364
D. TYRE VIBRATION DIAGNOSIS 365
4 MAINTENANCE, INSPECTION AND TESTS 366
A. PRELIMINARY INSPECTION 366
B. REGULAR MAINTENANCE 367
I. INFLATION 367
II. WHEEL BALANCING 368
III. TYRE ROTATION 368
IV. WHEEL RUN OUT 369
V. DO'S AND DON’TS 369
5 WHEEL AND TYRE REPLACEMENT 370
A. PRECAUTIONS DURING TYRE REPLACEMENT 370
B. TYRE REPLACEMENT 370
C. DEFECTIVE WHEEL ASSEMBLY REPLACEMENT 371
D. SPARE WHEEL REMOVAL PROCEDURE 371
E. WHEEL REMOVAL 372
F. TYRE CARE 374
BRAKES 375
1 TECHNICAL SPECIFICATIONS 378
2 TIGHTENING TORQUES 380
3 SPECIAL TOOLS 384
4 PRECAUTIONS 384
5 DIAGNOSIS 385
6 NESSECITY OF ABS WITH EBD 388
7 BRAKE HYDRAULIC LINES 389
8 VACUUM BRAKE BOOSTER 390
9 WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) 391
10 ABS COMPONENTS 395
A ABS 9 ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU / HCU) 395
B WHEEL SPEED SENSOR 397
C ABS SYSTEM FAILURE WARNING LIGHT 398
11 MAINTENANCE, ADJUSTMENTS & TEST 399
A FRONT BRAKE MAINTENANCE 399
B REAR BRAKE MAINTENANCE 401
C BLEEDING OF HYDRAULIC SYSTEM 403
D BRAKE TROUBLE SHOOTING 407
E ROAD TESTING 407
12 CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO 408
13 STOP LIGHT SWITCH ADJUSTMENT 409
14 SNAP TYPE BRAKE LIGHT SWITCH INSTALLATION PROCEDURE 410
15 ACCELERATOR PEDAL ASSEMBLY REMOVAL 411
16 BRAKE / CLUTCH PEDAL ASSEMBLY REMOVAL 411
17 FRONT BRAKE ASSEMBLY 413
A CALIPER BRAKE ASSSEMBLY EXPLODED VIEW 413
B FRONT BRAKE DISC 414
C FRONT BRAKE ADJUSTMENT, REMOVAL AND REFITMENT 414
D REMOVAL AND REFITMENT OF TMC & BOOSTER ASSEMBLY 421
18 REAR BRAKE ASSEMBLY 423
A REAR BRAKE ASSEMBLY EXPLODED VIEW 423
B REMOVAL AND REFITMENT OF REAR BRAKE ASSEMBLY REMOVAL 424
C WHEEL CYLINDER ASSEMBLY EXPLODED VIEW 426
D REMOVAL & ASSEMBLY OF WHEEL CYLINDER 427
E ASSEMBLING NEW AUTO ADJUSTER 427
F INSTALLATION OF BRAKE BACK PLATE 428
19 PARKING BRAKE ASSEMBLY 429
A LAYOUT 429
B REMOVAL OF PARKING BRAKE LEVER 430
C REMOVAL OF PARKING BRAKE CABLE 431
D INSTALLATION OF PARKING BRAKE CABLE 431
E INSTALLATION OF PARKING BRAKE LEVER 431
F PARKING BRAKE CABLE ADJUSTMENT 432
G PARKING BRAKE LEVER PRIMARY CABLE GREASING 432
20 REMOVAL AND REFITMENT OF ABS ECU / HCU 433
21 REMOVAL AND REFITMENT OF FRONT WHEEL SPEED SENSOR 434
22 REMOVAL AND REFITMENT OF REAR WHEEL SPEED SENSOR 435
23 TROUBLE SHOOTING & DIAGNOSIS 436
24 ABS ECU CONNECTOR 438
25 WHEEL SPEED SENSOR CONNECTOR 438
STEERING_MANDO 439
1. GENERAL INGOTMATION 441
A. TECHNICAL SPECIFICATION 441
B. INTRODUCTION 441
C. SYSTEM LAYOUT 442
2. TIGHTENING TORQUES 443
3. SPECIAL TOOLS 445
4. MAINTENANCE, INSPECTION AND TEST 446
A. PRELIMINARY INSPECTION 446
B. REGULAR MAINTENANCE 447
5. ON VEHICLE REPAIRS 449
A. STEERING WHEEL REMOVAL 449
B. STEERING COLUMN REMOVAL 450
C. INTERMEDIATE SHAFT REMOVAL 452
D. ECU REMOVAL 452
E. MOTOR REMOVAL 453
F. RACK & PINION ASSEMBLY REMOVAL 454
6. STEERING RACK AND PINION ASSEMBLY EXPLODED VIEW 455
7. OVERHAULING OF STEERING RACK & PINION ASSEMBLY 456
8. DO'S & DON’T'S 458
9. WHEEL ALIGNMENT 461
10. TROUBLESHOOTING AND DIAGNOSIS 463
11. STEERING ANGLE CALIBRATION PROCESS 467
12. TUNING DATA SELECTION 472
13. EPAS ECU REPLACEMENT AND SOFTWARE UPDATE PROCEDURE IN FIELD 473
BODY 477
1. LAYOUT 480
2. TIGHTENING TORQUES 481
3. SPECIAL TOOLS 483
4. ON VEHICLE REPAIRS 484
4.1. BONNET REMOVAL 484
4.2. FLOOR CONSOLE REMOVAL 486
4.3. DASHBOARD REMOVAL 488
4.4. GLOVE BOX REMOVAL 495
4.5. SIDE AIR VENTS REMOVAL 496
4.6. FRONT BUMPER REMOVAL 496
4.7. REAR BUMPER REMOVAL (TIAGO) 498
4.8. REAR BUMPER REMOVAL (TIGOR) 499
4.9. FRONT DOOR REMOVAL 500
4.10. FRONT DOOR TRIMS REMOVAL 501
4.11. DOOR INNER LOCK HANDLE REMOVAL 503
4.12. FRONT OUTER DOOR LOCK REMOVAL 504
4.13. FRONT DOOR LATCH REMOVAL 506
4.14. FRONT DOOR GLASS AND WINDOW WINDING MECHANISM REMOVAL 507
4.15. REAR DOOR REMOVAL 508
4.16. REAR DOOR TRIM REMOVAL 509
4.17. REAR OUTER DOOR LOCK REMOVAL 510
4.18. DOOR LATCH REAR REMOVAL 511
4.19. TAIL GATE REMOVAL 512
4.20. TAIL GATE LATCH CABLE REMOVAL 514
4.21. TAIL GATE TRIM REMOVAL 515
4.22. OUTER REAR VIEW MIRROR REMOVAL 515
4.23. INNER REAR VIEW MIRROR REMOVAL 516
4.24. FRONT ROW SEAT REMOVAL 516
4.25. REAR ROW SEAT REMOVAL (TIAGO) 517
4.26. REAR ROW SEAT REMOVAL (TIGOR) 519
4.27. REAR ROW SEAT ARMREST REMOVAL 520
4.28. FRONT SEAT BELT REMOVAL 521
4.29. REAR SEAT BELT REMOVAL (TIAGO) 523
4.30. REAR SEAT BELT REMOVAL (TIGOR) 524
4.31. “A” PILLAR TRIM REMOVAL 525
4.32. FRONT SCUFF PLATE REMOVAL 527
4.33. “B" PILLAR TRIMS REMOVAL 527
4.34. “C” PILLAR TRIM REMOVAL 528
4.35. GRAB HANDLES REMOVAL 529
4.36. SUNVISOR REMOVAL 529
4.37. ROOF LINER REMOVAL 530
4.38. PLENUM COVER REMOVAL 530
4.39. GEAR LEVEL BOOT REMOVAL 531
4.40. BONNET INSULATION REMOVAL 531
4.41. GLASS REMOVAL 532
4.42. FUEL FILLER ASSEMBLY REMOVAL 533
4.43. FRONT WHEEL ARCH LINER REMOVAL 534
4.44. REAR WHEEL ARCH LINER REMOVAL 535
4.45. FRONT FENDER REMOVAL 535
4.46. REAR WIPER MOTOR REMOVAL 537
4.47. FRONT WIPER REMOVAL 538
HVAC 539
1 TECHNICAL SPECIFICATIONS 541
2 TIGHTENING TORQUES 542
3 PRECAUTIONS 545
4 HVAC UNIT EXPLODED VIEW 546
5 HVAC SYSTEM LAYOUT AND WORKING 547
6 COMPONENTS OF HVAC SYSTEM 549
A. CONTROL PANEL 549
B. HVAC UNIT 552
C. BLOWER RESISTER 555
D. CONDENSOR AND RECEIVER DRIER 556
E. CONDENSER SEALING DUCTS 556
F. PRESSURE SENSOR 556
7 TROUBLESHOOTING 558
8 MAINTENANCE 572
9 ON VEHICLE REMOVAL 579
A. CONTROL PANEL ASSEMBLY 579
B. COMPRESSOR 583
C. BLOWER 583
D. BLOWER RESISTER 584
E. AIR FILTER 584
F. TXV 585
G. PRESSURE SENSOR 586
H. HVAC UNIT 586
I. CONDENSOR SEALING DUCT 587
J. CONDENSOR 587
10 REFRIGERANT HOSES/PIPES LAYOUT 588
11 DO’S & DONT’S 589
FATC 590
1 TECHNICAL SPECIFICATIONS 592
2 TIGHTENING TORQUES 594
3 FATC LAYOUT 597
4 FATC CONTROL PANEL DETAILS 598
4 FATC CONTROL PANEL REMOVAL 601
6 CONTROL PANEL CONNECTOR DETAILS 602
7 FATC SENSOR 604
A. SOLAR LOAD SENSOR (FOR TIAGO ONLY) 604
B. OAT SENSOR 605
C. THERMISTOR OR THERMO SENSOR 606
D. AIR INLET ACTUATOR 607
E. LINEAR POWER MODULE 609
ELECTRICAL 610
1 TECHNICAL SPECIFICATION 615
A. BATTERY 615
B. STARTER MOTOR 617
C. ALTERNATOR 625
2 LIGHTING SYSTEM 628
A. BULB SPECIFICATIONS (TIGOR) 628
B. BULB SPECIFICATIONS (TIAGO) 629
C. FASTENERS TORQUE VALUE TABLE 629
D. GENERAL SYMPTOMS AND DIAGNOSTICS 630
E. HEAD LAMP (SINGLE CHAMBER) 633
F. HEAD LAMP (DUAL CHAMBER) (IF APPLICABLE) 637
G. ROOF LAMP 641
H. HIGH MOUNTED STOP LAMP (FOR TIGOR) 642
I. HIGH MOUNTED STOP LAMP (FOR TIAGO) 643
J. TAIL LAMP (FOR TIAGO) 644
K. TAIL LAMP (FOR TIGOR) 646
L. FRONT FOG LAMP 648
M. REGISTRATION PLATE LAMP 649
N. REVERSE LAMP (FOR TIGOR) 650
O. TAIL GATE SWITCH LAMP (FOR TIGOR) 650
P. DRL (IF APPLICABLE) 651
3 WIPER & WASHER SYSTEM 652
4 SWITCHES 658
A. COMBI SWITCH 658
B. STEERING LOCK CUM IGNITION SWITCH 665
C. FASCIA SWITCHES 667
D. HAZARD SWITCH 669
E. MIRROR SWITCH 670
F. WINDOW WINDING MODULE 671
G. POWER WINDOW SWITCHES & INHIBIT SWITCH 673
H. STEERING WHEEL SWITCHS 676
I. FUEL FLAP SWITCH 678
J. CNG CUTOFF SWITCH 679
K. ENGINE START-STOP (ESS) OFF SWITCH (IF EQUIPPED) 680
L. DOOR HANDLE SWITCH REMOVAL 681
M. TAILGATE HANDLE SWITCH 682
5 HORN 684
6 POWER SOCKETS 686
7 INFOTAINMENT 687
A. INFOTAINMENT SYSTEM DISPLAY DETAILS (LEVEL B) 688
B. INFOTAINMENT SYSTEM DISPLAY DETAILS (LEVEL A) 690
C. USB/AUX PORT 692
D. SPEAKERS 693
E. TWEETER 694
F. ANTENNA 695
G.MICROPHONE 696
8 INSTRUMENT CLUSTER 697
A. CNG INSTRUMENT CLUSTER VARIANTS 697
B. FEATURES 698
C. BASIC FUNCTIONAL MATRIX 701
D. TELL TALES MATRIX 702
E. TELL TALES DISCRIPTION 704
F. DRIVER INFORMATION SYSTEM 708
G. REMINDER FEATURES 715
H. MAIN CONNECTOR PIN-OUTS 716
I. FUEL GAUGE DETAILS 717
J. CHIME TABLE 717
K. DISPLAY SCREEN FLOW AND SETTINGS 718
L. REMOVAL OF INSTRUMENT CLUSTER 719
9 IMMOBILIZER SYSTEM 720
A. IMMOBILIZER SYSTEM DESCRIPTION 720
B. TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB 722
C. IMMOBILIZER SYSTEM STATUS IN EMS ECU 723
D. IGNITION REMOTE KEY (IF APPLICABLE) 724
E. IGNITION E-KEY (IF APPLICABLE) 727
F. IGNITION E-KEY LEARNING PROCEDURE 729
G. PAIRING OF VCU-ECU & LIN BASED BCM IMMOBILIZER 729
H. MAINTENANCE AND TROUBLE SHOOTING 730
I. TWO SMART KEYS SCENARIO 731
10 BODY CONTROL MODULE 732
A. REMOVAL OF BCM 732
B. CONNECTION DETAILS 733
C. BCM SPECIFICATION 737
D. BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIXS 738
E. BCM FEATURES 744
F. BCM REPLACEMENT STRATEGY 746
G. BCM FUNCTIONS 747
11 FUSE AND RELAY BOX 748
A. FUSE AND RELAY BOX LAYOUT 750
B. BATTERY MOUNTED FUSE BOX (BDU): 751
C. ENGINE FUSE AND RELAY BOX 752
D. CABIN FUSE AND RELAY BOX 756
E. FUSE AND RELAY REPLACEMENT 758
12 REVERSE PARK ASSIST SYSTEM 759
A. PARK ASSIST 759
B. PARK ASSIST FUNCTIONALITY OVERVIEW 759
C. PARK ASSIST INDICATIONS 759
D. PARK ASSIST ACTIVATION / DEACTIVATION PROCEDURE 759
E. PARK ASSIST DELAY TIMER 759
F. PARK ASSIST LIMITATIONS 760
G. PARK ASSIST SYSTEM MAINTENANCE 760
H. RPAS ARCHITECTURE WITHOUT CONTROLLER (THROUGH BCM) 761
I. SENSOR CONNECTOR DETAILS 762
J. ECU TO SENSOR ELECTRICAL INTERFACE 763
K. REMOVAL OF SENSOR 764
13 REVERSE PARK ASSIST WITH CAMERA (IF APPLICABLE) 767
A. REAR VIEW CAMERA (IF APPLICABLE) 768
B. REAR VIEW CAMERA REMOVAL (IF APPLICABLE) 769
C. TROUBLESHOOTING 770
14 PASSIVE ENTRY PASSIVE START (PEPS) (IF APPLICABLE) 771
A. PEPS ECU 772
B. START STOP SWITCH (IF APPLICABLE) 774
C. ELCTRONIC STEERING COLUMN LOCK (ESCL) 775
D. LF ANTENNAS 777
15 RAIN LIGHT SENSOR SYSTEM (IF APPLICABLE) 780
A. RAIN LIGHT SENSOR 780
B. FUNCTIONAL DETAILS 783
C. FAIL SAFE MODES OF RLS & BCM 784
SUPPLEMENTARYRESTRAINT SYSTEM 785
1. WORKING OF RESTRAINTS 787
2. SRS SYSTEM COMPONENTS LAYOUT 788
3. SYSTEM LAYOUT 790
4. SAFETY PRECAUTIONS 791
5. DISPOSAL OF FAULTY AIR BAG UNIT 793
6. SRS POST ACCIDENT PROCEDURE 794
7. TIGHTENING TORQUES 795
8. COMPONENTS 798
8.1. RESTRAINT WITHOUT AIRBAGS 798
8.2. RESTRAINT WITH AIRBAGS 798
A. ECU 798
B. FRONT IMPACT SENSORS 802
C. AIRBAGS 803
D. FRONT SEAT (DRIVER) BELT BUCKLE 805
E. RPLL BELTS 805
F. CLOCK SPRING 808

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