1 592

TIAGO AMT

TIAGO AMT 1
TRANSAXLE 5
1 PRECAUTION 8
2 TRANSAXLE GENERAL INFORMATION 9
3 TECHNICAL SPECIFCICATIONS 10
4 TIGHTENING TORQUES 11
5 SPECIAL TOOLS 12
A. CLUTCH 12
B. TRANSAXLE 12
6 DIAGNOSIS OF TRANSAXLE 17
7 SERVICE SCHEDULE OF TRANSAXLE 17
8 CUT SECTION OF TRANSAXLE 18
9 EXPLODED VIEWS OF TRANSAXLE 19
10 REMOVAL OF TRANSAXLE FROM VEHICLE 28
11 TRANSAXLE TA65 STAR AMT DISASSEMBLY (ON BENCH) 31
12 SUB ASSEMBLIES 37
CLUTCH 52
1. GENERAL INFORMATION 55
2 TEHCNICAL SPECIFCICATIONS & TIGHTENING TORQUES 55
3. DIAGNOSIS 58
4. CLUTCH 60
A. THEORY OF DIAPHRAGM SPRING CLUTCH 60
B. CONSTRUCTIONAL DETAILS 61
C. FACTOR AFFECTING CLUTCH WEAR 63
D. REMOVAL OF CLUTCH FROM THE CAR 63
E. INSTALLATION OF CLUTCH ON THE CAR 63
5. MAINTENANCE, ADJUSTMENT AND TESTS TRANSAXLE 64
DRIVESHAFT 65
1. GENERAL INFORMATION 68
2 GENERAL GUIDELINES FOR TESTING DRIVE SHAFT NOISE 69
3. TESTING FOR NOISE 69
4. DRIVE SHAFT PARTS 70
5. DISASSEMBLY PROCEDURE FOR TRIPOT JOINT 71
6. DISASSEMBLY AND ASSEMBLY OF CV JOINT ASSEMBLY (OUTER) 74
AMT KIT 78
1. AMT-KIT LOCATION ON VEHICLE(LAYTOU) 81
2 NOMENCLATURE FOR AMT KIT 82
3. TIGHTENING TORQUES AND CONSTRUCTIONAL DETAILS 83
4. SPECIAL TOOLS 86
5. PRECAUTIONS 89
6. ON VEHICLE PROCEDURES 90
A. DEPRESSURIZATION OF AMT KIT 90
B. AMT KIT REMOVAL (FROM TOP) 93
7. ON BENCH PROCEDURES 96
A. OIL TANK REMOVAL AND RE-FITMENT 96
B. MECHATRONIC GEAR ACTUATOR UNIT (MGA) REMOVAL AND RE-FITMENT 98
C. TRANSMISSION CONTROL UNIT (TCU) REMOVAL AND RE-FITMENT 101
D. DC MOTOR REMOVAL AND RE-FITMENT 104
E. HYDRAULIC OIL ACCUMLATOR REMOVAL AND RE-FITMENT 105
F. CLUTCH POSITION SENSOR REMOVAL AND RE-FITMENT 105
G. POWER UNIT (PWU) BASE PLATE REMOVAL AND RE-FITMENT ON BENCH 106
CONSOLE 107
1. AMT GEARBOX SHIFTER AND SHIFTING MECHANISM 110
2 DRIVING MODES 110
3. GEAR SHIFTER CENTER CONSOLE REMOVAL AND RE-FITMENT ON VEHICLE 112
4. GEAR SHIFTER PIN CONFIGURATION 114
INSTRUMENT CLUSTER 115
1. GENERAL INFORMATION 118
2 BASIC FUNCTIONAL MATRIX 120
3. TELL TALES MATRIX 121
4. DRIVER INFORMATION SYSTEM 127
5. REMINDER FEATURES 132
6. MAIN CONNECTOR PIN-OUTS 133
7. FUEL GAUGE DETAILS 134
8. TEMPERATURE BAR GRAPH DETAILS 135
9. CHIME TABLE 136
10. DISPLAY SCREEN FLOW AND SETTINGS 136
11. REMOVAL OF INSTRUMENT CLUSTER 140
12. IMMOBILIZER SYSTEM 142
13. TROUBLESHOOTING THROUGH IMMOBILIZER STATUS BULB 147
14. .IMMOBILIZER SYSTEM STATUS IN EMS ECU 148
COMPONENT REPLACEMENT 150
1 Document Scope 153
2 Intended Audience 153
3 Terminologies 153
4 Confidentiality 153
5 Contacts at Tata Motors 153
6 Routine Procedure for Component Replacement 154
6.1 Matrix of Routine Procedure for Component Replacement 154
6.2 Routine Procedure for TCU replacement 155
6.3 Routine Procedure for Actuation system replacement 156
6.4 Routine Procedure for Gear Box replacement 157
6.5 Routine Procedure for Pump/Accumulator/Clutch Actuator Replacement 158
6.6 Routine Procedure for Valve bock and TCU replacement 159
6.7 Routine Procedure for Clutch Sensor replacement 160
6.8 Routine Procedure for Clutch replacement 161
6.9 Routine Procedure for Primary shaft speed sensor replacement 162
6.10 Routine Procedure for Rubber Bellow replacement 163
6.11 Routine Procedure for Reservoir replacement 163
6.12 Routine Procedure for Gear Shift Lever or Sports/Eco replacement 164
6.13 Routine Procedure for Electric Motor replacement 164
6.14 TCU programming (Flashing) 165
6.15 Routine Procedure for AMT Kit replacement 166
DIAGNOSTIC TROUBLE SHOOTING CODES LIST FOR AMT 168
1. P0914-02: Gear Position Sensor Circuit Fixed Signal High Level 176
2. P0914-01: Gear Position Sensor Circuit Fixed Signal Low Level 179
3. P0914-03: Gear Position Sensor Circuit Period Error 182
4. P0914-05: Gear Position Sensor Circuit PWM Duty high 185
5. P0914-04: Gear Position Sensor Circuit PWM Duty low 188
6. P1853-02: Gear/shift Position Sensor Wrong supply voltage Vbatt Error 191
7. P1853-01: Gear/shift Position Sensor Wrong supply voltage Gnd Error 194
8. P0904-02: Shift Position Sensor Circuit Fixed Signal High Level 197
9. P0904-01: Shift Position Sensor Circuit Fixed Signal Low Level 200
10. P0904-03: Shift Position Sensor Circuit Period Error 203
11. P0904-05: Shift Position Sensor Circuit PWM Duty high 206
12. P0904-04: Shift Position Sensor Circuit PWM Duty low 209
13. P0805-02: Clutch Position Sensor Circuit Fixed Signal High Level 212
14. P0805-01: Clutch Position Sensor Circuit Fixed Signal low Level 215
15. P0805-03: Clutch Position Sensor Circuit Period Error 218
16. P0805-05: Clutch Position Sensor Circuit PWM Duty high 221
17. P0805-04: Clutch Position Sensor Circuit PWM Duty low 224
18. P1852-02: Clutch Position/Hyd Press Sensor Wrong supply voltage Vbatt Error 227
19. P1852-01: Clutch Position/Hyd Press Sensor Wrong supply voltage Gnd Error 230
20. P0932-02: Hydraulic Pressure Sensor Circuit Signal over Max Threshold 233
21. P0932-01: Hydraulic Pressure Sensor Circuit Signal under Min Threshold 237
22. P0932-07: Hydraulic Pressure Sensor Circuit Wrong value sensor 240
23. P0932-03: Hydraulic Pressure Sensor Circuit Wrong signal spikes 243
24. P0820/P0821/P0822/P0823-02: Gear Lever Sensor Circuit Over Max Threshold 246
25. P0820/P0821/P0822/P0823-01: Gear Lever Sensor Circuit Under min. Threshold 250
26. P0825 -02: Gear Lever Sensor Circuit Signal Not valid 254
27. P0825 -01: Gear Lever Sensor Circuit Misuse 258
28. P0715 -03: Clutch Speed Sensor Circuit Signal absent 263
29. P0715 -01: Clutch Speed Sensor Circuit Signal Wrong 266
30. P0715 -02: Clutch Speed Sensor Circuit Signal Wrong Spikes 269
31. P2900 -01: Sport Switch input circuit Switch Stuck 272
32. P0725-02: Engine Speed Input Circuit Signal not valid 275
33. P0725-03: Engine Speed Input Circuit Signal Abse 278
34. P0725-01: Engine Speed Input Circuit Signal wrong 281
35. P0505 -02: Idle Engine Speed Input Signal Implausible / Signal Wrong 284
36. P2903 -02: Accelerator Pedal Position Signal not valid 287
37. P2906 -02: Generated Engine Torque Signal not valid 290
38. P2906 -03: Engine loss Torque Signal not valid 293
39. P1981 -02: Driver Engine Torque Signal not valid 296
40. P2906 -04: Engine Wish Torque Signal not valid 299
41. P2907 -02: Engine Maximum Torque Signal not valid 302
42. P0703 -02: Brake switch input circuit Signal not valid 305
43. P0710 -02: Engine Water Temperature Signal not valid 308
44. P0716 -02: Vehicle speed input Signal not valid 311
45. P0716 -03: Vehicle speed input Signal Absent 314
46. P0716 -01: Vehicle speed input Signal Wrong 317
47. P0710 -03: External Temperature Signal not valid 320
48. P0900-04: Clutch electrovalve Open Circuit 323
49. P0900-02: Clutch electrovalve Short to supply 326
50. P0900-01: Clutch electrovalve Short to Ground 329
51. P0900-05: Clutch electrovalve Short to supply/open circuit 332
52. P0750-04: Gear 1 electrovalve Open Circuit 335
53. P0750-02: Gear 1 electro valve Short to supply 338
54. P0750-01: Gear 1 electrovalve Short to Ground 341
55. P0750-05: Gear 1 electrovalve Short to supply/open circuit 344
56. P0755-04: Gear 2 electrovalve Open Circuit 347
57. P0755-02: Gear 2 electrovalve Short to supply 350
58. P0755-01: Gear 2 electrovalve Short to Ground 353
59. P0755-05: Gear 2 electrovalve Short to supply/open circuit 356
60. P1889-04: Shift electrovalve Open Circuit 359
61. P1889-02: Shift electrovalve Short to supply 362
62. P1889-01: Shift electrovalve Short to Ground 365
63. P1889-05: Shift electrovalve Short to supply/open circuit 368
64. P185C-05: Hydraulic pump Supply Open Circuit /Short to supply 371
65. P185C-01: Hydraulic pump Supply Short to ground 374
66. P185C-03: Hydraulic pump Supply Device closed 377
67. P185C-07: Hydraulic pump Supply Short to supply 381
68. P081A-03: Cranking Enable Short to ground/open circuit 384
69. P081A-02: Cranking Enable Short to supply 386
70. P1884-04: Reverse Lamp relay open circuit 389
71. P1884-02: Reverse Lamp relay short to supply 392
72. P1884-01: Reverse Lamp relay short to ground 395
73. P2904-01: Clutch System Not opening before shi 398
74. P2904-02: Clutch System Closing during Engage 401
75. P2904-03: Clutch System Overheat 404
76. P2908-01: Clutch System Control error 408
77. P1905-02: Clutch System Clutch locked 410
78. P2905-01: Gearbox System Disengage failed 413
79. P2909-01: Gearbox System Shift failed 417
80. P2905-02: Gearbox System engage failed 421
81. P2905-03: Gearbox System unintended disengage 425
82. P2909-02: Gearbox System Shift Locked 429
83. P190B-01: Gearbox System unintended engage 433
84. P190C-07: Gearbox System Control Error 436
85. P190D-01: Gearbox System Clutch over speed 439
86. P0942- 01: Hydraulic Circuit Pressure Low 442
87. P0942- 07: Hydraulic Circuit Pump Overheating 446
88. P2712- 07: Hydraulic Circuit Leakage too high 450
89. P2901- 01: Hydraulic Circuit Accumulator discharged 453
90. P0780- 07: Hydraulic Circuit System Misuse 456
91. P184A- 01: Hydraulic Circuit Pump Timeout 459
92. P0562-04: Battery Supply 1 Open circuit 462
93. P0560-01: Battery Supply 1 Wrong Value 465
94. P0560-02: Ignition Key voltage Wrong Value 468
95. P0945-04: Battery Supply 2 Open circuit 471
96. P1711-01: Battery Supply under shift threshold 474
97. P1711-02: Battery Supply over threshold 476
98. P1711-07: Battery Supply under low threshold 478
99. P0604- 08: TCU ROM Checksum Error 480
100. P0604- 07: TCU RAM Integrity Error 482
101. P062F- 07: TCU EEPROM Tuning Data Alteration Error 484
102. P062F- 08: TCU EEPROM Grid Data Alteration Error 486
103. P1704- 07: TCU EEPROM System Data Alteration Error 488
104. P060A- 07: Safety Microprocessor Integrity failure 489
105. P060A- 08: Safety Microprocessor Output failure 490
106. P0701- 02: Electro valves Driver 1 SPI Device fault 491
107. P0701- 01: Electro valves Driver 1 Thermal warning 493
108. P0701- 03: Electro valves Driver 1 Device closed 495
109. P0701- 04: Electro valves Driver 1 Device open 497
110. P184D- 02: Electro valves Driver 2 SPI Device fault 499
111. P184D- 01: Electro valves Driver 2 Thermal warning 501
112. P0881- 02: TCU 12V Internal Supply Device Open 503
113. P0881- 03: TCU 12V Internal Supply Device closed* 505
114. P0880- 04: SMP 5V power Supply under low threshold 507
115. P0880- 06: SMP 5V power Supply under medium threshold 509
116. P0880- 02: SMP 5V power Supply under low threshold 511
117. P0880- 03: TCU 5V power Supply Device Closed 513
118. P1401- 07: Level 2 Intervention-Safety input failure 515
119. P1401- 08: Level 2 Intervention-system problem 517
120. P060C-07: Level 3 Intervention-system problem 519
121. P1844 -07: Grid Self tuning Procedure Error 521
122. P080A -07: Kiss point Selftuning Procedure Error 524
123. P185B -07: Clutch Stroke Selftuning Error 526
124. P1886-07:- Dual port RAM check 528
125. U00 1-01:- CAN EMS Error 529
126. C0082-00 :- ABS Status CAN signal Invalid 530
Preliminary Check for IVN Related DTC's 531
127. U0001-88 - Vehicle Communication Bus A- Bus off 532
128. U0121 -08:- Lost communication with Antilock Braking SystemModule- ABS/ESP Bus signal/ Message Failure 534
129. U0155-08:- Lost communication with Instrument Panel ClusterModule- Bus signal/ Message Failure 540
130. U0100-08 Loss of communication with Engine Control Module-Bus Signal/ Message Failure 546
131. P1C10-01:- Invalid Data Received From ECM -CyclicRedundancy Check Error 556
132. P1C11-02:- Invalid Data Received From ECM -Message Rolling Counter Error 559
133. P1C12-01:- Invalid Data Received From ECM -CyclicRedundancy Check Error 561
134. P1C13-02:- Invalid Data Received From ECM -Message Rolling Counter Error 564
135. P1C14-01:- Invalid Data Received From IPC -CyclicRedundancy Check Error 566
136. P1C15-02:- Invalid Data Received From IPC -Message Rolling Counter Error 568
137. P1986 -07 Variant code procedure not completed 570
138. U0001-02 Engine Limp Home signal-Signal not valid 572
Generic Troubleshooting Guidelines 573
CAN Bus Architecture & Network Topology 574
IVN Preliminary Check 575
Abbreviations 576
Appendix 577
Diagnostic Trouble Codes List 581

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