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TIAGO EV-SERVICE MANUAL

TIAGO EV 1
TABLE OF CONTENT 4
HIGH VOLTAGE ELECTRICALSYSTEM (HV) 5
TABLE OF CONTENTS 6
1. GENERAL INFORMATION 8
A. TOOLS 8
I. INSULATED TOOLS 8
II. GENERAL TOOLS 8
B. HAND GLOVES 8
C. PPES FOR HV 9
D. MEASURING TOOLS 12
E. SAFETY INSTRUCTIONS: COLOURED CONE SYSTEM 14
F. DO’S AND DON’TS 16
G. SAFETY WHILE SERVICING 19
H. WASHING INSTRUCTIONS 23
I. ELECTRICAL COMPONENT INFORMATION 24
J. MOTOR COMPARTMENT 34
2. TYPES OF CHARGING 35
A. NORMAL / AC CHARGING 37
B. AC CHARGING (WALL MOUNT UNIT 44
C. FAST CHARGING 46
3. TIGHTENING TORQUES 49
4. SPECIAL TOOL LIST 54
5. HV CONNECTOR CONNECTION &LOCKING PROCESS 57
6. HV COMPONENT IN UNDER BONNETCOMPARTMENT 60
A. 3IN1 UNIT ASSY REMOVAL 60
B. PDU SERVICEABILITY 62
C. VEHICLE CONTROL UNIT REMOVAL 64
D. VACCUM PUMP REMOVAL 65
E. E-DRIVE REMOVAL 66
F. REDUCER OIL LEVEL CHECKING / DRAIN /FILLING DO & DONTS 69
I. OIL LEVEL CHECK 69
II. DISCHARGE AND FILLING OFLUBRICATING OIL 69
7. TRACTION COOLING SYSTEM (TCS) 70
A. SYSTEM LAYOUT 70
B. CIRCUIT SCHEMATIC 70
C. TCS COOLANT DRAINING PROCEDURE 71
D. TCS COOLANT FILLING PROCEDURE 71
E. TCS COOLING PUMP REMOVAL 72
F. RADIATOR FAN REMOVAL 73
G. RADIATOR REMOVAL 74
H. CONDENSER REMOVAL 75
I. TCS AUX TANK RESERVIOR REMOVAL 76
8. HV BATTERY 77
A. SYSTEM LAYOUT 77
B. BATTERY PACK STORAGE GUIDELINES 78
C. HV BATTERY REMOVAL 78
9. BATTERY COOLING SYSTEM (BCS) 83
A. SYSTEM LAYOUT 83
B. CIRCUIT SCHEMATIC 84
C. BCS COOLANT DRAINING PROCEDURE 85
D. BCS COOLANT FILLING PROCEDURE 85
E. COMPRESSOR 86
F. BATTERY COOLING PUMP REMOVAL 88
G. BCS COOLANT TANK REMOVAL 89
H. CHILLER UNIT (HEAT EXCHANGER)REMOVAL 90
I. HV / LV CHARGER PORT & CABLEREMOVAL 91
10. CRADLE 95
A. CRADLE EXPLODED VIEW 95
B. CRADLE REMOVAL 97
LV SYSTEM 99
TABLE OF CONTENTS 100
1. GENERAL PRECAUTIONS 103
2. BATTERY 107
3. LIGHTING SYSTEM 110
A. BULB SPECIFICATIONS 110
B. FASTENERS TORQUE VALUE TABLE 110
C. GENERAL SYMPTOMS AND DIAGNOSTICS 110
D. HEAD LAMP 114
E. SIDE REPEATER LAMP (LH/RH) (IFAPPLICABLE) 120
F. ROOF LAMP 121
G. TAIL LAMP 122
H. FRONT FOG LAMP 124
I. REGISTRATION PLATE LAMP (IFAPPLICABLE) 125
J. DAYLIGHT RUNNING LAMP (DRL) 126
4. WIPER & WASHER SYSTEM 127
5. SWITCHES 133
A. COMBI-SWITCH (IF APPLICABLE) 133
B. FASCIA SWITCHES (IF APPLICABLE) 141
C. HAZARD SWITCH (IF APPLICABLE) 142
D. MIRROR SWITCH 143
E. WINDOW WINDING MODULE 144
F. POWER WINDOW SWITCHES & INHIBITSWITCH 148
G. STEERING WHEEL SWITCHES 152
H. DRIVE MODE KNOB 154
I. STEERING LOCK CUM IGNITION SWITCH 155
6. HORN 157
7. POWER SOCKETS 159
8. INFOTAINMENT SYSTEM 160
A. USB/AUX PORT 164
B. SPEAKERS 165
C. TWEETER 166
D. ANTENNA 168
E. MICROPHONE 169
9. INSTRUMENT CLUSTER 171
A. BASIC FUNCTIONAL MATRIX 172
B. INSTRUMENT CLUSTER 174
C. TELL TALES DETAILS 175
D. DRIVER INFORMATION SYSTEM 179
E. REMINDER FEATURES 186
F. MAIN CONNECTOR PIN OUTS 189
G. TEMPERATURE BAR GRAPH DETAILS 190
H. CHIME TABLE 190
I. DISPLAY SCREEN FLOW AND SETTINGS 192
J. REMOVALOF INSTRUMENT CLUSTER 193
10. IMMOBILIZER 195
11. IGNITION KEY 200
A. IGNITION REMOTE KEY (IF APPLICABLE) 200
B. IGNITION KEY (IF APPLICABLE) 203
12. BODY CONTROL MODULE (BCM) 209
A. BCM CONNECTOR PIN SIGNALS APPLICABILITY MATRIX 215
B. BCM FEATURES 222
C. BCM REPLACEMENT STRATEGY 224
D. BCM FUNCTIONS 225
13. VECU 227
14. FUSE AND RELAY BOX DETAILS 231
A. BONNET BAY FUSE AND RELAY BOX 234
B. CABIN FUSE AND RELAY BOX 238
15. REVERSE PARK ASSIST SYSTEM 243
A. SENSOR CONNECTOR DETAILS (IFAPPLICABLE) 248
B. REAR VIEW CAMERA 253
C. TROUBLESHOOTING 259
16. PASSIVE ENTRY PASSIVE START (PEPS) 260
A. PEPS ECU 261
B. START STOP SWITCH (IF APPLICABLE) 263
C. ELECTRONIC STEERING COLUMN LOCK(ESCL) 264
D. LF ANTENNAS 266
17. TELEMATICS (IF APPLICABLE) 268
A. TATA MOTORS CONNECTED CAR SYSTEM 268
B. THE CONNECTED CAR MODULERECORDS THE FOLLOWINGINFORMATION 268
C. TCM LOCATION 268
D. PRE-CHECKS FOR INSTALLATION OF THETELEMATICS CONTROL MODULE 268
E. PRE-CHECKS / TASKS TO BE DONEBEFORE REPLACING THE TELEMATICSCONTROL MODULE 268
F. TCM REMOVAL PROCEDURE 269
G. CONNECTOR PIN & USB DETAILS 270
18. RAIN LIGHT SENSOR SYSTEM (IFAPPLICABLE) 271
A. RAIN LIGHT SENSOR 271
B. FUNCTIONAL DETAILS 274
C. FAIL SAFE MODES OF RLS & BCM 275
DRIVESHAFT 277
TABLE OF CONTENTS 278
1. INTRODUCTION 279
2. DRIVE SHAFT PARTS 280
3. GENERAL GUIDELINES FOR TESTINGDRIVE SHAFT NOISE 281
4. TESTING FOR NOISE 282
5. TIGHTENING TORQUES 283
6. SPECIAL TOOLS 284
7. ON VEHICLE REMOVAL OF DRIVE SHAFT(LH & RH SIDE) 285
8. ON VEHICLE ASSEMBLY OF DRIVE SHAFT(LH & RH SIDE) 286
9. DISASSEMBLY PROCEDURE FOR DRIVESHAFT 287
10. ASSEMBLY PROCEDURE FORDRIVESHAFT 289
11. PRECAUTION TO AVOID THE DAMAGE TODRIVE SHAFT 290
12. DO’S AND DON’T’S FOR DRIVE SHAFT 291
FRONT & REAR SUSPENSION 292
TABLE OF CONTENTS 293
1. TECHNICAL SPECIFICATIONS 294
2. TIGHTENING TORQUES 295
3. SPECIAL TOOLS 303
A. FRONT SUSPENSION 303
B. REAR SUSPENSION 308
4. DIAGNOSIS 309
5. PRECAUTIONS 311
6. SUSPENSION SYSTEM 312
7. EXPLODED VIEWS FRONT SUSPENSION SYSTEM 315
A. ASSEMBLY FRONT STRUT EXPLODED VIEW 315
B. LOWER ARM EXPLODED VIEW 316
C. ANTI ROLL BAR MOUNTING EXPLODED VIEW 317
D. FRONT AXLE ASSEMBLY EXPLODED VIEW 318
8. ON VEHICLE PROCEDURE FRONTSUSPENSION 319
A. REMOVAL AND INSTALLATION OF STRUTASSEMBLY 319
B. DISASSEMBLY AND ASSEMBLY OFFRONT STRUT 320
C. REMOVAL AND INSTALLATION OF WHEELHUB 323
D. REMOVAL AND INSTALLATION OF ANTIROLL BAR 326
E. REMOVAL AND INSTALLATION OF LOWERARM ASSEMBLY 329
F. REMOVAL AND INSTALLATION LOWERARM BALL JOINT 331
G. REMOVAL AND INSTALLATION OF LOWERARM RUBBER BUSHES 332
H. PROCEDURE FOR CHECKING THE BALLJOINT PLAY LOWER ARM 334
9. EXPLODED VIEWS REAR SUSPENSION SYSTEM 335
A. REAR SHOCK ABSORBER EXPLODED VIEW 335
B. REAR HUB ASSEMBLY EXPLODED VIEW 336
C. PIVOT MOUNTING BRACKET AND BUSH EXPLODED VIEW 337
10. ON VEHICLE PROCEDURE REARSUSPENSION 338
A. DISASSEMBLY AND ASSEMBLY OF REARSHOCK ABSORBER FROM VEHICLE 338
B. DISASSEMBLY AND ASSEMBLY OF REARSHOCK ABSORBER 338
C. REMOVAL AND INSTALLATION OFTORSION BEAM 342
D. TWIST BEAM BUSH REMOVAL 345
11. SUSPENSION PRE-LOADING CONDITION 347
WHEELS AND TYRES 348
TABLE OF CONTENTS 349
1. GENERAL INFORMATION 350
A. SPECIFICATIONS 350
B. TYRE PRESURE DETAILS 350
C. CONSTRUCTION 351
D. TIGHTENING TORQUES 354
2. GENERAL SYMPTOMS DIAGNOSIS 355
A. DIAGNOSIS CHART 355
B. TYRE WEAR PATTERN 357
C. WEAR CAUSES 358
D. TYRE VIBRATION DIAGNOSIS 359
3. MAINTENANCE, INSPECTION AND TESTS 360
A. PRELIMINARY INSPECTION 360
I. VISUAL INSPECTION 360
II. PRECAUTIONS 360
B. REGULAR MAINTENANCE 360
I. INFLATION 360
II. WHEEL BALANCING 361
III. TYRE ROTATION 362
IV. WHEEL RUNOUT 363
V. DO’S AND DON’TS 363
4. WHEEL AND TYRE REPLACEMENT 364
A. PRECAUTIONS DURING TYREREPLACEMENT 364
B. TYRE REPLACEMENT 364
C. WHEEL ASSEMBLY REPLACEMENT 365
D. WHEEL REMOVAL 366
E. TYRE CARE 367
STEERING (MANDO) 369
TABLE OF CONTENTS 370
1. GENERAL INFORMATION 371
A. TECHNICAL SPECIFICATION 371
B. INTRODUCTION 371
C. SYSTEM LAYOUT 373
2. TIGHTENING TORQUES 374
3. SPECIAL TOOLS 377
4. MAINTENANCE, INSPECTION AND TEST 378
A. PRELIMINARY INSPECTION 378
B. REGULAR MAINTENANCE 379
5. ON VEHICLE REPAIRS 382
A. STEERING WHEEL REMOVAL 382
B. STEERING COLUMN REMOVAL 383
C. INTERMEDIATE SHAFT REMOVAL 385
D. ECU REMOVAL 386
E. MOTOR REMOVAL 387
F. RACK & PINION ASSEMBLY REMOVAL 387
6. STEERING RACK AND PINION ASSEMBLY EXPLODED VIEW 389
7. OVERHAULING OF STEERING RACK ANDPINION ASSEMBLY 390
A. PRECAUTIONS 390
B. DISASSEMBLY OF RACK & PINON 390
C. INSPECTION OF DISMANTLED PARTS 390
D. ASSEMBLY OF RACK & PINON 391
E. OBJ ON-VEHICLE REMOVAL 391
8. DO’S & DON’TS 392
9. WHEEL ALIGNMENT 395
10. TROUBLESHOOTING AND DIAGNOSIS 397
11. STEERING ANGLE CALIBRATION PROCESS 402
12. TUNING DATA SELECTION 409
13. ELECTRIC POWER ASSISTED STEERING (EPAS) ECU REPLACEMENT AND SOFTWAREUPDATE PROCEDURE IN FIELD 410
A. EPAS ECU REPLACEMENT – AUTOMATIC (IF FITTED 411
B. EPAS ECU FIELD SOFTWARE UPGRADE/RE FLASH – MANUAL 412
C. EPAS ECU FIELD SOFTWARE UPGRADE/RE FLASH – AUTOMATIC (IF FITTED) 413
BRAKES 414
TABLE OF CONTENTS 415
1. TECHNICAL SPECIFICATIONS 418
2. TIGHTENING TORQUES 420
3. SPECIAL TOOL 425
4. PRECAUTIONS 426
5. DIAGNOSIS 427
6. NESSECITY OF ABS WITH EBD 430
7. BRAKE HYDRAULIC LINES 431
8. VACUUM BRAKE BOOSTER 432
9. WORKING OF ANTI-LOCK BRAKINGSYSTEM (ABS) 434
A. BRAKING WITHOUT ABS IN OPERATION 434
B. BRAKING WITH EBD INTO OPERATION 434
C. BRAKING WITH ABS INTO OPERATION 435
D. FAIL-SAFE FUNCTION 436
10. ABS COMPONENTS 437
A. ABS 9 ELECTRONIC CONTROL UNIT/HYDRAULIC CONTROL UNIT (ECU / HCU): 437
B. WHEEL SPEED SENSOR 439
C. ABS SYSTEM FAILURE WARNING LIGHT 439
11. MAINTENANCE, ADJUSTMENTS & TEST 441
A. FRONT BRAKE MAINTENANCE 441
I. INSPECTION OF PADS 441
II. INSPECTION OF CALIPER 442
III. DISC INSPECTION 442
B. REAR BRAKE MAINTAINANCE 443
C. BLEEDING OF HYDRAULIC SYSTEM 445
I. BRAKE BLEEDING PROCEDURE 445
II. ABS SECONDARY CIRCUIT BLEEDINGPROCEDURE (USING DIAGNOSTIC TOOL) 446
D. BRAKE TROUBLE SHOOTING 449
E. ROAD TESTING 449
12. CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO 450
13. STOP LIGHT SWITCH ADJUSTMENT 451
14. SNAP TYPE BRAKE LIGHT SWITCHINSTALLATION 452
A. CHECK AIR TIGHTNESS 452
B. CHECK OPERATION 452
C. CHECK AIR TIGHTNESS UNDER LOAD 452
15. ACCELERATOR PEDAL ASSEMBLYREMOVAL 453
16. BRAKE / CLUTCH PEDAL ASSEMBLYREMOVAL 454
17. FRONT BRAKE ASSEMBLY 456
A. CALIPER BRAKE ASSSEMBLY EXPLODED VIEW 456
B. FRONT BRAKE DISC 457
C. FRONT BRAKE ADJUSTMENT, REMOVALAND REFITMENT 457
I. REMOVAL OF CALIPER FROM CARRIER 457
II. ASSEMBLY OF CALIPER TO THE CARRIER 458
III. REMOVAL OF BRAKE PAD 460
IV. ASSEMBLY OF BRAKE PAD 462
V. REMOVAL OF CARRIER 463
VI. ASSEMBLY OF CARRIER 463
VII. REMOVAL OF FRONT BRAKE DISC 464
D. REMOVAL AND REFITMENT OF TMC &BOOSTER ASSEMBLY 465
18. REAR BRAKE ASSEMBLY 467
A. REAR BRAKE ASSEMBLY EXPLODED VIEW 468
B. REMOVAL AND REFITMENT OF REARBRAKE ASSEMBLY REMOVAL 469
C. WHEEL CYLINDER ASSEMBLY EXPLODED VIEW 471
D. REMOVAL & ASSEMBLY OF WHEELCYLINDER 472
F. INSTALLATION OF BRAKE BACK PLATE 473
19. PARKING BRAKE ASSEMBLY 474
A. LAYOUT 474
B. REMOVAL OF PARKING BRAKE LEVER 475
C. REMOVAL OF PARKING BRAKE CABLE 475
D. INSTALLATION OF PARKING BRAKECABLE 476
F. PARKING BRAKE CABLE ADJUSTMENT 477
G. PARKING BRAKE LEVER PRIMARY CABLEGREASING 477
20. REMOVAL AND REFITMENT OF ABS ECU/ HCU 478
21. REMOVAL AND REFITMENT OF FRONTWHEEL SPEED SENSOR 480
22. REMOVAL AND REFITMENT OF REARWHEEL SPEED SENSOR 481
23. TROUBLE SHOOTING & DIAGNOSIS 482
24. ABS ECU CONNECTOR 484
25. WHEEL SPEED SENSOR CONNECTOR 485
26. INDIRECT TIRE PRESSURE MONITORING SYSTEM (ITPMS) 486
FATC 488
TABLE OF CONTENTS 489
1. TECHNICAL SPECIFICATIONS 491
2. FATC SYSTEM & LAYOUT 493
3. FATC UNIT AIR FLOW LAYOUT 494
4. BATTERY COOLING SYSTEM LAYOUT 495
5. SCHEMATICS OF HVAC & BATTERY COOLING SYSTEM (BCS) 496
6. HVAC UNIT ELECTRICAL CIRCUIT DIAGRAM 497
7. TIGHTENING TORQUES 498
8. PRECAUTIONS 502
9. FATC CONTROL PANEL 504
10. CONTROL PANEL CONNECTOR DETAILS 509
11. FATC UNIT 511
12. COMPRESSOR 514
13. CHILLER UNIT 516
14. COOLANT PUMP 517
15. BLOWER 518
16. AC FILTER 519
17. TXV 520
18. HVAC UNIT REMOVAL 521
19. FATC SENSORS AND ACTUATORS 522
A. LINEAR PRESSURE SENSOR 522
B. CONDENSER AND RECEIVER DRIER 522
C. SOLAR LOAD SENSOR 523
D. OAT SENSOR 525
E. THERMISTOR OR THERMO SENSOR 526
F. AIR INLET ACTUATOR 527
G. LINEAR POWER MODULE 529
H. PTC HEATER 530
20. REFRIGERANT HOSES/PIPES 531
21. DO’S & DONT’S 532
22. TROUBLESHOOTING 533
23. MAINTENANCE 545
A. PRELIMINARY INSPECTION 545
I. AC SYSTEM PERFORMANCE TEST 545
II. LEAK DETECTION 549
B. REGULAR MAINTENANCE 549
I. REFRIGERANT RECOVERY, RECYCLINGAND RECHARGING 549
II. FLUSHING OF AC SYSTEM 550
III. REPLENISHING COMPRESSOR OIL 551
IV. PRESSURE TEST USING MANIFOLDGAUGES 552
BODY 554
TABLE OF CONTENTS 555
1. GENERAL LAYOUT 557
2. TIGHTENING TORQUES 558
3. SPECIAL TOOLS 561
4. ON VEHICLE REMOVAL 562
A. BONNET REMOVAL 562
I. HOOD LATCH ASSEMBLY 562
II. BONNET LATCH RELEASE CABLEREMOVAL 563
B. FLOOR CONSOLE REMOVAL 564
C. DASHBOARD REMOVAL 567
I. WITH CROSS CAR BEAM 567
II. WITHOUT CROSS CAR BEAM (CCB) 570
III. ON BENCH COCKPIT DISMANTLING 574
D. GLOVE BOX REMOVAL 575
F. FRONT BUMPER REMOVAL 576
G. REAR BUMPER REMOVAL 577
H. FRONT DOOR REMOVAL 578
I. FRONT DOOR TRIMS REMOVAL 579
J. DOOR INNER LOCK HANDLE REMOVAL 580
K. FRONT OUTER DOOR LOCK REMOVAL 581
L. FRONT DOOR LATCH REMOVAL 582
M. FRONT DOOR GLASS AND WINDOWWINDING MECHANISM REMOVAL 583
N. REAR DOOR REMOVAL 585
O. REAR DOOR TRIM REMOVAL 586
P. REAR OUTER DOOR LOCK REMOVAL 587
Q. DOOR LATCH REAR REMOVAL 588
R. TAIL GATE REMOVAL 589
I. TAIL GATE LATCH 590
II. TAIL GATE STRIKER REMOVAL 591
III. TAIL GATE LOCK REMOVAL 592
S. TAIL GATE LATCH CABLE REMOVAL 592
T. TAIL GATE TRIM REMOVAL 593
U. ORVM REMOVAL 594
V. INNER REAR VIEW MIRROR REMOVAL 595
W. FRONT ROW SEAT REMOVAL 595
X. REAR ROW SEAT REMOVAL 596
Y. FRONT SEAT BELT REMOVAL 598
Z. REAR SEAT BELT REMOVAL 600
AA. “A” PILLAR TRIM REMOVAL 601
AB. FRONT SCUFF PLATE REMOVAL 603
AC. “B” PILLAR TRIMS REMOVAL 603
AD. “C” PILLAR TRIMS REMOVAL 604
AE. GRAB HANDLE REMOVAL 605
AF. SUNVISOR REMOVAL 606
AG. ROOF LINER REMOVAL 606
AH. PLENUM COVER REMOVAL 607
AI. BONNET INSULATION REMOVAL 607
AJ. GLASS REMOVAL 608
AK. HV / LV CHARGER PORT & CABLEREMOVAL 609
AL. FRONT WHEEL ARCH LINER REMOVAL 612
AM. REAR WHEEL ARCH LINER REMOVAL 613
AN. FRONT FENDER REMOVAL 614
AO. REAR WIPER MOTOR REMOVAL 615
AP. FRONT WIPER REMOVAL 616
SRS 618
TABLE OF CONTENTS 619
1. WORKING OF RESTRAINTS 620
2. SYSTEM LAYOUT 622
3. SAFETY PRECAUTIONS 623
4. DISPOSAL OF FAULTY AIR BAG UNIT 625
5. SRS POST ACCIDENT PROCEDURE 627
6. TIGHTENING TORQUES 628
7. COMPONENTS 631
A. RESTRAINT WITHOUT AIRBAGS 631
B. RESTRAINT WITH AIRBAGS 631
I. ECU 631
II. FRONT IMPACT SENSOR (FIS) 636
III. AIR BAGS 637
IV. FRONT SEAT (DRIVER) BELT BUCKLE 639
V. RPLL BELTS 640
VI. CLOCK SPRING 642

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