SERVICE MANUAL BOOK - 1 SERVICE MANUAL ALTROZ BSVI PHASE-2 MY23 SUPPLIMENT
Developed by: Technical Literature Cell. Release Date : MaY 2023 / First Edition. The information provided in this manual is based on the latest product information available at the time of publication. . C Copyright 2023 TATA MOTORS All rights reserved. The information in this manual shall not be reproduced or copied, in whole or in part, in any form without written permission from TATA MOTORS PASSENGER VEHICLES LTD. Vehicles are subject to modification in design, specification and equipment. Also refer the Service Circulars released by Customer Support about product & procedures.
INTRODUCTION This Supplement Service manual provides information pertaining to technical Specifications, repair, maintenance and overhaul of different aggregates fitted on TATA ALTROZ BSVI PHASE-2 MY23. All the data contained in this manual is based on the latest product information available at the time of publication and with the assumption that the person is well aware of general Automobile practices. This manual emphasizes the special features of the vehicle and thus benefits our workman, who is conversant with general Automobile practices. The contents which are not covered in this supplement service manual have to be read in conjunctions with “TATA ALTROZ BSVI PHASE-2” Service manual. For ease of use, this workshop manual is divided into 4 volumes, comprising several sections. Each aggregate has a separate section. THE BOOK– 1 CONTAINS ELECTRICAL BODY THE BOOK– 2 CONTAINS DIAGNOSTIC TROUBLE SHOOTING CODES (DTC) THE BOOK– 3 CONTAINS SERVICE SCHEMATICS THE BOOK– 4 CONTAINS INFO. FITMENT DRAWINGS
ALTROZ BSVI PHASE 2 MY23 SUPPLEMENT TABLE OF CONTENT SR. NO. AGGREGATE 1 ELECTRICAL 2 BODY
ALTROZ MY23 SUPPLIMENT ALTROZ MY23 ELECTRICAL
ALTROZ MY23 SUPPLIMENT
ALTROZ MY23 SUPPLIMENT TABLE OF CONTENTS 1 WIRELESS CHARGING ..................................................................................................................1 A. COMPONENTS ...........................................................................................................................1 B. INTERFACE DIAGRAM ................................................................................................................1 C. CHARGING FUNCTION ...............................................................................................................2 D. CHARGING STATUS DISPLAY FUNCTION ..................................................................................2 E. CONDITIONS TO CHARGE PHONE PROPERLY..........................................................................2 F. CONNECTOR PIN & DETAILS......................................................................................................3 H. DO’S AND DON’T ........................................................................................................................5 I. WPC EU REPLACEMENT .............................................................................................................6 2. AI R PURIFI ER.................................................................................................................................8 A. AIR PURIFIER SENSOR REMOVAL ............................................................................................8 3. FUSE AND RELAY BOX DETAILS...................................................................................................9 A. BATTERY MOUNTED FUSE BOX ................................................................................................9 B. ENGINE FUSE AND RELAY BOX.................................................................................................9 C. CABIN FUSE AND RELAY BOX .................................................................................................11 4. FASCIA SW ITCH ES .................................................................................................................... 13 A. FRONT FOG LAMPS .................................................................................................................13 B. REAR FOG LAMPS .................................................................................................................... 13 C. DOOR LOCKING / UNLOCKING SWITCH ..................................................................................13 D. AUTOMATED ENGINE START-STOP SWITCH ..........................................................................13 5. FRONT USB PORT & C TYPE ........................................................................................................18 6. REAR USB PORT ......................................................................................................................... 19
ALTROZ MY23 SUPPLIMENT 7. MOOD LIGHTS .............................................................................................................................. 20 A. MOOD LIGHT ON BEZEL FLOOR CONSOLE USB FRONT .........................................................20 B. MOOD LIGHT BELOW DRIVER SIDE LOWER PANEL ................................................................21 C. MOOD LIGHT BELOW GLOVE BOX...........................................................................................21 D. MOOD LIGHT BELOW REAR CONSOLE LOWER ......................................................................22 E. FRONT DOOR MOOD LIGHT & TRIMS REMOVAL .....................................................................22 F. REAR DOOR MOOD LIGHT & TRIMS REMOVAL........................................................................24 8. SHARK FIN ANTENNA .................................................................................................................. 26
ELECTRICAL 1 1. WIRELESS CHARGING (IF APPLICABLE) Wireless Power Charging is a convenience feature to charge the electronic device like Smart phone, tablet using wireless charging technology, without a need to plugin wire in the device. Wireless charger shall use the principle of electromagnetic induction method to charge Smart phone wirelessly. NOTE: The WPC would support only those smart phones which are Qi compatible. Please refer to the smart phone. Manual or the smart phone manufacturer homepage to check whether your smart phone supports Qi function. A. WIRELESS CHARGING COMPONENTS 1. WPCF ECU UNIT Wireless Power Charger with Fan ECU contains upper housing, lower housing, FAN, fan duct cover and internal electronics as single unit for wireless charging function. LOCATION The location of the WPC in vehicle is in the Centre console area near Drive Mode Rotary Switch. Wireless Power Charging (WPC) ECU - Generates power up to 15 W and transfer power wirelessly by magnetic induction. Anti-skid Mat - Hold the position of smart phone placed on it against any jerk and acts a charging contact surface for the smart phone. Head unit - It is status display unit to display the status of wireless power charger Status symbol and text display is displayed on Head unit. 2. CHARGING MAT / ANTISKID MAT The anti-skid mat is advisable to maintain the position of the Smart phone on the charging pad without skidding. It is recommended to place the Smart phone centrally at the anti- skid mat with display facing up. Holes and channels in antiskid mat ensures uniform air flow distribution on its surface. Qi Symbol indicates that the WPC ECU is Qi standard certified.
ELECTRICAL 2 B. INTERFACE DIAGRAM The below interface diagram shows the WPC ECU/module. The power transfer takes place between the WPC ECU / module and the smart phone device. The inputs to the unit are Ignition, accessories and ground. The unit has a single hardwire PWM output connected to Instrument cluster. C. CHARGING FUNCTION Following all the conditions are applicable in this feature to function correctly Ignition ON (Engine OFF) Engine ON Smart phone placed in correct orientation on the antiskid mat as below. WPC system detects the presence of phone and starts charging as per the Qi standard protocol. The charging status is updated and displayed on the head unit. D. CHARGING STATUS DISPLAY FUNCTION Following all the various conditions that are detected by WPC system and displayed on Head Unit. 1. WPC system in standby mode 2. Smart phone charging ON 3. To Foreign object detection 4. Smart phone battery is full/ Charging completed 5. WPC ECU error (“Error” condition indicates abnormal operating conditions internal system fault or fan stuck/jam). “Error” message displayed on Head Unit E. CONDITIONS TO CHARGE PHONE PROPERLY 1. Keep the charging surface clear of any foreign objects (coins, credit cards, smart cards, keys etc.). 2. Place the smart phone on the charging area marked for positioning the phone, for best results place the smart phone at the center of the charging pad. 3. Do not use to thicker cover or cover with metal object. 4. Ensure that the phone is placed with display facing upwards and charging area touching the charging pad surface. 5. Turn ON the ignition to start the charging. NOTE: The wireless charging function is supported to charge smart phones which are Qi compatible. Certain features may not function as not supported by the smart phone manufacturer and not a malfunction of the wireless charging. Wireless charging stops with Ignition OFF. Wireless charging stops when the smart phone is not completely in touch with the charging pad surface or not positioned correctly on charging pad.
ELECTRICAL 3 F. CONNECTOR PIN & DETAILS Pin Out Details Pin No. Signal Name 1 ACC_Supply 2 IGN_Supply 3 PWM_Output1 4 BATT_GND 5 CAN_H 6 CAN-L 7 LED 1 8 LED 2 G. WPC EPC Trouble shooting Procedure 1. Pre-checks/tasks for trouble shooting the WPC ECU Table 1: Trouble shooting guide Effect of trouble Action to be taken Possible cause Charger taking more time for charging or frequent trip during charging. Check the FAN part/FAN Duct Check -T1 Smart phone not getting charged Check the status Check –T2 Foreign object detected message displayed on Instrument cluster Check WPC charging pad surface Check –T3 Error message displayed on Instrument cluster Check if High/ low voltage supply or High temperature or ECU faulty Check –T4 Check – T1 Check the operation of FAN integrated with wireless power charger: Fan integrated with wireless charger is workign by keeping phone on center of charger. Once charging starts lift phone and check. Fan will remain ON for 30 Sec post lifting phone. Check if anti-skid mat bottom surface has air blockage in vent channel and in its surface holes this can cause FAN air to block. Check if any dust or particles are present in FAN duct air path which can cause air blockage. If Fan is not working then charging tripping or slow charging can be observed. Check – T2 Check the operation of the wireless power charger ECU by following actions: Check if the Smart phone is placed correctly in the center of charging Pad. Check if the Smart phone is oriented correctly with display facing upwards and charging surface touching the charging pad and not placed upside down. The current WPC ECU supports on “Qi” compatible Smart phone devices hence please verify of the Smart phone support “Qi” wireless charging function. Check if Smart phone device protection cover is used which are non-standard, metallic, or very thick, as it reduces the charging efficiency. Metallic cover may halt the charging function. Check if Wireless charger is correctly fitted with trim maintaining the gap of <3 from charger surface to anti-skid mat surface and flushness of 0.5mm i.e gap between trim and ECU surface. No waviness shall be observed on Anti-skid mat surface. With all the above checks check for the “charging on” message on the Head Unit. Charging shall start with Pop up on Head Unit screen. After pop up an all-time indication of charging status on Head Unit status bar shall appear.
ELECTRICAL 4 Charging Mode ON - Pop up Charging full - Pop up Charging Mode On- All time Display Check – T3 Carry following checks when foreign object detection (FOD) error is displayed on the instrument cluster as shown: Check if any metallic objects, such as coins, clips and precious metals are detected on the charging pad or between the charging pad and the Smart phone. The metallic objects heat up and hence the charging function is halted to prevent overheating. Check cautiously the surface temperature of the charging pad. The error could be to prevent over heating due to high internal temperature of the WPC ECU. The Charging shall resume when the foreign matter is removed from the surface of the charging pad and charging mode shall be published on Head Unit screen. Normal operating mode resumes with real time status displayed on the Head Unit. Foreign Object Detection Error on Head Unit Foreign object detection (FOD) message may display due to 2 reasons: 1. If any metallic object is present between phone and charger. 2. If smaller phones are kept in corner mat which poor charging zone. Whenever FOD message is detected user shall rectify issue and keep phone in center of the mat area Check – T4 Following could be the reasons when message displaying “charging may be interrupted due to error” is displayed on the Head unit as shown. 1. When permanent failure of charger driver failure detected e.g. short circuit or open circuit. 2. When permanent Coil failure detected. 3. When permanent temperature sensor failure is detected. 4. Permanent memory failure detected. 5. When any other permanent component failure which lead to permanent failure in charger functionality. 6. Fan output short circuit or open circuit is detected. In case of above faults, there could be a WPC internal system fault and would need a WPC ECU replacement. “Error” message displayed on Head Unit
ELECTRICAL 5 H. DO’S AND DON’T WARNING: If any metallic object such as coin/keys are located between wireless charging pad and phone back cover, the charging may get disrupted. Also, this may results in heat up of metallic objects. DO’S: 1. Please ensure that the phone is compatible to the charging standard “Qi”. 2. If there is any metallic object between smartphone and wireless charger pad, immediately remove smart phone and metallic object after it has completely cooled down. Once any metallic object is detected on wireless charger post charging it displays its warning message on Infotainment unit, first remove smart phone then remove foreign object from the charging pad and place the smart phone again on charging pad. 3. In case of water/Liquid spillage on charging pad, dry out the pad surface area properly & clean the ECU surface area by removing Antiskid mat. Do not charge the smart phone until surface is completely dry. 4. The Phone charging status is information by phone and not charger. 5. Wireless charger works on principle of magnetic induction, i.e. it converts electrical energy into magnetic energy to transfer energy from charging pad to phone. Please maintain safe distance from the charger most of the time as it may cause irritation to sensory organs or active implants if implemented in the body. Please consult medical specialist in case implant organ in the body of the user. 6. Place the smart phone on the centre of the charging pad for effective charging with best results. 7. It is recommended to turn on Engine while charging phone on wireless charger to avoid vehicle battery drain. 8. User shall clean charging pad/mat periodically to avoid dust accumulation. 9. It is recommended to keep Vehicle AC at least 23 Deg Cel with Fan speed above 2 level as cool environment support efficient charging of the phone. 10.It is recommended to keep mobile phone at centre of charging pad for effective charging. In case small phone kept at corner do not start charging or foreign object detection message pop-up, please move phone to centre of pad. 11.Always use TATA MOTOR LIMITED approved charging pad for efficient charging. DON’TS: 1. Do not use metallic smart phone covers as it would halt the wireless charging function. The wireless charging may not function properly when there is a heavy & thick (more than 1 mm thick) accessory cover on the smart phone. 2. Do not place smart phone up-side down (screen face) on charging pad or do not misalign mobile phone on charging pad in such case smartphone will not charge. 3. During phone charging, the wireless charger and phone may become warm. In this case, charging will stop due to phone’s internal protection function. Charging may resume after phone cools down. 4. Please do not put any liquid (e.g. water, cold drink, and sanitizer), dust particles or flammable object on anti-skid mat. 5. Do not cover the wireless charger with a cloth or other object while charging. It may heat up the device and reduce the charging efficiency. 6. Do not disassemble, modify or remove the wireless charger. Also do not apply force or impact to the wireless charger.
ELECTRICAL 6 I. WPC ECU REPLACEMENT PROCEDURE 1. PRE-CHECKS/TASKS TO BE DONE BEFORE REPLACING THE WPC ECU After performing all the necessary checks as per the troubleshooting guide, at wire harness, switches, relays, circuit short to ground, short to battery or open etc. If no root cause is found i.e. fault is not rectified, then follow the below replacement procedure. 2. ECU REPLACEMENT PROCEDURE PREQUISITE: 1. Gateway (Instrument Cluster) shall be functional. 2. Vehicle configuration data shall be available on the server. 3. New WPC ECU assembly shall be available for replacement. REMOVAL: 1. Disconnect the negative (-) terminal of the battery. 2. Remove the Anti-skid mat from Console area. 3. Pull out gear shifter bezel. 4. Remove the console finishers LH & RH. 5. Disconnect Electrical Connection drive mode switch connection.
ELECTRICAL 7 6. Remove Parking brake cover. 7. Remove WPC ECU assembly connector. 8. REMOVE THE FINISHER FLOOR CONSOLE. 9. Unscrew the WPC ECU assembly with dedicated screw panel. 10.Take out the WPC ECU assembly from trim panel. FITMENT: For fitment, follow reverse procedure of removal.
ELECTRICAL 8 2. AIR PURIFIER (IF APPLICABLE) Cabin Air Purification The Climate Control System fitted with advance filter for cabin air purification Pollen Filter (If available): The filter takes care of dust particles and other pollutants. PM2.5 Combi filter (If available): This high efficiency filter cleans the PM2.5 particles and harmful gases coming from atmosphere pollution and volatile organic compounds. NOTE: Replace the Filter as per Maintenance schedule. If the vehicle is driven in heavy dusty conditions more frequent filter replacement are required. Replace the filter if you find poor ventilation, Cooling or Demisting. Air Quality Index: (If available) Climate control system fitted with FATC calculates Air Quality Index (AQI) of cabin using PM2.5 AQI Index. FATC System in AUTO Mode automatically sets the blower speed and switches to recirculation air mode to improve AQI inside the cabin. The calculated AQI is displayed on display unit along with severity index. NOTE: AQI calculation will be effective after 30 seconds after ignition ON and no value will be displayed during this period. If the AQI does not improve in some time, get the sensor and Cabin filter inspected. Vacuum the dust sensor as per the maintenance schedule. SERVICE SCHEDULE SR. NO. OPERATION KMS / MONTHS 1 Clean filter and check Air-conditioning / HVAC system for satisfactory performance. Every Service 2 Replace Pollen Filter. 15K / 12M 3 Replace Combi PM2.5 filter 15K/ 12M 4 Vacuum Dust Sensor for satisfactory performance. 15K/ 12M A. AIR PURIFIER SENSOR REMOVAL 1. Remove the noise barrier. 2. Access the Dust sensor/ air purifier from Codriver side. Remove the electrical connection. 3. Loosen three fastner and remove the dust sensor. FITMENT For fitment follow the removal procedure in reverse.
ELECTRICAL 9 3. FUSE AND RELAY BOX DETAILS A. BATTERY MOUNTED FUSE BOX (BDU) FUSE DETAIL FUSE NO. FUNCTION FUSE RATING F01 STARTER MOTOR 200 A This fuse box is directly mounted on battery positive terminal. Bus-bar type construction is used. WARNING If Fuse box cover is removed for any reason, it should be refitted properly at its original position. B. ENGINE FUSE AND RELAY BOX NOTE The fuse box layout is for reference purpose only. Please refer the sticker provided inside the fuse box cover.
ELECTRICAL 10 FUSE AND RELAY REPLACEMNET: 1. Remove the cover of the fuse box. 2. Take out the fuse or relay from its base. 3.Check the Fuse/relay. 4.If faulty replace with same ratting of fuse and relay. REMOVAL 1. Remove the Battery. (Refer battery removal process). 2. Remove the top cover of fuse box. 3. Remove the three mounting bolt of the fuse frame assembly. 4.Gently pull out the fuse frame and disconnect all the electrical connections.
ELECTRICAL 11 C. CABIN FUSE AND RELAY BOX This fuse box is part of main wiring harness. For details refer the below fuse box sticker fitted on steering column lower cover. For other pin out details of fuse box refer the power distribution II circuit schematics. LOCATION CABIN FUSE AND RELAY BOX DETAILS SR NO FUNCTION RATING F1 CLUSTER 5A F2 BLOWER MOTOR 30A F3 PEPS/ESCL ECU-BATT 10A F4 HEATED REAR SCREEN BCM 25A F5 BCM2- MID BCM 20A F6 WW ANTI-PINCH 25A F7 RPAS/ TELEMATICS/DUST SENSOR 5A F8 IGN FUSE-2 10A F9 IMMOB/EPAS/PEPS/GSL-IGN 5A F10 HVAC/ETC/ FATC 10A F11 RESTRAINTS CONTROL MODULE 10A F12 ACC BATT/OBD 15A F13 TRANSIST/INFOTAINMENT 20A F14 TAILGATE RELEASE 10A F15 CDL 15A F16 BCM3-MID BCM 20A F17 RELAY COILS 5A F18 IMMO BATT 5A F19 BCM1-MID BCM 20A F20B PEPS/BLOWER RLY 5A
ELECTRICAL 12 F20A ACCESSORIES FUSE 5A F21 REAR USB A -TYPE 5A F22 MIRROR ADJUST MOTOR/WIRELESS CHARGER(ACC) 5A F23 POWER SOCKET-1 15A F24B TELEMATICS BATT 5A F24A KEY IN 5A F25 NA NA F26 SUNROOF 20A F27 FRONT USB C TYPE 5A F28 NA NA F29 WIRELESS CHARGING(IGN) 5A F30 REAR WIPER RLY 10A FUSE AND RELAY REPLACEMENT 1. Pry out the fuse box cover on the dashboard panel. 2. Take out the fuse and relay from its base. 3. Check the Fuse/relay. 4. If faulty, replace with same ratting of fuse and relay. REPLACEMENT PROCEDURE FOR RELAYS 1. Turn the ignition key to lock position. 2. Check each relay, if faulty replace with same rating relay. 3. If replaced relay of same rating is not working properly, there is probably a serious electrical problem. REPLACEMENT PROCEDURE FOR FUSES 1. Turn the ignition key to lock position. 2. Check each fuse and look for broken/open controls link wire inside the fuse. If it is burnt, replace it with one of the spare fuses of same rating. 3. If replaced fuse of same rating burns out then, there is probably a serious electrical problem. Note: Use designated fuses only.
ELECTRICAL 13 4. FASCIA SWITCHES A. FRONT FOG LAMPS (IF FITTED): Front Fog Lamps are provided on front bumper to provide improve divisibility in adverse weather conditions to avoid accidents when visibility is poor. The front fog lamps can be switched ‘ON’ with ignition and parking lamp ‘ON’ and can remain on till the parking lamp is switched ‘OFF’. B. REAR FOG LAMPS (IF FITTED): The Rear Fog Lamp can be switched ‘ON’ with Ignition ON, Parking Lamp ON and Front Fog in ON Condition. The Rear Fog Lamp can be switched ‘ON’ with Ignition ON & Parking Lamp ON and can remain ‘ON’ till the parking lamp is Switched OFF. C. DOOR LOCKING / UNLOCKING SWITCH In fascia switch one Push type switch available to lock and unlock the vehicle. D. AUTOMATED ENGINE START-STOP (ESS) OFF SWITCH (IF EQUIPPED) In fascia switch one Push type non-Latch switch available to off the ESS function. For detail Refer Starting and Driving Section. FASCIA SWITCH REMOVAL 1. Remove mounting screws & Pull out the driver side steering lower panel. 2. Remove one mounting screw on fascia switch panel & pry out Fascia Switch Panel. 3. Disconnect electrical connection from the fascia switch assembly. 4. Take out the fascia switch panel 5. Fascia switch tightening torque 0.4N-m INSTALLATON: 1. Fit the fascia switch panel on fascia cover. 2. Tight the mounting screws of fascia switch panel. 3. Fit the electrical connection in fascia switch panel.
ELECTRICAL 14 CONNECTION PIN DETAILS
ELECTRICAL 15 CONNECTION DIAGRAM OF FACIA SWITCH
ELECTRICAL 18 5. FRONT USB PORT & C TYPE USB: External memory devices like memory sticks / Pen Drives, I-Pods can be connect for playing music tracks stored in these devices through the vehicles music system. LOCATION USB port & is fitted below the Fascia switch. PINOUT DETAILS 1. USB Connector PIN DESCRIPTION 1 NC 2 Vcc 3 D- 4 D+ 5 GNF 2. C Type Connector PIN DESCRIPTION 1 BATT +VE 2 BATT -VE (GND) REMOVAL 1. Gently pry out the module from the cutout. 2. Unlock & Remove USB connector & disconnect the electrical connections of C type connector.
ELECTRICAL 19 3. Take out the C type connector housing assy. REFITMENT For refitment, follow the procedure in reverse. 6. REAR USB PORT Location - Rear console REMOVAL AND REFITMENT 1. Remove the bezel holding Power socket. 2. Pry out Socket holder assembly from bezel. 3. Remove electrical connections from power socket. REFITMENT For refitment, follow the procedure in reverse.
ELECTRICAL 20 7. MOOD LIGHTS A. MOOD LIGHT ON BEZEL FLOOR CONSOLE USB FRONT LOCATION REMOVAL 1. Pull out Gear Shift Lever knob assembly with Bellow. 2. Disconnect electrical connection on Sport Mode Switch. 3. Pull Out the Floor Console upper front. 4. Pull out Bezel Floor Console USB Front. 5. Disconnect Electrical connection on Mood lamp & take it out. REFITMENT For refitment, follow the procedure in reverse.
ELECTRICAL 21 B. MOOD LIGHT BELOW DRIVER SIDE LOWER PANEL LOCATION It is located below Driver side Lower Panel. REMOVAL 1. Remove Electrical connection on Mood Lamp. 2. Pull out Mood lamp & Separate it. REFITMENT For refitment, follow the procedure in reverse. C. MOOD LIGHT BELOW GLOVE BOX LOCATION It is Located below Glove Box. REMOVAL 1. Remove Electrical connection on Mood Lamp. 2. Pull out Mood lamp & Separate it. REFITMENT For refitment, follow the procedure in reverse.
ELECTRICAL 22 D. MOOD LIGHT BELOW REAR CONSOLE LOWER LOCATION REMOVAL 1. Pull out Floor console Lower rear cover. 2. Remove Electrical connection on Mood Lamp. 3. Take out Mood lamp. REFITMENT For refitment, follow the procedure in reverse. E. FRONT DOOR MOOD LIGHT & TRIMS REMOVAL 1. Open the Door. 2. Pry out the Mirror adjustment & Window winding switch cover. 3. Disconnect the electrical connection of mirror adjustment switch & take out the switch assy. 4. Remove the switch assembly from bezel and disconnect the electrical connector & take out the switch assy. NOTE: Same procedures are to be followed for co-drivers and passengers window module switches.
ELECTRICAL 23 5. Remove the mounting screw and clip and pull out the arm rest. 6. Disconnect Electrical connection on Mood Lamp Assembly. 7. Pull out Mood Lamp Assembly & Separate it. 8. Loosen and remove the mounting screw of inner handle. 9. Insert plastic wedge pin and remove the door trim. NOTE While lifting door trim, care should be taken such that tree clips don’t get damage. Below image gives the location of tree clips on door trim. FITMENT For fitment, follow the reverse procedure of removal. NOTE “For Side door Rattling Noise, Door Latch and striker setting need to be done & maintain 1 mm under flush condition.”
ELECTRICAL 24 F. REAR DOOR MOOD LIGHT & TRIMS REMOVAL 1. Open the Door. 2. Remove window-winding switch from door pull outer. 3. Remove the mounting screw and pull out the armrest. 4. Disconnect the window winding connection and remove the switch. 5. Disconnect Electrical connection on Mood Lamp Assembly. 6. Pull out Mood Lamp Assembly & Separate it. 7. Loosen and remove the mounting screw of inner handle. 8. Pull out the door corner trims.
ELECTRICAL 25 9. Remove the mounting screw of door corner. 10. Insert plastic wedge pin and remove the door trim. NOTE While lifting door trim, care should be taken such that tree clips don’t get damage. Below image gives the location of tree clips on door trim. FITMENT For fitment follow the reverse procedure of removal. NOTE “For Side door Rattling Noise, Door Latch and striker setting need to be done & maintain 1 mm under flush condition.”
ELECTRICAL 26 8. ANTENNA (AM+FM+GPS) (If Applicable) The antenna designed to effectively capture radiated RF signals in the AM and FM bands. LOCATION Antenna is located on the roof, above the Back windshield glass. REMOVAL 1. Remove the head lining assembly (Refer Body section) 2. Disconnect the electrical connection. 3. Loosen the fixing screw and take out the antenna from top. REFITMENT For Re-fitment follow the removal procedure in reverse. Torque specified for fixing screw: 4 Nm±1.
ALTROZ MY23 SUPPLIMENT ALTROZ MY23 BODY
ALTROZ MY23 SUPPLIMENT . .
ALTROZ MY23 SUPPLIMENT TABLE OF CONTENTS 1. SUNROOF ......................................................................................................................................1 A. ON VEHICLE REMOVAL ..............................................................................................................1 B. DO’S AND DON’T ...................................................................................................................... 10 C. SUN ROOF / TILT AND SLIDE ROOF .........................................................................................12 D. ANTI-PINCHING FUNCTION ......................................................................................................14 E. SCHEMATIC AND ROUTING DIAGRAM .....................................................................................15 F. INSPECTION OF SUN ROOF MOTOR AND CIRCUIT .................................................................16 G. SUNROOF MOTOR INITIALIZATION..........................................................................................17 H. SUN ROOF COMPONENTS .......................................................................................................18 I. DIAGNOSTIC INFORMATION AND PROCEDURES .....................................................................19 J. DUST CLEANING METHOD .......................................................................................................25 J. ASSEMBLY AND DISMANTLING ................................................................................................26 1. HVAC AIR FILTER ........................................................................................................................ 29
BODY 1 1. SUNROOF A. ONVEHICLE REMOVAL 1. Disconnect the battery negative terminal. NOTE: Before removing sunroof Place protective covers on the following: Carpet, Steering Wheel, Instrumental Panel, Seats, Hood, Doors, Deck Lid, Exterior Glass, and Roof. (Refer Body section for removal procedures). 2. Remove Driver side and Co-Driver side Sunvisor. 3. Remove Roof Lamp and disconnect its electrical connection. 4. Remove 2 mounting screws on Roof console Housing. 5. Disconnect electrical connection on microphone and sunroof switch. 6. Remove All Grab Handles. 7. Remove A, B, C Pillars. 8. Remove Beeding. 9. Remove three tree clips from rear side on Head Liner. 10. Remove Head Liner.
BODY 2 11. Unplug all the wiring harness connected to sunroof, Remove all the cables routed and clipped on to the sunroof. 12. Unplug all the drain hoses from 4 corners of the sunroof. 13. Remove all the mountings and give support to Sunroof and take it out. NOTE Due to the weight of the sunroof assembly it is recommended that you use Jacks to support the sunroof assembly to avoid Twisting of guide rails during handling. FITMENT 1. Position the sunroof onto the mounting location. 2. Attach all screws with washer. Do not tighten until the Guide rail aligned with the factory mounting points. 3. Once all fasteners are aligned and then start tightening securely. 4. Maintain tightening torque of 7±10% N-m 5. Plug all the wiring harness to the sunroof, Route all the cables and clip it on to the sunroof. 6. Plug all the drain hoses to all 4 corners of the sunroof. 7. Fix the Beeding. 8. Fix A, B and C Pillar. 9. Fix All Grab Handles. 10. Connect electrical connection on microphone and sunroof switch. 11. Tighten 2 mounting screws on Roof console Housing. 12. Connect electrical connection on Roof Lamp and Tighten Roof Lamp. 13. Fix the Sunvisors. 14. Connect Battery –Ve Terminal. NOTE Due to the weight of the sunroof assembly it is recommended that you use Jacks to support the sunroof assembly to avoid Twisting of guide rails during handling.
BODY 3 1. WIND DEFLECTOR REMOVAL 1. Position the Glass panel in the open position. 2. Use flat blade screwdriver to pry open spring holder (black plastic part) on both the sides. FITMENT For fitment follow the removal procedure in reverse. NOTE Observe the spring holder orientation before removal; label and mark if necessary. 2. GLASS PANEL REMOVAL 1. Position the Glass panel in the Close position. 2. Pull and remove the flex covers on both the sides. 3. Remove the Four (4) M5 Screws both the sides on the glass panel bracket using T25 Torx driver. 4. Remove Glass panel from the vehicle.
BODY 4 WARNING Do not operate sunroof after removing glass panel from the Vehicle, it will damage the rear water channel and lead to severe mechanism damage. FITMENT For fitment follow the removal procedure in reverse. GLASS PANEL ADJUSTMENT FRONT Adjust the front of the glass panel by loosening the Four (4) M5 screws on the either side. Adjust the glass panel so the front edge is between 1mm higher or flush with the roof ring and tighten the screws. 3. SUNSHADE REMOVAL 1. Remove the glass panel. (Refer glass panel removal procedure). 2. Manually operate the sunshade to slide front.
BODY 5 3. Use flat blade screwdriver to pry open the feet slip. 4. After removing 8 feet slips, sunshade can be removed from the vehicle. FITMENT For fitment follow the removal procedure in reverse. NOTE Observe the Sunshade orientation before removal; label and mark if necessary. 4. ELECTRIC DRIVE ASSEMBLY REMOVAL Remove the following Interior Trim: Garnish Mouldings, Sun Visors, Overhead Consoles, Coat Hooks, Assist Straps, Factory Headliner. 1. Unplug wiring harness connected to Electric drive. 2. Remove all three (3) screws from the Electric drive. 3. Remove the electric drive from the sunroof. FITMENT For fitment follow the removal procedure in reverse.
BODY 6 5. REAR WATER CHANNEL ASSEMBLY REMOVAL 1. Remove sunroof. 2. Unlock Hinge snaps using a flat screw driver on both the Sides and lift the water channel from sunroof. NOTE Observe the Leaf spring orientation before removal; label and mark if necessary. FITMENT For fitment follow the removal procedure in reverse. 6. CORNER COVER PIECE REMOVAL 1. Remove sunroof. 2. Unlock Corner cover snaps using a flat screw driver on both the Sides and lift the cover from Guide rail ends. NOTE Observe the Corner cover orientation before removal; label and mark if necessary. FITMENT For fitment follow the removal procedure in reverse.
BODY 7 7. CONNECTING PART REMOVAL 1. Remove sunroof. 2. Remove Glass Panel from Sunroof. 3. Unlock Connecting part snaps on both the sides and Pull it the direction as shown. NOTE Observe the Connecting part orientation before removal; label and mark if necessary. FITMENT For fitment follow the removal procedure in reverse. 8. COLISSA GUIDE ASSEMBLY REMOVAL 1. Remove sunroof. 2. Remove Glass Panel from Sunroof. 3. Remove connecting part. 4. Slide front guide along guide Rail till Colissa reaches the cut-out provided to disassemble. Rotate it along the hinge to lift it from Rear Guide.
BODY 8 5. Unlock the Hinge snap from the front guide by pulling in the Direction as shown. Remove the Colissa guide from Mechanism. NOTE Observe the Colissa guide orientation before removal; label and mark if necessary. FITMENT For fitment follow the removal procedure in reverse. NOTE During installation, Collisa should be moved until arrow marking is positioned above Guide RR as shown. This ensures correct mechanism assembly position. 9. RETAINING HOOK GUIDE AC REMOVAL 1. Remove sunroof. 2. Remove Glass Panel from Sunroof. 3. Rear Water Channel 4. Remove Corner cover piece. 5. Remove connecting part. 6. Push the spring loaded Retainer and unlock Retaining hook from guide rail as shown. 7. Slide the Retaining Hook Guide along the Guide rail till the end. 8. Remove it from Guide rail. NOTE Observe the Hook guide orientation before removal; label and mark if necessary. FITMENT For fitment follow the removal procedure in reverse.
BODY 9 10. GUIDE RR AC REMOVAL 1. Remove sunroof. 2. Remove Glass Panel from Sunroof. 3. Remove Electric drive 4. Remove Rear Water Channel 5. Remove Corner Cover Piece 6. Remove Connecting part. 7. Remove Collisa guide Assembly. 8. Remove Retaining Hook Guide. 9. Slide the Retaining Guide RR along the Guide rail till the end. 10. Separate it from Cable carrier and remove it from Guide rail. NOTE Observe the Guide RR orientation before removal; label and mark if necessary. FITMENT For fitment follow the removal procedure in reverse. 11. GUIDE FR ASSY REMOVAL 1. Remove sunroof. 2. Remove Glass Panel from Sunroof. 3. Remove Electric drive 4. Remove Rear Water Channel 5. Remove Corner Cover Piece 6. Remove Connecting part. 7. Remove Collisa guide Assembly. 8. Remove Retaining Hook Guide. 9. Remove Guide RR AC. 10. Slide the Guide FR along the Guide rail till the end and remove it from Guide rail. NOTE Observe the Guide FR orientation before removal; label and mark if necessary. FITMENT For fitment follow the removal procedure in reverse.
BODY 10 B. DO’S AND DON’T DO’S 1. Ensure that Operator/fitter always using hand gloves while touching the Sunroof glass surface. 2. At the time of sunroof ASM loading/unloading operator/fitter needs to use hand gloves while touching the Sunshade ASM or its visible surface. 3. Apply optimum force on the headliner while assembling headliner to Reinf.frame B with the help of Dual lock fastener. 4. Ensure that guide rail channel area is neat & clean before loading the sunroof ASM (no dust/unwanted things in this area to avoid breakdown/damage of mechanism). 5. Always try to keep sunroof ASM in covered condition when not in use. 6. Always try to handle Sunroof ASM smoothly.
BODY 11 DON’T 1. Don’t touch the Sunroof glass surface with bare hands. 2. Don’t touch the Sunshade ASM or its visible surface with bare hands while sunroof ASM loading/unloading. 3. Don’t apply excess force on the Headliner while assembling headliner to Reinf.frame B with the help of Dual lock fastener to avoid deformation of Reinf.frame B. 4. Guide rail channel area with dust/small particle of thermocol in it may leads to mechanism breakdown/damage. 5. Sunroof ASM kept in open condition causes, dust on glass surface which gives poor aesthetic, also dust in guide rail channel area may leads to breakdown of mechanism. 6. Don’t handle Sunroof ASM inappropriate way which may leads to bend/damage of its sub ASM.
BODY 12 C. SUN ROOF / TILT AND SLIDE ROOF 1. Precautions for Sun Roof i) Water Leakage Test Perform water leakage test after installing Glass Panel Assy. Adjust Glass Panel Assy mount position again in case of water leakage. (Replace Glass Panel Assy if sun roof weather-strip included in Glass panel Assy is defective.) Do not apply excessive water pressure during water leakage test. ii) Installation and Replacement Do not apply large impact to sun roof motor, such as by dropping it. Do not pinch any object during initialization of sun roof motor, sun roof cable. iii) Anti-Pinching Function Check Do not use any part of your body such as hand or arm to check this function. Pay enough attention to avoid body from being pinched during check. Anti-pinching function works only in auto tilt down and sliding function in closing direction. Do not check in manual operation function. Roof may deform if hard material such as hammer handle is pinched. (Use hammer handle wrapped with cloth.) iv) Precautions for Disassembly and Reassembly Sun roof consists of many component parts and the following precautions should be observed when performing disassembly and reassembly. Inappropriate handling will spoil its original performance. Check that ignition is “OFF” or battery negative (–) cable is disconnected when operating the sun roof manually. Do not disassemble parts except the parts indicated for disassembly. After performing misalignment correction or emergency manual movement of motor(s) for sunroof, initialize sun roof motors. (Sun Roof Motor Initialization) Check sliding rail surfaces for cleanliness and clean the surfaces if any foreign material is present. Apply grease to sliding parts of sun roof. WARNING During emergency operation of the sun roof motor, the roof may move suddenly and can cause personal injury. (Sun Roof Motor Removal and Installation): Check that ignition is “OFF” or battery negative (-) cable is disconnected when performing emergency operation of the sun roof motor.
BODY 13 2. Sun Roof System General Description Sun roof system consists of sun roof unit, sun roof motors with sun roof control modules and sun roof switch. The system can perform slide and tilt operations. Sun roof system is controlled by the sun roof control modules built in motor. Sun roof switch has “OPEN”, “CLOSE” and “TILT” positions. By operating this switch, the sun roof performs the actions shown in the following table depending on its position. Sunroof operation table Slide operation Tilt operation Sunroof position Sunroof switch input Fully opened Partially opened Closed Fully Tilt up Tilt region (Partially tilt) OPEN1ST Detent No motion Slide-open (Manually) Slide-open (Manually) No motion No motion OPEN 2nd Detent No motion Slide-open (Auto) Slide-open (Auto) No motion No motion CLOSE 1st Detent Slide-close (Manually) Slide-close (Manually) No motion Tilt Down (Manually) Tilt Down (manually) CLOSE 2nd Detent Slide-close (Auto) Slide-close (Auto) No motion Tilt Down (Auto) Tilt Down (Auto) Center press No motion No motion Tilt up (Auto) Tilt Down (Auto) Tilt up (Auto) Sun roof system has auto-slide to fully open and fully close the sun roof by one switch operation. Sun roof system has anti-pinching function in slide close operation and tilt down operation. Description of Auto-Slide: Auto Slide Function Auto slide function can be activated as follows with ignition “ON”. o Auto slide-open: Fully closed or partly opened sun roof opens fully by pressing sun roof switch “OPEN” to 2nd detent/step. o Auto slide-close: Fully or partly opened sun roof closes fully by pressing sun roof switch “CLOSE” to 2nd detent/step. Auto motion is suspended/stopped if any “OPEN”, “CLOSE” or “TILT” switch of the sun roof switch is pressed during auto operation.
BODY 14 D. ANTI-PINCHING FUNCTION Sun roof system is provided with an anti-pinching function which works at closing operation of the sun roof glass. 1. Reverse Operation Stroke of Anti-Pinching Function Anti-pinching function of the sun roof glass works in closing direction. When a pinching load exceeding the preset value is applied to the auto-slide-closing sun roof glass, it reverses the sun roof glass. Operating range in auto sliding mode of the sun roof glass is from fully opened position to closed position. In this operating range, antipinching function works to fully reverse the sun roof glass when a pinching load exceeding the preset value is applied to the auto-slide-closing sun roof glass. Pinching some object (during auto closing) Auto reverse Sun Roof Fail-Safe Function The control module in sun roof motor (for sun roof glass) stops auto-sliding. Fail-safe condition Loss of sunroof position data in control module of sunroof motor. Fail-safe cancel condition Initialization of sun roof motor is completed.
BODY 15 E. SCHEMATIC AND ROUTING DIAGRAM 1. Sun Roof System Circuit Diagram
BODY 16 F. INSPECTION OF SUN ROOF MOTOR AND CIRCUIT i) Voltage Check 1. Checking is done with sunroof connector still connected. 2. Check voltage using circuit tester. Terminal no. Wire color Signal spec Observation Condition Typical voltage 1 Ground for motor drive/ Signal All Approx. 0 V 3 ACC signal input ACTIVE Hi ・ON： Battery voltage ・OFF：OPEN ACC “OFF” Approx. 0 V ACC “ON” Approx. 12 V 4 S/R SW input C ACTIVE Low ・ON：GND ・OFF：OPEN ACC “ON” “C” switch: Pressed Approx. 0 V ACC “ON” “C” switch: Not Pressed Approx. 12 V 5 S/R SW input A ACTIVE Low ・ON：GND ・OFF：OPEN ACC “ON” “A” switch: Pressed Approx. 0 V ACC “ON” “A” switch: Not Pressed Approx. 12 V 6 Power supplyinput for control unit and motor. All Approx. 12 V 10 S/R SW input B ACTIVE Low ・ON：GND ・OFF：OPEN ACC “ON” “B” switch: Pressed Approx. 0 V ACC “ON” “B” switch: Not Pressed Approx. 12 V
BODY 17 G. SUNROOF MOTOR INITIALIZATION NOTE If an object is trapped during the sun roof motor initialization, the initialization is failed and the antipinching function is disabled. Do not pinch any object during the sun roof motor initialization. 1. Set ignition “ON”, and press “CLOSE” side of sunroof switch to fully CLOSE Sun Roof. 2. Keep pressing “CLOSE” side of sun roof switch for more than 10 seconds, sunroof will move to tilt up position after sunroof movement stop release the switch. 3. After Step 2, within 4 secs press “Close” side of sun roof switch and hold it. Check that sunroof opens fully and closes automatically, if not please start again from step 2. 4. Conduct slide open / close operation pressing “OPEN” / “CLOSE” of the sun roof switch just a little and check that manual functions work normally. 5. Conduct auto slide open / close operation pressing “OPEN” / “CLOSE” of the sun roof switch a bit longer and check that auto functions work normally. 6. Conduct anti-pinching function check. 4. Anti-Pinching Function Check NOTE If the sun roof pinches the hard part of the hammer handle or the like which is not wrapped with cloth, the roof of the vehiclemay be damaged. To avoid the roof damage, wrap hammer handle or the like with cloth for anti-pinchingfunction test. 1. Slide open sun roof fully. 2. Place hammer handle (2) wrapped with cloth (1) close to fully closed position. 3. Perform auto slide close of sun roof. 4. Check that sun roof glass reverses automatically to full open position, from the position the hammer handle is lightly pinched. If defect is found, initialize sun roof motor.
BODY 18 H. SUN ROOF COMPONENTS 1 FRAME ASM 11 STOPPER SUNSHADE 2 E-DRIVE ASM 12 SUNROOF GLASS CABLE 3 MECHANISM ASM RH 13 DRAIN HOSE 4 MECHANISM ASM LH 14 SUNROOF HOUSING BOLT 5 GLASS PANEL ASM 15 SUNROOF HOUSING NUT 6 SUNSHADE ASM 14a 3.5 ± 0.5 N-m 7 WIND DEFLECTOR ASM 14b 9.0 ± 1 N-m 8 CHANNEL WDR ASM 9 MOTOR SCREW 10 MECHANISM SCREW
BODY 19 I. DIAGNOSTIC INFORMATION AND PROCEDURES 1. Sunroof System Symptom Diagnosis Sr. No NG Type Seq. Issue Type Correction Reference Document 1 Sunroof Cannot operate Motor Can operate 1 Some object stuck in sun roof rail Remove or clean stuck object Owners manual 2 Incorrect installation of sun roof rail Install correctly W-002 3 Interference of sun roof parts Fix interference 4 Incorrect installation of sun roof cable Install correctly S-002 Motor Cannot Operate 1 Blown fuse Replace fuse. Fuse not in Webasto scope, 2 Faulty sun roof switch Check sun roof switch Switch is not in Webasto scope 3 Faulty wiring or grounding Check circuit Wire harness is not in Webasto scope (Check as per Inspection of Sun Roof Motor and Circuit) Sunroof System Sunroof Motor 4 Faulty sun roof motor Replace sun roof motor S-002 2 Rain Leakage 1 Incorrect installation position of the sun roof glass Adjust sun roof glass mounting position S-001 2 Faulty sun roof glass seal Replace Glass panel assembly S-001 3 Disconnected or clogged drain hose Check drain hose Drain hose not in Webasto scope 4 Damaged End cap or Frame A Replace Frame Assy, Sliding Roof S-005 5 Damaged Glass panel (Broken) Replace Glass panel assembly S-001 6 Damaged Water drain channel Replace Water drain channel Assy S-006 3 Auto Slide not working 1 Initialization is defective Initialize sun roof motors W-001 2 Incorrect installation position of sun roof glass Adjust sun roof glass mounting position S-001 3 Faulty sliding movement of sun roof unit Replace sun roof unit W-002 4 Faulty sun roof motor Replace sun roof motor S-002
BODY 20 4 Higher Sunshade Sliding force or Sunshade can not move 1 Sunshade stucks while moving or feels higher force at particular section 1. Check for any object stuck at rail slot and remove it 2. Check for dust accumulation at rail slot and clean it 2 Sunshade slider shoe damaged Replace with Sunshade Assy. S-003 5 False reversal 1 Obstruction of Deflector motion with Frame A or GPA Remove the obstruction 2 Dust accumulated on Deflector link and guide rail. Clean the Deflector link and Mechanism. W-003 3 Set plate damaged Replace Frame Assy S-005 6 Water drain channel damaged 1 Crack in Water Drain Channel Replace Water drain channel Assy S-006 2 Noise from WD bushing in tilt operation due to dust accumulation Replace Water drain channel Assy S-006 7 Wind deflector assy damaged 1 Crack in Wind deflector Assy Replace Wind deflector assy S-004 8 Noise in sunroof operation 1 Damage seal causing rubbing noise Replace sunroof glass Sunroof glass removal and installation 2 Dust accumulation in sunroof housing rail 1. Dust cleaning of sunroof assembly 2. If issue persist after one replace sunroof housing. 1. Dust cleaning method 2. Sunroof housing removal and installation. 3 Dust accumulation in mating area of drain channel and mechanism assembly. 1. Replace drain channel and dust cleaning of sunroof assembly. 2. If issue persist after one replace sunroof housing. 1. Drain channel removal and installation, Dust cleaning method 2. Sunroof housing removal and installation. 4 Dust accumulation in Wind Deflector spring. 1. Dust cleaning of sunroof assembly 2. If issue persist after one replace sunroof housing. 1. Dust cleaning method 2. Sunroof housing removal and installation. 9 If the issue is still there even after doing all the above troubleshooting, replace the Sunroof Assy W-002
BODY 21 2. Diagnostic Information and Procedures checklist NG Type Issue Type Correction Reference Document Sunroof Cannot operate Motor Can operate Some object stuck in sun roof rail Remove or clean stuck object Owner’s manual Incorrect installation of sun roof rail Install correctly W-002 Interference of sun roof parts Fix interference Incorrect installation of sun roof cable Install correctly S-002 Motor Cannot Operate Blown fuse Replace fuse. Fuse no in Webasto scope, Faulty sun roof switch Check sun roof switch Switch is not in Webasto scope Faulty wiring or grounding Check circuit Sunroof System Sunroof Motor Wire harness is not in Webasto scope Faulty sun roof motor Check sun roof motor S-002 Water Leakage Incorrect installation position of the sun roof glass Adjust sun roof glass mounting position S-001 Faulty sun roof glass seal Replace sun roof glass seal S-001 Disconnected or clogged drain hose Check drain hose Drain hose no in Webasto scope Auto Slide Initialization is defective Initialize sun roof motors W-001 Incorrect installation position of sun roof glass Adjust sun roof glass mounting position S-001 Faulty sliding movement of sun roof unit Replace sun roof unit W-002 Faulty sun roof motor Replace sun roof motor S-002
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