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TIGOR.EV UPGRADE SERVICE MANUAL

TIGOR.EV UPGRADE SERVICE MANUAL 1
HV ELECTRICALSYSTEM 5
CONTENTS 6
1. GENERAL INFORMATION 8
A. TOOLS 8
B. HAND GLOVES 8
C. PPES FOR HV 9
D. MEASURING TOOLS 12
E. SAFETY INSTRUCTIONS 13
F. DO’S AND DON’TS 14
G. SAFETY WHILE SERVICING 17
H. WASHING INSTRUCTIONS 21
I. ELECTRICAL COMPONENT INFORMATION 22
J. MOTOR COMPARTMENT 24
2. TYPES OF CHARGING 25
A. NORMAL CHARGING 26
B. FAST CHARGING 31
3. TIGHTENING TORQUES 33
4. SPECIAL TOOLS 38
5. INSTRUCTION FOR WORKING ON HV COMPONENTS ON VEHICLE 40
6. HV CONNECTOR CONNECTION & LOCKING PROCESS 41
7. ON VEHICLE REMOVAL 45
A. 3 IN 1 UNIT 45
B. VEHICLE CONTROL UNIT 47
C. VACCUM PUMP REMOVAL 48
D. E - DRIVE REMOVAL 48
E. REDUCER OIL LEVEL CHECKING / DRAIN / FILLING DO & DONTS 52
8. TRACTION COOLING SYSTEM (TCS) 53
A. SYSTEM LAYOUT 53
B. CIRCUIT SCHEMATICS 53
C. TCS COOLANT DRAINING PROCEDURE 54
D. TCS COOLANT FILLING PROCEDURE 54
E. TCS COOLANT PUMP REMOVAL 55
F. RADIATOR FAN REMOVAL 55
G. RADIATOR REMOVAL 56
H. CONDENSOR REMOVAL 57
I. AUX TANK RESERVIOR REMOVAL 59
9. HV BATTERY 60
A. SYSTEM LAYOUT 60
B. BATTERY PACK STORAGE GUIDELINE 60
C. HV BATTERY REMOVAL 61
10. BATTERY COOLING SYSTEM (BCS) 65
A. SYSTEM LAYOUT 65
B. CIRCUIT SCHEMATICS 65
C. BCS COOLANT DRAINING PROCEDURE 66
D. BCS COOLANT FILLING PROCEDURE 66
E. COMPRESSOR 67
F. BATTERY COOLING PUMP REMOVAL 68
G. BCS COOLANT TANK REMOVAL 69
H. CHILLER UNIT (HEAT EXCHANGER) REMOVAL 70
I. HV / LV CHARGER PORT & CABLE REMOVAL 71
11. CRADLE 74
A. CRADLE EXPLODED VIEW 74
B. CRADLE REMOVAL 76
D. A, B, & C MOUNT FITMENT SEQUENCE 78
LV ELECTRICAL SYSTEM 80
CONTENTS 81
1. LIGHTING SYSTEM 83
A. BULB SPECIFICATION 83
B. FASTENERS TORQUE VALUE TABLE 83
C. GENERAL SYMPTOMS AND DIAGNOSTICS 84
D. HEAD LAMP (DUAL CHAMBER) 87
2. COMBI SWITCH 93
A. DESCRIPTION 93
B. COMBI SWITCH CONNECTION DETAILS 94
C. REMOVAL OF COMBI SWITCH 98
D. COMBI STALK REPLACEMENT PROCEDURE 98
E. PINOUT DETAILS 99
3. FASCIA SWITCH 100
A. DESCRIPTION 100
B. FUNCTION 100
C. REMOVAL OF FASCIA SWITCH 101
D. CONNECTION DETAILS 102
E. CONNECTION DIAGRAMS 103
4. RAIN LIGHT SENSOR SYSTEM 107
A. RAIN LIGHT SENSOR 107
B. FUNCTIONAL DETAILS 110
C. FAIL SAFE MODES OF RLS & BCM 111
5. STEERING SWITCH 112
A. DESCRIPTION 112
B. CONNECTOR DETAILS 113
C. REMOVAL OF STEERING SWITCH 114
6. ITPMS 115
A. INTRODUCTION 115
B. INDIRECT TPMS 115
C. REMOVAL OF STEERING SWITCH 115
D. ITPMS REST PROCEDURE 116
E. CHARGING THE TIRE WITH ITPMS 116
7. DOOR TRIMS 117
A. FRONT DOOR TRIMS REMOVAL 117
B. DOOR INNER LOCK HANDLE REMOVAL 118
C. REAR DOOR TRIM REMOVAL 118
8. INSTRUMENT CLUSTER 120
A. BASIC FUNCTIONAL MATRIX 121
B. INSTRUMENT CLUTER 123
C. TELL TALES DETAILS 124
D. DRIVER INORMATION SYSTEM 128
E. REMINDER FEATURES 136
F. MAIN CONNECTOR PIN OUTS 138
G. TEMPERATURE BAR GRAPH DETAILS 139
H. CHIME TABLE 140
I. DISPLAY SCREEN FLOW AND SETTINGS 141
J. REMOVAL 142
BRAKES 144
CONTENTS 145
1. TECHNICAL SPECIFICATIONS 147
2. TIGHTENING TORQUES 149
3. SPECIAL TOOLS 155
4. PRECAUTIONS 155
5. DIAGNOSIS 156
6. NESSECITY OF ABS WITH EBD 159
7. BRAKE HYDRAULIC LINES 160
8. VACUUM BRAKE BOOSTER 161
9. WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) 162
10. ABS COMPONENTS 166
10.1. ABS 9 ELECTRONIC CONTROL UNIT CIRCUIT 166
10.2. ABS 9 ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU / HCU) 167
10.3. WHEEL SPEED SENSOR 168
10.4. ABS SYSTEM FAILURE WARNING LIGHT 169
11. MAINTAINANCE, ADJUSTMENTS & TEST 170
11.1. FRONT BRAKE MAINTENANCE 170
11.2. REAR BRAKE MAINTENANCE 172
11.3. BLEEDING OF HYDRAULIC SYSTEM 174
11.4. BRAKE TROUBLE SHOOTING 178
11.5. CHECKLIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO 179
11.6. STOP LIGHT SWITCH ADJUSTMENT 180
12. SNAP TYPE BRAKE LIGHT SWITCH INSTALLATION PROCEDURE 181
13. REGENERATION SENSOR REMOVAL 182
14. ACCELERATOR PEDAL ASSEMBLY REMOVAL 182
15. BRAKE PEDAL ASSEMBLY REMOVAL 183
16. REPAIRS 185
16.1. FRONT BRAKE ADJUSTMENT, REMOVAL AND REFITMENT 186
16.2. REMOVAL OF FRONT BRAKE DISC 194
16.3. REMOVAL & REFITMENT OF TMC & BOOSTER ASSEMBLY 195
16.4. REAR BRAKE ASSEMBLY 197
16.5. REMOVAL AND REFITMENT REAR BRAKE ASSEMBLY 198
16.6. EXPLODED VIEW OF WHEEL CYLINDER 200
16.7. REMOVAL OF WHEEL CYLINDER 201
16.8. PARKING BRAKE ASSEMBLY 203
16.9. REMOVAL OF PARKING BRAKE LEVER 204
16.10. REMOVAL AND INSTALLATION OF PARKING BRAKE CABLE 205
16.11. PARKING BRAKE CABLE ADJUSTMENT 206
16.12. REMOVAL & REFITMENT OF ABS ECU / HCU 207
16.13. REMOVAL & REFITMENT OF FRONT WHEEL SPEED SENSOR 208
16.14. REMOVAL & REFITMENT OF REAR WHEEL SPEED SENSOR 209
16.15. REMOVAL & REFITMENT OF VACUUM PUMP 210
17. TROUBLE SHOOTING & DIAGNOSIS 211
18. ABS ECU CONNECTOR 213
FATC 214
CONTENTS 215
1. TECHNICAL SPECIFICATION 217
2. FATC SYSTEM & LAYOUT 218
3. FATC UNIT AIR FLOW LAYOUT 219
4. BATTERY COOLING SYSTEM LAYOUT 220
5. SCHEMATICS OF HVAC & BATTERY COOLING SYSTEM (BCS) 221
6. HVAC UNIT ELECTRICAL CIRCUIT DIAGRAM 222
7. TIGHTENING TORQUES 223
8. PRECAUTIONS 226
9. FATC CONTROL PANEL 227
10. CONTROL PANEL CONNECTOR DETAILS 233
11. FATC UNIT 234
12. COMPRESSOR 236
13. CHILLER UNIT 238
14. COOLANT PUMP 238
15. BLOWER 239
16. AC FILTER 239
17. TXV 240
18. HVAC UNIT 240
19. FATC SENSORS AND ACTUATORS 241
A. LINEAR PRESSURE SENSOR (LPS) 241
B. CONDENSER AND RECEIVER DRIER 241
C. SOLAR LOAD SENSOR 242
D. OAT SENSOR 243
E. THERMISTER OR THERMO SENSOR 245
F. AIR INLET ACTUATOR 246
G. LINEAR POWER MODULE 247
H. PTC HEATER 248
20. REFRIGERANT HOSES / PIPES 249
21. DO’S AND DONT’S 250
22. TROUBLESHOOTING 251
23. MAINTAINANCE 264
23.1. PRELIMINARY INSPECTION 264
A. AC SYSTEM PERFORMANCE TEST 264
B. LEAK DETECTION 266
23.2. REGULAR MAINTAINANCE 266
A. REFRIGERANT RECOVERY, RECYCLING AND RECHARGING 266
B. FLUSHING OF AC SYSTEM 267
C. REPLENISHING COMPRESSOR OIL 268
D. PRESSURE TEST USING MANIFOLD GAUGES 269
BODY 270
REAR SEAT BELT REMOVAL 270
SUPPLEMENTARYRESTRAINT SYSTEM(SRS) 272
CONTENTS 273
1. WORKING OF RESTRAINTS 274
2. SYSTEM LAYOUT 276
3. SAFETY PRECAUTIONS 277
4. DISPOSAL OF FAULTY AIR BAG UNIT 279
5. SRS POST ACCIDENT PROCEDURE 280
6. TIGHTENING TORQUES 281
7. COMPONENTS 283
7.1. RESTRAINT WITHOUT AIRBAGS 283
7.2. RESTRAINT WITH AIRBAGS 283
A. ECU 283
B. FRONT IMPACT SENSORS 287
C. AIRBAGS 288
D. FRONT SEAT (DRIVER) BELT BUCKLE 290
E. RPLL BELTS 291
F. CLOCK SPRING 293

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