SERVICE MANUAL BOOK - 1 ALTROZ BNCAP BSVI SUPPLEMENT
Developed by: Technical Literature Cell. Release Date : JAN 2024 / First Edition. The information provided in this manual is based on the latest product information available at the time of publication. . C Copyright 2024 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 PASSSENGER 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 Service manual provides information pertaining to technical Specifications, repair, maintenance and overhaul of different aggregates fitted on TATA ALTROZ BNCAP BSVI. 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” 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 ESP BODY SRS THE BOOK – 2 CONTAINS DIAGNOSTIC TROUBLE SHOOTING CODES (DTC) LIST THE BOOK – 3 CONTAINS SERVICE SCHEMATICS THE BOOK – 4 CONTAINS INFO. FITMENT DRAWINGS
TABLE OF CONTENT SR. NO GROUP 1 ELECTRICAL 2 ESP 3 BODY 4 SRS
ELECTRICAL ELECTRICAL
ELECTRICAL CONTENTS 1 INSTRUMENT CLUSTER ...................................................................................................... 1 2 FUSE AND RELAY BOX DETAILS....................................................................................... 11 A FUSE AND RELAY BOX: LAYOUT ............................................................................. 13 B BATTERY MOUNTED FUSE BOX .............................................................................. 13 C ENGINE FUSE AND RELAY BOX............................................................................... 14 D CABIN FUSE AND RELAY BOX ................................................................................. 16 E FUSE AND RELAY REPLACEMENT .......................................................................... 17 3 USB/TYPE-C PORT .............................................................................................................. 18 4 INFOTAINMENT SYSTEM .................................................................................................... 19 5 SWITCHES............................................................................................................................ 21 A PASSENGER AIRBAG SWITCHES ............................................................................ 21 B PASSENGER AIRBAG INDICATOR SWITCH ............................................................ 22 C E-CALL AND I-CALL SWITCH .................................................................................... 24 D SUNROOF SWITCH ................................................................................................... 26 E FASCIA SWITCHES.................................................................................................... 28 6 WIRELESS HARGING .......................................................................................................... 31 7 HEAD UP DISPLAY (HUD) ................................................................................................... 38 8 SURROUND VIEW SYSTEM (SVS) ................................................................................. 41 A SURROUND VIEW SYSTEM DETAILS ...................................................................... 41 B SVS INPUT OUTPUT BLOCK DIAGRAM ................................................................... 56 C SURROUND VIEW SYSTEM COMPONENTS REMOVAL.......................................... 57 D TROUBLESHOOTING ................................................................................................ 62 E TROUBLESHOOTING CHART ................................................................................... 64 F CAMERAS CALIBRATION .......................................................................................... 65 G DO’S AND DON’TS WHILE PERFORMING CALIBRATION ....................................... 66
ELECTRICAL
ELECTRICAL 1 1. INSTRUMENT CLUSTER FEATURES Dynamic and monitoring information (e.g. fuel level) to which the driver should respond, is indicated in the instrument cluster. The Instrument Cluster has following features: Analogue Gauge : Speedometer, Tachometer and Fuel gauge Bar graph: Engine coolant Temperature (as a part of LCD display), Fuel gauge LCD Display : Clock, Odometer & Trip meter (A & B) Tell tales Mode & Set switches Instrument Cluster
ELECTRICAL 2 CIRCUIT DIAGRAM
ELECTRICAL 3 PIN DETAIL PIN. NO. DESCRIPTION 1 BATTERY SUPPLY INPUT 2 HIGH BEAM INPUT (PP) 3 HARWIREDWAKEUP 2 (PP) 4 BATTERY GROUND 5 LIN (PP) 6 ECO MODE OUTPUT 7 SEATBELTSWICHDRVRSIG 8 IGNITION INPUT 9 IMMOBILIZER SIG 10 PWM WIRELESS CHARGER IN 11 FUEL SENDER 1 INPUT-MAIN SIDE 12 FUEL SENDER 2 INPUTTRANSFER SIDE 13 SIGNAL GROUND 1-FUEL SENDER 14 OUTSIDE AIR TEMPERATURE 15 SIGNAL GROUND 2-OAT 16 STEERING SWITCH INPUT PIN. NO. DESCRIPTION 17 ENGINE OIL PRESSURE SWITCH INPUT (PP) 18 BATTERY CHARGE TELLTALE INPUT 19 PARK BRAKE TELLTALE INPUT 20 BRAKE FLUID TELLTALE INPUT 21 PARK BRAKE REDUNDANT INPUT 22 VEHICLE CAN H 23 VEHICLE CAN L 24 SPARE DIGITAL INPUT 3 (PP) 25 DIAGNOSTIC CAN H 26 DIAGNOSTIC CAN L 27 SPARE PWM OUTPUT 1 (PP) 28 HARD WAKE UP INPUT 1 (PP) 29 PRND PWM OUTPUT 30 SPARE PWM OUTPUT 3 (PP) 31 SPORTS LED OUTPUT 32 SPARE PWM OUTPUT 2 (PP)
ELECTRICAL 4 BASIC ELECTRICAL SPECIFICATIONS: SR.NO. PARAMETERS SPECIFICATIONS 1 Nominal Voltage 13.5 V DC 2 Operating Voltage range 8 to 16 V DC 3 Test voltage 13.5 V DC 4 Boot-up time < 0.5 secs. 5 Operating Current 2 Amps. Max. @ all loads ON 6 Sleep mode (Ignition off) current < 1mA 7 Operating Temperature −30°C to +70°C 8 Storage Temperature −40°C to +85°C
ELECTRICAL 5 REMOVAL OF INSTRUMENT CLUSTER: WARNING Remove the key from key barrel. This is necessary to ensure proper initialization of Instrument Cluster Parameters like Odometer value learning from Immobilizer and DTCs in other ECUs against Instrument Cluster. Removing Instrument Cluster with Key IN is strictly prohibited otherwise it will corrupt the odometer value. 1. Remove cluster hood gently from its position by using screw driver. 2. Remove steering wheel. (Refer “Removal & refitment of steering wheel" from Steering Section.) 3. Remove steering nacelle Lower. (Refer “Removal & Refitment of steering nacelle" from Steering Section.) 4. Lower steering column from top mounting to access lower mounting of Instrument cluster. (Refer Steering section). 5. Loosen the lower mounting screw of the instrument cluster. 6. Loosen the mounting screw of the instrument cluster cover 7. Now remove the upper mounting screws of the instrument cluster. 8. Remove Instrument cluster electrical connections. 9. Remove Instrument cluster REFITMENT Follow the procedure in reverse order for fitment. WARNING Swapping to analyze cluster defect: It is strictly prohibited to swap clusters for defect analysis from vehicles or from available stock. Due to immobilizer Odometer learning strategy, cluster odometer value will change permanently to a higher value. For defect analysis, use Diagnostics Tool or ETC (Engineering Test MODE
ELECTRICAL 6 2. TELL TALES TELL TALES COLOR INDICATOR REMARK Turn Signal Green One of these symbols illuminates when the turn indicators is switched ‘ON’. Turn signal lamps can be operated only when the ignition supply is ‘ON’ and by using the turn indicator switch on the combi-switch. The direction indicator arrow (LHS) and (RHS) on the instrument cluster flashes along with external indicator lights as selected. Both telltales will blink simultaneously when Hazard switch is pressed. Tick-Tock sound will be given when any one or both the telltales are ON. High Beam Blue Illuminates when the high beam head bulbs are switched ON or flashed. LV Battery charging Red This symbol lights up when the ‘IGN’ is turned ‘ON’ and should go ‘OFF’ after the engine start. If it remains ‘ON’ while the engine is running, it indicates that the battery is not getting charged. Switch off all unnecessary electrical equipment and get the problem attended at TATA authorized Service center. Park Brake cum Low Brake Fluid/ABS or EBD Malfunction. Red This indicator comes ‘ON’ for approximately 4 seconds when ignition is turned 'ON' and goes ‘OFF’. If it remains ‘ON’, it may indicate: 1. Brake fluid level is low. 2. Parking brake is applied. It shall go ‘OFF’ when it is released. 3. Fault in ABS / EBD (Electronic Brake force distribution) system ABS Indicator Amber Illuminates momentarily when ignition is switched ‘ON’ once vehicle is cranked, it goes OFF. Illuminates continuously if there is any malfunction in ABS. Normal braking system will be operational without assistance of ABS. Contact TATA MOTORS Authorized Service Centre urgently. Airbag Indicator Red The air bag warning symbol illuminate for approximately 4 seconds when the ignition is turned ‘ON’ and goes ‘OFF’. Warning: If it remains ‘ON’ or blinks, Get the problem attended to at TATA authorized Service center. Driver Seat Belt Indicator Red Seat belt warning indicator comes ‘ON’ for 4 seconds, when ignition is turned ‘ON’ irrespective of seat belt buckle status. If seat belt is not fastened then Telltale will be ON as initial warning with No audio chime. If seat belt remains unbuckled and vehicle speed goes above 15 kmph, Final Warning will start with audio chime for 90 seconds continuously. Note: Once the seat belt is fastened, the buzzer and
ELECTRICAL 7 TELL TALES COLOR INDICATOR REMARK warning indicator will go ‘OFF’. Seat belt audio alarm remains OFF when reverse gear is engaged. Co-Driver Seat Belt Indicator (Passenger) Red Seat belt warning indicator comes ‘ON’ for 4 seconds, when ignition is turned ‘ON’ irrespective of seat belt buckle status. If Co-Driver is present & its seat belt is not fastened then Telltale will be ON as initial warning with No audio chime. If seat belt remains unbuckled and vehicle speed goes above 15 kmph, Final Warning will start with audio chime for 90 seconds continuously. Note: Once the seat belt is fastened, the buzzer and warning indicator will go ‘OFF’. Seat belt audio alarm remains OFF when reverse gear is engaged. Rear Passenger Seat Belt Indicator Red Seat belt warning indicator comes ‘ON’ for 4 seconds, when ignition is turned ‘ON’ irrespective of seat belt buckle status. If Rear Passenger is present & its seat belt is not fastened then Telltale will be ON as initial warning with No audio chime. If seat belt remains unbuckled and vehicle speed goes above 15 kmph, Final Warning will start with audio chime for 90 seconds continuously. Note: Once the seat belt is fastened, the buzzer and warning indicator will go ‘OFF’. Seat belt audio alarm remains OFF when reverse gear is engaged. Rear Middle Seat Belt Indicator Red Seat belt warning indicator comes ‘ON’ for 4 seconds, when ignition is turned ‘ON’ irrespective of seat belt buckle status. If Rear Middle is present & its seat belt is not fastened then Telltale will be ON as initial warning with No audio chime. If seat belt remains unbuckled and vehicle speed goes above 15 kmph, Final Warning will start with audio chime for 90 seconds continuously. Note: Once the seat belt is fastened, the buzzer and warning indicator will go ‘OFF’. Seat belt audio alarm remains OFF when reverse gear is engaged. Rear Driver Seat Belt Indicator Red Seat belt warning indicator comes ‘ON’ for 4 seconds, when ignition is turned ‘ON’ irrespective of seat belt buckle status. If Rear Driver is present & its seat belt is not fastened then Telltale will be ON as initial warning with No audio chime. If seat belt remains unbuckled and vehicle speed goes above 15 kmph, Final Warning will start with audio chime for 90 seconds continuously.
ELECTRICAL 8 TELL TALES COLOR INDICATOR REMARK Note: Once the seat belt is fastened, the buzzer and warning indicator will go ‘OFF’. Seat belt audio alarm remains OFF when reverse gear is engaged. Immobilizer Red This symbol is of a system that disables vehicle starting if User do not use the original key. The user has to use original key for authentication and unlocking the car. Refer to Immobilizer section for details. Lamp Blink: Car is in immobilized condition when key is not inserted. Lamp OFF: Normal condition (Authenticated user) and vehicle shall start. Lamp ON: Problem with key/system. Get the problem attended to at TATA authorized Service center. Check Engine Lamp Amber This symbol lights up when the ‘IGN’ is turned ‘ON’ and shall go ‘OFF’ after 4 sec. Caution: Illuminates continuously if a fault arises in Engine Management System. Contact the TATA MOTORS Authorized Service Centre. Speed Limit lamp Amber When the vehicle speed cross 80 km/hrs., Speed limit Warning indicator turn ‘ON’ along with chime for every 2 minute one beep (Audible warning) When the vehicle speed is reduce below 75 km/hrs, Speed limit Warning Indicator and chime will get turns ‘OFF’ If vehicle speed crosses 120 km/hrs. Speed limit Warning indicator turn ‘ON’ along with chime for every 2 sec one beep (Audible warning) When the vehicle speed is reduce below 115 km/hrs., Speed limit Warning Indicator and chime will work as defined in point 1 EPAS Fault indicator Amber This feature monitors the Electric Power Steering system state to warn the driver in case of EPAS malfunction. Door Open Indicator Red This feature monitors the Door Input and warns Driver if any Door is Open Transmission Oil Temperature High Indicator Amber This feature monitors the transmission Oil temperature and warns the driver, if it is beyond an acceptable threshold. Note: Only applicable to AMT/DCT vehicles PEPS Indication (IGN & ACC) Green Amber This feature monitors the IGN and ACC status and Indicate to Driver if IGN is ON or ACC is ON. ESS Auto Start Lamp Green This feature monitors the ESS states and shows the current status of ESS.
ELECTRICAL 9 TELL TALES COLOR INDICATOR REMARK ESS Auto Stop Tell-tale Amber This feature monitors the ESS states and shows the current status of ESS. Cruise Control lamp Green This symbol lights up when the ‘IGN’ is turned ‘ON’ and shall go ‘OFF’ after 4 sec. The Cruise Control is used to indicate the status of cruise control system to the driver. Lamp ON indicates cruise control feature is present and it is activated. Malfunction Indication Bulb Amber Illuminates momentarily when ignition is switched ‘ON’ once engine is cranked, it goes OFF. It remains ‘ON’ if there is malfunction in Engine system. Engines performance deteriorates while it is running. Avoid high speeds and Contact TATA MOTORS Authorized Service Centre for rectification. Low Engine Oil Pressure Indicator Red When the Ignition is turned ‘ON’, this symbol lights up and goes ‘OFF’ as soon as the required engine oil pressure is developed after starting the engine. Warning: If the low oil pressure indicator does not glow or remains ‘ON’ with the ‘IGN’ ‘ON’ and engine is running, it indicates a fault in the electrical circuit / lubrication system. Take your car to a TATA Authorized Service Centre. Low Fuel Indicator Amber This symbol lights up when ignition is turned ‘ON’. The symbol lights up continuously if fuel level in the tank is low. Fuel needs to be filled immediately.. The warning light flashes to indicate a fault in fuel system. Contact TATA MOTORS Authorized Service Centre immediately. High Coolant Temperature Red This symbol lights up when the ignition is turned ‘ON’ and goes ‘OFF’ in approx. 4 sec. If the engine is overheating, this indicator blinks along with an audible buzzer at this stage, take the car to the nearest authorized Service outlet. This symbol blinks and audible buzzer sounds simultaneously when engine coolant temperature is more than normal. When engine coolant temp increases to hazardous level, telltale shall blink with RED color and it is accompanied by audio warning. Warning: Never remove the radiator pressure cap from the radiator when the engine is hot. Do not restart the engine until the problem has been duly attended.
ELECTRICAL 10 TELL TALES COLOR INDICATOR REMARK DRL indication Green This symbol illuminates when the Day Time Running lamp is ‘ON’. DRL are used for increasing the visibility of the vehicle to other driver during day time. To activate and deactivate DRL, keep the Ignition switch is ‘ON’ position and switch ON-OFF parking lamp twice within approx. 3 seconds. ESP Amber If continuously ON then ESP system is at fault condition, please take your vehicle to nearest TATA authorized service center at the earliest. Sport Mode Amber This symbol lights up when the Valid UID (User Identification Device) is not detected inside the Press Brake / Clutch (Used in PEPS Vehicles) Amber This symbol lights up when the ‘IGN’ is turned ‘ON’ and remains ON until user press clutch / brake to start the engine. This symbol is turns OFF when vehicle is in Cranking / Running Mode. Key Not Detected (Used in PEPS Vehicles) Amber This symbol lights up when the Valid Smart key is not detected inside the vehicle. HHC Fault indicator Amber In case of malfunction in HHC system this indicator will glow. It will remain ON until fault recovers. Position Lamp indicator Green Position Lamp Indicators used to display/Indicate the Position Lamp to Driver
ELECTRICAL 11 2. FUSE AND RELAY BOX DETAILS CHECKING FUSES If any electrical unit in the vehicle has stopped functioning, fuses should be checked first. A blade type fuse has test taps provided to allow checking of the fuse itself without removing it from the fuse block. The fuse is okay if the test light comes on when its one lead is connected to the test taps (one at a time) and the other lead of the test light is grounded. Remember to turn the ignition switch to ON to ensure all circuits are live. CAUTIONS IN EVENT OF BLOWN FUSE When a fuse is blown, there are two probable causes. One is that it is blown due to flow of current exceeding its rating. The other is that it is blown due to repeated on/off current flowing through it. Which of these two causes were responsible for the fuse to be blown can be determined by visual check as described below. 1. Fuse blown due to current exceeding rating The illustration shows the state of a fuse blown due to this cause. In this case, do not replace the fuse with a new one quickly since a current heavy enough to blow the fuse has flowed through it. First, check the circuit for shorts and check for abnormal electric parts. After correcting shorts or replacing parts, use only a fuse of the same capacity as a replacement. Never use a fuse of larger capacity than the original fuse. If a larger capacity fuse is used, electric parts or wiring could be damaged, or could start a fire. 2. Fuse blown due to repeated turning current on and off: The illustration shows the state of a fuse blown due to repeated current on/off. Normally, this type of problem occurs after a fairly long period of use and is less frequent than above. In this case, simply replace with a new fuse of the same capacity. CHECKING RELAYS 1. By using a relay, a heavy current can be turned on and off by a switch using much less current. For example, in the circuit shown here, when the switch is turned on (closed), current flows to the coil of the relay. Then, its contact is turned on (closed) and the light comes on. The current flowing through the switch is much less than that for the light. 2. Relays may be classified as the normally open-type or the normally closed-type, depending on their contact construction. NOTE: The De-energized state means that no current is flowing through the coil. The energized state means that current is flowing through the coil.
ELECTRICAL 12 (a) The normally open-type When a normally open relay as illustrated here is checked, there should be no continuity between terminals 30 and 87 when the relay is deenergized. There should be continuity between terminals 30 and 87 when battery voltage and ground are applied to terminals 85 and 86. The relay condition is determined by this check. NOTE Check the relay in both condition, i.e. energized and not energized (b) The normally closed-type When a normally closed relay as illustrated here is checked, there should be continuity between terminals 30 and 87 when the relay is deenergized. There should be no continuity between terminals 30 and 87 when battery voltage and ground are applied to terminals 85 and 86. The relay condition is determined by this check. NOTE: Check the relay in both conditions, i.e. Energized and not energized. (c) The NO NC (Changeover) type It has 2 relay out pins. One will be in contact in the changeover state as in NC relay. When it is energized it brakes the NC contact and connect the other output pins.
ELECTRICAL 13 A. FUSE AND RELAY BOX: LAYOUT LOCATIONS B. BATTERY MOUNTED FUSE BOX Battery Mounted Fuse Box Fuse No. Function Fuse Rating PF1 STARTER MOTOR 200 A PF1 STARTER MOTOR WARNING: If fuse box cover is removed for any reason, it should be refitted properly in its original position.
ELECTRICAL 14 C. ENGINE FUSE AND RELAY BOX This fuse box is directly connected to Battery Positive terminal through Battery Mounted Fuse box and Bus-bar structure is used in this fuse box. NOTE The fuse box layout is for reference purpose only. Please refer the sticker provided inside the fuse box cover. Fuse box Sticker layout Fuse Puller and Spare Fuses location inside Engine Compartment Fuse box: Fuse No. Function Fuse Rating F0 - - F1 COCKPIT F/B SUPPLY 60A F2 RADIATOR FAN-1 40A F3 STARTER SOLENOID BATT 25A F4 H/L HIGH BEAM 15A F5 FUEL PUMP BATT 15A F6 - - F7 H/L LOW BEAM 15A F8 - - F9 F9-GLOW PLUG / DCT ECU 60A/30A F10 EPAS 60A F11 RADIATOR FAN-2 40A F12 UNDER BONNET F/R BOX 50A F13 EMS BATT 10A F14 COMPRESSOR 10A F15 ABS ECU BATT 25A F16 HORN BATT 15A F17 BRAKE LAMP BATT 10A F18 ABS PUMP 40A F19 INTERIOR F/B BATT 60A F20 IGNITION LOAD 60A F21 IGNITION COIL 15A F22 - - F23 - - F24 ABS ECU IGNITION 5A F25 - - F26 - - F27 EMS RELAY COILS & SENSORS 15A F28 EMS ECU SUPPLY 20A F29 EMS INJECTOR 10A F30 FRONT WIPER MOTOR 20A F31 - - F32 STARTER MOTOR FEEDBACK 5A F33 - - F34 - - F35 REVERSE LAMPS/BRAKE SWITCH 10A F36 - - F37 - - F38 - -
ELECTRICAL 15 Fuse No. Function Fuse Rating R1 IGNITION RELAY 40A R2 EMS RELAY 40A R3 RADIATOR FAN FAST RLY1 40A R4 - - R5 - - R6 FRONT WIPER RLY 20A R7 RADIATOR FAN SLOW RLY 20A R8 INT. WIPER ON/OFF RLY 20A R9 DUAL HORN RLY 20A R10 - - R11 HEAD LAMP LOW RLY 20A R12 HEAD LAMP HIGH RLY 20A R13 STARTER RLY-1 20A R14 STARTER RLY-2 20A R15 AC CLUTCH RLY 20A R16 FUEL PUMP RLY 20A R17 - - R18 - - R19 - - R20 - - REMOVAL 1. Remove the Battery. (For procedure, refer Battery removal process in Electrical section.) 2. Remove the top cover of fuse box. 3.Remove the mounting bolt of the fuse frame assembly. 4.Gently pull out the fuse frame and disconnect all the electrical connections. 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. FITMENT For fitment follow reverse procedure of the removal.
ELECTRICAL 16 D. CABIN FUSE AND RELAY BOX This fuse box is part of Cabin wiring harness. For details refer the below fuse box sticker fitted on dashboard inside the Cover Steering Column. For other pin out details of fuse box refer the power distribution II circuit schematics. LOCATION Behind Cover Steering Column CABIN FUSE AND RELAY BOX DETAILS Fuse No. Function Fuse Rating F1 CLUSTER 5A F2 BLOWER MOTOR 30A F3 PEPS/ESCL ECUBATT 10A F4 HEATED REAR SCREEN BCM 25A F5 BCM2- BASE/MID BCM 20A F6 WW ANTI-PINTCH 25A F7 RPAS/TELEMATICS IGN/DUST SENSOR 5A F8 IGN FUSE-2 10A F9 IMMOB/EPAS/PEPS/G SL-IGN 5A F10 HVAC/FATC 10A F11 RESTRAINTS CONTROL MODULE 10A F12 ACC BATT/OBD 15A F13 TRANSIST/INFOTAINM ENT 7" 20A INFOTAINMENT 10.25" 30A F14 TAILGATE RELEASE 10A
ELECTRICAL 17 F15 CDL 15A F16 BCM3-MID BCM 20A F17 RELAY COILS 5A F18 IMMO BATT 5A F19 BCM1-BASE/MID BCM 20A F20 PEPS/BLOWER RLY 5A ACCESSORIES FUSE 5A F21 REAR USB A TYPE 5A F22 MIRROR ADJUST MOTOR/WIRELESS CHARGING(ACC) 5A F23 POWER SOCKET-1 15A F24 TELEMATICS BATT 5A KEY IN 5A F25 VENTILATED SEAT DDR/CO-DR 10A F26 SUNROOF 20A F27 FRONT USB C TYPE 5A F28 - - F29 WIRELESS CHARGING(IGN) 5A F30 REAR WIPER RLY 10A E. FUSE AND RELAY REPLACEMENT Removal Fuse box is located behind the glove box. To access the fuse box, Cover Steering Column needs to be removed first. Remove 1. Remove the Cover Steering Column (refer for body draft for removal) 2. Remove the mounting screw and Pull out the fuse from fuse box modules from available cutout as shown below. 3. If fuse is blown, replace with same rating fuse from spare fuses provided in engine compartment fuse box 4. Fit back the glove box by following reverse procedure. 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. CIRCUIT SCHMATICS Refer Book 3 DTCs Refer Book 2
ELECTRICAL 18 3. USB/TYPE-C PORT USB External memory devices like memory sticks / Pen Drives, I-Pods can be connected for playing music tracks stored in these devices through the vehicles music system. TYPE - C CHARGER C Type USB is used for fast charging of mobiles which are having C type interface. LOCATION USB and AUX ports are fitted below the Fascia switch. PINOUT DETAILS USB Connector PIN DESCRIPTION 1 VCC - 2 USB2 D - 3 USB2 D + 4 GND TYPE - C connector PIN DESCRIPTION 1 BATT +VE - 2 BATT -VE (GND) REMOVAL 1. Remove the Infotainment unit and disconnect electrical connection of the USB/Type C port unit. (Refer Infotainment removal procedure). 2. Gently pry out the module from the cutout. 3. Remove the USB/ Type C port unit. FITMENT For fitment follow the removal procedure in reverse.
ELECTRICAL 19 4. INFOTAINMENT SYSTEM Infotainment system is provided on the center console. To operate this system, please refer infotainment manual, which is provided along with the Owner’s Manual. INFOTAINMENT DISPLAY 10.25 PINOUT DETAILS
ELECTRICAL 20 4 POL CONNECTOR DETAILS PIN DESCRIPTION 1 DISP BATT 2 HARD WIRED WAKEUP 2 3 NC + 4 DISP GND LVDS Connector PIN DESCRIPTION 1 LVDS CONNECTOR SPECIFICATIONS: Operating voltage: 8-16V Test voltage: 13.5V Operating current: 1A Maximum current: 2A Operating temperature: -30ºC - 70ºC Storage temperature: -40ºC - 85ºC Leakage current: 0.1mA REMOVAL 1. Carefully pry out Display cap. 2. Remove the mounting screw of HMI Display. 3. Disconnect the electrical connection. FITMENT For fitment follow the removal procedure in reverse.
ELECTRICAL 21 5. SWITCHES A. PASSENGER AIRBAG (PAB )SWITCHES A. FUNCTION Passenger Airbag switch is used to activate and de-activate the passenger Airbag in the Vehicle. The Switch located on the left side of the dashboard. This switch can be accessed once the co-driver side door is opened. PAB Switch ON: When an adult is seated in the front passenger seat, ensure that PAB switch is turned to ‘ON’ position. This will ensure that the passenger airbag is operational in the event of a collision. PAB Switch OFF: If it required to fit a child restraint on the front passenger seat, ensure that PAB switch is turned to ‘OFF’ position. This will ensure that the passenger airbag must be deactivated. This switch can be operated by using ignition /Remote Key LOCATION CONNECTOR DETAILS PIN NO DESCRIPTION 01 Feed (From Airbag) 02 On state LED in PAB Indicator 03 Return (To Airbag ECU) 04 Ground Switch Schematic
ELECTRICAL 22 REMOVAL 1. Remove the left side cover of the dashboard. 2. Remove switch wiring Harness connector. 3. Remove the Switch. REFITMENT 1. Replace the new switch. 2. Connect Vehicle side switch connector. 3. Press and snap fit the switch. 4. Refit the left side cover of dashboard. B. PASSENGER AIRBAG (PAB) INDICATOR Passenger Airbag operational status indicator is used to notify occupant whether Passenger Airbag is activated (ON) or deactivated (OFF) in vehicle. LOCATION PAB indicator is located on roof panel near inner rear view mirror.
ELECTRICAL 23 PAB Indicator ON: When the PAB switch is turned to ‘ON’ position to activate the airbag, ‘ON symbol & text’ will illuminate in amber color. PAB Indicator OFF: When the PAB switch is turned to ‘OFF’ position to deactivate the airbag, ‘OFF symbol & text’ will illuminate in amber color. CONNECTOR DETAILS PIN NO DESCRIPTION 01 PAB Switch 02 ECU 03 Ignition Supply 04 Ground SWITCH SCHEMATIC REMOVAL 1. Remove Overhead console Bezel 2. Remove PAB indicator wiring Harness connector. 3. Remove the Switch
ELECTRICAL 24 REFITMENT 1. Replace the new indicator. Connect Vehicle side switch connector 2. Press and snap fit the switch. 3. Refit the overhead console C. E-CALL AND I-CALL SWITCH FUNCTION I-Call switch: This switch is used to connect the related services when pressed. I -Call switch is mounted on overhead console near roof Lamp. E-Call (SOS) Switch: This switch is used to connect the related services when pressed. E – Call & I call switch mounted in overhead console near the roof lamp. LOCATION I-call, E-Call switch mounted on the roof console
ELECTRICAL 25 CONNECTOR DETAILS PIN NO DESCRIPTION 01 Digital Input Wakeup 02 Analog Input Diagnostic 03 Analog Input 04 Green On Stage +VE 05 Red On Stage +VE 06 Parking illumination output(+Ve) 07 Common Ground switch & Status indicator 08 Symbol parking illumination Ground CIRCUIT DETAILS REMOVAL 1. Disconnect the negative terminal of battery Remove Overhead console Bezel. 2. Remove I-Call/E-Call switch wiring Harness connector. 3. Pry out the I-Call/E-Call Switch.. REFITMENT Follow the reverse procedure for fitment.
ELECTRICAL 26 D. SUNROOF SWITCH FUNCTION This switch is used to open, close, till up & tilt down the sunroof as and when required with switch intended operation. 1. Pull the knob away from the windshield to open the sunroof. It will be having two detents. 2. Push the knob towards the windshield to close the sunroof. It will be having two detents. 3. Press at the center of the knob for tilt up/down function. Sunroof switch mounted in overhead console near roof lamp. NOTE: For additional details refer sunroof section of owner’s manual. For additional details refer sunroof section of owner’s manual. LOCATION WORKING CONNECTOR DETAILS PIN NO DESCRIPTION 01 PAB Switch 02 ECU 03 Ignition Supply 04 Ground
ELECTRICAL 27 CIRCUIT DETAILS REMOVAL 1. Disconnect the negative terminal of battery Remove Overhead console Bezel. 2. Remove sunroof switch wiring Harness connector. 3. Pryout the sunroof Switch. REFITMENT Follow the reverse procedure for fitment.
ELECTRICAL 28 E. FASCIA SWITCHES (IF APPLICABLE) 1. 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’. 2. CENTRAL LOCK/UNLOCK: To open the door, press the Lock/unlock door switch located on the fascia switch 3. 360° CAMERA (SVS) SVS (Surrounding View system) function newly added in fascia the switch at 4th location. The 360°surround view system is a parking assist system which facilitates parking by helping the driver see objects around the vehicle. SVS knob is non latch cable and to use CDL function, we have to press knob at (4th location) from fascia switch. The Surround parking view comes on infotainment after pressing the “SVS” button in Fascia system which also shows the view when you’re moving forward 4. IDLE STOP START SWITCH (ISS) (IF EQUIPPED) Your car is equipped with push Button on right side of the dashboard to Enable OR Disable ISS function. LOCATION CONNECTOR DETAILS PIN NO DESCRIPTION 01 PARKING + VE 02 DRIVE MODE SIG IN 03 NC IND IN 04 FRONT FOG SIG IN 05 FRONT FOG IND IN 06 REAR FOG SIG IN 07 REAR FOG IND IN 08 ESS OFF SIG IN 09 ESS OFF IND IN 10 NA 11 DRIVE MODE SIG OUT 12 NC IND OUT 13 FRONT FOG SIG OUT 14 FRONT FOG IND OUT 15 REAR FOG SIG OUT 16 REAR FOG IND OUT 17 ESS OFF SIG OUT 18 ESS OFF IND OUT 19 NA 20 PARKING GROUND
ELECTRICAL 29 CIRCUIT DETAILS
ELECTRICAL 30 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 REFITMENT Follow the reverse procedure for fitment. 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 31 6. 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 32 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 33 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 34 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 35 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 36 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 37 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 38 7. HUD (HEAD UP DISPLAY) The head up display is a transparent display where important information of cluster is projected. The HUD screen can be seen from driver’s front position. LOCATION HUD (Head Up Display) are fitted top of the Instrument Cluster Hood. PINOUT DETAILS PIN PIN DETAILS 1 IGN 2 IMAGE UP 3 IMAGE DOWN 4 ON/OFF 5 B+ 6 GND 7 CAN_H 8 CAN_L REMOVAL 4. Remove the Instrument Cluster Hood. 5. Loosen and remove the 4 mounting screw and take out 6. Disconnecct the wiring harness and Remove the HUD (Head Up Display) Assy. FITMENT For fitment follow the removal procedure in reverse.
ELECTRICAL 39 CHUD THEMES AND ADJUSTMENT SETTINGS Startup screen Theme1-Minimum Speed, TBT, DTE Theme2- Standard Speed, TBT, Low Fuel, Door Open Status Theme3-Maximum Speed, TBT, Low Fuel, Door Open Status, DTE Adjustment screen Brightness and Display Height
ELECTRICAL 40 CHUD SWITCH OPERATION 1. HUD Switch: a. Short press – Short press of this switch will change Themes on CHUD display. b. Long press – - Long press for more than 1.5 sec CHUD must ON or OFF & Combiner glass must Open or Close respectively. 2. UP switch: a. Short press – - Short press will activate Height adjustment. - Combiner angle will be adjusted to move display UP / DOWN based on short press of UP or DOWN buttons. b. Long press – - Long press will activate Brightness adjustment. - Once user entered in Brightness adjustment, user can use UP / DOWN buttons short press to adjust setting to Maximum / Minimum. 3. DOWN switch: a. Short press – - Short press will adjust Brightness or Height setting (whichever setting is currently active), to its minimum limit. Height adjustment: (To activate this setting – short press UP/DOWN button) 1. The limits are -10 to +10. 2. With UP button short press, display must move UP. 3. With DOWN button short press display must move DOWN. Brightness adjustment: (To activate this setting – Long press UP button for 5 sec) 1. The Limits are 0 to +20. 2. With UP button short press brightness must increase. 3. With DOWN button short press brightness must decrease.
ELECTRICAL 41 8. SURROUND VIEW SYSTEM (SVS) (IF EQUIPPED) Surround view system displays the surroundings around the vehicle to the driver for safe and comfortable drive. SVS assists the driver while reversing and maneuvering the vehicle at lower speeds. A. SURROUND VIEW SYSTEM DETAILS I. SVS FUNCTION WORKING PROCEDURE • SVS system shall be activated either by a hard switch, Soft switch or by engaging the reverse gear. • Once the system gets activated the SVS will start to display the default view along with top view and different view options which are appeared on the right side on the display. • User can interact with the system to switch to all other modes of view through the options available on infotainment display II. CAMERA LOCATION The Surround view system has the following features 1. 2D view 2. 3D view 3. Front corner view 4. Rear corner view 5. Full view 6. Settings 7. Cancel icon
ELECTRICAL 42 III. ACTIVATION OF SVS The function is activate when the following steps are performed 1. Surround view hard switch is pressed. 2. Surround view soft switch is pressed. 3. The shift lever is in D (Drive), N (Neutral) or R (Reverse) and vehicle speed is under 17Kmph and surround view soft/hard switch is pressed. 4. Engage the reverse gear and vehicle speed is below 17Kmph. IV. DEACTIVATION OF SVS SVS function is deactivate when one of the following step is perform. 1. Surround view hard switch is pressed again 2. Surround view soft switch(cancel icon) is pressed again 3. Vehicle speed is more than 17Kmph 4. Disengage the reverse gear NOTE • When vehicle speed is more than 17Kmph, the SVS function will turn off. The function will not automatically turn on again, even though vehicle speed gets below 17Kmph. Press the button again, to turn on the function. • When vehicle speed is more than 17Kmph SVS screen will be switch to only rear view during reverse gear. • During vehicle speed is more than 17Kmph and driver activate through soft switch/hard switch rear view shall display to user.
ELECTRICAL 43 V. SURROUND VIEW SYSTEM FEATURES The Surround view system has the following features 2D view 3D view Front corner view Rear corner view Full view Settings Cancel icon VI. 2D VIEW By selecting 2D Icon which is available on the right corner side of the infotainment screen, cameras provide about 360 degree 2D top view of vehicle's surrounding. In 2D top view mode 4 camera icons will be present around the model car image to switch to different sides of view. The different 2D views are as follows.2D Top view + Front view. 1. 2D Top view + Front view 2. 2D Top view + Rear view 3. 2D Top view + Left views 4. 2D Top view + Right view Fig 1.a. 2D top + front view Fig 1.b. 2D top + right view
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