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1.2L REVOTRON ENGINE
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1.4 ENGINE TESTS AND MAINTENANCE
A. PRELIMINARY INSPECTION
NOTE
It is always advisable to first use the
diagnostic tool and rectify the electrical
faults, before commencing with mechanical
repairs/ troubleshooting. Refer ENGINE
MANAGEMENT SYSTEM section in this
group for procedure.
GENERAL
1. Check for leakage of Oil, Fuel, and Coolant.
2. Check for overheating of engine.
3. Check for unusual smoke.
4. If there is any fault in the Engine
Management system
(EMS)
then the MIL
indicator in the instrument cluster will come
ON. In such a case connect the diagnostic
tester.
(For procedure refer EMS section).
Before proceeding to carry out actual
reconditioning of engine, it is desirable to have a
preliminary inspection of engine to ascertain
whether an engine reconditioning is necessary
and if so, to what extent.
Most common reasons for which engine is
reconditioned are
1. Loss of power.
2. Excessive engine oil consumption.
3. Extremely low engine oil pressure.
4. Mechanical failures.
To know exact reason and general condition of
engine, proceed as follows
i. Loss Of Power
Loss of engine power may be due to
a. EMS is in limp-home mode due to some
critical fault.
b. Clogged air filter / exhaust passage /
catalytic converter.
c. Defective fuel system
d. Clutch slippage
e. Brake binding
f. Turbocharger
ii. EMS is in limp-home mode
If the EMS detects some major fault in the
system it switches to limp-home mode, where it
runs at a reduced torque. Connect the diagnostic
tester and check if any faults are present in the
Engine EMS, if found rectify them.
(For details
refer Engine Management Section)
iii. Clogged Air filter / Loss of Charge Air
Pressure/ Choked Exhaust Silencer /
catalytic converter
Loss of power with unusual black smoke from
engine exhaust indicates lack of air or low air
charging pressure to engine cylinders. Clean air
filter & inter cooler fins. Check all joints for air
leakage. If power loss with black smoke is still
felt, check exhaust silencer for choking. Clean
and replace silencer if necessary. Check for kink
formation in exhaust piping.
iv. Defective Fuel System
Check the Fuel system for fuel flow. If the flow is
restricted change the filter.
v. Clutch Slippage
Clutch slipping can be confirmed by any of the
following two methods:
Method 1:
1. Drive the vehicle in 1st or 2nd gear at a
minimum speed corresponding to that gear.
2. With the accelerator pedal in a fully pressed
position, gradually apply brake with left foot.
3. If the engine stalls, the clutch does not slip.
Method 2 :
1. Drive the vehicle with weight equal to GVW in
3rd gear on a level ground.
2. Allow the speed to drop upto 15kmph.
3. Now press the accelerator pedal fully.
4. With slipping clutch the car will not pick up
speed, also a clutch burning smell could be
noticed.
5. If this does not occur, the clutch does not
slip.
vi. Brake Binding
During driving apply brakes number of times and
then shift gear to neutral position and check free
rolling of vehicle. Check brake drums/brake discs
for overheating and if necessary jack up the
vehicle and check wheels for free rotation.