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1.5L REVOTORQ 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
Check for leakage of Oil, fuel, and Coolant.
Check for overheating of engine.
Check for unusual smoke.
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.
B. ENGINE TESTS
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 / clogged intercooler fins
/loss of charge air pressure / choked exhaust
passage / Closed Coupled Catcon (CCC).
c. Loss of engine compression
d. Defective fuel system
e. Clutch slippage
f. Brake binding
g. Turbocharger
a.
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)
b.
Clogged Air filter/Loss of Charge Air
Pressure/ Choked Exhaust Silencer /
Closed Coupled Catcon (CCC)
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.
c.
Checking Engine Compression Pressure
If loss of power is not on account of defective
fuel system, lack of air, choked exhaust
system, clutch slipping and brake binding,
check engine compression as follows.
Warm up engine preferably by road drive to
get a coolant temperature of about
80ºC.
Stop the engine.
Remove the air filter.
Remove the injector back-leak pipes and
high pressure pipes from rail to injector
.Disconnect rail pressure sensor.
Plug the common rail outlet with suitable
caps.
Remove all injectors.
Fit adapter
(Part no 2871 5890 07 01
)
in
place of one injector.