SERVICE MANUAL MOTORS
Developed by: Technical Literature Cell. Release Date : Aug 2017/ First Edition. The information provided in this manual is based on the latest product information available at the time of publication. . C Copyright 2017 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. 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 NEXON. 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. For ease of use, this workshop manual is divided into 3 volumes, comprising several sections. Each aggregate has a separate section. THE BOOK– 1 CONTAINS General Engine (Petrol & Diesel). Clutch Transaxle Driveshaft Suspension Steering Brakes Body Electrical HVAC FATC SRS THE BOOK– 2 CONTAINS Diagnostic Trouble Shooting Codes (DTC) List of All ECU’s THE BOOK– 3 CONTAINS Circuit Schematics
INDEX SR. NO GROUP 1 GENERAL 2 PETROL ENGINE 3 DIESEL ENGINE 4 CLUTCH 5 TRANSAXLE 6 DRIVESHAFT 7 SUSPENSION 8 STEERING 9 BRAKE 10 BODY 11 ELECTRICAL 12 HVAC 13 FATC 14 SRS
GENERAL GENERAL
GENERAL INTRODUCTION This manual provides the information on good workshop practices and technical specification It also provides information on Service Schedule required for TATA NEXON. All maintenance work should be carried out as per the service Schedule chart.
GENERAL Contents 1.1. GOOD WORKSHOP PRACTICES AND SAFETY PRECAUTIONS ......................................................... 1 1.2. PRECAUTION FOR ELECTRICAL CIRCUIT SERVICE ........................................................................... 2 1.3. PRECAUTIONS OF COMMON RAIL SYSTEM (CR SYSTEM) ................................................................ 3 1.4. VEHICLE JACKING AND LIFTING POINTS............................................................................................. 5 1.5. JACK, AND TOOL BAG LOCATION ........................................................................................................ 6 1.6. NUMBERING SYSTEM .............................................................................................................................. 7 1.6.1. CHASSIS NUMBERING SYSTEM ................................................................................................... 7 1.6.1. AGGREGATE NUMBERING SYSTEM ............................................................................................ 9 1.7. CHASSIS TYPE AND SALES DESIGNATIONS ..................................................................................... 10 1.8. TECHNICAL SPECIFICATIONS (PETROL) ............................................................................................ 11 1.9. TECHNICAL SPECIFICATIONS (DIESEL) ............................................................................................. 14 1.10. VEHICLE DIMENSIONS......................................................................................................................... 17 1.11. RECOMMENDED LUBRICANTS & COOLANTS.................................................................................. 18 1.12. SERVICE AND MAINTENANCE............................................................................................................ 20
GENERAL 1 1.1 GOOD WORKSHOP PRACTICES AND SAFETY PRECAUTIONS: • Always ensure that all the repair / maintenance work carried out should be as per the instructions provided in the workshop manual. • Use protective clothing, apron, hand gloves, and safety shoes while working in the workshop. • Do not wear watch, rings and belt while serving the vehicle. • Keep your work area, equipment and tools clean at all times. • Make sure you use the proper tool for the job and use it the right way. The improper tool or its incorrect use can damage the part you are working on or cause injury or both. • Never keep the tools on the floor/vehicle. The tools should be kept in the tool box after use. • Cover fenders, seats, steering wheel and any other parts those are likely to get scratched/soiled before starting any service work. • While servicing the vehicle in engine running condition make sure that the gear shifting lever is in neutral position and parking brake is fully applied. Never run the engine without proper ventilation and adequate means of getting rid of exhaust gases. • Prior to removing or disassembling parts, they must be inspected carefully to isolate the cause for which the service is called for. • All the reusable dismantled components must be kept in clean enamel coated white tray sequentially in an orderly manner to facilitate their accurate and proper reinstallation. • Never reuse the parts like oil seals, gaskets, packing, O-rings, locking washers, split pins, self locking nuts and certain other parts. • Plug the ports / openings of aggregates such as Common rail / Injectors, HP Pump TMC, etc., whenever removed from the car. • For correct reinstallation of fuel lines / vacuum lines attach tag describing the correct positions • Make sure only the branded lubricants, coolant, corrosion protection coatings and sealants are used. • Check all the lines for leaks related to the systems like fuel, oil, coolant, vacuum, exhaust and brakes after servicing. • For vehicles equipped with high pressure fuel injection systems do not disconnect the fuel line between the injector and the fuel pump without releasing the fuel pressure, fuel can be sprayed out under pressure. Precaution for Catalytic Converter (Petrol Engine): Caution: If large amount of unburnt fuel goes into the converter, it may overheat and create a FIRE hazard. To prevent this, observe the following precautions: • Use only unleaded gasoline. • Engine compression checks should be carried out within the shortest possible time. • If necessary, then only conduct a spark jump test within the shortest possible time. • Do not run the engine when the fuel tank is nearly empty to avoid engine misfire and damage to catalytic converter. Precaution for Catalytic Converter (Diesel Engine): • The Catalytic converter should not be dropped from a height. If dropped, it should not be used. • Ensure exhaust system and catalytic converters are not blocked and free from obstruction. • Avoid parking of vehicle over inflammable materials, such as dry leaves; grass etc. as exhaust system is hot enough to initiate fire. • Avoid push start or tow-starting the vehicle. (Use jump leads) • Avoid long (not more than 10 seconds) repeat (not more than 3 times) starting of the vehicle. Investigate the cause for difficulty in starting and rectify the same. • Avoid long idling (to warm-up) if the engine is running rough, after a cold start. • Avoid switching “OFF” the ignition when driving down the hill. • Avoid fuel almost empty in the tank. • Avoid pre- coating / painting of Catalytic Converter.
GENERAL 2 1.2. PRECAUTION FOR ELECTRICAL CIRCUIT SERVICE: • Disconnect the negative cable of the battery while servicing the electrical parts that do not require battery power and insulate the negative terminal properly. • While removing the battery first disconnect the negative cable and then the positive cable. While reinstalling the battery, first connect the positive cable and then negative cable. • Be sure to turn the ignition switch off before disconnecting and connecting coupler to avoid electronic parts damage • Do not touch the electrical terminals of parts which use microcomputers (e.g. electronic control units like ECM etc.) to avoid damage to these parts from static electricity from your body • Always use the correct voltmeter, ohmmeter for taking measurement to avoid damage to the electronic control unit and sensors. • Make sure to insert the probe from wire harness side of the connector for taking measurement. • Make sure the connector halves are mating properly and terminals seating precisely in the connector body. • Dirt / corroded terminals result in improper contact. The terminals should be cleaned carefully. • Improper contact pressure between mating terminals disturbs the connectivity between them. • Replace the damaged connector body to avoid exposure of the terminals in case of inadequate contact pressure.
GENERAL 3 1.3 PRECAUTIONS OF COMMON RAIL SYSTEM (CR SYSTEM) Follow the below recommended cleanliness procedures before removal of any system components: This is to prevent dust entry in the system and to avoid damage to the precisely machined common rail system components: • Wash hands before the work. If necessary, wear new plastic gloves. • As soon as there is an opening into the system, it must be blocked using special cap. After removal and plugging, each component of the injection system must be stored in a new hermetically sealed bag. • All plugs / caps and packaging are disposable and should be discarded after single use. • •Before disconnecting the battery make sure that no data is required from the electronic control unit (ECU), as battery cable disconnection will erase any fault codes and idle / drive values held in the keep alive memory (KAM). It is not necessary to disconnect or remove electronic control modules. • Disconnect the battery negative cable. • Follow the cleanliness and safety instructions and use the correct tightening torques. • Once the engine stops wait for 5 min., and then start working on the CR system. Do not work on the injection system with the engine running. • After opening the injection circuit, it is strictly for-bidden to use any tools/ equipment made of a material which may cause a risk of shedding particles or fibers (wood, cloth, cardboard…). In the same way, the use of a blower, brush or bristles is banned because these tools are liable to intro-duce contaminants into the system. • Avoid cleaning of the injectors, even with an ultrasonic cleaner. • The packaging for the spare parts should be opened just before use. The special caps must not be removed until the final connection/installation. The plugs and bags must be discarded after use. • Any part dropped must not be used. Before in-stalling the injector, it is essential to ensure that the wells are clean. • Before connecting the harness, check the cleanliness of the connectors, particularly any fluids near electrical connections. • Before removing any CR components, vacuum external area with the help of vacuum cleaner to avoid possible contamination. Don’ts • HP pipes are one time use only avoid unnecessary removal and do not reuse. • Do not leave open inlets and outlets of CR components–Cap them immediately • Flushing of CR components should be avoided. • Do not remove battery, sensor & Actuator connections when key is ON • Do not spray water on the ECU • Sensor connections should not be removed un-necessarily • HP pipe lines should not be bent and force should not be applied. • Failed or broken CR components should not be used, leakage may cause injury • Don’t let ECU body touch any metallic part while the ECU is powered ON (Ignition key switched “ON”). • Never try to dismantle any engine part while the ECU is powered ON. • Don’t keep any sensor branch hanging /loose while assembly. Fix them properly using clips provided in W/H. • Don’t try to crank the engine without connecting any of the sensors. • Don’t remove any sensor /injector connector once fitted and locked properly. • Do not run the vehicle with Check Engine lamp ON. • Do not remove back-leak pipes unless the Injectors have to be removed. • Do not bleed the air by removing or loosening the HP pipes. • Do not start the vehicle if battery voltage is low. • The ECU gets tripped if the battery voltage is be-low 6 volts. Replace the battery and then start the engine. • Do not remove the rail unnecessarily. • Do not clean the Injectors with pressurized water. The injector is not designed to be washed with pressurized water. • Do not clean the HP pipes with compressed air, oil or water. Cleaning may dirt HP pipes and CR system. • Do not use any failed/ broken water Sedimenter /fuel filters, even if there’s no external sign of damage.
GENERAL 4 Do’s • Monitor battery voltage continuously – recharge battery if voltage drops below 10 Volts • Drain water from Sedimenter / filter at regular intervals • Fix the rubber cover to the ECU to prevent dust / moisture entry inside ECU. • EMS W/H to be properly routed as specified using clamps / clips and brackets. • Do check for any faults /malfunctioning in the sys-tem using diagnostics tool before cranking the engine (after any repair). • Do fix ECU connector branch properly while transporting engine. • If engine does not start check the respective fuses related to CR components. • When Injectors are replaced/Changed Injector IC values (IMA code) must be loaded correctly as per cylinder order. • Plug the port of Common rail system components whenever any pipe connections are removed. • Tighten the mounting nuts / cap nuts etc. only to the specified torque values. • Always remove the Injectors before dismantling the cylinder head. This is to avoid damage to the injector nozzle tips which protrude out of cylinder head. In case of HP pump removal handle the pump with proper care to avoid any damage to inlet pipe, venturi and connectors. Characteristics of the workplace All interventions on the injection system must be carried out in a clean workshop. This means that the workshop • Must be regularly cleaned to prevent the accumulation of dust. • Must not contain machine tools and welding equipment which may be capable of generating swaf or metallic or other particles. Entry into a dedicated repair workshop: • Room closed without air movement with clean surfaces from floor to ceiling. • Clean, smooth workbench or equivalent (stainless steel type, no wood, cardboard or paint). • No eating or smoking. General remarks The operators working clothes must be clean. This means that they must not carry dust or metal particles liable to contaminate the injection and must be manufactured from lint free, non flocking material to avoid contamination of the injection system by fibres. Safety recommendations • any intervention on the system • As a fuel spray can lead to heavy wounds, it is highly recommended : not to intervene on the system with engine running • Any intervention on the system must be achieved by qualified and trained agent. • Never start the engine if battery is not well reconnected. • Do not use the ECU metal box as a Ground. • Disconnect the ECU when using an arc welding station.
GENERAL 5 1.4 VEHICLE JACKING AND LIFTING POINTS: Make sure you follow the manufacturer’s instructions while lifting the car on two post lift. • Always ensure vehicle balance in service while applying two post lift to under body. • Care should be taken that the two post lift arm is not in contact with the bracket, brake or fuel pipes etc. • Before servicing, make sure to lock the lift after the vehicle is lifted up. • Following fig shows the front and the rear jacking points by two post lift JACKING POINTS Front and Rear jacking point USING THE FLOOR JACK: • Use the jacks at the locations as shown in the below. • Do not apply the jack against any part which may get deformed. • If front end or rear end of the vehicle is to be jacked ensure the wheels on ground and the parking brake is applied. Front jacking point Rear jacking point
GENERAL 6 TOWING THE VEHICLE: • For towing a car, the best way is to use a wrecker. Alternatively use a rigid tow bar. • Avoid using a flexible cable or rope as your car may crash into the car towing your car when it stops suddenly. • Switch ‘ON’ the hazard warning signals of both the cars to warn other road users. • Where possible, keeps the engine idling so that power steering assistance and brake vacuum are available. • Limit the speed to 20-30 Kmph. • In case of brake failure, use the parking brake to control the car. 1.5 JACK AND TOOL BOX LOCATION IN VEHICLE: Tool kit, tow hook, jack and spare wheel are provided in Tray below rear floor. 1. Tool kit 2. Tow hook 3. Jack 4. Spare wheel
GENERAL 7 1.6 NUMBERING SYSTEM: 1.6.1 CHASSIS NUMBERING SYSTEM Chassis number consists of 17 digits as – MAT 403071 9 N A 07231 MAT: Indicates produced in TATA Motors, India. Barrel 1: Chassis type, sales designation. Example 1) 627101 - TATA NEXON XE FITTED WITH 1.5 CRAIL 110PS BS4 DIESEL ENGINE, HVAC UNIT, EPAS, TRANSAXLE, DAB+PAB+ABS, 5 Nos. WHEEL RIMS, 5 Nos. 195/60 R16 RADIAL TUBELESS TYRES. W.B. 2498. SEATING CAPACITY 4+DRIVER. 2) 627201 - TATA NEXON XE FITTED WITH 1.2L TURBO 110PS BS4 PETROL ENGINE, HVAC UNIT, EPAS, TRANSAXLE, DAB+PAB+ABS, 5 Nos. WHEEL RIMS, 5 Nos. 195/60 R16 RADIAL TUBELESS TYRES. W.B. 2498. SEATING CAPACITY 4+DRIVER. Barrel 2: Indicates the year of production CODE YEAR G 1.1.2016 to 31.12.2016 H 1.1.2017 to 31.12.2017 J 1.1.2018 to 31.12.2018 K 1.1.2019 to 31.12.2019 L 1.1.2020 to 31.12.2020 M 1.1.2021 to 31.12.2021 N 1.1.2022 to 31.12.2022 P 1.1.2023 to 31.12.2023 R 1.1.2024 to 31.12.2024 S 1.1.2025 to 31.12.2025 T 1.1.2026 to 31.12.2026 V 1.1.2027 to 31.12.2027 W 1.1.2028 to 31.12.2028 X 1.1.2029 to 31.12.2029 Barrel 3: Indicates the plant location CODE PLANT LOCATION 0 WC-1, Lucknow 1 Jamshedpur - I 2 Jamshedpur - II 3 Jamshedpur - III 4 WC-2, Lucknow 5 EC-1, Lucknow 6 Dharwad - I 7 D - Block, Pune 8 H - Block, Pune 9 J - Block, Pune, First Assy Line A EC - 2, Lucknow B IBF - 1, Lucknow C APD, Chichwad D Pantnagar - V E Pantnagar - VI
GENERAL 8 CODE PLANT LOCATION F Dharwad - II H Pantnagar - VII J Pantnagar - IV K Sanand L TML, Ranjangaon - II M Lucknow - MASOP N J - Block, Pune, Second Assy Line P K - Block, Pune, First TCF Line R J14 - Block, Pune S J13 - Block, Pune T TML, Ranjangaon - I U E9 - Block, Pune V Pantnagar - I W K - Block, Pune, Second TCF Line X Singur Y Pantnagar - II Barrel 4: Indicates the Month of Manufacturing. CODE MONTH A January B February C March D April E May F June G July H August J September K October N November P December Barrel 5: Indicates cumulative serial number of chassis produced during the year at each plant location. Serial Number:-This starts with 00001 on every 1st Jan (calendar year) at each Plant location. After 99999 will start with A0001 and continue till Z9999. Letters I, O, Q are not used in this serial numbering system.
GENERAL 9 1.6.2 AGGREGATE NUMBERING SYSTEM: ENGINE: Numbering XXXXXX XX X X XX X XXXXX 1 2 3 4 5 6 7 e.g.: REVTRN 0 3 C UY K 00033 Barrel 1: Indicates engine model Example: For Petrol: REVTRN03CUYK00033 For Diesel: 1.5CRAIL01DUYW02621 Barrel 2: Variation in basic model 14: 475 IDI indirect injection turbo charged intercooled diesel engine, 70 PS @ 4500 rpm, meeting EURO-III / BHARAT STAGE – III emission norms. Barrel 3: ‘L’ in case of LHD executions punching of ‘L’ is not required if engine is same for RHD and LHD executions. Barrel 4: Month of production Month Code Month Code Jan A July G Feb B Aug H March C Sep J April D Oct K May E Nov L June F Dec M Barrel 5: Year of production Year Code 2014 VY 2015 UY 2016 TY 2017 SY 2018 RY Barrel 6: Indicates plant location P - for ‘K’ block, Pune Barrel 7: Serial No. Indicates Serial No. of engine. The barrel consists of 5 digits and commences from serial number 00001 &will start every year on first January. TRANSAXLE: Numbering (TA65*) XX XX X X XXXXX 1 2 3 4 5 Barrel 1: Indicates basic model TA65* Barrel 2: First digit indicates control of vehicle as below: 1 - For normal control vehicle 3 - Full forward control vehicle Second digit indicates first and second gear speed ratio with version of gear box as below - E.g.: F- for first gear ratio 3.42 / second gear ratio1.95 with 5 gear version, Gear final 4.4 with speedo ratio --- Barrel 3: Indicates year of production Year Code 2012 B 2013 C 2014 D 2015 E Barrel 4: Indicates plant location. P-for ‘K’ block, Pune Barrel 5: Serial No. Indicates Serial No. of Transaxle. The barrel consists of 5 digits and commences from serial number 00001 &will start every year on first January. BODY SHELL: Numbering XX X X XXXXX 1 2 3 4 Barrel 1 - Indicates, Basic model Barrel 2 - Indicates year of production Year Code 2014 VY 2015 UY 2016 TY 2017 SY 2018 RY Barrel 3 - Indicates plant location P for K Block Pune Barrel 4 - Indicates cumulative serial number to start every year with 00001 on first January.
GENERAL 10 1.7. CHASSIS TYPE AND SALES DESIGNATIONS: CHASSIS TYPES NO. DESCRIPTION DIESEL 627101 TATA NEXON XE FITTED WITH 1.5 CRAIL 110PS BS4 DIESEL ENGINE, HVAC UNIT, EPAS, TRANSAXLE, DAB+PAB+ABS, 5 Nos. WHEEL RIMS, 5 Nos. 195/60 R16 RADIAL TUBELESS TYRES. W.B. 2498. SEATING CAPACITY 4+DRIVER. 627121 TATA NEXON XM FITTED WITH 1.5 CRAIL 110PS BS4 DIESEL ENGINE, HVAC UNIT, EPAS, TRANSAXLE, DAB+PAB+ABS, 5 Nos. WHEEL RIMS, 5 Nos. 195/60 R16 RADIAL TUBELESS TYRES. W.B. 2498. SEATING CAPACITY 4+DRIVER. 627161 TATA NEXON XT FITTED WITH 1.5 CRAIL 110PS BS4 DIESEL ENGINE, HVAC UNIT, EPAS, TRANSAXLE, DAB+PAB+ABS, 5 Nos. WHEEL RIMS, 5 Nos. 195/60 R16 RADIAL TUBELESS TYRES. W.B. 2498. SEATING CAPACITY 4+DRIVER. 627163 TATA NEXON XZ FITTED WITH 1.5 CRAIL 110PS BS4 DIESEL ENGINE, HVAC UNIT, EPAS, TRANSAXLE, DAB+PAB+ABS, 5 Nos. WHEEL RIMS, 5 Nos. 215/60 R16 RADIAL TUBELESS TYRES. W.B. 2498. SEATING CAPACITY 4+DRIVER. 627162 TATA NEXON XZ+ FITTED WITH 1.5 CRAIL 110PS BS4 DIESEL ENGINE, HVAC UNIT, EPAS, TRANSAXLE, DAB+PAB+ABS, 5 Nos. WHEEL RIMS, 5 Nos. 215/60 R16 RADIAL TUBELESS TYRES. W.B. 2498. SEATING CAPACITY 4+DRIVER. PETROL 627201 TATA NEXON XE FITTED WITH 1.2L TURBO 110PS BS4 PETROL ENGINE, HVAC UNIT, EPAS, TRANSAXLE, DAB+PAB+ABS, 5 Nos. WHEEL RIMS, 5 Nos. 195/60 R16 RADIAL TUBELESS TYRES. W.B. 2498. SEATING CAPACITY 4+DRIVER. 627221 TATA NEXON XM FITTED WITH 1.2L TURBO 110PS BS4 PETROL ENGINE, HVAC UNIT, EPAS, TRANSAXLE, DAB+PAB+ABS, 5 Nos. WHEEL RIMS, 5 Nos. 195/60 R16 RADIAL TUBELESS TYRES. W.B. 2498. SEATING CAPACITY 4+DRIVER. 627261 TATA NEXON XT FITTED WITH 1.2L TURBO 110PS BS4 PETROL ENGINE, HVAC UNIT, EPAS, TRANSAXLE, DAB+PAB+ABS, 5 Nos. WHEEL RIMS, 5 Nos. 195/60 R16 RADIAL TUBELESS TYRES. W.B. 2498. SEATING CAPACITY 4+DRIVER. 627263 TATA NEXON XZ FITTED WITH 1.2L TURBO 110PS BS4 PETROL ENGINE, HVAC UNIT, EPAS, TRANSAXLE, DAB+PAB+ABS, 5 Nos. WHEEL RIMS, 5 Nos. 215/60 R16 RADIAL TUBELESS TYRES. W.B. 2498. SEATING CAPACITY 4+DRIVER. 627262 TATA NEXON XZ+ FITTED WITH 1.2L TURBO 110PS BS4 PETROL ENGINE, HVAC UNIT, EPAS, TRANSAXLE, DAB+PAB+ABS, 5 Nos. WHEEL RIMS, 5 Nos. 215/60 R16 RADIAL TUBELESS TYRES. W.B. 2498. SEATING CAPACITY 4+DRIVER.
GENERAL 11 1.8. TECHNICAL SPECIFICATIONS: ( PETROL) VARIANTS NEXON – XZ+ NEXON - XZ NEXON - XT NEXON - XM NEXON - XE ENGINE Engine Model TATA 1.2RVT (BS4) Description 1.2L NG TC REVOTRON Bore / Stroke 77 mm x 85.8 mm Engine Capacity 1198 cc Capacity Of Cooling System 5.5 Lit (Water + Coolant) Compression Ratio 9.6 Engine Oil Capacity Max. 3.5 litres Firing Order 1-2-3 MAX Engine Output 110ps @ 5000 rpm MAX. Torque 170Nm @ 1750-4000 rpm No Of Cylinders 3 inline CLUTCH Type Dry, Single Plate Clutch Lining (Outside Dia.) 228 mm Total Friction Area 386 sq cm STEERING Type Column Mounted Electric Power Assisted Steering System Steering Wheel 360 mm dia.
GENERAL 12 VARIANTS NEXON – XZ+ NEXON - XZ NEXON - XT NEXON - XM NEXON - XE TRANSAXLE Model TA 6300 Type Synchromesh on all forward gears and sliding mesh on reverse gear No. of gears 6 forward and 1 reverse Gear Ratios 1st 3.67 2nd 1.913 3rd 1.218 4th 0.895 5th 0.69 6th 0.578 Reverse 3.545 Final Drive Ratio 4.44 BRAKES Service Brakes Vacuum Assisted independent dual circuit; Diagonal split Hydraulic Brake on Front & Rear through tandem master cylinder acting on all 4 wheels with Automatic wear adjusters (Optional on Rear Wheels) ABS with EBD (Optional), Foot Operated. Front Brake Disc Brake , C54 Rear Brake 200 mm dia. drum brakes Parking Brake Cable operated Mechanical on rear wheels BODY Type Steel monocoque body.
GENERAL 13 VARIANTS NEXON – XZ+ NEXON - XZ NEXON - XT NEXON - XM NEXON - XE SUSPENSION Front McPherson strut Rear Double acting telescopic type Antiroll Bar At front WHEELS AND TYRES Tyre Option I : 195/60 R16 (Radial-Tubeless) Option ll : 215/60 R16 (Radial/Tubeless) Wheel Rims Option I : 6.1 X 16 steel wheel Option ll : 6.5Jx16 alloy wheel No. of Wheels Front - 2, Rear - 2, Spare - 1 FUEL TANK Fuel Petrol Capacity 44 litres ELECTRICAL SYSTEMS System Voltage 12V (-ve earth) Alternator Capacity 14.5V, 110A Battery 12V, DIN 44 PERFORMANCE Max. Speed 165 kmph PASSENGER CAPACITY Capacity 2 front + 3 rear GROUND CLEARANCE (IN MM) 165 (Laden)- 195/60 R16 184 (Laden)- 215/60 R16
GENERAL 14 1 . 9 . TECHNICAL SPECIFICATIONS: ( DIESEL) VARIANTS NEXON – XZ+ NEXON - XZ NEXON - XT NEXON - XM NEXON - XE ENGINE Engine Model TATA 1.5RTQ (BS4) Description 1.5L REVOTORQ ENGINE BS4 Bore / Stroke 76 mm x 82.5mm Engine Capacity 1497 cc Capacity Of Cooling System 6.5 Litres Compression Ratio (16.0 +/- 1) : 1 Engine Oil Capacity Max. 5.0 Litres Firing Order 1-3-4-2 MAX Engine Output 110ps @ 3750 rpm MAX. Torque 260 Nm @ 1500 - 2750 rpm No Of Cylinders 4 inline CLUTCH Type Dry, Single Plate Clutch Lining (Outside Dia.) 228 mm Total Friction Area 386 sq cm STEERING Type Column Mounted Electric Power Assisted Steering System Steering Wheel 360 mm dia.
GENERAL 15 VARIANTS NEXON – XZ+ NEXON - XZ NEXON - XT NEXON - XM NEXON - XE TRANSAXLE Model TA 6300 Type Synchromesh on all forward gears and sliding mesh on reverse gear No. of gears 6 forward and 1 reverse Gear Ratios 1st 3.308 2nd 1.913 3rd 1.218 4th 0.895 5th 0.690 6th 0.578 Reverse 3.545 Final Drive Ratio 4.33 BRAKES Service Brakes Vacuum Assisted independent dual circuit; Diagonal split Hydraulic Brake on Front & Rear through tandem master cylinder acting on all 4 wheels with Automatic wear adjusters (Optional on Rear Wheels) ABS with EBD (Optional), Foot Operated. Front Brake Disc Brake , C54 Rear Brake 200 mm dia. drum brakes Parking Brake Cable operated Mechanical on rear wheels BODY Type Steel monocoque body.
GENERAL 16 VARIANTS NEXON – XZ+ NEXON - XZ NEXON - XT NEXON - XM NEXON - XE SUSPENSION Front McPherson strut Rear Double acting telescopic type Antiroll Bar At front WHEELS AND TYRES Tyre Option I : 195/60 R16 (Radial-Tubeless) Option ll : 215/60 R16 (Radial/Tubeless) Wheel Rims Option I : 6.1 X 16 steel wheel Option ll : 6.5Jx16 alloy wheel No. of Wheels Front - 2, Rear - 2, Spare - 1 FUEL TANK Fuel Diesel Capacity 44 litres ELECTRICAL SYSTEMS System Voltage 12V (-ve earth) Alternator Capacity 14.5V, 110A Battery 12V, DIN 47.5 PERFORMANCE Max. Speed 165 kmph PASSENGER CAPACITY Capacity 2 front + 3 rear GROUND CLEARANCE (IN MM) 165 (Laden)- 195/60 R16 184 (Laden)- 215/60 R16
GENERAL 17 1.10. VEHICLE DIMENSIONS:
GENERAL 18 1.11. RECOMMENDED LUBRICANTS & COOLANTS Item Specification Company and Brand Qty. Engine Oil 5W3O ACEA A5/B5 TATA SS6579 CASTROL - Magnatec Professional T5W30 PETRONAS EXXON Mobil - Mobil Super 3000 TMGO 5W 30 Tata motors genuine oil TATA MOTORS Genuine Oil – Engine Oil Synth 5W30 3.5 Litres (Petrol) 5.0 Litres (Diesel) Coolant (Premixed) (Antifreeze agent + Soft water 40 : 60 ratio) Class II/JIS K2234 TATA SS7700S1 SUNSTAR CCI - Golden Cruiser LLC 2200NP IOCL TATA MOTORS GENUINE COOLANT KOOL PLUS 5.5 Litres (Petrol) 6.5 Litres (Diesel) Transaxle Oil Semi-Synthetic SAE 75W85 PETRONAS TATA MOTORS Genuine Transmission Oil Synth 75W85 2.4 Litres Brake Fluid / Clutch Fluid IS 8654 Type II DOT 4 TATA SS7711 PETRONAS - TATA MOTORS Genuine Brake Oil DOT 4S SUNSTAR CCI - Golden Cruiser Tata Genuine Brake Fluid(DOT4) Optional - CASTROL — Universal Brake Fluid DOT 4 As required Refrigerant R-134a - 470 ± 20 gms Compressor Oil N D-8 - 120 + 20 gm (Petrol) 100 + 20 gm (Diesel)
GENERAL 19 FUEL, LUBRICANTS AND COOLANTS FUEL (DIESEL) Normal grade BS IV compliant diesel conforming to IS1460 or EN 590 or equivalent is recommended to be used as fuel. At very low temperature, fluidity of diesel may become insufficient due to paraffin separation. It is therefore necessary to mix supplementary fuel with summer or winter grade diesel. Ratio for mixing of supplementary fuel and diesel are shown in the table. Ambient temperature Summer Supplementary upto ˚C Percentage Summer grade diesel Supplementary fuel Up to 0 100 0 0 to -10 70 30 -10 to -15 50 50 Care should be taken that diesel and supplementary fuel are thoroughly mixed before filling. Ambient temperature Summer Supplementary upto ˚C Percentage Winter grade diesel Supplementary fuel Up to -15 100 0 -15 to -20 70 30 -20 and below 50 50 WARNING Do not mix gasoline or alcohol with diesel. This mixture can cause explosion. Do not use premium diesels available in the market for example extra premium / Turbojet etc. NOTE Where oxidation catalytic converter is fitted, it is mandatory to use Diesel fuel with Sulphur contents as under. Use of any other diesel fuel can increase the pollutants. Recommended Fuel Specification for engine Parameter Unit BS III Cetane Number (min) CN 51 Sulphur content mg/kg 50 Lubricity (HFRR) micron 460 FUEL (PETROL) Unleaded regular grade petrol conforming to IS 2796:2008and BS IV specification and RON not less than 91 is recommended. It is always recommended to use correct fuel to get optimum emission performance. NOTE Always use petrol of a correct specification in a vehicle fitted with catalytic converter. Even single fill of leaded petrol will seriously damage the catalytic converter. LUBRICANTS AND OILS Please use only recommended grades for good performance. DO NOT mix grease of different brands and optional grades. Replace old grease completely. The oil change periods recommended in maintenance schedule should be adhered. Coolants Qty: 1. Approx. 5.5 Liters for Petrol 2. Approx. 6.5 Liters for Diesel Presence of dirt in coolant chokes up passages in radiator, cylinder head and crankcase, thereby causing overheating of engine. To prevent rust formation and freezing of coolant inside the passages of radiator, crankcase and cylinder head use premixed coolant as recommended. It is recommended that the entire cooling system should be drained and filled with fresh premixed coolant. Engine coolant antifreeze coolant as per class II/JIS K2234. NOTE We strongly recommend refilling your car’s engine coolant only at a TATA Authorised service centre.
GENERAL 20 1.12 SERVICE AND MAINTENANCE
GENERAL 21
GENERAL 22
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GENERAL 24 # Kms or Months whichever occurs earlier
ENGINE 1.2L REVOTRON ENGINE
1.2L REVOTRON ENGINE CONTENTS 1.1. GENERAL INFORMATION ................................................................................................................ 1 A ENGINE INTRODUCTION.................................................................................................................... 1 B ELECTRONIC CONTROL UNIT........................................................................................................... 2 C TECHNICAL SPECIFICATION............................................................................................................. 3 D SPECIAL TOOLS.................................................................................................................................. 4 E ASSEMBLY CLEARANCES ................................................................................................................. 7 F SEALANTS ........................................................................................................................................... 7 G LEAKAGE RATES ................................................................................................................................ 8 H RECOMMENDED LUBRICANTS & COOLANTS .............................................................................. 8 I SERVICE SCHEDULE.......................................................................................................................... 9 1.2. TROUBLESHOOTING ........................................................................................................ 10 1.3. CONSTRUCTIONAL AND SERVICE DETAILS ........................................................................... 18 A ENGINE LIFTING HOOKS ................................................................................................................. 18 B INTAKE MANIFOLD ........................................................................................................................... 20 C CYLINDER HEAD COVER ................................................................................................................. 22 D CYLINDER HEAD-A ........................................................................................................................... 24 E CYLINDER HEAD-B ........................................................................................................................... 26 F CYLINDER BLOCK............................................................................................................................. 28 G LUBRICATION PUMP AND COMPONENTS..................................................................................... 30 H PISTON, CRANKSHAFT AND COMPONENTS................................................................................. 33 I ENGINE TIMING................................................................................................................................. 36 J TURBOCHARGER, CATCON AND COMPONENTS ........................................................................ 38 K FUEL INJECTION EQUIPMENT ........................................................................................................ 41 L AIR FILTER, SNORKEL AND BLOW-BY PIPE.................................................................................. 43 M WATER PUMP, THERMOSTAT AND COMPONENTS ..................................................................... 45 N STARTER MOTOR AND ALTERNATOR........................................................................................... 48 O COMPRESSOR, AUTO-TENSIONER AND BELT ............................................................................. 50
1.2L REVOTRON ENGINE P ENGINE SUSPENSION...................................................................................................................... 52 Q INTERCOOLER AND HOSES............................................................................................................ 55 1.4. ENGINE TESTS AND MAINTENANCE ......................................................................................... 57 A PRELIMINARY INSPECTION............................................................................................................. 57 B ENGINE TESTS……………………… ....................................................... ……………………………..58 I ENGINE COMPRESSION TEST ................................................................................................... 58 II ENGINE OIL CONSUMPTION TEST ............................................................................................ 59 III ENGINE OIL PRESSURE TEST ................................................................................................... 60 C REGULAR MAINTENANCE…… ........................................................................................................ 61 I ENGINE OIL AND FILTER CHANGE............................................................................................ 61 II ENGINE COOLANT REPLACEMENT........................................................................................... 63 III AIR FILTER ELEMENT REPLACEMENT ..................................................................................... 64 IV SPARK PLUG REPLACEMENT .................................................................................................... 65 V AIR CONDITIONER COMPRESSOR AND ALTERNATOR BELT REPLACEMENT ................... 68 1.5. REPAIR AND INSPECTION DETAILS ........................................................................................... 69 A ACCESSORY DRIVING BELT ........................................................................................................... 69 B TIMING CHAIN ................................................................................................................................... 69 C CYLINDER HEAD............................................................................................................................... 69 D VALVES .............................................................................................................................................. 70 E CYLINDER HEAD VALVE SEATS ..................................................................................................... 72 F ROCKER ARM AND SHAFTS............................................................................................................ 73 G HYDRAULIC LASH ADJUSTER......................................................................................................... 73 H CAMSHAFT ........................................................................................................................................ 74 I PISTON AND PISTON RINGS ........................................................................................................... 75 J CONNECTING RODS ........................................................................................................................ 76 K CRANKSHAFT.................................................................................................................................... 78 L CRANK CASE..................................................................................................................................... 80 M FUEL TANK ........................................................................................................................................ 81
1.2L REVOTRON ENGINE N CANISTER PURGE VALVE ............................................................................................................... 81 O CANISTER.......................................................................................................................................... 82 1.6. ENGINE SYSTEM .............................................................................................................................. 83 A AIR INTAKE SYSTEM ........................................................................................................................ 83 B BLOW BY SYSTEM............................................................................................................................ 86 C LUBRICATION SYSTEM.................................................................................................................... 87 D EXHAUST SYSTEM ........................................................................................................................... 91 E COOLING SYSTEM............................................................................................................................ 94 F FUEL SYSTEM ................................................................................................................................... 97 1.7. ENGINE ON VEHICLE SERVICE PROCEDURE ....................................................................... 100 A ENGINE REMOVAL AND INSTALLATION ...................................................................................... 100 B AIR FILTER ASSEMBLY .................................................................................................................. 106 C INJECTION SYSTEM ....................................................................................................................... 107 D SPARK PLUG .................................................................................................................................. 108 E EXHAUST SYSTEM ......................................................................................................................... 109 F FUEL SYSTEM ................................................................................................................................. 115 G COOLING SYSTEM.......................................................................................................................... 121 H REMOVAL OF ACCESSORIES ....................................................................................................... 127 1.8. ENGINE OVEHAULING (ON OVERHAUL STAND) ................................................................. 128 A ENGINE DIS-ASSEMBLY................................................................................................................. 128 I REMOVAL OF INTAKE MANIFOLD............................................................................................ 128 II REMOVAL OF EXHAUST MANIFOLD........................................................................................ 130 III REMOVAL OF OIL SUMP ........................................................................................................... 134 IV REMOVAL OF SENSORS........................................................................................................... 135 V REMOVAL OF ACCESSORIES .................................................................................................. 136 VI REMOVAL OF TIMING CHAIN.................................................................................................... 140 VII REMOVAL OF CYLINDER HEAD AND CAMSHAFT.................................................................. 143 VIII REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES............................................................... 145
1.2L REVOTRON ENGINE IX REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES ............................................................ 147 B ENGINE ASSEMBLY........................................................................................................................ 152 I ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES .......................................................... 152 II ASSEMBLY OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES.................................. 156 III ASSEMBLY OF CYLINDER HEAD SUB-ASSEMBLIES............................................................. 159 IV ASSEMBLY OF CYLINDER HEAD ON CYLINDER BLOCK ...................................................... 161 V ASSEMBLY OF TIMING CHAIN.................................................................................................. 163 VI FITMENT OF CYLINDERHEAD COVER AND PERIPHERALS ................................................. 167 VII ASSEMBLY OF SENSORS ......................................................................................................... 170 VIII ASSEMBLY OF OIL SUMP .......................................................................................................... 171 IX ASSEMBLY OF EXHAUST MANIFOLD...................................................................................... 172 X ASSEMBLY OF INTAKE MANIFOLD .......................................................................................... 175 1.9. ENGINE MANAGEMENT SYSTEM .............................................................................................. 177 A ABBREVIATIONS ............................................................................................................................. 177 B AN OVERVIEW................................................................................................................................. 178 C ELECTRONIC CONTROL UNIT....................................................................................................... 179 D SENSORS… ..................................................................................................................................... 186 I T-MAP SENSOR.......................................................................................................................... 187 II LAMBDA SENSOR ...................................................................................................................... 188 III CAMSHAFT POSITION SENSOR............................................................................................... 190 IV KNOCK SENSOR ........................................................................................................................ 191 V CRANKSHAFT POSITION SENSOR .......................................................................................... 193 VI COOLANT TEMPERATURE SENSOR ....................................................................................... 194 E ACTUATORS.. .................................................................................................................................. 196 I IGNITION COIL............................................................................................................................ 197 II PURGE CONTROL VALVE ......................................................................................................... 198 III SOLENOID VALVE (OCV)........................................................................................................... 199 IV FUEL INJECTOR......................................................................................................................... 200
1.2L REVOTRON ENGINE V ELECTRONIC THROTTLE BODY............................................................................................... 201 F SWITCH.. .......................................................................................................................................... 203 I OIL PRESSURE SWITCH ........................................................................................................... 203 II THROTTLE PEDAL SENSOR ..................................................................................................... 204 III CLUTCH SWITCH ....................................................................................................................... 205 IV BRAKE SWITCH.......................................................................................................................... 206 V WHEEL SPEED SENSOR........................................................................................................... 207 VI ELECTRONIC VACUUM REGULATING VALVE........................................................................ 208 VII START STOP SWITCH ............................................................................................................... 209 VIII AC PRESSURE SENSOR ........................................................................................................... 210
1.2L REVOTRON ENGINE 1 1.1 GENERAL INFORMATION A. ENGINE INTRODUCTION Description The “1.2L NG TC: is a 3-Cylinder, 1200CC Gasoline Turbo-charged intercooled, MPFI, dual VVT engine and BS-IV compliant.” Features: Stiffened Aluminium Crankcase with Aluminium bed plate structure. Double Overhead Camshaft (DOHC) with 4 valves per cylinder. Variable valve timing (VVT) Timing chain drive system Three stage oil pump Silent Steel Oil Pan. Weight optimized hollow cam shafts Drive by wire technology (Electronic Throttle Control). Turbo-charged intercooled. Plastic intake manifold and head cover Light weight piston assembly Auto tensioner auxillary belt drive system Engine is BSIV OBD-II compliant. Advance Engine Management System from M/s BOSCH providing precise control for performance and emissions. Multi Point Fuel Injection (MPFI) Graded bearing system for Main bearing and con-rod big end.
1.2L REVOTRON ENGINE 2 B. ELECTRONIC CONTROL UNIT The engine management software in the vehicle's Engine Control Unit (ECU) controls the fuel injection and ignition system using a variety of sensors that provides the engine operating conditions and operates input information. The ECU includes self-diagnosis to help pinpoint any system malfunctions. Refer to the "Engine Management System" portion of this section for additional information. The MPFI type of fuel injection offers many advantages over a single point fuel injection system or a carburetor engine. The following paragraphs describe the advantages of the electronic fuel injected engine. Improved Engine Performance : The ECU precisely and instantly controls optimum fuel delivery and spark timing according to the operating conditions, inputs from the engine sensors, and operator input. This control improves vehicle response and acceleration. Increased Fuel Economy : The electronic fuel injection system allows the 1.2L NG TC engine to be Bharat Stage lV (BS-lV) compliant. By electronically controlling the air/fuel ratio of the combustion process, the engine maintains an air/fuel closer to stoichiometric (14.7:1, air to fuel), the optimum ratio for complete combustion of the fuel mixture. Decreased Exhaust Emissions : The use of electronic fuel injection also decreases exhaust emissions because the air/fuel ratio is precisely controlled through the ECU for operating conditions and driver input. The catalytic convertor also helps reduce exhaust emissions and specially manufactured to the fuel injection system's operation. Improved Cold Starting and Operation : By detecting the atmospheric and engine conditions in which the operator is starting and driving the vehicle, the ECU can adjust fuel mixture and ignition timing to help the vehicle start more easily when cold and to warm up faster. The MPFI ECU achieves all of these advantages by instantly compensating for changes in operating conditions and sensors inputs. This compensation is faster and more efficient than a mechanical system or human input.
1.2L REVOTRON ENGINE 3 C. TECHNICAL SPECIFICATION Model :- 1.2L NG TC REVOTRON Description 1.2L NG TC REVOTRON ENGINE BS4 Type :- Gasoline 4-stroke turbocharged intercooled MPFI, inline 3cylinder with 4 valves per cylinder, dual VVT engine. Engine Configuration :- Transverse mounted inline 3-cylinder engine Engine Management System :- BOSCH Engine Management System / Cube Lite Bore/Stroke :- 77 mm X 85.8 mm Engine Capacity :- 1198 cc Radiator Coolant :- Water and Ethylene Glycol, 60:40 Compression Ratio :- 9.6 Maximum Engine Power Output :- 110ps @ 5000 rpm Maximum Engine Torque Output :- 170Nm @ 1750-4000 rpm Engine Firing Order :- 1-2-3 Oil Capacity :- 3.5 L Cooling System Capacity :- 5.5 Lit (Water + Coolant) Spark Plug Type :- BOSCH, YR5NII33S (0.7 to 0.8 mm gap) BOSCH, YR5ME0 Air Filter :- Engine Mounted, Dry Paper Cartridge type. Oil Filter :- Spin on Full flow Paper type Fuel Filter Integrated with In-tank fuel pump Timing :- Chain Drive Emission Norms :- Bharat Stage lV Ignition Coil Details :- Epoxy Molded Coil Type Ignition Coil (Supply Voltage 5-16V)
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