SERVICE MANUAL (Volume – 1)
Published by: Tata Motors Limited Literature Development Cell PVBU- Customer Support, K-Block Sector 15 & 15A, PCNTDA, Chikhali, Pune – 410 501 Developed by: Technical Literature Cell - ERC Printed by: xxxxxx The information provided in this manual is based on the latest product information available at the time of publication. The right is reserved to make changes at any time without notice. © Copyright 2014 TATA MOTORS All rights reserved. The material in this manual shall not be reproduced or copied, in whole or in part, in any form without written permission from TATA MOTORS.
INTRODUCTION: Dear User, Welcome to the world of BOLT and ZEST. This vehicle hails from the family of new generation cars that are being rolled out from the TATA MOTORS. It has come out of extensive research & development by TATA MOTORS. The BOLT and ZEST vehicles incorporate all the advanced features of TATA MOTORS precision and advanced technology. This manual provides information pertaining to technical Specifications, repair, maintenance and overhaul of different components / Aggregates of car which are fitted on the BOLT and ZEST. The BOLT and ZEST service manual has the following sections: The Volume-1 contains General Engine (Revotron 1.2T) Engine (Quadrajet 75PS) Engine (Quadrajet 90PS) The Volume-2 contains Drivetrain (TA65 Star) Drivetrain (C 549) Suspension Brakes Steering Body SRS Air-conditioning Electrical (Part-1) The Volume-3 contains Electrical (Part-2) The vehicle diagnostics / troubleshooting details are provided in the TML diagnostic tool. In case of any further information / Technical advice, please refer to the Service Circulars / Bulletins issued periodically or please contact your nearest Customer Support offices. You can also write to us at: Tata Motors Limited Literature Development Cell PVBU – Customer Support, K-Block, Sector 15 & 15A, PCNTDA, Chikhali, Pune-410501, Maharashtra.
GROUP INDEX GROUP No. SECTION 1 GENERAL 2 ENGINE-REVOTRON 1.2T 3A ENGINE (QUADRAJET 75PS) 3B ENGINE (QUADRAJET 90PS)
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.
GENERAL 2 • 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 3 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 4 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 forbidden 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 installing 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. Do’s
GENERAL 5 • 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. • If the fuel tank is dry (no diesel) fill diesel and use priming pump to suck the diesel till fuel filter. • 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 • Disconnect the battery before 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 6 1.4 LIFTING, JACKING, TOWING POINTS USING THE TWO POST LIFT 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 jacking point 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. 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.
GENERAL 7 1.5 JACK AND TOOL BAG LOCATION IN VEHICLE: Inside the luggage compartment and mounted on the tail gate outer sill panel. Above suspension tower
GENERAL 8 1.6 NUMBERING SYSTEM: 1.6.1 CHASSIS NUMBERING SYSTEM Chassis number consists of 15 digits (5 barrels) as indicated 1 2 3 4 5 xxxxxx x xx x xxxxx Location : The chassis number is punched on left long member below co driver door. Barrel 1: Chassis type, sales designation. Example 1) 611652- BOLT XM QJET 75PS ABS BS4 2) 623226- ZEST XM RT 85PS ABS BS4 Barrel 2: Indicates the manufacturing month 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 3: Indicates the manufacturing year Year Code 2011 B 2012 C 2013 D 2014 E 2015 F Barrel 4: Indicates the plant location 9 For J-Block, Pune First Assy Line N For J-Block, Pune, Second Assy Line. P For K- Block, Pune First TCF Line. B For J3(Bay-2) Block, Pune Assy.Line R For J14-Block, Pune S For J13 - Block, Pune T For TMJ,Ranjangaon U For E9 - Block.Pune V For Uttarakhand Barrel 5: Indicates cumulative serial number of chassis produced during the year at each plant location.
GENERAL 9 1.6.2 AGGREGATE NUMBERING SYSTEM: ENGINE: Numbering (REVOTRON) XXXXXX XX X X XX X XXXXX 1 2 3 4 5 6 7 Barrel 1: Indicates engine model Example: 475 IDT: For TDi Engine 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 NUMBERING FOR QUADRAJET ENGINE: The Label gives the following information: 1. Supplier identification code - 2 Numerical Digits 2. Assembly Code - 1 Numerical Digit 3. Engine number plate - 7 Numerical Digits 4. Engine number plate check digit - 1 Numerical Digit 5. Engine drawing number - 11 Numerical Digits 6. Engine type code - 4 Numerical Digits 7. Production line code - 2 Numerical Digits 8. Filler - 1 Numerical Digit set to fixed zero to uniform the label to the standards. 9. Label check digit - 1 Numerical Digit
GENERAL 11 TRANSAXLE (C 549) THE LABEL GIVES THE FOLLOWING CODES: 1. Supplier identification code - 2 numerical digits 2. Production line code - 1 numerical digit 3. Transmission type code - 3 numerical digits 4. Transmission number plate - 7 numerical digits 5. Check digit - 1 numerical digit
GENERAL 12 1.7 LOCATION OF CHASSIS AND AGGREGATE NUMBERS: CHASSIS NUMBER (Driver side, “B” Pillar) ENGINE NUMBER (QUADRAJET ENGINE) (On “A” mount bracket) ENGINE NUMBER (REVOTRON ENGINE On “A” mount bracket TRANSAXLE (C 549) (Near Clutch Slave Cylinder) TRANSAXLE (TA 65*) (Near Clutch Release Leaver)
GENERAL 13 1.8 CHASSIS TYPE AND SALES DESIGNATIONS: FOR BOLT FOR ZEST Chassis Types No Sales Designation Description 608001 BOLT XE 1.2RT 85PS BOLT XE 1.2RT 85PS BS4 608051 BOLT XT 1.2RT 85PS ABS BOLT XT 1.2RT 85PS ABS BS4 608071 BOLT XM 1.2RT 85PS ABS BOLT XM 1.2RT 85PS ABS BS4 611601 BOLT XE QJET 75PS BOLT XE QJET 75PS BS4 611361 BOLT XMS 1.2RT 85PS ABS BOLT XMS 1.2RT 85PS ABS BS4 611465 BOLT XT QJET 75PS ABS BOLT XT QJET 75PS ABS BS4 611652 BOLT XM QJET 75PS ABS BOLT XM QJET 75PS ABS BS4 611656 BOLT XM QJET 75PS BOLT XM QJET 75PS BS4 Chassis Types No Sales Designation Description 623201 ZEST XE RT 85PS ZEST XE RT 85PS BS4 623226 ZEST XM RT 85PS ABS ZEST XM RT 85PS ABS BS4 623227 ZEST XMS 1.2RT 85PS ABS ZEST XMS 1.2RT 85PS ABS BS4 623251 ZEST XT RT 85PS ABS ZEST XT RT 85PS ABS BS4 624001 ZEST XE QJET 75PS ZEST XE QJET 75PS BS4 624027 ZEST XMA QJET 90PS ZEST XMA QJET 90PS BS4 624028 ZEST XMS QJET 90PS ABS ZEST XMS QJET 90PS ABS BS4 624026 ZEST XM QJET ABS ZEST XM QJET ABS 90PS BS4 624051 ZEST XT QJET ABS ZEST XT QJET ABS 90PS BS4
GENERAL 14 1.9 TECHNICAL SPECIFICATION FOR BOLT: 1. ENGINE Model : 1). TATA 1.3L SDE (75PS) 2). TATA 1.3L SDE (90PS) (IF FITTED) 3). TATA 1.2L REVOTRON TURBO (85PS) Type : 1). Four stroke, 4 cylinder, water cooled, Indirect injection type, Turbo Intercooled diesel engine. 2). Four stroke, 4 cylinder, water cooled, direct injection type, 1.3 QUADRAJET Turbo Intercooled diesel engine. 3). Four stroke, Four Cylinder Water Cooled Multi point Fuel Injection Engine. No. Of Cylinder : Four Inline Bore / Stroke : 1). 69.6 mm x 82 mm 2). 69.6 mm x 82 mm 3). 75 mm X 67.5 mm Capacity : 1). 1248 cc 2). 1248 cc 3). 1192.823461 cc Max. Engine Output : 1). 75 PS at 4000 rpm 2). 90 PS at 4000 rpm 3). 85 PS at 5000 rpm Max. Torque : 1). 190 Nm @ 1750-3000 rpm 2). 200 Nm @ 1750-3000 rpm 3). 140 Nm @ 1500-3500 rpm Compression Ratio : 1). 17.6:1 2). 17.6:1 3). 9.0:1 Firing Order : 1 - 3 - 4 – 2 Engine Oil Capacity : 1). 3.2 Litre. 2). 3.2 Litre 3). 4.0 Litre 2. CLUTCH Type : Single plate dry friction diaphragm type. Outside diameter : 215mm (1.3L SDE (75PS) and (90PS)) of clutch lining 200mm (REVOTRON) Friction area : 386 sq.cm. (1.3L SDE (75PS) and (90PS) 346 sq. cm. (REVOTRON)
GENERAL 15 3. TRANSAXLE Model : FIAT C-549 (5 Speed) with overdrive Type : 5-speed manual, Synchromesh on all forward gears and sliding mesh for reverse gear No. of gears : 5 forward, 1 reverse. Model : TA-65-5*(5 Speed) with overdrive Type : 5-speed manual, Synchromesh on all forward gears and sliding mesh for reverse gear No. of gears : 5 forward, 1 reverse. GEAR RATIOS: 1.3L SDE (75PS) 1.3L SDE (90PS) REVOTRON TURBO 1st - 3.909 4.273 3.64 2nd - 2.238 2.238 1.95 3rd - 1.444 1.444 1.27 4th - 1.029 1.029 0.88 5th - 0.767 0.767 0.714 Rev. - 3.909 3.909 3.58 (Final Drive) 3.563 3.929 3.765 4. STEERING Type : Electric Power Assisted Steering (Column mounted) Mechanical steering gearbox with ratio- 44mm/rev Type-2- Proposed under commonly-CAB to share tech specs Collapsible (tube-in-tube), tillable (+3° /-2°) PMSM M2 Brushless DC motor with 2.4 Nm torque. Max current usage at 12 VDC- 60 Amp at max rack load. Steering Wheel : 380mm 5. BRAKES Service brakes : Dual circuit diagonal split hydraulic brakes through tandem master cylinder. Front brake : New C54 caliper suitable to 254mm OD & 22mm thick ventilated disc Rear brake : 200mm with 20.64 wheel cylinder Parking brake : Lever type console mounted cable operated Mechanical linkages acting on rear wheels
GENERAL 16 6. BODY Type : Hatch back; five doors; steel monocoque body; passenger car. 7. SUSPENSION Front : McPherson Strut type. Rear : Twist beam Antiroll Bar : At Front. 8. WHEELS and TYRES Tyre : 175/65R14 Tyre Pressure : Front-30-35 psi, Rear- 28-32 psi Wheel rims : 5J X 14" steel rims No. of wheels : Front - 2, rear - 2, spare - 1. 10. FUEL TANK Capacity : 44 Liters 11. ELECTRICAL SYSTEMS System Voltage : 12 volts (-Ve earth) Alternator Capacity : 47.5 (1.3L SDE (75PS) and (90PS)) : 44 (1.3L SDE (75PS) and (90PS)) Battery : 12 V, (1.3L SDE (75PS) and (90PS)) : 12 V, (REVOTRON) 12. PERFORMANCE Max. Speed : 151 kmph (1.3L SDE (75PS) and (90PS)) : 160 kmph (REVOTRON) 13. PASSENGER CAPACITY : 2 Front + 3 Rear
GENERAL 17 1.10. TECHNICAL SPECIFICATION FOR ZEST 1. ENGINE Model : 1). TATA 1.3L SDE (90PS) 2). TATA 1.2L REVOTRON TURBO (85PS) Type : 1). Four stroke, 4 cylinder, water cooled, direct injection type, 1.3 QUADRAJET Turbo Intercooled diesel engines. 2). Four stroke, Four Cylinder Water Cooled Multi point Fuel Injection Engine. No. Of Cylinder : Four Inline Bore / Stroke : 1). 69.6 mm x 82 mm 2). 75 mm x 67.5 mm Capacity : 1). 1248 cc 2). 1193 Max. Engine Output : 1). 90 PS at 4000 rpm 2). 85 PS at 5000 rpm Max. Torque : 1). 200 Nm @ 1750-3000 rpm 2). 140 Nm @ 1500-3500 rpm Compression Ratio : 1). 17.6:1 2). 17.6:1 3). 9.0:1 Firing Order : 1 - 3 - 4 – 2 Engine Oil Capacity : 1). 3.2 Litre. 3). 4.0 Litre 2. CLUTCH Type : Single plate dry friction diaphragm type. Outside diameter : 215mm (1.3L SDE (90PS)) of clutch lining 200mm (REVOTRON) Friction area : 386 sq.cm. (90PS) 346 sq. cm. (REVOTRON) 3. TRANSAXLE Model : FIAT C-549 (5 Speed) with overdrive Type : 5-speed manual, Synchromesh on all forward gears and sliding mesh for reverse gear No. of gears : 5 forward, 1 reverse. Model : TA-65-5*(5 Speed) with overdrive Type : 5-speed manual, Synchromesh on all forward gear and sliding mesh for reverse gear No. of gears : 5 forward, 1 reverse.
GENERAL 18 GEAR RATIOS: 1.3L SDE (75PS) 1.3L SDE (90PS) REVOTRON TURBO 1st - 3.909 4.273 3.64 2nd - 2.238 2.238 1.95 3rd - 1.444 1.444 1.13 4th - 1.029 1.029 0.78 5th - 0.767 0.767 0.636 Rev. - 3.909 3.909 3.58 (Final Drive) 3.563 3.929 3.765 4. STEERING Type : Electric Power Assisted Steering (Column mounted) Mechanical steering gearbox with ratio- 44mm/rev Steering Wheel : 380mm 5. BRAKES Service brakes : Dual circuit diagonal split hydraulic brakes through tandem master cylinder. Front brake : New C54 caliper suitable to 254mm OD & 22mm thick ventilated disc Rear brake : 200mm with 19.05 wheel cylinder Parking brake : Lever type console mounted cable operated Mechanical linkages acting on rear wheels 6. BODY Type : Compact Sedan; five doors; steel monocoque body; passenger car. 7. SUSPENSION Front : McPherson Strut type. Rear : Twist beam Antiroll Bar : At Front. 8. WHEELS and TYRES Tyre : 185/60-R15 Tyre Pressure : Front-30-35 psi, Rear- 28-32 psi Wheel rims : 5.5 J X 15" steel rims No. of wheels : Front - 2, rear - 2, spare - 1. 10. FUEL TANK Capacity : 44 liters
GENERAL 19 11. ELECTRICAL SYSTEMS System Voltage : 12 volts (-Ve earth) Alternator Capacity : 110 Amp (1.3L SDE (75PS) and (90PS)) : 90 Amp (REVOTRON) Battery : 12 V, 47.5 Ah (1.3L SDE (75PS) and (90PS)) : 12 V, 44 Ah (REVOTRON) 12. PERFORMANCE Max. Speed : 158 kmph (1.3L SDE (75PS)) : 158 kmph (1.3L SDE (90PS)) : 155 kmph (REVOTRON) 3. PASSENGER CAPACITY : 2 Front + 3 Rear
GENERAL 20 1.11 A Vehicle Dimensions A ) For BOLT
GENERAL 21 1.11 B Vehicle Dimensions B) For ZEST
GENERAL 22 1.12 RECOMMENDED LUBRICANTS & COOLANTS FOR BOLT AND ZEST (QUADRAJET) ITEM SPECIFICATION COMPANY AND BRAND QTY ENGINE OIL (Quadrajet) ACEA 5W30 A5/B5 PETRONAS SYNTIUM 5000 TM 5W30 CASTROL- Magnatec Professional T 5W30 3.2 Litres COOLANT (Antifreeze agent + Soft water (50 : 50 ratio) Class II / JIS K2234 Tata ss7700 SUNSTAR CCI – Golden Cruiser LLC2200NP IOCL - Servo Cool TM Plus ANSYSCO - Puroblue 7.5 Litres TRANSAXLE (Quadrajet) Semi-Synthetic SAE 75W80 PETRONAS- Tutela ZC75FF 2.2 Litres POWER STEERING OIL ATF-A Dexron III CASTROL1 HPCL - HP ATF DEX III EXXON Mobil - Mobil Multipurpose ATF 1.0 Litres BRAKE / CLUTCH FLUID SAE J 1703, DOT 4 PETRONAS-Tutela –TOP 45 DOT 4 CASTROL UBF DOT 4 (Optional) As required ANTI RUST TREATMENT AND SOUND DEADENING DINITROL - Dinitrol / WUERTH - Wuerth / 3M - 3M / Waxoyl - Waxoyl — WIND SCREEN SEALANT WUERTH - Wuerth / 3M - 3M / Car System - Car System —
GENERAL 23 FOR BOLT AND ZEST (REVOTRON) ITEM SPECIFICATION COMPANY AND BRAND QTY ENGINE OIL ACEA 5W30 A5/B5 CASTROL- Magnatec Professional T 5W30 PETRONAS SYNTIUM 5000 TM 5W30 4.0 Litres COOLANT (Antifreeze agent + Soft water 50 : 50 ratio) Class II / JIS K2234 TATA SS7700 SUNSTAR CCI – Golden Cruiser LLC2200NP IOCL - Servo Cool TM Plus ANSYSCO - Puroblue 6 Litres TRANSAXLE Monograde SAE 80W API GL4 HPCL – HP Gear Oil EP 80 CASTROL- HYPOY 80 EPT 1.8 Litres POWER STEERING OIL ATF- A Dexron III 1.0 Litres BRAKE / CLUTCH FLUID SAE J 1703, DOT 4 PETRONAS-Tutela –TOP 45 DOT 4 CASTROL UBF DOT 4 (Optional) As required ANTI RUST TREATMENT AND SOUND DEADENING DINITROL - Dinitrol WUERTH - Wuerth 3M - 3M — — WIND SCREEN SEALANT WUERTH - Wuerth 3M - 3M Car System - Car System — —
GENERAL 24 FUEL, LUBRICANTS AND COOLANTS FUEL (DIESEL) High Speed 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 up to Deg. 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 up to Deg. 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. NOTICE: 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 1 Cetane Number (min) CN 51 2 Sulphur content mg/kg 350 3 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. Recommended grades of engine oil for range of ambient temperature Ambient Temp 0ºCGrade Engine Oil - 5 and above SAE 15W/40 - 10 to 0 SAE 5W30 - 20 and -10 SAE 0W30 Coolants Qty: Approx. 5.4 Liters 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. Windscreen Washer Anti-frost Make – Anti-frost- K Concentration - 1 : 5 For 0C 1 : 1 For 100C 2 : 5 For 160C 1 : 0 For 370C NOTE: We strongly recommend refilling your car’s engine coolant only at a TATA Authorised service centre.
GENERAL 25 1.13 SERVICE AND MAINTENANCE (BOLT / ZEST) Sr. No. Maintenance Schedule Operations Frequency Km 5000-5500 15000-15500 30000-30500 45000-45500 60000-60500 75000-75500 90000-90500 105000-105500 GENERAL 1 Wash the vehicle & Clean Condenser Fins. EVERY Service • • • • • • • • 2 Drain water from Fuel Filter Bowl. EVERY Service • • • • • • • • 3 Check & Top up Fluids (If required): Coolant, Brake Fluid, Battery Electrolyte, Wind Screen washer fluid. EVERY Service • • • • • • • • 4 Check fuel lines for leakage. EVERY Service • • • • • • • • 5 Check clutch pedal height and cable. EVERY Service • • • • • • • • 6 All standard checks as per job card. EVERY Service • • • • • • • • 7 Check rubber boots & bushes for damages and replace if required. 30,000 • • • 8 Check rubber hanger (Muffler) and replace if damaged. EVERY Service • • • • • • • • ENGINE (Quadrajet ) 1 Clean air filter element (more frequently for vehicle operating in severe condition 15,000 • • • • • • • • 2 Change engine oil and Oil filter. ( 15,000 km Or 12 Months whichever is earlier ) 15,000 • • • • • • • 3 Check for the DTCs in the “Engine Control Unit”. Take corrective action. If required. 15,000 • • • • • • • • 4 Change fuel filter. 15,000 • • • • • • • 5 Replace air filter element (more frequently for vehicle operating in severe condition ) 45,000 • •
GENERAL 26 6 Change coolant ( 60,000 km or 2 years whichever is earlier) 60, 000 • 7 Replace Timing chain (for Quadrajet 90 PS only) 60, 000 • ENGINE (REVOTRON 1.2T) 1 Clean air filter element (more frequently for vehicle operating in Severe condition) 15,000 • • • • • 2 Replace air filter element (more frequently for vehicle operating in Severe condition) 45,000 • • 3 Change engine oil and Oil filter 15,000 km or 1 year whichever is earlier 15,000 • • • • • • • 4 Change fuel filter 30,000 • • • 5 Check accessory drive belts for tension, wear or damage & replace if required 15,000 • • • • • • 6 Replace accessory drive belts 60, 000 • 7 Change coolant ( 60,000 km or 2 years whichever is earlier) 60, 000 • 8 Replace timing belt ( 1,05,000 Kms or 5 years whichever is earlier ) 1,05,000 • 9 Replace Spark Plugs 30,000 • • • 10 Valve Clearance (Check & Adjust if necessary) 30,000 • • • TRANSAXLE 1 Check oil level and top up if necessary (Qudrajet with C549) 75,000 • 2 Change oil (Revotron with TA 65*) 15,000 • • • • • • • BRAKES 1 Check front brake pads & rear brake linings. Replace if necessary 15,000 • • • • • • • 2 Replace brake fluid (45,000 kms or 2 years whichever is earlier) Check brake system components for Leakages 45,000 • • WHEELS & TYRES 1 Rotate tyres 15,000 • • • • • • •
GENERAL 27 FRONT & REAR SUSPENSION 1 Check & Adjust Wheel alignment & Balancing if required 15,000 • • • • • • • ELECTRICAL 1 Check headlamp focusing and adjust if necessary 30,000 • • • A.C. SYSTEM 1 Check Airconditioning / HVAC System for satisfactory performance, Clean A/c Filter EVERY Service • • • • • • • •
ENGINE
Revotron 1.2T CONTENTS 2.1. GENERAL INFORMATION A ENGINE INTRODUCTION.................................................................................................................... 1 B ELECTRONIC FUEL INJECTION CONTROL...................................................................................... 2 C TECHNICAL SPECIFICATION ............................................................................................................. 3 D OIL AND LUBRICANTS........................................................................................................................ 4 E SERVICE SCHEDULE.......................................................................................................................... 5 F TIGHTENING TORQUE SPECIFICATION........................................................................................... 6 G SPECIAL TOOLS.................................................................................................................................. 9 2.2. TROUBLESHOOTING ........................................................................................................ 11 2.3. CONSTRUCTIONAL AND SERVICE DETAILS A INTAKE MANIFOLD............................................................................................................................ 19 B CYLINDER HEAD AND COVER ........................................................................................................ 20 C CYLINDER HEAD ............................................................................................................................... 22 D CYLINDER BLOCK............................................................................................................................. 24 E MOVING PARTS................................................................................................................................. 26 F ENGINE TIMING................................................................................................................................. 28 G EXHAUST MANIFOLD........................................................................................................................ 30 H FUEL INJECTION EQUIPMENT ........................................................................................................ 32 I LUBRICATION PUMP AND COMPONENTS..................................................................................... 34 J ENGINE SUSPENSION...................................................................................................................... 36 K AIR INTAKE SYSTEM ........................................................................................................................ 38 L SPECIAL INSTALLATION .................................................................................................................. 41 2.4. ENGINE TESTS AND MAINTENANCE A PRELIMINARY INSPECTION............................................................................................................. 43 B ENGINE TESTS i ENGINE COMPRESSION TEST ................................................................................................... 45 ii ENGINE OIL CONSUMPTION TEST ............................................................................................ 46
Revotron 1.2T iii ENGINE OIL PRESSURE TEST ................................................................................................... 47 C REGULAR MAINTENANCE i ENGINE OIL AND FILTER CHANGE ............................................................................................ 48 ii ENGINE COOLANT REPLACEMENT........................................................................................... 49 iii AIR FILTER ELEMENT REPLACEMENT...................................................................................... 51 iv SPARK PLUG REPLACEMENT .................................................................................................... 52 v FUEL FILTER REPLACEMENT .................................................................................................... 54 vi AIR CONDITIONER COMPRESSOR BELT REPLACEMENT...................................................... 55 vii ALTERNATOR BELT REPLACEMENT......................................................................................... 56 2.5. REPAIR AND INSPECTION DETAILS A TIMING BELT...................................................................................................................................... 59 B CYLINDER HEAD ............................................................................................................................... 59 C VALVES .............................................................................................................................................. 60 D CYLINDER HEAD VALVE SEATS ..................................................................................................... 62 E ROCKER ARM AND SHAFTS............................................................................................................ 62 F CYLINDER HEAD VALVE GUIDES ................................................................................................... 63 G CAMSHAFT ........................................................................................................................................ 64 H PISTON AND PISTON RINGS ........................................................................................................... 65 I CONNECTING RODS......................................................................................................................... 66 J CRANKSHAFT.................................................................................................................................... 68 K FUEL TANK ........................................................................................................................................ 70 2.6. ENGINE SYSTEM A AIR INTAKE SYSTEM ........................................................................................................................ 73 B BLOW BY SYSTEM............................................................................................................................ 76 C LUBRICATION SYSTEM .................................................................................................................... 77 D EXHAUST SYSTEM ........................................................................................................................... 80 E COOLING SYSTEM............................................................................................................................ 82
Revotron 1.2T 2.7. ENGINE ON VEHICLE SERVICE PROCEDURE A ENGINE REMOVAL............................................................................................................................ 87 B ENGINE INSTALLATION.................................................................................................................... 90 2.8. ENGINE OVEHAULING (ON OVERHAUL STAND) A ENGINE DIS-ASSEMBLY i REMOVAL OF INTAKE MANIFOLD.............................................................................................. 93 ii REMOVAL OF EXHAUST MANIFOLD.......................................................................................... 96 iii REMOVAL OF OIL SUMP ........................................................................................................... 100 iv REMOVAL OF SENSORS ........................................................................................................... 100 v REMOVAL OF TIMING BELT ...................................................................................................... 101 vi REMOVAL OF CYLINDER HEAD ............................................................................................... 104 vii REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES............................................................... 105 viii REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES ............................................................ 107 B ENGINE ASSEMBLY i FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES................................................................. 111 ii FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES...................................... 113 iii FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES .............................................................. 114 iv FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK .......................................................... 117 v FITMENT OF OIL SUMP ............................................................................................................. 123 vi FITMENT OF ENGINE SENSORS AND PERIPHERALS ........................................................... 124 vii FITMENT OF EXHAUST MANIFOLD AND PERIPHERALS....................................................... 127 viii FITMENT OF INTAKE MANIFOLD AND PERIPHERALS........................................................... 129 2.9. ENGINE MANAGEMENT SYSTEM A ABBREVIATIONS ............................................................................................................................. 135 B AN OVERVIEW................................................................................................................................. 136 C ELECTRONIC CONTROL UNIT....................................................................................................... 137 D SENSORS i T-MAP SENSOR.......................................................................................................................... 144 ii LAMBDA SENSOR ...................................................................................................................... 146
Revotron 1.2T iii CAMSHAFT POSITION SENSOR........................................................................................... 148 iv KNOCK SENSOR ................................................................................................................... 149 V CRANKSHAFT POSITION SENSOR ...................................................................................... 151 vi COOLANT TEMPERATURE SENSOR.................................................................................... 153 vii BOOST PRESSURE SENSOR ............................................................................................... 154 E ACTUATORS i IGNITION COIL....................................................................................................................... 157 ii WG PWM ACTUATOR............................................................................................................ 158 iii DUMP VALVE......................................................................................................................... 160 iv PURGE CONTROL VALVE..................................................................................................... 161 v FUEL INJECTOR.................................................................................................................... 163 vi ELECTRONIC THROTTLE BODY........................................................................................... 164 F SWITCH i OIL PRESSURE SWITCH....................................................................................................... 166 3.0 LIST OF DIAGNOSTIC TROUBLE SHOOTING CODES....................................................168
Revotron 1.2T 1 2.1 GENERAL INFORMATION : A. ENGINE INTRODUCTION : Description : The Revotron 1.2T is 4 cylinder, 1.2L Gasoline Turbo-charged intercooled, MPFI (Multi Point Fuel Injection) engine. Features of Engine are : Multi Point Fuel Injection (MPFI) Single Overhead Camshaft (SOHC) with 2 valves per cylinder. Stiffened Cast Iron Crankcase. New generation Water-cooled Turbocharger. Advance Engine Management System from M/s BOSCH providing precise control for performance and emissions. Engine is BSIV OBD-II complaint. Silent Steel Oil Pan. Drive by wire technology (Electronic Throttle Control).
Revotron 1.2T 2 B. Electronic Fuel Injection Control : 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 to 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 Revotron 1.2T 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.
Revotron 1.2T 3 C. TECHNICAL SPECIFICATION : Model Revotron 1.2T Type Gasoline 4-stroke turbocharged intercooled MPFI, inline 4 cylinder with 2 valves per cylinder. Engine Configuration Transverse mounted inline 4-cylinder engine Engine Management System BOSCH Engine Management System Bore/Stroke 75mm X 67.5mm Engine Capacity 1193 cc Coolant Class II/JIS K2234 TATA SS7700 Compression Ratio 9:1 Maximum Engine Power Output 85PS @ 5000rpm Maximum Engine Torque Output 140Nm @ 1500-3500rpm Engine Firing Order 1-3-4-2 Oil Capacity 4.0L Cooling System Capacity 6 lit. (water + coolant) Spark Plug Type BOSCH, YR7ME (0.7 to 0.8 mm gap) Air Filter Engine Mounted, Dry Paper Cartridge type. Oil Filter Spin on Full Paper type Timing Belt Drive Weight of Engine Base Engine + Aux. Drive without engine oil - 128 Kg Special Items/Features Gasoline Turbocharged engine Emission Norms Bharat Stage lV Compliance
Revotron 1.2T 4 D. RECOMMENDED LUBRICANTS AND FLUID CAPACITIES : ITEMS SPECIFICATION COMPANY BRAND QUANTITY ENGINE ACEA 5W30 A5/B5 Castrol Magnatec Professional T5W30 4 Litres ANTIFREEZE ENGINE COOLANT (40:60 ; coolant:water) Class II/JIS K2234 TATA SS7700 Sunstar CCI Golden Cruiser LLC2200NP 6 Litre IOCL Servo Cool TM Plus Ansysco Puroblue
Revotron 1.2T 5 E. SERVICE SCHEDULE : SR NO MAINTENANCE SCHEDULE OPERATIONS FREQUENCY 5000 - 5500 15000 - 15500 30000 - 30500 45000 - 45500 60000 - 60500 75000 - 75500 90000 - 90500 105000 - 105500 ENGINE (Revotron 1.2T) 1 Clean air filter element (More frequently for vehicle operating in severe condition) 15,000 • • • • • • 2 Replace air filter element (More frequently for vehicle operating in severe condition) 45,000 • • 3 Change engine oil and Oil filter. (15,000 km Or 12 Months whichever is earlier 15,000 • • • • • • • 4 Change fuel filter 30,000 • • • 5 Check accessory drive belts for tension, wear or damage and replace if required 15,000 • • • • • • 6 Replace accessory drive belts 60,000 • 7 Change coolant (60,000 km or 2 years whichever is earlier) 60,000 • 8 Replace timing belt (1,05,000 km or 5 years whichever is earlier) 1,05,000 • 9 Replace Spark Plugs 30,000 • • • 10 Valve Clearance (Check and Adjust if necessary) 30,000 • • •
Revotron 1.2T 6 F. TIGHTENING TORQUE SPECIFICATIONS : Fastener Fastener Type and Size Torque (Kgfm) (Nm) Main Bearing Cap Bolts M10 X 1.5 5.5 54 Cylinder head Bolts M10 X 1.5 See Note 1 Spark plug to Cylinder Head M12 X 1.25 1.5 to 2.5 15 to 25 Cylinder Head Cover to Cylinder Head HEX.FL.Screw M6 0.8 to 1 8 to 9.81 Oil sump to Cylinder Block HEX.FL.Screw M6 1 9.81 Sealing Plug For Oil Gallery, Block Rear M14 X 1.5 3.5 34 Oil Sump Drain Plug M12 X 1.5 3.5 34 Timing Cover Rear to Cylinder Block HEX.FL.Screw M10 0.8 to 1 8 to 9.81 Timing Cover Rear to Cylinder Head HEX.FL.Screw M8 0.8 to 1 8 to 9.81 Timing Cover Rear to Oil Pump HEX.FL.Screw M6 0.8 to 1 8 to 9.81 Timing Cover Front (Bottom) to Oil Pump HEX.FL.Screw M6 0.8 to 1 8 to 9.81 Timing Cover Front (Upper & Lower) HEX.FL.Screw M6 0.8 to 1 8 to 9.81 Sealing Plug For Oil Gallery, Cylinder Head Mc 10 X 1 2.5 25 Rear Cover Crankcase on Cylinder Block Screw M6 1 9.81 Oil Filter Cap on Cylinder Head - 1.2 12 Vacuum Pump on Cylinder Head HEX.FL.Screw M6 1.5 15 Dipstick Tube to Cylinder Block HEX.FL.Screw M8 2 20 PCV Valve Assembly to Cylinder Head Cover - 0.18 to 0.29 1.7 to 2.9 Connecting Rod Bolt M8 X 1 4.5 44 Flywheel on Crankshaft Flange Bolt M10 X 1.5 5 49 Crankshaft Gear to Crankshaft Bolt M14 X 1.5 4 +600 39 +600 Vibration Damper 5 Groove & A/C Pulley to Crankshaft Gear M8 2.5 25 Timing Belt Tensioner to Cylinder Block HEX.FL.Bolt M10 4.5 44 Cam Thrust plate to Cylinder Head Cap Screw M6 1 9.81 Timing Belt Idler to Cylinder Block HEX.FL.Bolt M10 4.5 44 Camshaft Gear to CamShaft HEX.Bolt M12 8 78 Rocker Nut on Rocker Arm Adjusting Screw M9 2 to 2.5 20 to 25 Rocker Shaft to Cylinder Head Screw M6 1 9.81 Fuel Rail on Intake Manifold HEX.FL.SCREW M8 2 20 Injector Retainer on Fuel Rail HEX.FL.Screw M5 0.5 to 0.6 5 to 6 Exhaust Manifold on Cylinder Head Clinch Nut M8 X 1.25 1.9 to 2.1 19 to 21 Intake Manifold on Cylinder Head Clinch Nut M8 X 1.25 1.9 to 2.1 19 to 21
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