• MUMBAI • PUNE • SERVICE MANUAL BOOK 1
Designed and Published by : TATAMOTORS LIMITED Literature Development Cell PCBU-Customer Support,K-Block Sector 15 & 15A, PCNTDA, Chikhali, Pune - 410501 Printed by : XXXX / E-2012 / 500 / Revised Edition The information provided in this manual is based on the latest product information available at the time of printing. In case of any further information/ technical advice, please refer to the service circulars / bulletins issued periodically. Reproduction or translation of the entire part of the workshop manual is strictly prohibited without the written approval of TATAMOTORS.
Dear user, welcome to the world of “ TATA NANO”. This vehicle hails from a family of new generation cars that are being rolled out from the TATAMOTORS. It is the outcome of extensive research & development by TATAMOTORS. This manual provides information pertaining to technical Specifications, repair, maintenance and overhaul of different aggregates fitted in the car. This manual emphasizes the special features of the vehicle and thus benefits our workman, who is conversant with general Automobile practices. The repair procedures outlined in this manual emphasize the special aspects of the product. This will enable you to build and maintain a reputation of quality service. This manual is divided into two books. The Book 1 contains the following groups: • General • Precautions • Engine • Drivetrain • Suspension The Book 2 contains the following groups: • Brakes • Steering • Electrical • Body • HVAC In case of any advice or suggestions you can also write us at : TATAMOTORS LIMITED Literature Development Cell PCBU – Customer Support, K-Block, Sector 15 & 15A, PCNTDA, Chikhali, Pune-410501 INTRODUCTION :
GROUP INDEX ( BOOK - 1 ) SR. No. GROUP PAGE NO. 1. GENERAL 001 2. PRECAUTIONS 029 3. ENGINE 041 4. DRIVETRAIN 309 5. SUSPENSION 423 GENERAL PRECAUTIONS ENGINE DRIVETRAIN SUSPENSION
GENERAL 1 GENERAL 1. GENERAL
2 GENERAL
GENERAL 3 GENERAL INTRODUCTION This Manual provides workshop practices and repair procedures for the TATA NANO. The procedures outlined in thismanual provide focus on the specialized aspects of the vehicles, assuming the technician is proficient in common workshop practices and repairs. Using this manual as a guide will assist in achieving a reputation for and trusted workmanship. This manual provides repair instruct ions for components manufactured by TATA MOTORS LIMITED. This Manual does not provide overhaul procedures for certain proprietary components supplied to TATA MOTORS from other companies. In this case, the component requires direct factory service from the supplier. The “General” section of theworkshopmanual provides important information such as ‘How to use theManual’, critical lubricant / fluid brands and types, vehicle specifications, Jacking instructions, aggregate numbering system and the service maintenance schedule.
4 GENERAL
GENERAL 5 GENERAL HOW TO USE THIS MANUAL Manual Sections For ease of use, this workshop manual comprising with several sections, each vehicle system has a separate section. To facilitate location of the desired section, page tabs are located on each page. Starting at the top of the page for section 1, for each subsequent section the page tabs are located closer to the bottom of the page. The manual is divided into following main groups. • Section 1 – General information • Section 2 – Precautions • Section 3 – Engine • Section 4 – Drive train • Section 5 – Suspension System • Section 6 – Brake System • Section 7 – Steering System • Section 8 – Body Electrical • Section 9 – Body • Section 10 – HVAC System Each Group typically contains all information relating to that particular system, including: • Table of Contents • Precautions • Specification • Tightening torque • Special tools • Troubleshooting • System Description • Removal, Disassembly, inspection, assembly, and installation procedures. Locating a specific Content: To locate the Suspension Systemproceeds as follows: Choose the section 5 in the workshop manual. Find the appropriate page for ‘Suspension’ by referring to the table of Contents at the beginning of the section.
6 GENERAL
GENERAL 7 GENERAL CONTENTS SR. NO. DESCRIPTION PAGE NO. 1.1 AN OVERVIEW - NANO 19 1.2 ABBREVIATIONS 10 1.3 LIFTING, JACKING, TOWINGPOINTS 13 1.4 TIGHTENINGTORQUESOF STANDARDBOLTSANDNUTS 16 1.5 AGGREGATE NUMBERING SYSTEM 17 1.6 TECHNICALSPECIFICATIONS 20 1.7 VEHICLEDIMENSIONS 22 1.8 FUEL, LUBRICANTS & COOLANTS 23 1.9 SERVICE SCHEDULE 26
8 GENERAL
GENERAL 9 GENERAL Fuel-efficient engine TheTATANANO has a rear mounted rear-wheel drive, all-aluminum, two-cylinder, multi point fuel injection petrol engine. The lean design strategy has achieved minimum weight and maximum performance per unit of energy consumed and delivers high fuel efficiency. Performance is controlled by a specially designed electronic engine management system. Meets all safety requirements The TATA NANO’s safety performance exceeds current regulatory requirements. With an all sheetmetal body, it has a strong passenger compartment, with safety features such as crumple zones, intrusion-resistant doors, seat belts, strong seats and anchorages, and the rear tailgate glass bonded to the body. Tubeless tyres further enhance safety. Environment-friendly The TATA NANO’s exhaust emission performance exceeds regulatory requirements. The high fuel efficiency also ensures that the car has low carbon dioxide emissions, thereby providing the twin benefits of an affordable transportation solution with a low carbon footprint. Besides all these, TATA vehicles are backed by a well established service network with trained and skilled manpower that ensures proper maintenance. 1.1 AN OVERVIEW - NANO Your NANO comes from a family of new generation cars of TATA MOTORS. It is the outcome of extensive research and development by TATA MOTORS LIMITED. We are happy to present the NANO to you and hope it brings the joy, pride and utility of owning a car for personal mobility. The NANO’s design and features combined with easy maneuverability and economic life cycle cost make it ideal for operating under a wide range of conditions. Stylish, comfortable TheTATA NANO, designed with a family in mind, has a roomy passenger compartment with generous leg space and head room. Four persons can comfortably sit inside the car. Four doors with high seating position make ingress and egress easy. It can effortlessly maneuver on busy roads in cities as well as in rural areas. Its mono-volume design ensures both space and maneuverability. The car is available in Standard, Deluxe & Luxury versions. All versions offer a wide range of body colours, and other accessories so that the car can be customised to an individual’s preferences and taste.
10 GENERAL 1.2 ABBREVIATION LIST DOJ Double Offset Joint DRL Daytime Running Light DTC Diagnostic Trouble Code (Diagnos tic Code) dB Decibel DG DG abbreviation is used for Crank Shaft Position Sensor Dia. Diameter ºK Degree Kelvin DIM. Dimension DP Distributor Pump E EBD Electronic Brake Distribution ECM Engine Control Module ECT Sensor Engine Coolant Temp. Sensor (Water Temp. Sensor, WTS) ECU Electronic control Unit EFI Electronic Fuel Injection EGR Exhaust Gas Recirculation, EGR Modulator: EGR VacuumModulator EGR SV EGR Solenoid Vacuum Switching Valve Valve, EGR VSV) EGRT Sensor EGRTemperature Sensor (Recircu lated Exhaust Gas Temp. Sensor) EGT Exhaust Gas Temperature ELR Emergency Locking Retractor EMS Engine Management System EOBD Engine On Board Diagnostics ESA Electronic SparkAdvance EVAP Evaporative Emission EVAP Evaporative Emission Canister Canister (Charcoal Canister) EVAP Valve EVAP Solenoid Purge Valve EVAP TVV EVAP Thermal Vacuum Valve (Bimetal Vacuum Switching Valve, BVSV) EVRV Electronic Vacuum Regulating Valve F FAW Front Axle Weight Fig. Figure FICD Fast Idle Control Device FIA Valve Fast IdleAir Valve (Air Valve) FIP Fuel Injection Pump Fr. Front FTS Fuel Temperature Sensor A ATDC After Top Dead Center API American Petroleum Institute ATF Automatic Transmission Fluid AC Alternating Current A/C Air Conditioning A/C SV Valve Air Conditioning Solenoid Vacuum Valve (A/C Vacuum Switching Valve, A/C VSV) ABDC After Bottom Dead Center ADCs device Analog to Digital convertor device A/F Air Fuel Mixture Ratio ABS Anti-lock brake system AMP Ampere AMF Air Mass Flow AOS Anti-Oscillation Strategy APC Accelerometer Pilot Control ARB Anti-Roll Bar B B+ Battery Positive Voltage BTDC Before Top Dead Center BBDC Before BottomDead Center BS II Bharat Stage II emission norms BS III Bharat Stage III emission norms C Cam Sensor Camshaft Position Sensor (Crank Angle Sensor, CAS) CO CarbonMonoxide CPP Switch Clutch Pedal Position Switch (Clutch Start Switch) CPU Central Processing Unit CKNL CheckNano Lamp (MIL) Service Ind. COM Computer Serial Port (RS-232) CRS Child Restraint System cc Cubic Centimeter CG Center of Gravity CIA Cold IdleAdvance cm Centimeter cm2 Square Centimeter D DC Direct Current DLC Data Link Connector (Assembly Line Diag. Link, ALDL, Serial Data Link, SDL) DOHC Double Over Head Camshaft
GENERAL 11 GENERAL LED Light Emitting Diode LH Left Hand M m3 Cubic Meters MAP ManifoldAbsolute Pressure MAF Sensor Mass Air Flow Sensor (Air Flow Sensor, AFS, Air Flow Meter, AFM) MAP Sensor ManifoldAbsolute Pressure Sensor (Pressure Sensor, PS) Max Maximum Min Minimum MIL Malfunction Indicator Lamp M/T Manual Transmission MKg Meter per Kilogram ml Milliliter MΩ Mega Ohms MPFI Multi-point Fuel Injection N N Newton NC Normally Closed NLS Needle Lift Sensor Nm Newton Meter (torque) NO Normally Open NOx Nitrogen Oxide NVH Noise Vibration Harshness O Ω Ohm OD Outside Diameter OBD On –Board Diagnostic system (Self – Diagnosis Function) OHC Over Head Camshaft O2S Oxygen Sensor O2 Oxygen P PAB Passenger Air Bag PAG Poly Alkaline Glycol PCRV Pressure-Conscious Regulating Valve PCBU Passenger Car Business Unit PDI Pre-Delivery Inspection PLA Progressive Low LoadAdvance PS Power Stroke P/S Power Steering PSP Switch Power Steering Pressure Switch PCV Positive Crank Case Ventilation G gm Gram GEN Generator GND Ground GVW Gross Vehicle Weight H HC Hydrocarbons HCU Hydraulic Control Unit HD Heavy Duty HLA Hydraulic LashAdjuster HP High Pressure hr Hour HRC Rockwell Hardness Number HVAC Heating, Ventilation, and Air Conditioning HO2S Heated Oxygen Sensor Hz Hertz I IAC Valve IdleAir Control Valve (Idle Speed Control Solenoid Valve, ISC Solenoid Valve) IAT Sensor IntakeAir Temperature Sensor (Air Temperature Sensor, ATS) IC Inter Cooler ID Inside Diameter IDI Indirect Injection IGN Ignition IIum Illumination IMV Inlet Metering Valve ISC Idle Speed Control (Valve) ISA Screw Idle SpeedAdjusting Screw I/O drivers Input Output drivers J JCAE Jonhson Control Automotive Electronics K kg Kilogram kg m Kilogrammeter KHz Kilohertz km Kilometer km/h Kilometer per hour kpa Kilo Pascal L L Litre LCD Liquid Crystal Display
12 GENERAL VNT Variable Nozzle Turbine (Turbo charger) VSV Vacuum Solenoid Valve W W Watt Wt Weight PWM Pulse with Modulation PSI Pounds per Square Inch. R RAW Rear Axle Weight Ref. Reference RFF Rollers Finger Flowers RFC Relay Radiator Fan Control Relay (Radiator Fan Motor Relay) RH Right Hand RPM Revolution per Minute RON Research Octane Number Rr Rear RRU Refrigerant Recovery Units S SAE Society of Automotive Engineers SFI Sequential Multi port Fuel Injection SOHC Single Over Head Camshaft SV Valve Solenoid VacuumValve s Seconds T TBI Throttle Body Fuel Injection (Single – Point Fuel Injection, SPI) TCM Transmission Control Module (A/T Controller, A/TControl Module) TC Turbocharger TCIC Turbocharger with Intercooler TDC Top Dead Center TO SV Valve Throttle Opener Solenoid Vacuum Valve (Throttle Opener Vacuum Switching Valve) TP Sensor Throttle Position Sensor TPC Valve Tank Pressure Control Valve (2Way Check Valve) TVV Thermal VacuumValve (Thermal Vacuum Switching valve, TVSV, Bimetal Vacuum Switching Valve, BVSV) TWC Three Way Catalytic Converter (Three Way Catalyst) 2WD 2Wheel Drive TMC TandemMaster Cylinder TPS Throttle Position Sensor V VIN Vehicle Identification Number VSS Vehicle Speed Sensor V Volts
GENERAL 13 GENERAL 1.3 LIFTING, JACKING, TOWING POINTS Using The Two Post Lift: When using a 2 post lift to raise the vehicle for servicing, always follow these points: • Observe the hoist manufacturer’s rating, safety precautions, and usage guidelines. • Make sure the hoist contacts the appropriate lift points on the vehicle undercarriage. • Balance the vehicle properly on the lift arms. • Once the lift raises the vehicle to the desired position, lockout the hoist arms to prevent movement. Following fig. shows the front and the rear jacking points by two post lift WARNING • Do not raise the hoist unless the vehicle is properly balanced on the lift arms. The vehicle may fall, causing severe injury, death or damage the vehicle. • Do not allow the lift arms to contact the vehicle fuel or brake lines, engine oil pan, fuel tank, or other parts susceptible to damage from the vehicle’s weight during lifting. Front Jacking Points Rear Jacking Points
14 GENERAL Using The Floor Jack (The Jack is located below co-driver seat): Use the jack at the locations as shown in the fig. below. Do not apply jack against any part which may get deformed. Jacking point locations are shown below. Kindly follow them for safe jacking. If front end or rear end of the vehicle is to be jacked, ensure thewheels are on ground and the parking brake is applied. WARNING Always engage the parking brake, place the vehicle in gear, and check the wheels on the opposite side of the vehicle when using a floor jack to raise the vehicle. Severe injury, death, and/or vehicle damage may occur if the vehicle rolls off the jack. Observe the floor jack manufacturer’s rating, safety precautions, and usage guidelines. If the jack is designed to fit in the lower body pinch joint (i.e. factory jack), the jacking locations are directly behind the front wheels and directly in front of the rear wheels. For non pinch joint style jacks, locate the floor jack lift head in the same locations as the lift hoist.
GENERAL 15 GENERAL TOWING THE VEHICLE Towing Guidelines: If towing the vehicle is necessary the best method of towing is by a flatbed tow vehicle. If a flatbed tow vehicle is not available, use a dolly or a rigid tow bar. Follow the additional points listed below: 1. Make sure the tow vehicle capacity is rated sufficiently 2. Always use the hazard indicators when towing a vehicle. 3. Avoid using a flexible cable or rope to tow the vehicle, particularly when the engine cannot provide power steering or brake assistance. 4. Where possible, keep the engine idling so that power steering assistance and brake vaccum are available. 5. Limit the speed to 20-30 kmph. 6. In case of brake failure, use the parking brake to control the car. 7. TATA MOTORS has not rated Nano to tow other vehicles or trailers. Do not use Nano for towing purposes. Recovery Points CAUTION The recovery / tow hook included in the vehicle tool kit is for recovery and low-speed towing only. Do not use the hook for long distance towing. Loss of control and/or vehicle damage may occur if the hook is used outside these guidelines. Recovery points are located in the front and rear bumpers of the vehicle. The vehicle tool kit contains a recovery/tow hook that threads into the recovery point at the front and rear bumpers. To access the rear recovery point, pry the cover out of the bumper and thread the hook into the hole at the recovery point. • Use the hook to free the vehicle from mud, snow, or to pull the vehicle onto a wrecker. • Always remove the hook and return to the vehicle tool kit when not in use. Transporting the vehicle : The towing eyes can be used to pull the vehicle onto a trailer or transporter for transporting purposes. To secure, only lash the vehicle down by the wheels or tyres. Your vehicle could otherwise be damaged.
16 GENERAL 1.4 TIGHTENING TORQUES OF STANDARD BOLTS & NUTS Whenever the tightening torques are not specified, use the following values for these fasteners. METRICNUT/BOLT IDENTIFICATIONMARKINGS Identify the grade of metric nuts and bolts by locating the marking on the nut or bolt head. Following fig. shows the typical grade marking locations for hardware used on the vehicle. Bolt/Nut Size Pitch (threads/ mm) Wrench Size (mm) Nut/Bolt Grade 8 (Nut) / 8.8 (Bolt) Torque 10 (Nut) / 10.9 (Bolt) Torque N.m kg-m N.m kg-m M6 1 10 8.5 - 10.0 0.85 - 1.0 12 - 14 1.2 - 1.4 1 13 - - 32 - 39 3.2 - 3.9 1.25 13 21 - 25 2.1 - 2.5 29 - 35 2.9 - 3.5 1 17 46 - 56 4.6 - 5.6 64 - 78 6.4 - 7.8 1.5 19 41 - 51 4.1 - 5.1 58 - 70 5.8 - 7.0 1.5 19 75 - 91 7.5 - 9.1 104 - 127 10.4 - 12.7 1.75 19 72 - 88 7.2 - 8.8 99 - 121 9.9 - 12.1 1.5 21 126 - 154 12.6 - 15.4 176 - 215 17.6 - 21.5 2 21 113 - 138 11.3 - 13.8 162 - 198 16.2 - 19.8 1.5 27 189 - 231 18.9 - 23.1 266 - 325 26.6 - 32.5 2 27 176 - 215 17.6 - 21.5 248 - 303 24.8 - 30.3 M8 M10 M12 M14 M16
GENERAL 17 GENERAL 1.5 AGGREGATE NUMBERING SYSTEM Chassis Numbering System : Chassis number consists of 17 digits (6 barrels) as indicated MAT XXXXXX X X X XXXXX 1 2 3 4 5 6 Location: The chassis number is punched on ‘B’ Pillar bottom (driver side) and Front cross member. Chassis Number - on ‘B’ pillar Chassis Number - Front crossmember Barrel 1: MAT It indicates vehicle produced in TATAMotors, India. Barrel 2: Chassis Type Number : 9.7:1 CR 612 202 Nano Std Nano Car with 273 SI MPFI BS - II Petrol Engine, Standard Version 612 201 Nano Std Nano Car with 273 SI MPFI BS - III Petrol Engine, Standard Version 612 203 Nano Std Nano Car with 273 SI MPFI BS - IV Petrol Engine, Standard Version 612 222 NanoCX Nano Car with 273 SI MPFI BS - II Petrol Engine, Deluxe Version with AC 612 221 NanoCX Nano Car with 273 SI MPFI BS - III Petrol Engine, Deluxe Version with AC 612 223 NanoCX Nano Car with 273 SI MPFI BS - IV Petrol Engine, Deluxe Version with AC 612 251 NanoLX Nano Car with 273 SI MPFI BS - III Petrol Engine, Luxury Version with HVAC 612 252 NanoLX Nano Car with 273 SI MPFI BS - IV Petrol Engine, Luxury Version with HVAC 10.3:1 CR 612 206 Nano Std. Nano Car with 273 SI MPFI BS - III Petrol Engine, Standard Version 612 207 Nano Std Nano Car with 273 SI MPFI BS - IV Petrol Engine, Standard Version 612 226 NanoCX Nano Car with 273 SI MPFI BS - III Petrol Engine, Deluxe Version with AC 612 227 NanoCX Nano Car with 273 SI MPFI BS - IV Petrol Engine, Deluxe Version with AC 612 256 NanoLX Nano Car with 273 SI MPFI BS - III Petrol Engine, Luxury Version with HVAC 612 257 NanoLX Nano Car with 273 SI MPFI BS - IV Petrol Engine, Luxury Version with HVAC
18 GENERAL ENGINENUMBERINGSYSTEM Engine Aggregate Number: 1 2 3 4 5 6 XXXXXXX XX X XX X XXXXX Engine Model / Type Engine Number Engine aggregate number consists of two sections as below. Section 1: Engine Model / Type (7 digits) (2-digits) XXXXXXX XX Section 2: Engine Number X XX X XXXXX Barrel 3: Production Year YEAR CODE YEAR CODE 2008 8 2011 B 2009 9 2012 C 2010 A 2013 D Barrel 4: Production Plant Location Provides the plant location where TATAMOTORS built the vehicle. CODE PLANT LOCATION 6 Dharwad 7,8,9,P, N,R,S,U,W Pune V,Y,Z Uttarakhand X Singur K Sanand Barrel 5: Production Month MONTH CODE MONTH CODE January A July G February B August H March C September J April D October K May E November N June F December P Barrel 6: Serial Number Cumulative serial number of chassis produced during the year at each plant location. Engine Model / Type Variation In Basic Model Barrel 1: Engine Model Name -273 MPFI Barrel 2: Engine Model Variation 01 273 MPFI Gasoline Engine, Manual Transmission, 624 cc,35PS@5500 rpm, Meeting BS-III emission norms. 03 273 MPFI Gasoline Engine, Manual Transmission, 624cc, 35PS @ 5500 rpm, Meeting BS-II emission norms. 04 273 MPFI Gasoline Engine, Manual Transmission, 624 cc with 10.3CR, 38 PS, Meeting BS-IV emission norms. 05 273 MPFI Gasoline Engine, Manual Transmission, 624 cc with 9.7CR, 35 PS @ 5250 (+ 250 rpm), Meeting BS-IV emission norms. 06 273 MPFI Gasoline Engine, Continuous Variable Transmission, 624cc with 10.3CR, 37PS, Meeting BS-IV emission norms. 07 273 MPFI Gasoline Engine, Manual Transmission, 624cc with 10.3CR, 37PS, Meeting BS-IV emission norms. Year Of Production Sr. Number Month Of Production Plant Location
GENERAL 19 GENERAL Barrel 3: Production Month MONTH CODE MONTH CODE January February March April May June A B C D E F July August September October November December G H J K N P Barrel 4: Production Year YEAR CODE YEAR CODE 2008 RZ 2012 XY 2009 QZ 2013 WY 2010 ZY 2014 VY 2011 YY 2015 UY Barrel 5: Production Plant Location Provides the plant location where TATAmotors built the vehicle CODE PLANT LOCATION S, R Uttarakhand 5, 6, 7, 8, 9, N, P, W, A, B, D, F, J Pune K Sanand Barrel 6: Serial Number Serial number of engine. The barrel consists of 5 digits and commences from serial number 00001 and will start every year on first January. TRANS AXLE NUMBERINGSYSTEM Basic Model Control (Veh. Type) Version Year Of Production Plant Code Serial No. 1 2 3 4 5 XX X X X X XXXXX Barrel 1: Transaxle Model Name The first part of the transaxle code provides the transaxlemodel name. Transaxle TA59 is represented by “41”. Barrel 2: Transaxle Control / Ratio. First digits indicates control of vehicle. 1 - For Normal control vehicle 3 - For Full forward control vehicle Second digits indicate gear ratio and the version of gear box. Barrel 3: Production Year YEAR CODE YEAR CODE 2008 RZ 2012 XY 2009 QZ 2013 WY 2010 ZY 2014 VY 2011 YY 2015 UY Barrel 4: Production Plant Location Provides the plant location where TATAMOTORS built the vehicle. CODE PLANT LOCATION S, R Uttarakhand 5, 6, 7, 8, 9, N, P, W, A, B, D, F, J Pune K Sanand Barrel 5: Serial Number Serial number of Transaxle. The barrel consists of 5 digits and commences from serial number 00001 and will start every year on First January.
20 GENERAL 1.6 TECHNICAL SPECIFICATION 1. ENGINE Model : 273 MPFI Type : 4 Stroke, water cooled, multipoint fuel injection system No. of Cylinders : 2 in-line Bore / Stroke : 73.5 mm x 73.5 mm. Capacity : 624 cc Max. Engine Output : 35 PS @ 5250 + 250 rpm (with 9.7:1 CR) as per IS:14599/ISO:1585 38 PS @ 5500 + 250 rpm (with 10.3:1 CR) as per IS:14599/ISO:1585 Max. Torque : 48 Nm @ 3000 + 500 rpm (with 9.7:1 CR) as per IS:14599/ISO:1585 51.8 Nm @ 4000 + 500 rpm (with 10.3:1 CR) as per IS:14599/ISO:1585 Firing Order : 1-2 Compression Ratio : 9.7 : 1 / 10.3 : 1 Coolant : 30 : 70 (For 9.7:1 CR) 50:50 (For 10.3:1 CR) (Water: ethylene glycol) Engine Oil Capacity : 2.5 Litre 2. CLUTCH Type : Single plate dry friction diaphragm type Outside dia. of clutch lining : 160 mm Friction Area : 212 cm2 3. TRANSAXLE Type : Synchromesh on all forward gears, sliding mesh for reverse gear. No. of gears : 4 forward & 1 reverse Gear ratios : 1st - 3.45 2nd - 1.94 3rd - 1.26 4th - 0.838 REV. - 3.08 (9.7:1 CR) / 3.07 (10.3:1 CR) Final drive ratio : 4.5 (9.7:1 CR) / 4.2 (10.3:1 CR) Model : TA 59 - 4/3.45 (4 Speed). 4. SUSPENSION Front : Independent, Lower wishbone, McPherson Strut type (Anti-roll bar is fitted in new vehicle) Rear : Independent, Semi-trailing arm with coil spring and gas filled shock absorbers. 5. STEERING Type : Mechanical Rack & Pinion steering gear with steering column. Steering Wheel : 350 mm dia. Ratio : 15 : 1 6. BRAKES Type : Dual circuit, H-type split hydraulic brake. Front Brakes : 180 mm dia. drum brake Rear Brakes : 180 mm dia. drum brake Parking Brakes : Lever type, Cable operated mechanical linkages acting on rear wheels. 7. WHEELS AND TYRES Tyres : Front :135/70R12 (Radial Tubeless)/ Rear: 155/65R12 (Radial Tubeless) Spare :135/70R12 (Radial Tubeless)
GENERAL 21 GENERAL Wheel Rims : 4B X 12 No. of Wheels : Front - 2 , Rear - 2, Spare Wheel - 1 8. FUELTANK Capacity : 15 litres 9. BODY : Semi-mono Volume, Mini size, 4 door, steel monocoque body. 10.ELECTRICAL SYSTEMS System Voltage : 12 Volts -ve earth Battery : 12V, 25 AH (STD. & CX) ; 12V, 35 AH (LX) Alternator : 12V, 70A (withAC) - (LX,CX) Capacity : 12V, 70A (without DFM) - (STD.) 11. PERFORMANCE Max. speed : 105 kmph 12.WEIGHTS (kg) (TOLERANCE AS PER EEC 92/21) Complete vehicle kerb weight : 600 (For STD) / 615 (For Deluxe) / 635 (For Luxury) as per ISO:1176 (with spare wheel & tools) Gross Vehicle Weight : 900 (For STD) / 915 (For Deluxe) / 935 (For Luxury) Payload : 300 13.PASSENGERCAPACITY : 2 front + 2 rear 14.LUGGAGESPACE Net inside loading space : 0.15 Cubic Meter Upto rear seat back rest; 0.5 Cubic Meter Upto \ front seat back rest when rear seats folded. 15. MAIN CHASSIS DIMENSIONS (IN mm) Wheel Base : 2230 Track Front : 1325 Track Rear : 1315 Front Overhang : 464 Rear Overhang : 405 Overall Length : 3099 Max. Width : 1495 - Over body / 1750 - Over ORVM Overall Height (Unladen/laden) : 1652 / 1613 Minimum Turning Circle Dia. : 8.0 m Minimum Turning Clearance . : 8.3 m Circle Dia Ground Clearance : 180 mm - Unladen CR - Compression Ration
22 GENERAL 1.7 VEHICLE DIMENSIONS
GENERAL 23 GENERAL Kindly use only following genuine oils, coolants , lubricants , anti rust & sound deadening coats, windscreen sealant, branded by TATA motors for optimum performance of your car... 1.8 FUEL, LUBRICANTS & COOLANTS FUEL : Vehicles with catalytic converter : Unleaded regular grade petrol confirming to IS 2796/ DIN 51607 (or equivalent) and octane rating not less than 88 RON for BS-II & 91 RON for BS-III and BS-IV is recommended to be used as fuel. (RON stands for Research Octane Number). LUBRICANTS : Engine Oil : (A) Oil filling cap (B) Oil level dipstick ITEM SPECIFICATION COMPANY&BRAND QTY. ENGINEOIL SAE 15W40 CASTROL-Castrol GTXCompact 15W40 2.5 Ltrs API SJ COOLANT 50:50 ratio SCCI - Golden Cruiser Premium 1400 NA 2 Ltrs (W/OAC) (50:50) premixed HPCL - Thanda Raja P TGO 3.8 Ltrs CASTROL - Radicool ( With HVAC) TRANSAXLE EP 80 CASTROL - Extreme Pressure 80 EP 1.15 Ltrs HPCL - Gear Oil EP 80 TGO BRAKE DOT 3 HPCL - Super Duty Brake Fluid DOT - 3 As FLUID CASTROL - Universal Brake Fluid DOT 3 required SCCI -Golden Cruiser TGBF DOT 3 ANTI RUST DINITROL - Dinitrol — TREATMENT WUERTH - Wuerth — and SOUND 3M - 3M — DEADENING WIND WUERTH - Wuerth — SCREEN 3M - 3M — SEALANT Car System - Car System —
24 GENERAL Oil Drain Plug Recommended grade of engine oil confirming to 15W40 API - SJ specification & range of ambient temperature at which these can be used are given in the table below. Ambient temp. Engine Oil in deg. C grade -10o & above SAE 15W/40 Transaxle : Use recommended brand of EP 80 grade oil. Oil Filling Cap Oil Level Plug Grease for steering rack : EP 2 Servo Gem. Oil Drain Plug
GENERAL 25 GENERAL COOLANTS 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 JIS K2234, Class 2. Brake Fluid : I S8654 (2001) /DOT 3. Windscreen Washer Antifrost Make - Antifrost- K Concentration - 1 : 5 For 00C 1 : 1 For 100C 2 : 5 For 160C 1 : 0 For 370C (A) Brake Fluid Reservoir (B) Windshield Washer Reservoir
26 GENERAL 1.9 SERVICE SCHEDULE 1-1.5 10 - 10.5 20 - 20.5 30 - 30.5 40 - 40.5 50 - 50.5 60 - 60.5 70 - 70.5 80 - 80.5 90 - 90.5 100 - 100.5 GENERAL 1 Wash the vehicle & clean condenser fins Every Service • • • • • • • • • • • 2 Check & top up fluids (if required) :Engine oil, Every Service • • • • • • • • • • • Coolant,Brake fluid, Wind screen washer fluid, Adjust wind screen washer nozzles if required. 3 Check fuel lines & transaxle housing for leakages 10000 • • • • • • • • • • 4 Check rubber boots & bushes for damage 20000 • • • • • 5 All standard checks as per job card (As applicable) Every Service • • • • • • • • • • • ENGINE 1 Clean air filter element (More frequent cleaning if dust 10000 • • • • • • • • • • condition is severe) 2 Replace air filter element (More frequent replacement. 30000 • • • if dust condition is severe) 3 Change Engine oil and Oil filter (10000 km OR 10000 • • • • • • • • • • 2 months whichever is earlier) 4 Change fuel filter 10000 • • • • • • • • • • 5 Check drive (Alternator & AC) belts for tension, Every Service • • • • • • • • • • • adjust tension if required, replace if necessary 6 Replace Alternator belt (40000 km OR two years 40000 • • whichever is earlier ) 7 Replace AC compressor belt, if required 100000 • 8 Check timing belt, replace if necessary 40000 • • 9 Replace timing belt 100000 • 10 Change coolant (40000 km OR 2 years whichever is 40000 • • earlier) 11 Replace Spark Plug 30000 • • • 12 Check HT lead on engine for cracks or deformation 40000 • • (Only visual check.Do not remove),replace if necessary. 13 Check the radiator core for dust, mud or mug 10000 • • • • • • • • • • accumulation and clean core from outside if required TRANSAXLE 1 Change Transaxle oil and clean drain plug. 20000 • • • • • 2 Inspect Driveshaft for Boot cuts, etc Every Service • • • • • • • • • • • 3 Check & Adjust free play of Clutch release cable Every Service • • • • • • • • • • • BRAKES 1 Check front and rear brake linings. Clean or 20000 • • • • • Replace, if necessary. 2 Clean the brake drums with air. 10000 • • • • • • • • • • 3 Replace brake fluid (40000 km OR 2 years whichever 40000 • • is earlier) and check brake system components for leakages SR FREQUENCY NO OPERATIONS in KM x 1000 km
GENERAL 27 GENERAL WHEELS & TYRES 1 Tyre Swapping with balancing ( Front with Front & 10000 • • • • • • • • • • Rear with Rear) FRONT & REAR SUSPENSION 1 Check and adjust wheel alignment 10000 • • • • • • • • • • ELECTRICAL 1 Check specific gravity and level of battery 10000 • • • • • • • • • • electrolyte (10000 km OR Every 1 year) 2 Check headlamp focusing 30000 • • • AC SYSTEM 1 Check AC / HVAC system for satisfactory Every Service • • • • • • • • • • • performance 2 Clean HVAC/AC unit air filter after Every 5000 3 Replace HVAC/AC unit air filter after Every 25000 DIAGNOSTIC 1 Check for the DTC in the ‘Engine Control Unit’using Every Service • • • • • • • • • • • diagnostic tool. Take corrective action if necessary Clear the DTCs SR FREQUENCY NO OPERATIONS in KM x 1000 km 1-1.5 10 - 10.5 20 - 20.5 30 - 30.5 40 - 40.5 50 - 50.5 60 - 60.5 70 - 70.5 80 - 80.5 90 - 90.5 100 - 100.5 Servicing of the car can be done at any TATAMOTORS Authorised Dealer Workshop, TATAMOTORS Authorised Service Centre (TASC) or TATAMOTORS Authorised Service Point (TASP). The details of their locations are given in this manual. Warranty claims can be settled by any TATA MOTORS Authorised Dealer for all failures, while all warranty claims excluding the consideration on the replacement of major aggregates, can be settled by any TASC which is authorised for handling warranty claims. TASPs will not handle warranty repairs. Service Instructions : The Tata Nano has been manufactured to give you economical and trouble free performance. To achieve this please follow the instructions as stated. Your Car is entitled to Three free services (labour only). The free service coupons are attached to the sales invoice. Please present these coupons to the servicing dealer while availing free services. 1st free service - At 1000-1500 km. OR 3 month whichever is eariler 2nd free service - At 10000-10500 km. OR 12 months whichever is eariler 3rd free service - At 20000-20500 km. OR 24 months whichever is eariler All services other than free services are chargeable.
28 GENERAL
PRECAUTIONS 29 PRECAUTIONS 2. PRECAUTIONS
30 PRECAUTIONS
PRECAUTIONS 31 PRECAUTIONS INTRODUCTION The symbols below are used in this document to alert the service technician to an area of potential hazard or to note something of importance. The warning, and caution text identifies the hazard type, location, and avoidance. WARNING: WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION: CAUTION indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate personal injury or property damage. NOTE: NOTE is used to highlight information useful to the technician to properly complete the work
32 PRECAUTIONS
PRECAUTIONS 33 PRECAUTIONS CONTENTS SR. NO. DESCRIPTION PAGE NO. 2.1 GENERAL SAFETY PRECAUTIONS 35 2.2 GENERAL SERVICE PRECAUTIONS 39
34 PRECAUTIONS
PRECAUTIONS 35 PRECAUTIONS 2.1 GENERAL SAFETY PRECAUTIONS SAFE SERVICE During vehicle maintenance or service, the service technician may be exposed to certain components or conditions including, but not limited to: exhaust gas (carbonmonoxide), fuel, oils, refrigerant, materials under pressure, rotating components, and electrical current. Any of these components or conditions has the potential to cause bodily injury or death if proper precautions are not taken. The servicing technician is obligated and responsible for identifying and recognizing these inherent hazards to protect themselves, other personnel , and proceeding safely in order to complete their required tasks. Fai lure to comply wi th any of these requirements could result in serious damage to the vehicle and the property where the vehicle is situated, as well as severe personal injury or death to the service technician and other people at the site. The individual performing the vehicle repair procedures outlined in this manual must possess independent training that will enable them to perform their assigned tasks properly and safely. The technician must read and understand the content in this manual and any referenced materials before performing any work the vehicle. When performing any service, the technician maintains responsibility for knowing and complying with any applicable governing standards and regulations. The contents of this manual include suggested best working practices and procedures related to the servicing of the specified vehicle. Safety warnings show potential areas of hazards. These procedures in this manual are issued for guidance only and do not take precedence over the previously stated individual responsibility and local safety regulations. SAFEWORKSHOP PRACTICES Protecting the environment Protect the environment by using proper disposal procedures for engine oil, engine coolant, fuel, tyres, brake lining, and batteries. Follow all governing regulations for proper disposal of these materials. Proper Attire Always wear proper attire when performing service on the vehicle. Proper attire guidelines to follow while servicing the vehicle include, but are not limited to, the following points: • Always wear approved safety glasses • Do not wear loose-fitting clothing; keep clothing away from moving parts while the engine is running. • Metal buttons and zippers will damage the painted finish. • To help protect yourself and your valuables, remove all rings, necklaces, watches, and other jewelry. • Wear steel-toe shoes to provide foot protection. • Using automotive work gloves when working on the vehicle may prevent burns, cuts, or other injuries. Work Area A proper work area is important to ensure safety while working on the vehicle. Follow the points listed below for a proper workplace: • Make sure the area has adequate ventilation to disperse harmful exhaust gases (carbonmonoxide) and other fumes. • Make sure the work area (includes floors, workbenches, tools) is clean and free from debris and clutter. • Do not allow other people or animals near the vehicle during service. • Always engage the parking brake and/or use wheel chocks to prevent the vehicle frommoving. Supporting the Vehicle Always make certain the vehicle is properly supported at the designated lift points for the method of lifting being used. A vehicle that is supported improperly may fall, causing damage to the vehicle, severe personal injury, or death. Refer to “Section 1 - General” in this manual for instructions on how to properly support the vehicle.
36 PRECAUTIONS FLAMMABLEMATERIALS WARNING: Fuel and fuel vapors are extremely flammable! Use extreme caution when working with fuel, otherwise a fire or explosion may occur, causing severe personal injury or death. CAUTION: Petrol and Diesel fuels are irritants, Wash hands thoroughly and immediately after handling fuel. Exposure to flammable materials such as petrol and diesel fuel is possible when performing vehicle service. The list below provides points to follow when working with flammable materials: • Minimize skin contact with any flammable materials. • Properly ventilate the area so that the flammable fumes do not become concentrated. • Never smoke or have an open flame in the work area. • Always check for leaks after fuel system repairs. • Clean up fuel spills with absorbent material immediately, using proper disposal procedures. CAUTION: Do not reverse the negative (-) and positive (+) battery cable connections; serious damage to the vehicle electrical system will result. ELECTRICAL SYSTEMPRECAUTIONS WARNING: • Keep all open flames and sparks away from the battery! During normal operation, batteries generate dangerous explosive gases that may explode if exposed to open flames or sparks. • Battery electrolyte is harmful and will cause chemical burns and damage to vehicle surfaces. Wear a protective face shield /clothing and take care when working with the battery. When working with the vehicle electronic components, observe the following points: Always disconnect the negative (-) battery cable, unless battery voltage is required to perform the diagnosis or repair. Always disconnect the negative (-) battery cable, before disconnecting (+) cable. While reinstalling the battery, first connect the positive (+) cable and then the negative (-) battery cable. Before disconnecting any components, make sure the negative battery cable is disconnected or the ignition switch is rotated to the “OFF” position.
PRECAUTIONS 37 PRECAUTIONS When reconnecting the wire harness or components, make sure that connectors and terminals are fully engaged. Electrical malfunction may occur otherwise. Test wiring connections by ‘wiggling’ the wires in the connector (inset). Repair or replace wiring as necessary. Dirty, corroded, loose, or damaged terminals/wiring insulation creates poor connectivity, short circuits, and other malfunctions. Clean or repair terminals/ wiring as necessary. Static electricity will damage the vehicle ECU (Engine Control Unit) and other sensitive components. Avoid touching the terminals and connectors of sensitive electrical components. When testing sensitive components and electrical circuits with an ohmmeter or voltmeter, make sure that the probes will not damage the electrical system. Do not expose the ECU or other sensitive electrical components to water, heat or shock of any type. Damage to the component will occur if exposed to any of these conditions. When disengaging electrical connectors, never pull on the wire. Always pull the connector apart by disengaging the locking tab and pulling on the connector body. Damage to the wiring or connector will occur otherwise.
38 PRECAUTIONS COOLING SYSTEMPRECAUTIONS WARNING: • Coolant is poisonous to humans and animals. Use care when handling coolant, otherwise death or injury may occur. • Never loosen or remove the coolant reservoir cap while the engine cooling system is still hot. Removing the reservoir cap may allow hot coolant or steam to escape, causing severe burns. When working with the engine or the engine coolant system, observe the following precautions: • The electric radiator fan, may operate at any time. Use care when working near the radiator fan. Disconnect the battery negative (-) cable whenever possible. • Always add the recommended brand and mixture of coolant to the engine cooling system. Using a mixture or brand other than recommended may damage the cooling system components. Refer to “Section 1 - General” in this manual • Engine coolant is poisonous. Do not ingest or allow animals to ingest engine coolant. Always dispose of engine coolant properly to avoid harming the environment. CATALYTIC CONVERTER / EXHAUST SYSTEM PRECAUTIONS WARNING: • Engine emits deadly carbon monoxide (CO) gas, which will cause asphyxiation in enclosed areas. Always make sure the work area is well ventilated. • Fire/Burn Hazard–Exhaust system components become extremely hot. Always allow sufficient cool ing time before working with exhaust components and never park over flammable material. Severe burns will occur if skin contact is made with hot exhaust system components. • Do not allow large quantities of unburned fuel to enter the catalytic converter (i.e. from improperly performed compression test). The catalytic converter and other emission components are easily damaged by unused fuel. • Use only UNLEADED fuel in petrol vehicles. Damage to the catalytic converter and/or emission components will occur if the proper fuel is not used in the vehicle. • Do not run the vehicle with a low fuel level. Damage to the catalytic converter may occur if the engine misfires.
PRECAUTIONS 39 PRECAUTIONS 5. When removing or disconnecting components with many lines, hose, or electrical connections, label each connection to aid in the proper connection during installation. 2.2 GENERAL SERVICE PRECAUTIONS 1. Investigate the cause of the complaint or problem prior to removing or disassembling the component for repair. Investigating will help ensure proper diagnosis of the problem. 2. Be certain to follow procedures and specification guidelines (i.e. torque values) when performing repairs. 3. Always use the proper tool for the job, particularly if the repair procedure requires use of a special tool. Personal injury or damage may occur to the part or vehicle if the proper tool is not used. 4. Protect the fenders, seats or other body panels fromdamage when performing work on the vehicle. Use a proper cover or other suitable protection while carrying out repairs. 6. Always plug / cap open lines or ports to avoid contamination of that system with dirt or debris. 7. Never reuse consumable parts or hardware such as oil seals, gaskets, O-rings, lock washers, selflocking nuts, split pins, pre coated fasteners etc. Always replace these parts with new, unused items. 8. When loosening or disconnecting fuel, coolant, or brake line connections, always check for leaks after reconnecting or tightening the connection. 9. Always use the recommend brand, type, and quantity of fuel, fluids, and lubricants. Refer to the table located in “Section 1 – General” of this manual for the recommended fluids.
40 PRECAUTIONS 10.When disassembling a component, place the parts in a clean tray in the order of disassembly. This aid with reassembly of the component as well as prevent parts from becoming lost.
ENGINE 273 MPFI 41 ENGINE 3. ENGINE 273 MPFI
42 ENGINE 273 MPFI
ENGINE 273 MPFI 43 ENGINE TATA NANO (PETROL) is Powered by 273 MPFI BS-III or BS-IV Engine which produces 35 PS@5250 + 250 rpm (with 9.7:1 CR) / 38 PS@ 5500 + 250 rpm (with 10.3:1 CR) & Torque of 48 Nm @ 3000 + 500 rpm (with 9.7:1 CR) / 51.8 Nm @ 4000 + 500 rpm (with 10.3:1 CR) TATA 273 SI MPFI is a Spark Ignition Multipoint Fuel Injection Water Cooled Petrol Engine with SOHC (Single Over Head Camshaft) valve mechanism. TATA 273 SI MPFI engine is fitted with 32 Bit inbuilt microprocessor intelligence into the engine control system. TATA 273 SI MPFI engine provides better engine performance, better cold starting & warm up, better fuel economy, quick response & conforms to the BS-III or BS-IV emission norms. INTRODUCTION
44 ENGINE 273 MPFI
ENGINE 273 MPFI 45 ENGINE 3.1 GENERAL INFORMATION 49 TECHNICALSPECIFICATIONS 51 FEATURES OF 273 MPFI ENGINE 52 TIGHTENINGTORQUE 53 SPECIAL TOOLS & EQUIPMENTS 55 GENERAL SYMPTOMS & DIAGNOSTICS 59 3.2 ONVEHICLEPROCEDURES 63 IMPORTANTON VEHICLEMAINTENANCE PROCEDURES 65 ENGINEOIL REPLACEMENT 67 OILFILTERREPLACEMENT 68 AIR FILTER ELEMENTCLEANINGAND REPLACEMENT 69 FUEL FILTER REPLACEMENT 70 TAPPETSETTING 71 ALTERNATOR BELT - REMOVAL & REFITMENT PROCEDURE 72 COMPRESSOR BELT - REMOVAL & REFITMENT PROCEDURE 73 TIMING BELT - REMOVAL& REFITMENT PROCEDURE 75 CYLINDER HEAD - REMOVAL& REFITMENT PROCEDURE 80 COMPRESSION PRESSURE CHECKINGPROCEDURE 83 3.3 ENGINEMECHANICAL 85 PRELIMINARY INSPECTIONOF ENGINE 87 REMOVAL OF ENGINE FROM VEHICLE 89 3.3.1 CYLINDERHEAD 93 GENERAL DESCRIPTION 95 EXPLODED VIEW 96 CYLINDERHEADOVERHAUL 98 CYLINDER HEAD REMOVAL FROM ENGINE BLOCK 98 DISMANTLINGOF CYLINDER HEAD SUBASSEMBLIES 102 INSPECTION & REPAIR DATA 105 ASSEMBLY OF CYLINDER HEAD SUBASSEMBLIES 112 3.3.2 ENGINEBLOCK 117 GENERAL DESCRIPTION 119 EXPLODED VIEW 120 ENGINE BLOCK OVERHAUL 122 DISMANTLINGOF ENGINE BLOCK SUBASSEMBLIES 122 INSPECTION & REPAIR DATA 127 ASSEMBLY OF ENGINE BLOCK SUBASSEMBLIES 137 REFITMENTOF ENGINEACCESSORIES 150 ENGINETESTING 152 INSTALLATIONOF ENGINEON VEHICLE 152 CONTENTS SR. NO. DESCRIPTION PAGE NO.
46 ENGINE 273 MPFI 3.4 ACCELERATOR 153 EXPLODED VIEWS & CABLE ROUTING 155 SYSTEMMAINTENANCE 157 3.5 COOLINGSYSTEM 161 GENERAL DESCRIPTION 163 SYSTEMSCHEMATICS 163 EXPLODED VIEWS 164 SPECIFICATIONS 166 SYSTEM COMPONENTS 167 SYSTEM MAINTENANCE 168 3.6 LUBRICATIONSYSTEM 177 GENERAL DESCRIPTION 179 SYSTEMSCHEMATICS 179 SPECIFICATIONS 180 SYSTEM MAINTENANCE 181 3.7 FUEL SYSTEM 193 GENERAL DESCRIPTION 195 SYSTEMSCHEMATICS 195 EXPLODED VIEWS 196 PRECAUTIONS, SPECIFICATIONSANDTIGHTENINGTORQUE 197 SYSTEM COMPONENTS 198 SYSTEM MAINTENANCE 202 EVAPORATIVE EMISSION CONTROLSYSTEM 212 3.8 INTAKE SYSTEM 215 GENERAL DESCRIPTION 217 EXPLODED VIEWS 218 SYSTEM MAINTENANCE 219 3.9 EXHAUST SYSTEM 225 GENERAL DESCRIPTION 227 EXPLODED VIEWS 228 TIGHTENINGTORQUE 229 SYSTEM COMPONENTS 230 SYSTEM MAINTENANCE 232 3.10 IGNITION SYSTEM 237 GENERAL DESCRIPTION 239 SYSTEMSCHEMATICS 239 SYSTEM MAINTENANCE 240 CONTENTS SR. NO. DESCRIPTION PAGE NO.
ENGINE 273 MPFI 47 ENGINE SR. NO. DESCRIPTION PAGE NO. 3.11 ENGINEMANAGEMENTSYSTEM 245 ABBREVIATIONS 247 AN OVERVIEW 248 3.11.1 ECU (ELECTRONICCONTROLUNIT) 249 ECU BLOCK DIAGRAM 250 ECU PINASSIGNMENTDETAILS 251 ECUHANDLINGANDCARE 252 ECUON VEHICLE REMOVAL, INSPECTIONAND REFITMENT PROCEDURE 253 3.11.2 SENSORS 254 CRANK SHAFT POSITION SENSOR 254 COOLANTTEMPERATURE SENSOR 255 TMAP SENSOR 257 KNOCK SENSOR 258 THROTTLEPOSITIONSENSOR 259 LAMBDA (OXYGEN) SENSOR 262 VEHICLE SPEED SENSOR 263 3.11.3 ACTUATORS 265 CANISTER PURGE VALVE 265 FUEL INJECTOR 266 IGNITIONCOIL 268 INTAKEAIR CONTROLVALVE (IACV) 271 COMPONENTFITMENTDATA 273 3.11.4 DTC (DIAGNOSTIC TROUBLECODE) 277 DTCLIST 279 LAPTOP BASEDDIAGNOSTIC TESTER 287 BLINK CODE 302 3.11.5 TROUBLE SHOOTINGANDDIAGNOSIS 304 REPAIRINGSTEPS 304 VEHICLE TROUBLE SHOOTING FLOWCHART 305 SENSORANDACTUATORTESTING 306 EMERGENCY SERVICE TIPS 308 CONTENTS
48 ENGINE 273 MPFI
ENGINE 273 MPFI 49 ENGINE 3.1 GENERAL INFORMATION
50 ENGINE 273 MPFI
ENGINE 273 MPFI 51 ENGINE MODEL 273 MPFI TYPE 4 Stroke, water cooled, multipoint fuel injection, SOHC NO. OF CYLINDERS 2 in-line BORE/STROKE 73.5 mm x 73.5 mm ENGINECAPACITY 624 cc MAX. ENGINE POWEROUTPUT 35 PS @ 5250 + 250 rpm (9.7:1 CR) / 38 PS @ 5500 + 250 rpm (10.3:1 CR) MAX. TORQUE 48 Nm @ 3000 + 500 rpm (9.7:1 CR) /51.8 Nm @ 3000 + 500 rpm (10.3:1 CR) COMPRESSIONRATIO 9.7 : 1 / 10.3 : 1 FIRINGORDER 1 - 2 (3600 Firing) FUEL SYSTEM Sequential Injection with Close Loop Air / Fuel Control Supported by Bosch EMS. IGNITIONSYSTEM Waste Spark Ignition supported by Bosch EMS. EMISSIONCOMPLIANCE BS III or BS IV ENGINEOILCAPACITY 2.5 Litre (Drain & Refill) / 2.7 Litre (Engine overhaul) COOLANTCAPACITY 2 Litres without HVAC ; 3.8 litres with HVAC COOLANTSPECIFICATION 50 : 50 (For 10.3:1 CR) / 30 : 70 (For 9.7:1 CR) AIRFILTER Dry (Paper) Type OILFILTER Spin-On Full Flow Paper Type FUEL INJECTIONPUMP Rotary Type with Electric Stop Solenoid EMS BOSCH EMS RECOMMENDEDOIL SAE 15W40API-SJ FUELTANK CAPACITY 15 Litres CR - COMPRESSION RATIO TECHNICAL SPECIFICATIONS :
52 ENGINE 273 MPFI FEATURES OF 273 MPFI ENGINE TATA 273 MPFI engine uses BOSCH Multipoint fuel injection system. Various sensors located at various points in the engine, sense important parameters of the engine operation & send signals to a ECU located in engine compartment. Based on predetermined engine mapping, the ECU precisely controls the fuel delivery injection timing to ensure optimum fuel utilization with minimum emission. TATA273 MPFI engine has following features: Cranking Mode: • Better Engine Performance Optimum fuel quantity and Spark timing is calculated by ECU for any operating condition. • Better Cold Starting and Warm up ECU identifies cranking condition and quick starting is ensured by providing sufficient fuel quantity and optimum spark timing. For quicker warm up, idling speed is increased as a function of Water and Air temperature inputs to the ECU. • Good Startability due to Reduced Engine Load ECU identifies cranking mode & switches ‘OFF’ the A/C relay & CPV (Canister Purge Valve). Idling Mode: • Better Idling Stability ECU receives inputs from Water Temp., Engine Load, Battery Voltage, Manifold Vaccum & Engine Speed by closed loop control which facilitate ECU to achieve better idle speed stability. • Better Idling Stability whenever idle state changes ISC Valve position (steps) is continuously memorized & renewed in memory. • ’LIMP HOME’ Idle Speed Vehicle Downtime/Breakdown ProtectionAgainst failure of following Sensor is achieved by ’LIMP HOME’ Idle Speed feature. 1.Throttle Position Sensor (TPS) 2.T-MAP Sensor 3.Vehicle Speed Sensor 4.Water Temp. Sensor Engine Stall Protection: When engine RPM is low, ECU cuts A/C relay which faci l itate better idle stabi l ity & user convenience. Acceleration Mode: • High Engine Speed Control Fuel is cut beyond 5600 rpm to avoid adverse effect on engine safety. • High Vehicle Speed Control Fuel is cut beyond 105 kmph to avoid adverse effect on vehicle safety. • Variable Acceleration Enrichment Transient condition is identified and suitable fuel enrichment is provided. • Emission The petrol injection engine has low emissions because the air fuel ratio is control led to stoichiometric using lambda sensor. Faster warm up from cold start ensures early operation of catalytic converter in turn reducing the emission. • Fuel Economy The 273 MPFI engine has a better fuel economy because the engine is optimized at each operating point, discretely. • Quick Response The 273 MPFI engine will have a better driveability and better acceleration since the fuel delivery and spark timing are controlled by ECU, which quickly responds to engine/Driver demands.
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