SERVICE MANUAL TATA PUNCH
SERVICE MANUAL TATA PUNCH - BOOK 1
Developed by: Technical Literature Centre. Release Date: June 2021 / First Edition. The information provided in this manual is based on the latest product information available at the time of publication. C Copyright 2021 TATA MOTORS All rights reserved. The information in this manual shall not be reproduced or copied, in whole or in part, in any form without written permission from TATA MOTORS Passenger Vehicles Limited. Vehicles are subject to modification in design, specification and equipment. Also refer the Service Circulars released by Customer Support about product & procedures.
INTRODUCTION This Service manual provides information pertaining to technical Specifications, repair, maintenance and overhaul of different aggregates fitted on TATA HORNBILL. All the data contained in this manual is based on the latest product information available at the time of publication and with the assumption that the person is well aware of general Automobile practices. This manual emphasizes the special features of the vehicle and thus benefits our workman, who is conversant with general Automobile practices. For ease of use, this workshop manual is divided into 3 volumes, comprising several sections. Each aggregate has a separate section.ss THE BOOK– 1 CONTAINS PETROL ENGINE (1.2L NG NA) TRANSAXLE MT (TA65*, 5 Speed) CLUTCH MT (200mm) DRIVESHAFT MT TRANSAXLE AMT (TA65*, 5 Speed) CLUTCH AMT (200mm) DRIVESHAFT AMT AMT KIT AMT CONSOLE SUSPENSION WHEELS & TYRES STEERING (MANDO) BRAKE HVAC (ETC) FATC BODY ELECTRICAL SRS THE BOOK– 2 CONTAINS Diagnostic Trouble Shooting Codes (DTC) List of All ECU’s THE BOOK– 3 CONTAINS Service Schematics
TABLE OF CONTENTS 1 PETROL ENGINE (1.2 L NG NA) 2 TRANSAXLE MT (TA 65*, 5 SPEED) 3 CLUTCH MT (200MM) 4 DRIVESHAFT MT 5 TRANSAXLE AMT (TA 65*, 5 SPEED) 6 CLUTCH AMT (200MM) 7 DRIVESHAFT AMT 8 AMT KIT 9 AMT CONSOLE 10 SUSPENSION 11 WHEELS & TYRES 12 STEERING 13 BRAKE(ABS) 14 HVAC 15 FATC 16 BODY 17 ELECTRICAL 18 SRS
ENGINE 1.2L REVOTRON ENGINE
1.2L REVOTRON ENGINE CONTENTS 1. GENERAL INFORMATION ............................................................................................................... 1 A ENGINE INTRODUCTION .................................................................................................. 1 B ELECTRONIC FUEL INJECTION CONTROL ..................................................................... 2 C TECHNICAL SPECIFICATION............................................................................................ 3 D SPECIAL TOOLS................................................................................................................ 4 E ASSEMBLY CLEARANCES................................................................................................ 7 F SEALANTS ......................................................................................................................... 7 G LEAKAGE RATES .............................................................................................................. 7 H OIL & LUBRICANTS ........................................................................................................... 8 I SERVICE SCHEDULE........................................................................................................ 9 2. TROUBLESHOOTING ........................................................................................................... 11 3. CONSTRUCTIONAL AND SERVICE DETAILS ............................................................................ 17 A ENGINE LIFTING.............................................................................................................. 17 B INTAKE MANIFOLD.......................................................................................................... 18 C CYLINDER HEAD AND COVER....................................................................................... 20 D CYLINDER HEAD-A ......................................................................................................... 22 E CYLINDER HEAD-B ......................................................................................................... 24 F CYLINDER BLOCK........................................................................................................... 25 G OIL SUMP......................................................................................................................... 27 H MOVING PARTS............................................................................................................... 28 I ENGINE TIMING............................................................................................................... 30 J EXHAUST MANIFOLD...................................................................................................... 32 K FUEL INJECTION EQUIPMENT ....................................................................................... 33 L LUBRICATION PUMP AND COMPONENTS .................................................................... 34 M AIR INTAKE SYSTEM ...................................................................................................... 36
1.2L REVOTRON ENGINE N SPECIAL INSTALLATION................................................................................................. 38 O ENGINE SUSPENSION.................................................................................................... 41 4. ENGINE TESTS AND MAINTENANCE ......................................................................................... 43 A PRELIMINARY INSPECTION ........................................................................................... 43 B ENGINE TESTS……………………… ........................................ ……………………………..44 I ENGINE COMPRESSION TEST................................................................................. 44 II ENGINE OIL CONSUMPTION TEST .......................................................................... 45 III ENGINE OIL PRESSURE TEST ................................................................................. 46 C REGULAR MAINTENANCE…… ....................................................................................... 47 I ENGINE OIL AND FILTER CHANGE .......................................................................... 47 II ENGINE COOLANT REPLACEMENT......................................................................... 48 III AIR FILTER ELEMENT REPLACEMENT.................................................................... 52 IV SPARK PLUG REPLACEMENT.................................................................................. 53 V AC COMPRESSOR AND ALTERNATOR BELT REPLACEMENT .............................. 55 5. REPAIR AND INSPECTION DETAILS .......................................................................................... 56 A ACCESSORY DRIVING BELT.......................................................................................... 56 B TIMING CHAIN ................................................................................................................. 56 C CYLINDER HEAD............................................................................................................. 56 D VALVES............................................................................................................................ 57 E CYLINDER HEAD VALVE SEATS .................................................................................... 58 F ROCKER ARM AND SHAFTS .......................................................................................... 58 G HYDRAULIC LASH ADJUSTER ....................................................................................... 59 H CAMSHAFT ...................................................................................................................... 59 I PISTON AND PISTON RINGS.......................................................................................... 60 J CONNECTING RODS....................................................................................................... 61 K CRANKSHAFT.................................................................................................................. 62
1.2L REVOTRON ENGINE L CRANK CASE................................................................................................................... 63 M FUEL TANK ...................................................................................................................... 64 N CANISTER PURGE VALVE.............................................................................................. 64 O CANISTER........................................................................................................................ 65 6. ENGINE SYSTEM ............................................................................................................................. 66 A AIR INTAKE SYSTEM ...................................................................................................... 66 B BLOW BY SYSTEM.......................................................................................................... 68 C LUBRICATION SYSTEM .................................................................................................. 69 D EXHAUST SYSTEM ......................................................................................................... 73 E COOLING SYSTEM.......................................................................................................... 75 F FUEL SYSTEM................................................................................................................. 78 7. ENGINE ON VEHICLE SERVICE PROCEDURE .......................................................................... 81 A FUSE BOX SHIFTING PROCEDURE............................................................................... 81 B ENGINE REMOVAL AND INSTALLATION ....................................................................... 82 C AIR FILTER ASSY ............................................................................................................ 88 D FUEL RAIL AND INJECTOR............................................................................................. 89 E SPARK PLUG................................................................................................................... 90 F EXHAUST SYSTEM ......................................................................................................... 90 G FUEL SYSTEM................................................................................................................. 94 H COOLING SYSTEM.......................................................................................................... 99 I COMPRESSOR AND ALTERNATOR BELT REMOVAL ................................................. 103 J TIMING BELT REMOVAL ............................................................................................... 104 K WATER PUMP................................................................................................................ 107 L SOLENOID ..................................................................................................................... 108 M ELECTRONIC THROTTLE BODY .................................................................................. 109 N STARTER MOTOR......................................................................................................... 109
1.2L REVOTRON ENGINE O ALTERNATOR................................................................................................................ 110 P COMPRESSOR .............................................................................................................. 110 8. ENGINE OVEHAULING (ON OVERHAUL STAND) .................................................................. 112 A ENGINE DIS-ASSEMBLY .............................................................................................. 112 I REMOVAL OF INTAKE MANIFOLD.......................................................................... 112 II REMOVAL OF EXHAUST MANIFOLD...................................................................... 113 III REMOVAL OF OIL SUMP......................................................................................... 115 IV REMOVAL OF SENSORS ........................................................................................ 115 V REMOVAL OF ACCESSORIES ................................................................................ 116 VI REMOVAL OF TIMING CHAIN ................................................................................. 119 VII REMOVAL OF CYLINDER HEAD AND CAMSHAFT ................................................ 121 VIII REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES ............................................. 122 IX REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES ........................................... 123 B ENGINE ASSEMBLY ..................................................................................................... 127 I ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES ......................................... 127 II ASSEMBLY OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES ................. 131 III ASSEMBLY OF CYLINDER HEAD SUB-ASSEMBLIES............................................ 133 IV ASSEMBLY OF CYLINDER HEAD ........................................................................... 134 V ASSEMBLY OF ENGINE TIMING CHAIN ................................................................. 136 VI ASSEMBLY OF ACCESSORIES DRIVING BELT ..................................................... 139 VII ASSEMBLY OF SENSORS AND PERIPHERALS..................................................... 141 VIII ASSEMBLY OF OIL SUMP ....................................................................................... 142 IX ASSEMBLY OF EXHAUST MANIFOLD .................................................................... 142 X ASSEMBLY OF INTAKE MANIFOLD S..................................................................... 144 9. ENGINE MANAGEMENT SYSTEM .............................................................................................. 145 A ABBREVIATIONS ........................................................................................................... 145
1.2L REVOTRON ENGINE B AN OVERVIEW............................................................................................................... 146 C ELECTRONIC CONTROL UNIT ..................................................................................... 147 D SENSORS… ................................................................................................................... 152 I T-MAP SENSOR....................................................................................................... 153 II LAMBDA SENSOR ................................................................................................... 154 III CAMSHAFT POSITION SENSOR............................................................................. 156 IV KNOCK SENSOR ..................................................................................................... 157 V CRANKSHAFT POSITION SENSOR ........................................................................ 158 VI COOLANT TEMPERATURE SENSOR ..................................................................... 159 E ACTUATORS.. ................................................................................................................ 161 I IGNITION COIL ......................................................................................................... 162 II PURGE CONTROL VALVE....................................................................................... 163 III SOLENOID VALVE (OCV) ........................................................................................ 164 IV FUEL INJECTOR ...................................................................................................... 165 V ELECTRONIC THROTTLE BODY ............................................................................ 166 F SWITCH.......................................................................................................................... 168 I OIL PRESSURE SWITCH......................................................................................... 168 II THROTTLE PEDAL SENSOR................................................................................... 169 III CLUTCH SWITCH..................................................................................................... 170 IV REVERSE LAMP SWITCH ....................................................................................... 170 V BRAKE SWITCH....................................................................................................... 171 VI VEHICLW SPEED SENSOR..................................................................................... 172
1.2L REVOTRON ENGINE 1 1. GENERAL INFORMATION: A. ENGINE INTRODUCTION : Description: The “1.2L REVOTRON" is a 1200 CC, 3-Cylinder Gasoline Engine, with MPFI, VCTi and BS-VI compliant. Features: Stiffened Aluminium Crankcase with Aluminium bed plate structure. Double Overhead Camshaft (DOHC) with 4 valves per cylinder. Variable cam timing- Intake (VCTi) Timing chain drive system Three stage oil pump Weight optimized hollow cam shafts Drive by wire technology (Electronic Throttle Control). Plastic intake manifold and head cover Light weight piston assembly Auto tensioner auxillary belt drive system Engine is BSVI OBD-II compliant. Advance Engine Management System from M/s BOSCH providing precise control for performance and emissions. Multi Point Fuel Injection (MPFI) Graded bearing system for Main bearing and con-rod big end.
1.2L REVOTRON ENGINE 2 B. Electronic Control : The engine management software in the vehicle's Engine Control Unit (ECU) controls the fuel injection and ignition system using a variety of sensors that provides the engine operating conditions and operates input information. The ECU includes self-diagnosis to help pinpoint any system malfunctions. Refer to the "Engine Management System" portion of this section for additional information. The MPFI type of fuel injection offers many advantages over a single point fuel injection system or a carburetor engine. The following paragraphs describe the advantages of the electronic fuel injected engine. Improved Engine Performance : The ECU precisely and instantly controls optimum fuel delivery and spark timing according to the operating conditions, inputs from the engine sensors, and operator input. This control improves vehicle response and acceleration. Increased Fuel Economy : The electronic fuel injection system allows the REVOTRON 110 engine to be Bharat Stage VI (BS-VI) compliant. By electronically controlling the air/fuel ratio of the combustion process, the engine maintains an air/fuel closer to stoichiometric (14.7:1, air to fuel), the optimum ratio for complete combustion of the fuel mixture. Decreased Exhaust Emissions : The use of electronic fuel injection also decreases exhaust emissions because the air/fuel ratio is precisely controlled through the ECU for operating conditions and driver input. The catalytic convertor also helps reduce exhaust emissions and specially manufactured to the fuel injection system's operation. Improved Cold Starting and Operation : By detecting the atmospheric and engine conditions in which the operator is starting and driving the vehicle, the ECU can adjust fuel mixture and ignition timing to help the vehicle start more easily when cold and to warm up faster. The MPFI ECU achieves all of these advantages by instantly compensating for changes in operating conditions and sensors inputs. This compensation is faster and more efficient than a mechanical system or human input.
1.2L REVOTRON ENGINE 3 C. TECHNICAL SPECIFICATION : Model :- 1.2L NG NA REVOTRON Description REVOTRON 1.2L NG NA Engine, BSVI Type :- Gasoline 4-Stroke MPFI, inline 3 cylinder with 4 valves per cylinder Engine Configuration :- Transverse mounted inline 3-cylinder engine Engine Management System :- BOSCH Engine Management System Bore/Stroke :- 77 mm X 85.8 mm Engine Capacity :- 1199 cc Radiator Coolant :- Class II/JIS K2234 TATA SS7700, Coolant ratio 60:40 Compression Ratio :- 11.3 Maximum Engine Power Output :- 63 kW @ 6000rpm Maximum Engine Torque Output :- 113 Nm @ 3300 rpm Engine Firing Order :- 1-2-3 Oil Capacity :- 3.5 L Cooling System Capacity :- 4 lit, (water + coolant) Spark Plug Type :- FM : RER8MC - (0.8 to 0.9 mm gap) Air Filter :- Dry (paper) type Oil Filter :- Spin on Full flow Paper type Fuel Filter Not Applicable Timing :- Chain Drive VCT DENSO Controller Assy Emission Norms :- Bharat Stage VI Compliance Ignition Coil Details :- Epoxy Molded Coil Type Ignition Coil (Supply Voltage 5-16V)
1.2L REVOTRON ENGINE 4 D. SPECIAL TOOLS : SR NO. TOOL DESCRIPTION TOOL PART NUMBER APPLICATION 1 Stand-Engine Support 5424 5890 2401 2 Overhauling stand 5425 5890 0605 3 Bracket LHEngine Overhauling stand 5424 5890 2403 4 Bracket RHEngine Overhauling stand 5424 5890 2402 5 Adapter 5438 5890 2403
1.2L REVOTRON ENGINE 5 SR NO. TOOL DESCRIPTION TOOL PART NUMBER APPLICATION 6 Pin-Flywheel locking On vehicle 5424 5890 0607 7 Pin-Flywheel locking In Standalone Condition 2868 5890 0604 8 Pin-Timing chain tensioner plunger locking 5424 5890 0604 9 Wedge-Oil Sump sealant cutting 5424 5890 0609 10 CompressorValve spring 2829 5890 0605
1.2L REVOTRON ENGINE 6 SR NO. TOOL DESCRIPTION TOOL PART NUMBER APPLICATION 11 Rail - Valve spring compressor 5424 5890 0606 12 Drift-Crank shaft rear oil seal 2699 5890 1803 13 Drift-Crank shaft front cover oil seal 2654 5890 0508 14 Spanner-Oil filter 5424 5890 1802 15 Guide pin for VCT 5424 5890 0614 16 Engine adaptor for Compression Test Refer tool ITCC7337
1.2L REVOTRON ENGINE 7 E. ASSEMBLY CLEARANCES Group Description Values (mm) 01 Crankshaft Axial Play 0.1 To 0.3 Main Bearing Clearance (Cold Condition) 0.013 To 0.046 Cylinder Head Gasket Compression 0.7 THK (In assembled condition) Balancer Shaft Axial play 0.1 to 0.25 Balancer Shaft Bearing clearance (Assembled condition) 0.02 to 0.046 03 Connecting Rod Axial Play (Big End) 0.05 To 0.35 Piston Play Clearance On Skirt (Bore To Piston Stamp Size) 0.055 To 0.075 Connecting Rod Bearing Clearance (Small End) (Cold Condition) 0.005 To 0.025 Connecting Rod Bearing Clearance (Big End) (Cold Condition) 0.027 To 0.066 Piston Topping (Piston Is Above Block Top Face) 0.19 ± 0.1 05 Camshaft Axial Play 0.1 To 0.3 Camshaft Bearing Clearance 0.04 To 0.082 Valve Stem Clearance, Inlet 0.017 To 0.043 Valve Stem Clearance, Exhaust 0.027 To 0.053 F. SEALANTS Sealant No. Sealant Type Use 56506005162 Adhesive Sealant Loctite 5188 Henkel For Sealing Block To Bed Plate 56506005162 Adhesive Sealant Loctite 5188 Henkel For Plug Mc 10x1 56506002350 Adhesive Bearing Retainer Hs Ts25408 For Core Plug 56506002350 Adhesive Bearing Retainer Hs Ts25408 For Vent Tube-Cyl Head 570501995303 Sealant Loctite 5910 (50 Ml. Tube Pack) For Oil Sump To Bedplate 570501995301 Sealant Loctite 5060 (50 Ml.Tube Pack) For Crank Sensor G. LEAKAGE RATES Region Pressure Leakage (Max.) Air Side 0.2 bar < 200 cc/min Water Side 0.7 bar < 20 cc/min
1.2L REVOTRON ENGINE 8 H. OIL & LUBRICATION ITEM SPECIFICATION COMPANY BRAND QUANTITY Engine oil 0W20 SS6588 Castrol GTX T 0W20 Petrol 3.5 L Exxon Mobil Mobil Super 3000 TM 0W20 Petronas PETRONAS Syntium 7000 TM 0W20 Coolant (Premixed) (Antifreeze agent +Soft water 40:60 ratio) Class II/JIS K2234 TATA SS7700S1 Ansysco Puroblue Petrol 4L Sunstar CCI Gloden Cruiser LLC2200NP IOCL TATA MOTORS GENUINE COOLANT KOOL PLUS Transaxle oil EP80WLL (Next Gen) TATA SS6582 CASTROL EXTREME PRESSURE 80 EP (1LX20) Petrol -1.8 L Petronas PETRONAS TATA MOTORS Genuine -Gear oil New Gen 80 EP LL IOCL IOCL TATA MOTORS Genuine gear oil 80 WLL Mobilube Mobilube GX - A 80W AMT Kit oil Hydraulic Oil PETRONAS TUTELA Cs – Speed As required Brake fluid SAE J1703 , DOT4 PETRONAS Tutela Brake fluid DOT 4 As required Sunstar CCI Golden Cruiser Tata Genuine Brake Fluid (DOT4) CASTROL Optional - CASTROL- Universal Brake Fluid DOT 4 Refrigerant R-134 A 450 ± 20 gm Compressor oil SP10 Sandan Vikas SP10 120± 15 ml
1.2L REVOTRON ENGINE 9 I. SERVICE SCHEDULE
1.2L REVOTRON ENGINE 10 # Kms or months whichever occurs earliers.
1.2L REVOTRON ENGINE 11 2. Troubleshooting: Starting Problems Condition Possible Cause Remedy Engine does not crank Insufficient battery voltage/charge test battery and charging system. Clean and tighten battery connections. Jump start engine. Battery or charging system component faulty. Replace as necessary. Engine starter motor defective. Repair or replace starter as necessary. Immobilizer system defective. (as equipped) Inspect system and repair as necessary. Engine components seized. Inspect engine components for seizure. Attempt to rotate crankshaft by hand. Overhaul engine as necessary. Engine cranks but does not start Obstructed air filter or air inlet. Clean or replace air filter or inlet. Incorrect valve/ignition timing or timing belt broken. Check timing system components and repair or replace as necessary. Faulty spark plugs, wires or ignition coil. Check ignition system components for proper operation. Replace as necessary. Malfunctioning engine management system component. Perform engine management system diagnostic test as described in this section of the manual. Defective Engine Control Unit (ECU) Replace as necessary. Malfunctioning emissions system component Check tank pressure valve, purge canister valve and charcoal canister. Repair or replace as necessary. Clogged or faulty fuel filter, fuel regulator, fuel line or fuel pump. Check fuel system components, repair or replace as necessary Clogged or faulty fuel injectors Check fuel injector operation. Replace as necessary. Improper firing order Check ignition system and fuel injector connections. Rectify as necessary. Inertia switch tripped or defective. Reset or replace as necessary. Engine Idle Problems Condition Possible Cause Remedy Engine Starts but does not idle Faulty ETC unit. Perform Diagnosis test. Replace as necessary. Fuel filter if clogged. Replace the fuel filter. Fuel lines are pinched or clogged Correct the routine to avoid pinch, or allow shop air to clear the clog in the fuel lines.
1.2L REVOTRON ENGINE 12 Improper Electrical supply at pump connector If electrical supply is in proper check electrical system. In adequate fuel pump pressure IF fuel pump does not built pressure then replace. Incorrect manifold absolute pressure (MAP) sensor signal input. Check for leakage at sensor. Perform diagnostic test. Engine idles erratically Disconnected or leaking vacuum line or vacuum leak at inlet manifold. Inspect all vacuum lines and connections. Repair or replace as necessary. Faulty ETC unit. Perform diagnostic test. Replace as necessary. Incorrect valve / ignition timing. Check timing system components and repair or replace as necessary. Fuel filter if clogged. Replace the fuel filter. fuel lines are pinched or clogged Correct the routine to avoid pinch, or allow shop air to clear the clog in the fuel lines. Improper Electrical supply at pump connector If electrical supply is in proper check electrical system. In adequate fuel pump pressure IF fuel pump does not built pressure then replace. Poor Engine Performance Condition Possible Cause Remedy Maximum RPM -low Insufficient battery voltage/charge - test battery and charging system. Clean and tighten battery connections Jump start engine. Battery or charging system component faulty. Replace as necessary. Obstructed air filter or air inlet Clean or replace air filter or inlet. Improper grade or contaminated fuel Rush fuel system with fresh, clean, fuel of the correct type. Replace fuel filter. Faulty spark plugs, wires, or ignition coil Check ignition system components for proper operation. Replace as necessary. Malfunctioning engine management system component Perform engine management system diagnostic test as described in this section of the manual. Fuel filter if clogged. Replace the fuel filter. fuel lines are pinched or clogged Correct the routine to avoid pinch, or allow shop air to clear the clog in the fuel lines. Improper Electrical supply at pump connector If electrical supply is in proper check electrical system. In adequate fuel pump pressure IF fuel pump does not built pressure then replace.
1.2L REVOTRON ENGINE 13 Incorrect crank angle signal Check sensor gap and adjust to 1.0 ± 0.4mm Clogged or faulty fuel injector(s) Check fuel injector operation. Replace as necessary. Improper firing order Check ignition system and fuel injector connections. Rectify as necessary. Poor acceleration or low power Insufficient battery voltage/charge - test battery and charging system Clean and tighten battery connections Battery or charging system component faulty. Replace as necessary. Obstructed air filter or air inlet Clean or replace air filter or inlet. Disconnected or leaking vacuum line or vacuum leak at inlet manifold Inspect all vacuum lines and inlet manifold. Repair or replace as necessary. Improper grade or contaminated fuel Flush fuel system with fresh, clean, fuel of the correct type. Replace fuel filter. Faulty spark plugs, wires, or ignition coil Check ignition system components for proper operation. Replace as necessary. Malfunctioning engine management system component Perform engine management system diagnostic test as described in this section of the manual. Defective Engine Control Unit (ECU) Replace as necessary. Malfunctioning emissions system component Check tank pressure valve, purge canister valve, and charcoal canister. Repair or replace as necessary. Fuel filter if clogged. Replace the fuel filter. fuel lines are pinched or clogged Correct the routine to avoid pinch, or allow shop air to clear the clog in the fuel lines. Improper Electrical supply at pump connector If electrical supply is in proper check electrical system. In adequate fuel pump pressure IF fuel pump does not built pressure then replace. Clogged or faulty fuel injector(s) Check fuel injector operation. Replace as necessary. Incorrect valve/ignition timing Check timing system components and repair or replace as necessary. Improper firing order Check ignition system and fuel injector connections. Rectify as necessary. Engine misfires Disconnected or leaking vacuum line or vacuum leak at inlet manifold Inspect all vacuum lines and inlet manifold. Repair or replace as necessary. Improper grade or contaminated fuel Rush fuel system with fresh, clean, fuel of the correct type. Replace fuel filter.
1.2L REVOTRON ENGINE 14 Faulty spark plugs, wires, or ignition coil Check ignition system components for proper operation. Replace as necessary. Incorrect crank angle signal. Check sensor gap and adjust to 1.0 ± 0.4mm Improper firing order Check ignition system and fuel injector connections. Rectify as necessary. Fuel filter if clogged. Replace the fuel filter. fuel lines are pinched or clogged Correct the routine to avoid pinch, or allow shop air to clear the clog in the fuel lines. Improper Electrical supply at pump connector If electrical supply is in proper check electrical system. In adequate fuel pump pressure IF fuel pump does not built pressure then replace. Engine Noise Condition Possible Cause Remedy Engine 'pings' or 'knocks' while accelerating or travelling uphill. Improper grade of fuel Fill fuel tank with a minimum BSVI Fuel Spark plugs excessively worn or gapped improperly. Inspect spark plugs. Replace if worn. Incorrect valve/ignition timing Check timing system components and repair or replace as necessary. Excessively worn camshaft Inspect camshaft lobes and run-out for excessive wear. Replace as necessary Fuel filter if clogged. Replace the fuel filter. fuel lines are pinched or clogged Correct the routine to avoid pinch, or allow shop air to clear the clog in the fuel lines. Improper Electrical supply at pump connector If electrical supply is in proper check electrical system. In adequate fuel pump pressure IF fuel pump does not built pressure then replace. 'Squeal' or 'chirping' while engine is running. Worn, oil-fouled, or improperly adjusted engine accessory belt. Check engine accessory belt condition and tension. Adjust or replace. Belt tensioner not properly tightened or defective Inspect the belt tensioners. Tighten or replace as necessary. 'Clunking' or 'rapping' noise from bottom end of engine Defective piston wrist pin, rod, or main bearings If noise occurs after taking foot off accelerator pedal, inspect piston wrist pins. If noise is constant inspect rod bearings and main bearings for proper clearance and condition Replace bearings as necessary.
1.2L REVOTRON ENGINE 15 'Tapping' or 'ticking' noise from the top end of the engine Fuel injectors worn excessively Fuel injectors will make some ticking noise. Replace fuel injectors if not putting out enough fuel to cylinders. Excessively worn camshaft Inspect camshaft. lobes and runout for excessive wear. Replace as necessary. Valve springs, tappets, or rocker arms worn Inspect valve train components; replace as necessary. Exhaust System Condition Possible Cause Remedy Engine emits white smoke from tailpipe. Obstructed air filter or air Inlet Clean or replace air filter or Inlet. Head gasket leaking coolant into combustion chamber Inspect engine oil for coolant and perform engine compression test. Engine cylinder head or block cracked Inspect engine oil for coolant and perform engine compression test. Engine oil or other substance on exhaust manifold Inspect exhaust manifold for foreign material. Improper grade or contaminated fuel Rush fuel system with fresh, clean, fuel of the correct type. Replace fuel filter. Engine emits blue smoke from tailpipe. Worn or damaged valve guide seals Remove rocker arm cover and inspect valve guide seals. Replace as necessary. Engine crankcase overfilled with oil Check oil level; drain oil as necessary. Worn I damaged piston ring(s) or cylinder bore, permitting oil blowby Perform engine compression test and/or leak-down test. Head gasket leaking oil into combustion chamber Inspect engine coolant for oil and perform engine compression test. Engine emits black smoke from tail pipe. Excess carbon deposits in combustion chamber Remove carbon deposits in combustion chamber using a commercially available cleaner Excess fuel entering cylinder(s) Check lambda/O2 and other engine sensors for proper operation. Test fuel injectors for proper operation or leakage. Check the fuel and emissions system for proper operation. Exhaust rubber hanger wear / crack. Ageing of rubber hanger Check the Exhaust rubber hangers & replaced if found crack / damage or wear. Cooling System Condition Possible Cause Remedy Overheating Low coolant level/ Cooling system leaking Check coolant level in reservoir and inspect system for leaks. Add coolant as necessary.
1.2L REVOTRON ENGINE 16 Defective thermostat Remove thermostat and check for proper opening at specified temperature. Defective water pump Inspect and replace water pump as necessary. Defective temperature sending unit Check coolant temperature sending unit Replace as necessary. Engine cooling fan malfunctioning Test operation of engine cooling fan. Repair or replace as necessary. Engine overloading Make sure vehicle brakes are not dragging. Vehicle overloaded. Make sure vehicle does not exceed weight limit with cargo. Engine lean condition Verify proper operation of fuel system components. Repair system or replace components as necessary. Head gasket leaking Test engine compression. Replace head gasket as necessary. Over cooling Defective thermostat Remove thermostat and check for proper opening at specified temperature. Defective temperature sending unit Check coolant temperature sending unit. Replace as necessary. Engine Lubrication System Condition Possible Cause Remedy Engine consumes oil Obstructed air filter or air Inlet Clean or replace air filter or inlet Worn piston rings Perform compression or leak-down test Worn valve guide seals or other valve train component. Inspect valve train components. Repair or replace as necessary Mechanical oil seal, O-ring, or gasket leaking Inspect engine oil seals and gaskets for visual signs of leakage. Replace seals or gaskets as necessary. Engine does not develop oil pressure Low oil level or Incorrect grade of oil Add proper grade of oil until level is at the 'MAX' mark on dipstick Faulty oil pressure sending unit Replace faulty sending unit as needed. Defective engine oil pump/oil pump relief valve stuck open Inspect oil pump operation. Repair or replace as necessary. Excessive wear of connecting rods, main bearings and journals, or other internal engine components. Repair/replace engine components. Oil Filter clogged strainer clogged Clean or replace.
1.2L REVOTRON ENGINE 17 3. CONSTRUCTIONAL AND SERVICE DETAILS: A. Engine Lifting : Engine Lifting : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Engine Lifting Hook (Front) 2 H/FL Screw M8X18 (Lifting Hook Front) 2.0+0.3 3 Engine Lifting Hook (Rear) 4 H/FL Screw M8X18 (Lifting Hook Rear) 2.0+0.3
1.2L REVOTRON ENGINE 18 B. Intake Manifold:
1.2L REVOTRON ENGINE 19 Intake Manifold : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 ETC to Intake Manifold (Hex Nut AM6) (4 Qty) 1 + 0.2 2 ETC to Intake Manifold (STUD CM6X45) (4 Qty) 1 + 0.2 3 Electronic Throttle Control 4 Gasket (For Electronic Throttle Control) 5 MAP Sensor 6 Hex FL Screw M6X10 0.8 7 Intake Manifold 8 Self-Locking Nut (Clinch Nut M8 X 1.25) (4 Qty)• 2.0+0.3 9 M8X30 at bottom of intake manifold on block (1 Qty) 2.5 10 Grommet on intake manifold (Bottom) 11 Gasket (Intake Manifold) (3 Nos) 12 Intake Manifold Stud 2.5 Note:- • This Symbol indicates critical tightening torque.
1.2L REVOTRON ENGINE 20 C. Cylinder Head Cover :
1.2L REVOTRON ENGINE 21 Cylinder Head Cover : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Hex FL Bolt M6X25 for Ignition Coil (3Qty) 1.0 ±0. 2 2 Ignition Coil (3Qty) 3 Cylinder head Cover 4 Gasket (Cylinder Head Cover)** 5 Hex. Bolt (Cylinder Head) (8Qty)• 5 + 180˚ 6 Washer 7 Gasket (Cylinder Head) 8 Dipstick 9 'O' Ring (Oil Filler Cap) 10 Hex. FL Screw M6X22 (Head Cover) (13Qty) 1.0 11 Oil Filler Cap 12 Solenoid Valve 13 Hex FL Nut AM6 for Solenoid valve (1Qty) 1.0 14 Stud C M6X20 for OCV 1.0 Note:- • This Symbol indicates critical tightening torque.
1.2L REVOTRON ENGINE 22 D. Cylinder Head-A :
1.2L REVOTRON ENGINE 23 Cylinder Head-A : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Hex FL Bolt M6X60 for ITG Bearing Cap Upper (4 Qty)• 1.5±0.15 2 ITG Bearing Cap Upper 3 Camshaft 4 ITG Bearing Cap Lower 5 Cylinder Head 6 Exhaust Valve 7 Intake Valve 8 Camshaft Bearing Cap (Inner) 9 H/FL Bolt M6X35 for Camshaft Brg. Cap (12 Qty)• 1.5 10 Dowel Bolt M6X35 for Camshaft Brg. Cap (12 Qty)• 1.5 11 Spring Seat 12 Valve Guide Seal 13 Valve Spring 14 Valve Spring Retainer 15 Lock Half 16 HLA RFF Assembly Note:- • This Symbol indicates critical tightening torque.
1.2L REVOTRON ENGINE 24 E. Cylinder Head-B : Cylinder Head-B : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Seal Plug M10X1 for Oil Gallery 2.0 + 0.3 2 Oil Pressure Switch 3 3 Coolant Temperature Sensor 3.5 4 H/FL Screw M6X14 for Cam Sensor 0.4 + 0.1 5 Cam Phase Sensor
1.2L REVOTRON ENGINE 25 F. Cylinder Block :
1.2L REVOTRON ENGINE 26 Cylinder Block : Note:- • This Symbol indicates critical tightening torque. No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Seal Plug M20x1.5 for oil gallery crankcase 2.5 2 Crankcase 3 Knock Sensor 4 Hex FL Screw M8X30 2.0+0.5 5 Sealing Plug M24X1.5 3.5 6 Crankshaft Oil Seal (Rear) 7 Hex FL Bolt M8X70 (8Qty) 3.2+0.6 8 Bed plate MB bolt M10 (10 Qty) • 5.0±0.5 , 120˚±15˚ 9 Bed Plate 10 Crank Angle Sensor 11 H/FL Screw M6X22 for Crank Angle Sensor 1.0+0.2 12 Deflector Plate Cyl. Block 13 Hollow Dowel,12H6 x10.6 x 12L 14 Hex FL Bolt M8x35 1.0 ± 0.1, 45˚ ± 5˚ 15 Balancer Mass 16 Cylindrical Pin 17 Balancer Shaft 18 Thrust Washer 19 CSK Socket Screw M6x20 (2 Qty) 1.2 – 1.5 20 Gear, Balancer Shaft 21 H/FL Bolt M12x45 5.0 ± 0.5, 45˚ ± 5˚
1.2L REVOTRON ENGINE 27 G. Oil Sump Oil Sump No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Oil Sump 2 Sealing Washer 3 Drain Plug 3.5 4 H/FL Screw M6X14 for Oil Sump (18 Qty) 0.8 5 Pipe seal 6 Water Bypass Assembly 7 H/FL Screw M6X14 1 + 0.2
1.2L REVOTRON ENGINE 28 H. Moving Parts: Note:- • This Symbol indicates critical tightening torque.
1.2L REVOTRON ENGINE 29 Moving Parts : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Top Ring 2 Taper Faced Ring 3 Oil Ring 4 Piston Pin 5 Round Wire Circlip 6 Connecting Rod 7 Bearing Half (Connecting Rod) 8 Bolt (Connecting Rod) (M8 X 1) (6 Qty)• 2.2+0.5 90˚ ± 5˚ 9 Woodruff Key 10 Crank Sensor Target Wheel 11 Assembly Vibration Damper Pulley 12 Washer (Damper Pulley) 13 Hex. Bolt M16x1• 14.5+0.3 90˚ ± 5˚ 14 CSK SOC Screw M6X20 for crank sensor wheel 1.7+0.3 15 Bearing Shell Half Lower (Crankshaft) 16 Bearing Shell Half Upper (Crankshaft) 17 Thrust Washer 18 Crankshaft 19 Flywheel 20 Hex. Bolt For Flywheel (M10 X 1.5) (6 Qty)• 3.5+0.5 25˚ ± 5˚ 21 Piston 22 Cylindrical Pin 23 Gear, Crankshaft 24 Cylindrical Pin 25 Bush
1.2L REVOTRON ENGINE 30 I. Engine Timing :
1.2L REVOTRON ENGINE 31 Engine Timing : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Fixed Blade 2 Sprocket Crankshaft 3 Hex Pivot Bolt for Chain Guide (Movable) 2.5 4 Chain 5 Exhaust Camshaft Sprocket To Camshaft, bolt M12x1.25 • ˚9 ± 5 % 6 Hex FL Bolt M6x25 (2 Qty) 1.0 7 Cam Guide Valve 8 Hex Bolt (Intake Camshaft VVT• ˚6 ± 0.5 9 Controller Assy, Valve Timing 10 Exhaust Variable Cam Timing 11 Tensioner Guide Rail 12 H/FL Screw M6 x14 (2 Qty) 1.0 13 Hex FL SCR M6X30 (2 Qty) 1.0 14 Tensioner Note:- • This Symbol indicates critical tightening torque.
1.2L REVOTRON ENGINE 32 J. Exhaust Manifold : Exhaust Manifold : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Gasket (Exhaust Manifold)) 2 H/FL Bolt M6 for heat shield (3 Qty) 1.5 3 Heat Shield 4 M8X1.25 Flange P/T Nut. (4 Qty) 2.0+0.3 5 Lambda Sensor 5.0±0.5 6 Exhaust Manifold 7 H/FL Screw M8X18 (2 Qty) 2.5 8 Stud C M8X25 for Exhaust (4 Qty) 2.5
1.2L REVOTRON ENGINE 33 K. Fuel Injection Equipment : Fuel Injection Equipment : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Hex FL Bolt M8X30 (Common Rail) (2 Qty) 2 + 0.3 2 Assembly Fuel Rail 3 Fuel Injector Clip 4 Fuel Injector 2.9 + 0.3
1.2L REVOTRON ENGINE 34 L. Lubrication Pump and Components :
1.2L REVOTRON ENGINE 35 Lubrication Pump and Lines : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Oil Pump Assy Complete 2 Hex FL Bolt M8X55 for Oil Pump Assy (6 Qty) 2.5 3 Hex FL Bolt M8X30 (2 Qty) 4 Oil Seal (Crankshaft) (Front) 5 Oil Pump 6 Hex FL Bolt M6X28 (13 Qty) 1.0 7 O-Ring (For Strainer assy) 8 Flanged Clinch Nut M6 (2 Qty) 1 + 0.2 9 Strainer Assembly (For Oil Pump) 10 Gasket (For Filter) 11 HEX FL BOLT M8X22 (For Filter) (3 Qty) 2.5 12 Adaptor (For Oil Filter Mounting) 13 Oil Filter Assembly ¾ th Turn 14 Oil Pressure Switch 3
1.2L REVOTRON ENGINE 36 M. Air Intake System :
1.2L REVOTRON ENGINE 37 Air Intake System : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Air Filter Housing Assembly 2 Filter Element 3 H/Fl Bolt M8x28 4 Hose, Air Filter To Throttle Body 5 Hex Fl Bolt M6x28 6 Washer 7 Hex Fl Nut Am6 8 Snorkel Assy 9 Grommet, Air Filter 10 Spr. Bd Clamp 27dx12w 11 Hose, Blowby 12 Spr. Bd Clamp 15dx12w
1.2L REVOTRON ENGINE 38 N. Special Installation :
1.2L REVOTRON ENGINE 39 Special Installation : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TOQUE (Kgf.m) 1 Belt 2 Hex FL Bolt M8X30 for Tensioner (Qty 2) 3 3 Belt Tensioner 4 Bracket for Compressor Mounting 5 Hex FL Bolt M8X28 (Bracket to block) (Qty 4) 3.5 6 Compressor 7 H/FL Bolt M8X80 for Compressor (Qty 3) 2.2+0.2 8 Hex. FL Bolt M8X100 for Water Pump (Qty 4) 2.5 9 Water Pump 10 Gasket For Water Pump 11 Hex FL SCR M6X18 to Thermostat 1.0 12 Bright Washer 13 Thermostat Housing 14 Alternator 15 Alternator Cover Fitment Bracket: 16 Alternator Guard 17 Hex FL Nut AM6 for Guard (Qty 2) 1.0 18 Hex. FL Bolt M8X80 for alternator (Qty 3) 3.5 19 Water Temperature Sensor 1.8-2.5
1.2L REVOTRON ENGINE 40 Special Installation : Special Installation : No. DESCRIPTION NO REUSE SEALANT LUBRICA TION TOQUE (Kgf.m) 20 Hex. FL Bolt M8X50 for Starter Motor (Qty 1) 2.4 21 Hex. FL Bolt M8X45 for Starter Motor (Qty 1) 2.4 22 Starter Motor
1.2L REVOTRON ENGINE 41 O. Engine Suspension
1.2L REVOTRON ENGINE 42 Engine Suspension ITEM NO. DESCRIPTION NO REUSE SEALANT LUBRICATION TIGHTENING TORQUE (kg-m) 01 B-Mount 02 H/FL Scr M10x30 6.1-6.6 03 Hex. Flange Nut M12x1.25 50% PreTorque 5.5 04 Washer 05 H/FL Scr M10x30 6.1-6.6 06 Hex FL Nut M10 50% PreTorque 3.3 07 H/FL Scr M10x30 6.1-6.6 08 H/FL Scr M10x30 6.1-6.6 09 A-Mount 10 H/FL Scr M10x40 6.1-6.6 11 Hex Flange Bolt 10.7-11.2 12 C-Mount 13 Hex Flange Bolt 10.7-11.2 14 Hex. Flange Nut Am12x1.25 15 Bracket, C-Mount 16 Bracket, B-Mount 17 H/FL Scr M10x40 4.1-4.6
1.2L REVOTRON ENGINE 43 4. ENGINE TESTS AND MAINTENANCE: A. PRELIMINARY INSPECTION : NOTE It is always advisable to first use the diagnostic tool and rectify the electrical faults, before commencing with mechanical repairs/ troubleshooting. Refer ENGINE MANAGEMENT SYSTEM section in this group for procedure. GENERAL : 1. Check for leakage of Oil, fuel, and Coolant. 2. Check for overheating of engine. 3. Check for unusual smoke. 4. If there is any fault in the Engine Management system (EMS) then the MIL indicator in the instrument cluster will come ON. In such a case connect the diagnostic tester. (For procedure refer EMS section). Before proceeding to carry out actual reconditioning of engine, it is desirable to have a preliminary inspection of engine to ascertain whether an engine reconditioning is necessary and if so, to what extent. Most common reasons for which engine is reconditioned are 1. Loss of power. 2. Excessive engine oil consumption. 3. Extremely low engine oil pressure. 4. Mechanical failures. To know exact reason and general condition of engine, proceed as follows i. LOSS OF POWER : Loss of engine power may be due to a. EMS is in limp-home mode due to some critical fault. b. Clogged air filter / exhaust passage / catalytic converter. c. Defective fuel system d. Clutch slippage e. Brake binding ii. EMS is in limp-home mode : If the EMS detects some major fault in the system it switches to limp-home mode, where it runs at a reduced torque. Connect the diagnostic tester and check if any faults are present in the Engine EMS, if found rectify them. (For details refer Engine Management Section) iii. Clogged Air filter / Loss of Charge Air Pressure/ Choked Exhaust Silencer / catalytic converter : Loss of power with unusual black smoke from engine exhaust indicates lack of air or low air charging pressure to engine cylinders. Clean air filter & inter cooler fins. Check all joints for air leakage. If power loss with black smoke is still felt, check exhaust silencer for choking. Clean and replace silencer if necessary. Check for kink formation in exhaust piping. iv. Defective Fuel System : Check the Fuel system for fuel flow. If the flow is restricted change the filter. v. Clutch Slippage : Clutch slipping can be confirmed by any of the following two methods: Method 1 : 1. Drive the car in 1st or 2nd gear at a minimum speed corresponding to that gear. 2. With the accelerator pedal in a fully pressed position, gradually apply brake with left foot. 3. If the engine stalls, the clutch does not slip. Method 2 : 1. Drive the gear with weight equal to GVW in 3rd gear on a level ground. 2. Allow the speed to drop upto 15kmph. 3. Now press the accelerator pedal fully. 4. With slipping clutch the car will not pick up speed, also a clutch burning smell could be noticed. 5. If this does not occur, the clutch does not slip. vi. Brake Binding : During driving apply brakes number of times and then shift gear to neutral position and check free rolling of vehicle. Check brake drums/brake discs for overheating and if necessary jack up the vehicle and check wheels for free rotation.
1.2L REVOTRON ENGINE 44 B. ENGINE TESTS : I. Engine Compression Test : Description : The engine compression test provides the technician with information regarding the condition of the engine piston rings/block, cylinder head gasket, and the valves. Before performing the engine compression test, make certain the loss of power or overheating cannot be attributed to something simple such as improper fuel, obstructed air filter, low oil or coolant level, or dragging brakes. Test Procedure : 1. If possible, bring the engine up to operating temperature (approximately 80° - 90° C) by starting and driving the vehicle for several minutes. 2. Make sure the vehicle battery is fully charged. 3. Remove the air filter element. 4. Label the spark plug coils and remove all spark plugs from the engine. CAUTION Use care not to damage the threads in the spark plug port when installing the compression test gauge adapter. 5. Install an engine compression test gauge (0 to 25 bar) into the number one engine cylinder spark plug port. . (Remove fuel injector connections to avoid fuel injection). 6. Depress the clutch and accelerator pedal fully and crank the engine 7. Have an assistant read and record the highest pressure obtained on the gauge. 8. Follow steps 5 through 7 for the three remaining cylinders, recording the pressure obtained on the gauge. 9. Compare the compression reading obtained for each engine cylinder. The minimum compression is 12±1 bar. 10. If the compression reading in a cylinder is below 10 bar, there may be leakage past the piston rings or valves. Squirt a several drops of oil into the cylinder bore and perform the compression test again. 11. If the compression improves after several drops of oil are squirted into the cylinder bore, the piston rings are most likely leaking. If the compression does not improve, the valves may be allowing leakage. 12. If the compression between two adjacent cylinders is below the minimum, there may be a leak in the head gasket between the cylinders. If suspecting a blown head gasket check the engine oil and coolant for signs of contamination. If coolant mixes with the oil in the sump, the oil will appear to be a dark, milky, substance. If cylinder compression is leaking into the coolant, bubbles will appear in the coolant reservoir while the engine is running.
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