SERVICE MANUAL MOTORS BSVI
Developed by: Technical Literature Cell. Release Date : Dec 2020 / Second Edition. The information provided in this manual is based on the latest product information available at the time of publication. . C Copyright 2020 TATA MOTORS All rights reserved. The information in this manual shall not be reproduced or copied, in whole or in part, in any form without written permission from TATA MOTORS. Vehicles are subject to modification in design, specification and equipment. Also refer the Service Circulars released by Customer Support about product & procedures.
INTRODUCTION This Service manual provides information pertaining to technical Specifications, repair, maintenance and overhaul of different aggregates fitted on TATA NEXON BSVI. All the data contained in this manual is based on the latest product information available at the time of publication and with the assumption that the person is well aware of general Automobile practices. This manual emphasizes the special features of the vehicle and thus benefits our workman, who is conversant with general Automobile practices. For ease of use, this workshop manual is divided into 3 volumes, comprising several sections. Each aggregate has a separate section. THE BOOK– 1 CONTAINS Petrol Engine Diesel Engine Transaxle MT Driveshaft MT Transaxle AMT Driveshaft AMT Suspension Steering (Bosch & Bosch - Mando Combination) Steering (Mando) Brakes ESP TPMS HVAC FATC Body (BUMPER & SUNROOF only) Electrical SRS (WITH AB10) SRS (WITH AB12) THE BOOK– 2 CONTAINS Diagnostic Trouble Shooting Codes (DTC) List of All ECU’s THE BOOK– 3 CONTAINS Circuit Schematics
INDEX SR. NO GROUP 1 PETROL ENGINE 2 DIESEL ENGINE 3 TRANSAXLE MT 4 DRIVESHAFT MT 5 TRANSAXLE AMT 6 DRIVESHAFT AMT 7 SUSPENSION 8 STEERING (BOSCH & BOSCH - MANDO COMBINATION) 9 STEERING (MANDO) 10 BRAKE 11 ESP 12 TPMS 13 HVAC 14 FATC 15 BODY (BUMPER & SUNROOF Only) 16 ELECTRICAL 17 SRS (WITH AB10) 17 SRS (WITH AB12) ***The contents which are not covered in this supplement service manual have to be read in conjunction with “TATA NEXON BSIV” Service manual. Refer Owner’s manual for latest Oil / Lubrication / Coolant details & Service schedule.
ENGINE BSVI 1.2L REVOTRON ENGINE
1.2L REVOTORN ENGINE CONTENTS 1.1. GENERAL INFORMATION..................................................................................................................... 1 A ENGINE INTRODUCTION.................................................................................................................... 1 B ELECTRONIC CONTROL UNIT........................................................................................................... 2 C TECHNICAL SPECIFICATION............................................................................................................. 3 D SPECIAL TOOLS.................................................................................................................................. 4 E ASSEMBLY CLEARANCE.................................................................................................................... 6 F SEALANTS ........................................................................................................................................... 6 G LEAKAGE RATES ................................................................................................................................ 6 1.2. TROUBLESHOOTING ............................................................................................................................ 7 1.3. CONSTRUCTIONAL AND SERVICE DETAILS................................................................................... 14 A ENGINE LIFTING HOOK.................................................................................................................... 14 B INTAKE MANIFOLD ........................................................................................................................... 15 C CYLINDER HEAD COVER ................................................................................................................. 16 D CYLINDER HEAD A ........................................................................................................................... 18 E CYLINDER HEAD B ........................................................................................................................... 20 F CYLINDER BLOCK............................................................................................................................. 22 G LUBRICATION PUMP AND COMPONENTS..................................................................................... 24 H PISTON, CRANKSHAFT AND COMPONENTS................................................................................. 27 I ENGINE TIMING................................................................................................................................. 29 J TURBOCHARGER, CATCON AND COMPONENTS ........................................................................ 31 K FUEL INJECTION EQUIPMENT ........................................................................................................ 33 L AIR FILTER, SNORKEL AND BLOW BY PIPE .................................................................................. 35 M WATER PUMP, THERMOSTAT AND COMPONENTS ..................................................................... 37 N STARTER MOTOR AND ALTERNATOR........................................................................................... 39 O COMPRESSOR, AUTO TENSIONER AND BELT ............................................................................. 40 P ENGINE SUSPENSION...................................................................................................................... 41 Q INTERCOOLER AND HOSES............................................................................................................ 44
1.2L REVOTORN ENGINE 1.4. ENGINE TESTS AND MAINTENANCE................................................................................................ 46 A PRELIMINARY INSPECTION............................................................................................................. 46 B ENGINE TESTS.................................................................................................................................. 47 C REGULAR MAINTENANCE ............................................................................................................... 50 I ENGINE OIL AND FILTER CHANGE................................................................................................. 50 II ENGINE COOLANT REPLACEMENT................................................................................................ 52 III AIR FILTER ELEMENT REPLACEMENT .......................................................................................... 53 IV SPARK PLUG REPLACEMENT ......................................................................................................... 54 V AIR CONDITIONER COMPRESSOR & ALTERNATOR BELT REPLACEMENT.............................. 56 1.5. REPAIR AND INSPECTION DETAILS................................................................................................. 57 A ACCESSORY DRIVING BELT ........................................................................................................... 57 B TIMING CHAIN ................................................................................................................................... 57 C CYLINDER HEAD............................................................................................................................... 57 D VALVES .............................................................................................................................................. 58 E CYLINDER HEAD VALVE SEATS ..................................................................................................... 60 F ROLLER FINGER FOLLOWER.......................................................................................................... 61 G HYDRAULIC LASH ADJUSTER......................................................................................................... 61 H CAMSHAFT (INTAKE AND EXHAUST) ............................................................................................. 62 I PISTON AND PISTON RINGS ........................................................................................................... 63 J CONNECTING ROD........................................................................................................................... 64 K CRANKSHAFT.................................................................................................................................... 66 L CRANK CASE..................................................................................................................................... 68 M FUEL TANK ........................................................................................................................................ 69 N CANISTER PURGE VALVE ............................................................................................................... 69 O CANISTER.......................................................................................................................................... 70 1.6. ENGINE SYSTEM ................................................................................................................................. 71 A AIR INTAKE SYSTEM ........................................................................................................................ 71 B BLOW BY SYSTEM............................................................................................................................ 74 C LUBRICATION SYSTEM .................................................................................................................... 75
1.2L REVOTORN ENGINE D EXHAUST SYSTEM ........................................................................................................................... 79 E COOLING SYSTEM............................................................................................................................ 82 F FUEL SYSTEM ................................................................................................................................... 85 1.7. ENGINE ON VEHICLE SERVICE PROCEDURE ................................................................................. 88 A ENGINE REMOVAL AND REFITMENT ............................................................................................. 88 B AIR FILTER ASSEMBLY .................................................................................................................... 94 C INJECTOR REMOVAL ....................................................................................................................... 95 D SPARK PLUG REMOVAL .................................................................................................................. 96 E EXHAUST SYSTEM REMOVAL......................................................................................................... 97 F FUEL SYSTEM ................................................................................................................................. 101 G COOLING SYSTEM.......................................................................................................................... 107 H REMOVAL OF ACCESSORIES ....................................................................................................... 112 1.8. ENGINE OVEHAULING (ON OVERHAUL STAND) ......................................................................... 114 A ENGINE DIS-ASSEMBLY................................................................................................................. 114 I REMOVAL OF INTAKE MANIFOLD................................................................................................. 114 II REMOVAL OF EXHAUST MANIFOLD............................................................................................. 116 III REMOVAL OF OIL SUMP ................................................................................................................ 118 IV REMOVAL OF SENSORS................................................................................................................ 119 V REMOVAL OF ACCESSORIES ....................................................................................................... 120 VI REMOVAL OF TIMING CHAIN......................................................................................................... 123 VII REMOVAL OF CYLINDER HEAD AND CAMSHAFT....................................................................... 125 VIII REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES ................................................................... 127 IX REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES ................................................................. 128
1.2L REVOTORN ENGINE B ENGINE ASSEMBLY........................................................................................................................ 132 I ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES ............................................................... 132 II ASSEMBLY OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES ...................................... 136 III ASSEMBLY OF CYLINDER HEAD SUB-ASSEMBLIES.................................................................. 138 IV ASSEMBLY OF CYLINDER HEAD .................................................................................................. 139 V ASSEMBLY OF ENGINE TIMING CHAIN........................................................................................ 141 VI ASSEMBLY OF CYLINDER HEAD COVER AND PERIPHERALS ................................................. 145 VII ASSEMBLY OF SENSORS .............................................................................................................. 147 VIII ASSEMBLY OF OIL SUMP .............................................................................................................. 148 IX ASSEMBLY OF EXHAUST MANIFOLD........................................................................................... 149 X ASSEMBLY OF INTAKE MANIFOLD............................................................................................... 152 1.9. ENGINE MANAGEMENT SYSTEM.................................................................................................... 154 A ABBREVIATIONS ............................................................................................................................. 154 B OVERVIEW....................................................................................................................................... 155 C ELECTRONIC CONTROL UNIT (ECU)............................................................................................ 156 D EMS SENSORS................................................................................................................................ 162 I MANIFOLD AIR PRESSURE SENSOR AND TEMPERATURE SENSOR (T-MAP) ....................... 163 II LAMBDA SENSOR ........................................................................................................................... 164 III CAMSHAFT POSITION SENSOR.................................................................................................... 166 IV KNOCK SENSOR ............................................................................................................................. 167 V CRANKSHAFT POSITION SENSOR ............................................................................................... 169 VI COOLANT TEMPRATURE SENSOR .............................................................................................. 170 E ACTUATORS.................................................................................................................................... 172 I IGNITION COIL................................................................................................................................. 173 II PURGE CONTROL VALVE .............................................................................................................. 174 III SOLENOID VALVE........................................................................................................................... 175 IV FUEL INJECTOR.............................................................................................................................. 176 V ELECTRONIC THROTTLE BODY.................................................................................................... 177
1.2L REVOTORN ENGINE F SWITCH............................................................................................................................................ 179 I OIL PRESSURE SWITCH ................................................................................................................ 179 II THROTTLE PEDAL SENSOR.......................................................................................................... 180 III CLUTCH SWITCH ............................................................................................................................ 181 IV BRAKE SWITCH............................................................................................................................... 182 V WHEEL SPEED SENSOR................................................................................................................ 183 VI ELECTRONIC VACCUM REGULATING VALVE (EVRV)................................................................ 184 VII START STOP SWITCH .................................................................................................................... 185 VIII AC PRESSURE SENSOR ................................................................................................................ 186
1.2L REVOTRON ENGINE 1 1.1 GENERAL INFORMATION A. ENGINE INTRODUCTION Description The “1.2L NG TC: is a 3-Cylinder, 1200CC Gasoline Turbo-charged intercooled, MPFI, dual VVT engine and BS-VI compliant.” Features: Stiffened Aluminium Crankcase with Aluminium bed plate structure. Double Overhead Camshaft (DOHC) with 4 valves per cylinder. Variable valve timing (VVT) Timing chain drive system Three stage oil pump Silent Steel Oil Pan. Weight optimized hollow cam shafts Drive by wire technology (Electronic Throttle Control). Turbo-charged intercooled. Plastic intake manifold and head cover Light weight piston assembly Auto tensioner auxillary belt drive system Engine is 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 UNIT The engine management software in the vehicle's Engine Control Unit (ECU) controls the fuel injection and ignition system using a variety of sensors that provides the engine operating conditions and operates input information. The ECU includes self-diagnosis to help pinpoint any system malfunctions. Refer to the "Engine Management System" portion of this section for additional information. The MPFI type of fuel injection offers many advantages over a single point fuel injection system or a carburetor engine. The following paragraphs describe the advantages of the electronic fuel injected engine. Improved Engine Performance : The ECU precisely and instantly controls optimum fuel delivery and spark timing according to the operating conditions, inputs from the engine sensors, and operator input. This control improves vehicle response and acceleration. Increased Fuel Economy : The electronic fuel injection system allows the 1.2L NG TC engine to be Bharat Stage 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 TC REVOTRON Description 1.2L NG TC REVOTRON ENGINE BS6 Type :- Gasoline 4-stroke turbocharged intercooled MPFI, inline 3cylinder with 4 valves per cylinder, dual VVT engine. Engine Configuration :- Transverse mounted inline 3-cylinder engine Engine Management System :- BOSCH Engine Management System / Cube Lite Bore/Stroke :- 77 mm X 85.8 mm Engine Capacity :- 1199 cc Radiator Coolant :- Water and Ethylene Glycol, 60:40 Compression Ratio :- 9.5 (+/- 0.3) :1 Maximum Engine Power Output :- 120ps @ 5500 rpm Maximum Engine Torque Output :- 170Nm @ 1750-4000 rpm Engine Firing Order :- 1-2-3 Oil Capacity :- 3.5 L Cooling System Capacity :- 5.5 Lit (Water + Coolant) Spark Plug Type :- BOSCH - YR5ME0 - 0.7 to 0.8 mm gap Air Filter :- Top mounted: Dry Paper Type Element Oil Filter :- Paper Type Oil filter element Fuel Filter Integrated with In-tank fuel pump Timing :- Chain Drive Emission Norms :- Bharat Stage VI 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 NO APPLICATION 1 Stand-Engine Support 5424 5890 2401 2 Engine mounting bracket for overhauling stand (LH) 5424 5890 2403 3 Engine mounting bracket for overhauling stand (RH) 5424 5890 2402 4 Fixture (Stand) Assembly Aggregate Repair 5425 5890 0605 5 Adaptor for engine mounting bracket LH (Petrol) 5438 5890 2403
1.2L REVOTRON ENGINE 5 SR NO TOOL DESCRIPTION TOOL PART NO APPLICATION 6 Flywheel locking pin 2871 5890 0675 7 Plunger locking pin 5424 5890 0604 8 Compressor-Valve spring 2829 5890 0605 9 Support Rail - Valve spring compressor 5424 5890 0606 10 Water pump coolant inlet pipe fitment tool 5424 5890 2002 11 Guide pin for VCT 5424 5890 0614
1.2L REVOTRON ENGINE 6 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) - 0.11 +/-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 7 1.2 TROUBLESHOOTING 1. 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. Fuses blown out (if any) Check for blown fuse. Replace the fuses if damaged. 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. (exhaust sensors and actuators) 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.
1.2L REVOTRON ENGINE 8 2. 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. 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. MIL & SIL check Check using diagnostic tool for MIL & SIL. Take corrective action. Defective EMS unit Check using diagnostic tool. . Take corrective action. 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. Incorrect MAP sensor signal Check and replace if necessary. Defective EMS ECU Check using diagnostic tool. . Take corrective action. Clogged injector Check for clogged injector. Take corrective action.
1.2L REVOTRON ENGINE 9 3. 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. 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. Exhaust system / Catcon damaged Check and take corrective action. 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.
1.2L REVOTRON ENGINE 10 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. Exhaust system / Catcon damaged Check and take corrective action. MIL & SIL check Check using diagnostic tool for MIL & SIL. Take corrective action. 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. 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.
1.2L REVOTRON ENGINE 11 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. Exhaust system / Catcon damaged Check and take corrective action. 4. 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 BSIV 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. '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.
1.2L REVOTRON ENGINE 12 5. 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. Mix of oil and water in oil cooler Check for oil and water mix up in oil cooler. Flush and clean. 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 blow-by 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. 6. 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. Defective thermostat Remove thermostat and check for proper opening at specified temperature. Defective water pump Inspect and replace water pump as necessary.
1.2L REVOTRON ENGINE 13 Defective temperature sensor unit Check coolant temperature sensor 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. Radiator water in/out leakage or clogged Check Radiator water in/out leakage or clogged and take corrective action. Over cooling Defective thermostat Remove thermostat and check for proper opening at specified temperature. Defective temperature sending unit Check coolant temperature sensing unit. Replace as necessary. 7. 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 14 1.3 CONSTRUCTIONAL AND SERVICE DETAILS A. Engine Lifting Hooks Engine Lifting Hooks No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Engine Lifting Hook (Front) 2 Hex. Flange Bolt M8X18 (Lifting Hook Front) (Qty. 4) 2.5
1.2L REVOTRON ENGINE 15 B. Intake Manifold Intake Manifold No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Intake Manifold Assy. 2 Electronic Throttle Body 3 Hex Flange Nut AM6 (4 Qty) 1.0 4 Stud CM6x45 (4 Qty.) 1.0 5 Hex Flange Screw M6x14 6 Hex Flange Screw M8x18 7 Bracket Assy., Intake Manifold (Plenum Side) 8 Hex Flange Nut M8 (4 Qty.) 2.0 + 0.3 9 Hex Flange Screw M6x18 10 Pressure/Temperature Sensor (Map Sensor) 11 Stud CM8x30 (4 Qty.) 2.5
1.2L REVOTRON ENGINE 16 C. Cylinder Head Cover Cylinder Head Cover No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Cover Assy., Cylinder Head 2 Ignition Coil (3 Qty.) 3 Hex Flange Bolt M6x25 (3 Qty.) 1.0 ± 0.2 4 Hex Flange Screw M6x22 (12 Qty.) 1.0 5 Hex Flange Bolt M6x40 (2 Qty.) 1.0 6 Solenoid Valve (2 Qty.) 7 Hex Flange Nut AM6• 1.0 8 Stud• 1.0
1.2L REVOTRON ENGINE 17 9 Hex Flange Bolt M6X65 10 Dipstick Assy. Note:- • This Symbol indicates critical tightening torque.
1.2L REVOTRON ENGINE 18 D. Cylinder Head-A
1.2L REVOTRON ENGINE 19 Cylinder Head-A No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Cap Assy.,Intermediate Bearing 2 Camshaft Assy. With Pin Exhaust (TC) 3 Check Valve (2 Qty.) 4 Hollow Dowel (4 Qty.) 5 Cap Assy.,Intermediate Bearing 6 Gasket, Vacuum Pump 7 Assy. Vacuum Pump 8 Hex Flange Screw M6x20 (3 Qty.) 9 Camshaft Assy. With Pin, Intake (TC) 10 Hollow Dowel (2 Qty.) 11 Hex Flange Bolt M6x1x60 (4 Qty.) 1.5 ± 0.15 12 Cap, Intermediate Bearing, Rear 13 Plug MC 8x1 14 Hex. Bolt (Camshaft Brg. Cap) (6 Qty.) 1.5 ± 0.15 15 Hex Flange Bolt M6x35 (6 Qty.) 1.5 ± 0.15 16 Camshaft Bearing Cap (Inner) (6 Qty.) 17 Hex Flange Bolt M6x1x60 (4 Qty.) 1.5 ± 0.15
1.2L REVOTRON ENGINE 20 E. Cylinder Head-B
1.2L REVOTRON ENGINE 21 Cylinder Head-B Note:- • This Symbol indicates critical tightening torque. No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Lock Half (12 Qty.) 2 Valve Spring Retainer (12 Qty.) 3 Spring (Valve) (12 Qty.) 4 Spring Seat (12 Qty.) 5 Hollow Dowel (2 Qty.) 6 Orifice For Oil Gallery (2 Qty.) 7 Core Plug 8 Valve Guide Seal (12 Qty.) 9 Valve Guide (12 Qty.) 10 Valve Seat Exhaust (12 Qty.) 11 Exhaust Valve: Tc (6 Qty.) 12 Gasket, Cyl Head 13 Intake Valve: Tc (6 Qty.) 14 Core Plug 15 Plug Mc10x1 16 Cylinder Head 17 Washer (8 Qty.) 18 Bolt, Cylinder Head Torx M10x1.5 (8 Qty.)• 1) 4+0.5 2) 185° ± 5° 19 Core Plug 20 Spark Plug (3 Qty.) 21 HLA RFF Assy. (12 Qty.)
1.2L REVOTRON ENGINE 22 F. Cylinder Block
1.2L REVOTRON ENGINE 23 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 3.5 2 Crankcase 3 Knock Sensor 4 Hex Flange Screw M8X30 2.0 ± 0.5 5 Sealing Plug M24X1.5 3.5 6 Crankshaft Oil Seal (Rear) 7 Hex Flange Bolt M8X70 (10 Qty) 3.2 8 Bed plate MB bolt M10 (8 Qty) • 1) 5.0 ± 0.5 2) 120° ± 15° 9 Bed Plate 10 Crank Angle Sensor 11 Hex Flange Screw M6X22 for Crank Angle Sensor 12 Deflector Plate Cyl. Block 13 Hollow Dowel,12H6 x10.6 x 12L 14 Hex Flange 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) 20 Gear, Balancer Shaft 21 Hex Flange Bolt M12x45• 5.0 ± 0.5 45° ± 5°
1.2L REVOTRON ENGINE 24 G. Lubrication Pump and Components
1.2L REVOTRON ENGINE 25 Lubrication Pump and Components No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Oil pump cover 2 Hex Flange Bolt M8x55 (6 Qty) 2.5 3 Hex Flange Bolt M8x30 (2 Qty) 2.5 4 Oil Seal (Crank Shaft Front) 5 Oil Pump Assy. 6 Hex Flange Bolt M6x28 (13 Qty) 1.0 7 Stud CM6x18 (2 Qty) 8 O-Ring 25.00x3.55 9 Oil Pump Strainer 10 Flanged Clinch Nut M6 (2 Qty) 1.0 11 Gasket, TC To Oil Return Tube 12 Hex Flange Screw M6x18 (2 Qty) 1.0 15 Cap Screw M5x10 (3 Qty) 0.8 16 Tube Assy, Turbocharger Oil Return 17 Gasket, TC Oil Return 18 Hex Flange Screw M6x12 1.0 19 Oil Sump 20 Hex Flange Screw M6x14 (18 Qty) 1.0 21 Sealing Washer (Oil Sump Drain Plug) 22 Magnetic Drain Plug 3.5 23 Hex Flange Bolt M8x50 (3 Qty) 2.5 24 Stiffener Bracket, Powertrain 25 Hex Flange Bolt M8x75 2.5 26 Pipe Union Bolt (2 Qty) 2.0 27 Sealing Washer 10x14 (4 Qty) 28 Tube Assy.
1.2L REVOTRON ENGINE 26 29 Hex Flange Screw M6x18 (4 Qty) 1.0 30 Oil Filter Assy. 3/4 turn 31 Holder, Oil Filter 32 Hex Flange Screw M8x25 (3 Qty) 2.5 33 Gasket (Oil Filter Holder) 34 O Ring 19x2.65 (2 Qty) 35 Oil Cooler Assy.
1.2L REVOTRON ENGINE 27 H. Piston, Crankshaft and Components Piston, Crankshaft and Components No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Top Ring (3 Qty) 2 Taper Faced Ring (3 Qty) 3 Oil Ring (3 Qty)
1.2L REVOTRON ENGINE 28 No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 4 Piston Pin (3 Qty) 5 Round Wire Circlip (6 Qty) 6 Connecting Rod (3 Qty) 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 + 3.0 90° ± 5° 14 CSK SOC Screw M6X20 for crank sensor wheel (3 Qty) 1.7 + 0.3 15 Bearing Shell Half Lower (Crankshaft) (4 Qty) 16 Bearing Shell Half Upper (Crankshaft) (4 Qty) 17 Thrust Washer (2 Qty) 18 Crankshaft 19 Flywheel 20 Hex. Bolt For Flywheel (M10 X 1.5) (6 Qty)• 3.5 + 0.5 25° ± 5° 21 Piston (3 Qty) 22 Cylindrical Pin 23 Gear, Crankshaft 24 Cylindrical Pin 25 Bush Note:- • This Symbol indicates critical tightening torque.
1.2L REVOTRON ENGINE 29 I. Engine Timing 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 Hex Bolt, Camshaft Bearing Cap (Exhaust Camshaft VVT ) • 6.0 ± 0.5 6 Hex Fl Bolt M6x25 (2 Qty) 1.0 7 Cam Guide Valve 8 Hex Bolt (Intake Camshaft VVT)• 6.0 ± 0.5 9 Controller Assy, Valve Timing 10 Variable Cam Timing 11 Tensioner Guide Rail
1.2L REVOTRON ENGINE 30 12 Hex Flange Screw M6 x14 (2 Qty) 1.0 13 Hex Flange Screw M6X30 (2 Qty) 1.0 14 Tensioner Note:- • This Symbol indicates critical tightening torque.
1.2L REVOTRON ENGINE 31 J. Turbocharger, Catcon and Components
1.2L REVOTRON ENGINE 32 Turbocharger, Catcon and Components No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Catcon Assy 2 Hex FL screw M8x20 (4 Qty) 2.5 3 Hex FL nut am8 2.0 + 0.3 4 Turbocharger Assy 5 Gasket, Turbocharger Intake 6 Gasket, Turbocharger Outlet 7 Hex Flange Screw M6x18 2.0 8 Hex Flange Screw M6x12 2.0 10 Hex Nut M6 (2 Qty) 1.0 11 Assy. Vacuum Modulator 12 Hose Assy, EVRV To NRV 13 Bracket - NRV Mounting 14 Hex Flange Screw M6x10 15 Hose (Vacuum Line T Connector To NRV) 16 Hose, EVRV To Turbocharger 17 Hose, EVRV Vent To Air Filter 18 One Way Check Valve (NRV For Vacuum Accumulator & EVRV Circuit) 19 Hex Flange Screw M8x18 2.0 20 EVRV Bracket 21 Heat shield rear heat shield 22 Heat shield Front 23 Washer A6.4 24 Hex FL screw M6x18 1.0 25 Hex FL screw M6x12 1.0 26 Hex Flange Nut AM8 (4 Qty) 3.0 27 Lambda sensor 5.0 ± 1.0 28 Oxygen sensor (Lambda sensor) 5.0 ± 1.0 29 EVRV Hose Separator
1.2L REVOTRON ENGINE 33 K. Fuel Injection Equipment
1.2L REVOTRON ENGINE 34 Fuel Injection Equipment No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Injector (3 Qty) 2 Injector Retainer (3 Qty) 3 Hex Flange Screw M5x10 (3 Qty) 0.5 – 0.6 4 Fuel Rail 5 Hex Flange Bolt M8x30 (2 Qty) 1.4 6 Bracket (To Hold Fuel Line) 7 Fuel Delivery Pipe Assy, Engine Rail 8 Purge Circuit 9 Assy. Vapor Line 10 Canister Purge Valve 11 Hex Flange Screw M6x10 12 Bracket, Purge Valve Mtg 13 Bracket, Assy Purge Circuit 14 Hex Flange Screw M6x10 (2 Qty)
1.2L REVOTRON ENGINE 35 L. Air Filter, Snorkel and Blow-by pipe
1.2L REVOTRON ENGINE 36 Air Filter, Snorkel and Blow-by pipe No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Air Filter Element 2 Air Filter Assy. 3 Hex Flange Screw M6x28 (2 Qty) 1.0 4 Separator Clamp 5 Hex Flange Screw M6x12 (2 Qty) 6 Bracket Hose Blow-By 7 Blow-by Hose Primary 8 Spring. Band Clamp 17Dx12W (2 Qty) 9 Washer (2 Qty) 10 Rubber Grommet (2 Qty) 11 Spacer (2 Qty) 12 Blow-by Hose Secondary 13 Hose Clamp (23 Dia.) (2 Qty) 14 Hose Clamp (70 Dia.) (2 Qty) 0.68 15 Hose, Air Filter To Tc 16 Hex Flange Screw M6x14 1.0 17 Bracket, Snorkel 18 Hex Flange Bolt M8x25 (2 Qty) 1.0 19 Washer (2 Qty) 20 Resonator Pipe 21 Hose Clamp (70 Dia.) 22 Hose, Resonator Box To Intake Pipe 23 Hex Flange Screw M6x12 (2 Qty) 1.0 24 Bracket, Air Filter 25 Rubber Grommet (On Engine For Air Filter) 26 Air filter top cover screw M5x20 (5 Qty.) 0.3-0.55
1.2L REVOTRON ENGINE 37 M. Water Pump, Thermostat and Components
1.2L REVOTRON ENGINE 38 Water Pump, Thermostat and Components No. DESCRIPTION NO REUSE SEALANT LUBRICATION TOQUE (Kgf.m) 1 Water Pump Assy. 2 Water Bypass Tube Assembly 3 Seal (Water Bypass Tube) 4 Hex Flange Bolt M8x55 (2 Qty) 2.5 5 Hex Flange Bolt M8x100 (2 Qty) 2.5 6 Tube Assy, TC coolant intake 7 Sealing Washer 12x15.5 8 Pipe Union bolt 8 M12x1.5 2.5 9 Tube Assy, TC coolant intake 10 Spring band clamp 23dx12w 11 Hose, Thermostat to bypass pipe 12 Thermostat Housing 13 Bright washer 6.4 2.5 14 Hex Flange Nut AM6 (3 Qty) 1.0 15 Tube assembly, oil cooler coolant return 16 Sealing Washer 14x18 17 Pipe union bolt 10 M14x1.5 2.5 18 Adapter (water bypass) 19 Tube Assy. Oil cooler coolant inlet
1.2L REVOTRON ENGINE 39 N. Starter Motor and Alternator Starter Motor and Alternator No. DESCRIPTION NO REUSE SEALANT LUBRICATION TOQUE (Kgf.m) 1 Starter Motor Assy. With Pigtail 2 Hex Flange Bolt M8x55 (3 Qty) 2.5 3 Alternator 4 Alternator, Guard Mtg Bkt 5 Hex Flange Bolt M8x85 (3 Qty) 3.5 6 Bracket, EMS Wiring Harness Mtg
1.2L REVOTRON ENGINE 40 O. Compressor, Auto-Tensioner and Belt Compressor, Auto-Tensioner and Belt No. DESCRIPTION NO REUSE SEALANT LUBRICA TION TOQUE (Kgf.m) 1 Compressor 2 Hex Flange Screw M8x30 (4 Qty) 2.5 3 Bracket (A.C. Comp. Mounting) 4 Auto Tensioner Assy. 5 Hex Flange Bolt M8x30 (2 Qty) 2.5 6 Belt 7 Hollow Dowel (2 Qty) 8 Hex Flange Bolt M8x85 (3 Qty) 3.0
1.2L REVOTRON ENGINE 41 P. Engine Suspension
1.2L REVOTRON ENGINE 42 Engine Suspension No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Nyloc Nut M10 6.1 ~ 6.6 2 Harden Washer 10.5 3 A-Mount Arm 4 A-Mount 5 Hex Flange Bolt (2 Qty) 6.1 ~ 6.6 6 Bracket, A-Mount 7 Hex Flange Bolt (Front Pulley) (2 Qty) 6.1 ~ 6.6 8 Hex Flange Bolt (Conical) 10.7 ~ 11.2 9 Hex Flange Screw M10x30 (3 Qty) 6.1 ~ 6.6 10 Hex Flange Bolt (Conical) 10.7 ~ 11.2 11 C-Mount 12 Hex Flange Screw M10x30 6.1 ~ 6.6 13 Hex Flange Screw M10x30 (4 Qty) 4.0 ~ 4.5 14 B-Mount Bracket 15 Socket Head Cap Screw (2 Qty) 6.1 ~ 6.6 16 Reinforcement Plate 17 Hex Flange Screw M8x12 (2 Qty) 2.0 ~ 2.5 18 Reinforcement Plate 19 B Mount Assy 20 Harden Washer 10.5 (2 Qty) 21 Screw M10x1.25x30 (2 Qty) 6.1 ~ 6.6 22 Hex Flange Nut Am12x1.25 (2 Qty) 10.7 ~ 11.2 23 Washer, Plain (2 Qty) 24 Stud B Mount (2 Qty) 25 Hex Flange Bolt M12x65 10.7 ~ 11.2
1.2L REVOTRON ENGINE 43 No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 26 Washer, Plain 27 Stud (3 Qty) 28 Hex Flange Nut Am10 (3 Qty) 6.1 ~ 6.6 29 Hex Flange Nut Am12x1.25 30 Bracket Assy,C-Mount 31 Hex Flange Bolt (2 Qty) 6.1 ~ 6.6 32 Reinforcement Plate 33 Hex Flange Screw M8x12 2.0 ~ 2.5
1.2L REVOTRON ENGINE 44 Q. Intercooler and Hoses
1.2L REVOTRON ENGINE 45 Intercooler and Hoses No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Intercooler Assy. 2 Hex. Flange Screw M6x14 (2 Qty.) 1.0 3 Spring Band Clamp 49Dx12W (2 Qty.) 4 Hose TC Pipe To Intercooler 5 Spring Band Clamp 53Dx12W (2 Qty.) 6 Hex. Flange Screw M6x25 (2 Qty.) 1.0 7 Assy. Isolator (For IC intake Pipe) (2 Qty.) 8 Pipe Assy. TC To IC 9 Spring Band Clamp 53Dx12W 10 Hose, TC Pipe To Intercooler Pipe 11 Spring Band Clamp 55Dx12W 12 Hex. Flange Screw M6x12 1.0 13 Spring Band Clamp 53Dx12W 14 Hose, IC Pipe To Intake Manifold 15 Spring Band Clamp 60Dx12W 16 Sensor, Air Temperature 17 Hex. Flange Screw M6x18 1.0 18 Hose, IC Pipe To Intake Manifold 19 Spring Band Clamp 53Dx12W (2 Qty.) 20 Pipe Assembly, IC To IM 21 Hose (IC To Intake Manifold) 22 Hex. Flange nut AM6 (2 Qty.) 1.0 23 Elbow, TC Compressor Outlet 24 Gasket, TC Outlet To IC Pipe Assy.
1.2L REVOTRON ENGINE 46 1.4 ENGINE TESTS AND MAINTENANCE A. PRELIMINARY INSPECTION NOTE It is always advisable to first use the diagnostic tool and rectify the electrical faults, before commencing with mechanical repairs/ troubleshooting. Refer ENGINE MANAGEMENT SYSTEM section in this group for procedure. GENERAL 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 f. Turbocharger 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 vehicle 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 vehicle 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.
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