ENGINE 1.2L BSVI PHASE-2 ENGINE 1.2L BSVI PHASE-2
TABLE OF CONTENTS GENERAL INFORMATION ........................................................................................................................1 1. ENGINE INTRODUCTION ...................................................................................................................1 A. ELECTRONIC CONTROL ...................................................................................................................2 B. TECHNICAL SPECIFICATION ............................................................................................................4 C. SPECIAL TOOLS .................................................................................................................................5 D. ASSEMBLY CLEARANCES .................................................................................................................9 E. SEALANTS.........................................................................................................................................10 F. LEAKAGE RATES ..............................................................................................................................10 G. RECOMMENDED LUBRICANTS & COOLANTS ..............................................................................10 H. TROUBLESHOOTING..............................................................................................................................11 2. CONSTRUCTIONAL AND SERVICE DETAILS.......................................................................................18 3. ENGINE LIFTING : .............................................................................................................................18 A. INTAKE MANIFOLD ...........................................................................................................................19 B. CYLINDER HEAD COVER ................................................................................................................21 C. CYLINDER HEAD-A ..........................................................................................................................23 D. CYLINDER HEAD-B : .........................................................................................................................25 E. CYLINDER BLOCK : ..........................................................................................................................26 F. OIL SUMP...........................................................................................................................................28 G. MOVING PARTS : ..............................................................................................................................29 H. ENGINE TIMING : ..............................................................................................................................32 I. EXHAUST MANIFOLD : .....................................................................................................................34 J. FUEL INJECTION EQUIPMENT ........................................................................................................35 K. LUBRICATION PUMP AND COMPONENTS ....................................................................................36 L. AIR INTAKE SYSTEM : ......................................................................................................................38 M. SPECIAL INSTALLATION :.................................................................................................................40 N. ENGINE SUSPENSION .....................................................................................................................43 O. ENGINE TESTS AND MAINTENANCE ...................................................................................................46 4. PRELIMINARY INSPECTION ...........................................................................................................46 A. ENGINE TESTS ................................................................................................................................47 B. ENGINE COMPRESSION TEST : ...............................................................................................47 I. ENGINE OIL CONSUMPTION TEST ..........................................................................................48 II. ENGINE OIL PRESSURE TEST .................................................................................................49 III. REGULAR MAINTENANCE ...............................................................................................................50 C. ENGINE 1.2L BSVI PHASE-2
ENGINE OIL AND FILTER CHANGE ..........................................................................................50 I. ENGINE COOLANT REPLACEMENT ........................................................................................51 II. AIR FILTER ELEMENT REPLACEMENT ...................................................................................52 III. SPARK PLUG REPLACEMENT : ................................................................................................53 IV. AC COMPRESSOR AND ALTERNATOR BELT REPLACEMENT...............................................55 V. REPAIR AND INSPECTION DETAILS .....................................................................................................57 5. ACCESSORY DRIVING BELT ...........................................................................................................57 A. TIMING CHAIN : .................................................................................................................................57 B. CYLINDER HEAD ..............................................................................................................................57 C. VALVES ..............................................................................................................................................58 D. CYLINDER HEAD VALVE SEATS .....................................................................................................60 E. ROLLER FINGER FOLLOWER ........................................................................................................61 F. HYDRAULIC LASH ADJUSTER (HLA) ..............................................................................................61 G. CAMSHAFTS (INTAKE & EXHUAST) ..............................................................................................61 H. PISTON AND PISTON RINGS ..........................................................................................................63 I. CONNECTING RODS .......................................................................................................................64 J. CRANKSHAFT ..................................................................................................................................66 K. CRANK CASE ....................................................................................................................................68 L. FUEL TANK .......................................................................................................................................69 M. CANISTER PURGE VALVE................................................................................................................69 N. CANISTER .........................................................................................................................................70 O. ENGINE SYSTEM.....................................................................................................................................71 6. AIR INTAKE SYSTEM .......................................................................................................................71 A. BLOW BY SYSTEM ...........................................................................................................................73 B. LUBRICATION SYSTEM ...................................................................................................................74 C. EXHAUST SYSTEM ..........................................................................................................................78 D. COOLING SYSTEM ..........................................................................................................................80 E. FUEL SYSTEM ..................................................................................................................................83 F. ON VEHICLE SERVICE PROCEDURE ...................................................................................................86 7. ENGINE REMOVAL AND REFITMENT FOR MT VEHICLE...............................................................86 A. ENGINE REMOVAL AND REFITMENT FOR AMT VEHICLE ............................................................92 B. AIR FILTER ASSEMBLY ....................................................................................................................97 C. INJECTION SYSTEM.........................................................................................................................97 D. SPARK PLUG.....................................................................................................................................98 E. EXHAUST SYSTEM REMOVAL.........................................................................................................99 F. ENGINE 1.2L BSVI PHASE-2
FUEL SYSTEM.................................................................................................................................102 G. COOLING SYSTEM .........................................................................................................................107 H. COMPRESSOR AND ALTERNATOR BELT REMOVAL ...................................................................110 I. TIMING BELT REMOVAL..................................................................................................................111 J. REMOVAL ..................................................................................................................................111 I. TIMING CORRECTION / ADJUSTING PROCEDURE ..............................................................114 II. WATER PUMP REMOVAL................................................................................................................115 K. SOLENOID REMOVAL .....................................................................................................................116 L. ELECTRONIC THROTTLE BODY REMOVAL .................................................................................117 M. STARTER MOTOR REMOVAL.........................................................................................................117 N. ALTERNATOR REMOVAL ................................................................................................................118 O. COMPRESSOR REMOVAL..............................................................................................................118 P. ENGINE OVERHAULING :( ON OVERHAUL STAND) .........................................................................120 8. ENGINE DISASSEMBLY .................................................................................................................120 A. REMOVAL OF INTAKE MANIFOLD :.........................................................................................120 I. REMOVAL OF CCC ...................................................................................................................121 II. REMOVAL OF OIL SUMP..........................................................................................................122 III. REMOVAL OF SENSORS.........................................................................................................122 IV. REMOVAL OF ACCESSORIES .................................................................................................123 V. REMOVAL OF TIMING CHAIN..................................................................................................126 VI. REMOVAL OF CYLINDER HEAD AND CAMSHAFT. ..............................................................127 VII. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES...........................................................128 VIII. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES...........................................................130 IX. ENGINE ASSEMBLY .......................................................................................................................133 B. ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES .........................................................133 I. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES ....................................135 II. ASSEMBLY OF CYLINDER HEAD SUB-ASSEMBLIES ...........................................................138 III. ASSEMBLY OF CYLINDER HEAD ...........................................................................................139 IV. ASSEMBLY OF ENGINE TIMING CHAIN..................................................................................141 V. ASSEMBLY OF ENGINE ACCESSORIES DRIVING BELT ......................................................145 VI. ASSEMBLY OF SENSORS AND PERIPHERALS ...................................................................146 VII. ASSEMBLY OF OIL SUMP......................................................................................................147 VIII. ASSEMBLY OF CCC.................................................................................................................148 IX. ASSEMBLY OF INTAKE MANIFOLD ........................................................................................148 X. ENGINE MANAGEMENT SYSTEM .......................................................................................................150 9. ENGINE 1.2L BSVI PHASE-2
ABBREVIATIONS.............................................................................................................................150 A. AN OVERVIEW ................................................................................................................................151 B. ELECTRONIC CONTROL UNIT (ECU) ...........................................................................................152 C. SENSORS ........................................................................................................................................157 D. MANIFOLD AIR PRESSURE SENSOR AND TEMPERATURE SENSOR (T-MAP) : ................158 I. LAMBDA SENSOR ...................................................................................................................159 II. CAMSHAFT POSITION SENSOR ............................................................................................161 III. KNOCK SENSOR .....................................................................................................................162 IV. CRANKSHAFT POSITION SENSOR : ......................................................................................163 V. COOLANT TEMPERATURE SENSOR : ...................................................................................165 VI. ACTUATORS....................................................................................................................................167 E. IGNITION COIL .........................................................................................................................168 I. PURGE CONTROL VALVE .......................................................................................................169 II. SOLENOID VALVE (OIL CONTROL VALVE) .............................................................................170 III. FUEL INJECTORS ...................................................................................................................171 IV. ELECTRONIC THROTTLE BODY ............................................................................................172 V. SWITCH ..........................................................................................................................................174 F. OIL PRESSURE SWITCH :........................................................................................................174 I. THROTTLE PEDAL SENSOR ..................................................................................................175 II. CLUTCH SWITCH ....................................................................................................................176 III. BRAKE SWITCH ......................................................................................................................177 IV. VEHICLE SPEED SENSOR ......................................................................................................178 V. WHEEL SPEED SENSOR.........................................................................................................179 VI. ENGINE 1.2L BSVI PHASE-2
GENERAL INFORMATION 1. ENGINE INTRODUCTION A. Description: The “1.2L REVOTRON” is a 1199 CC, 3-Cylinder Gasoline Engine, with MPFI, VCTi and BSVI Phase2 compliant. Features: Stiffened Aluminium Crankcase with Aluminium bed plate structure. • Double Overhead Camshaft (DOHC) with 4 valves per cylinder. • Dual VCT • 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 • Engine is BSVI Phase2 OBD-II compliant. • Multi Point Fuel Injection (MPFI) • Graded bearing system for Main bearing and con-rod big end. • ENGINE 1.2L BSVI PHASE-2 1
ELECTRONIC CONTROL B. 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 (BSVI Phase2) 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. ENGINE 1.2L BSVI PHASE-2 2
ENGINE 1.2L BSVI PHASE-2 3
TECHNICAL SPECIFICATION C. Model 1.2L REVOTRON08 Description 1.2L NA NG REVOTRON 110 377 DOHC VCT BSVI Phase2 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 / Cube Lite Bore/Stroke 77 mm X 85.8 mm Engine Capacity 1199 cc Coolant Water + Ethylene Glycol 60:40 Compression Ratio (11.3 ±0.3) :1 Maximum Engine Power Output 85 PS @ 6000rpm (62.5 kw @ 6000 rpm) 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 BOSCH : YR7SES (0.7 to 0.8 mm gap) FM : RER8MC (0.8 to 0.9 mm gap) Air Filter Dry Paper type Oil Filter Spin on Full flow Paper type Fuel Filter Integrated filter with intank Fuel pump Timing Chain Drive VCT MIKUNI Controller Assy Emission Norms Bharat Stage VI Phase2 Compliance Governor Controlled through ECU Weight of engine EASB ~82 kg and EASBA ~ 97 kg. Engine mounting 3 point transverse mounting Exhaust system Exhaust system with close coupled catalytic convertor Air Intake System Electronic throttle control Radiator frontal Area 0.24 sq meter Ignition Coil Details Epoxy Molded Plug Top type Ignition Coil (Supply voltage range 6-16V) ENGINE 1.2L BSVI PHASE-2 4
SPECIAL TOOLS D. SR.N O. TOOL DESCRIPTI ON TOOL PART NUMBAR APPLICATION 1 StandEngine Support 5424 5890 2401 2 Fixture (Stand) assembly aggregate repair 5425 5890 0605 3 Adaptor for engine mounting bracket LH (Petrol) 5438 5890 2403 4 Bracket LHEngine Overhauling stand 5424 5890 24 03 ENGINE 1.2L BSVI PHASE-2 5
SR.N O. TOOL DESCRIPTI ON TOOL PART NUMBAR APPLICATION 5 Bracket RHEngine Overhauling stand 5424 5890 24 02 6 Pin-Flywheel locking On vehicle 2871 5890 06 75 7 Pin-Flywheel locking In Standalone Condition 2702 5890 06 05 8 Pin-Timing chain tensioner plunger locking 5424 5890 06 04 9 Wedge-Oil Sump sealant cutting 5424 5890 06 09 ENGINE 1.2L BSVI PHASE-2 6
SR.N O. TOOL DESCRIPTI ON TOOL PART NUMBAR APPLICATION 10 CompressorValve spring 2829 5890 06 05 11 Rail - Valve spring compressor 5424 5890 06 06 12 Water pump coolant inlet pipe fitment tool 5424 5890 20 02 13 Drift-Crank shaft front cover oil seal 2654 5890 05 08 14 Drift-Crank shaft rear oil seal 2699 5890 18 03 ENGINE 1.2L BSVI PHASE-2 7
SR.N O. TOOL DESCRIPTI ON TOOL PART NUMBAR APPLICATION 15 Spanner-Oil filter 5424 5890 18 02 16 Guide pin for VCT 5424 5890 06 14 17 Injector Puller 18 Engine adaptor for Compression Test Refer tool ITCC7337 19 Alternator belt stopper 5424 5890 0619 20 Outer Stretch Belt removal tool 5427 5890 0602 ENGINE 1.2L BSVI PHASE-2 8
ASSEMBLY CLEARANCES E. SR.N O. TOOL DESCRIPTI ON TOOL PART NUMBAR APPLICATION 21 Inner Stretch Belt removal tool 5424 5890 0616 22 Inner stretch belt installation tool 5424 5890 0603 23 Outer stretch belt installation tool 5424 5890 0615 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) 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 ENGINE 1.2L BSVI PHASE-2 9
SEALANTS F. LEAKAGE RATES G. RECOMMENDED LUBRICANTS & COOLANTS H. GROUP DESCRIPTION VALUES (MM) 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 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 570501995303 Sealant Loctite 5910 (50 Ml. Tube Pack) For Oil Sump To Bedplate REGION PRESSURE LEAKAGE (MAX.) Air Side 0.2 bar < 200 cc/min Water Side 0.7 bar < 20 cc/min ITEM SPECIFICATION COMPANY AND BRAND QTY ENGINE OIL 0W20 LOW ASH BS VI SS6588 CASTROL - Magnatec Professional T 0W20 PETRONAS TATA MOTORS Genuine Oil – Engine Oil Synth 0W20 EXXON MOBIL - Mobil super 3000 TMGO 0W20 Tata motors genuine oil 3.5 Litres COOLANT (Pre-mixed) (Antifreeze agent : Soft water = 40 : 60 ratio) Class II/JIS K2234 TATA SS7700S1 SUNSTAR CCI - Golden Cruiser LLC 2200NP CASTROL - Castrol Radicoolant SFO Premix 4 Litres ENGINE 1.2L BSVI PHASE-2 10
TROUBLESHOOTING 2. 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. • 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. • Engine Starts but does not idle Faulty ETC unit. Perform Diagnosis test. Replace as • necessary. Fuel filter if clogged. Replace the fuel filter. • ENGINE 1.2L BSVI PHASE-2 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. 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 3. 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 ENGINE 1.2L BSVI PHASE-2 12
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. 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. • ENGINE 1.2L BSVI PHASE-2 13
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. 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 4. 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 Inspect spark plugs. Replace if worn. • ENGINE 1.2L BSVI PHASE-2 14
gapped improperly. 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. Adjust or replace. ‘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. Exhaust System 5. 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. ENGINE 1.2L BSVI PHASE-2 15
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 / 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. Cooling System 6. 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 Replace with new thermostat. • Defective water pump Inspect and replace water pump as • necessary. 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 ENGINE 1.2L BSVI PHASE-2 16
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 Replace with new thermostat. • Defective temperature sending unit Check coolant temperature sensing • unit. Replace as necessary. Engine Lubrication System 7. 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. • ENGINE 1.2L BSVI PHASE-2 17
CONSTRUCTIONAL AND SERVICE DETAILS 3. ENGINE LIFTING : A. Engine Lifting SR NO DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (KGF-M) 1 Lifting Hook (Front) 2 Hex FL SCREW M8X18 (4 Qty) 2.5 ENGINE 1.2L BSVI PHASE-2 18
INTAKE MANIFOLD B. ENGINE 1.2L BSVI PHASE-2 19
Intake Manifold Note: This Symbol indicates critical tightening torque. SR NO DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (KGF-M) 1 ETC to Intake Manifold (HEX FL NUT AM6) (4 Qty) 1.0 2 ETC to Intake Manifold (STUD BM6X40) (4 Qty) 1.0 3 Electronic Throttle Control 4 Grommet on intake manifold for air filter (Top) 5 MAP Sensor 6 Hex FL screw m6x12 1.0 7 Intake Manifold 8 HEX FL NYLOC NUT M8 (4 Qty) 2.0+0.3 9 HEX FL BOLT M8X30 at bottom of intake manifold on block (1 Qty) 2.5 10 Grommet on intake manifold (Bottom) 11 Intake Manifold Stud STUD CM8X30 (4 Qty) ENGINE 1.2L BSVI PHASE-2 20
CYLINDER HEAD COVER C. ENGINE 1.2L BSVI PHASE-2 21
Cylinder Head Cover : Note: • This Symbol indicates critical tightening torque. SR NO DESCRIPTION NO REUSE SEALANT LUBRICATIO N TORQUE (KGFM) 1 Hex FL Bolt M6X35 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)• 4.0 ±0.5 185˚+5˚ 6 Washer 7 Gasket (Cylinder Head) 8 Dipstick 9 ’O’ Ring (Oil Filler Cap) 10 Oil Filler Cap 11 Hex. FL Screw M6X22 (Head Cover) (13Qty) 1.0 12 Solenoid Valve 13 Hex FL Nut AM6 for Solenoid valve (1Qty) 1.0 14 Stud C M6X20 for OCV 1.0 15 Hex FL Bolt M6X65 (1Qty) 1.0 ENGINE 1.2L BSVI PHASE-2 22
CYLINDER HEAD-A D. ENGINE 1.2L BSVI PHASE-2 23
Note:- • This Symbol indicates critical tightening torque. SR NO DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (KGF-M) 1 Hex FL Bolt M6X60 for ITG Bearing Cap Upper (4 Qty)• 2 ITG Bearing Cap Upper 1.5±0.15 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±0.15 10 Dowel Bolt M6X35 for Camshaft Brg. Cap (12 Qty)• 1.5±0.15 11 Spring Seat 12 Valve Guide Seal 13 Valve Spring 14 Valve Spring Retainer 15 Lock Half 16 HLA RFF Assembly ENGINE 1.2L BSVI PHASE-2 24
CYLINDER HEAD-B : E. Cylinder Head-B : • SR NO DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (KGF-M) 1 Cam Phase Sensor (2 Qty) 2 H/FL Screw M6X14 for Cam Sensor (2 Qty) 1.0 3 Thermostat Housing ENGINE 1.2L BSVI PHASE-2 25
CYLINDER BLOCK : F. ENGINE 1.2L BSVI PHASE-2 26
Cylinder Block Note: • This Symbol indicates critical tightening torque. SR 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 Bolt main bearing cap torx M10x1.5 e14 8 Bed plate Hex/Fl bolt M8X70 (10 Qty) • 3.2±0.6 9 Bed Plate 10 Rotational Speed Sensor 11 H/FL Screw M6X16 for Crank Angle Sensor 1.0+0.2 12 Deflector Plate Cyl. Block ENGINE 1.2L BSVI PHASE-2 27
OIL SUMP G. SR 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) 1.0 5 Pipe seal 6 Water Bypass Assembly 7 H/FL Screw M6X14 (02 Qty) 1.0 ENGINE 1.2L BSVI PHASE-2 28
MOVING PARTS : H. Note:- • This Symbol indicates critical tightening torque. ENGINE 1.2L BSVI PHASE-2 29
Moving Parts : SR 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 ENGINE 1.2L BSVI PHASE-2 30
SR NO DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (KGF-M) 20 Hex. Bolt For Flywheel (M10 X 1.5) (6 Qty)• 3.5+0.5 25˚ ± 5˚ 21 Piston ENGINE 1.2L BSVI PHASE-2 31
ENGINE TIMING : I. ENGINE 1.2L BSVI PHASE-2 32
Engine Timing Note:- • This Symbol indicates critical tightening torque. SR 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 (Exhaust Camshaft VVT• ˚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 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 ENGINE 1.2L BSVI PHASE-2 33
EXHAUST MANIFOLD : J. Exhaust Manifold SR NO DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (KGF-M) 1 Exhaust Manifold 2 Gasket (Exhaust Manifold) 3 Stud C M8X25 for Exhaust (4 Qty) 2.5 4 M8X1.25 Flange P/T Nut. (4 Qty) 2.0+0.3 5 Lambda Sensor 5.0+1.0 6 Lambda Sensor 5.0+1.0 7 H/FL Screw M8X20 (2 Qty) 2.5 ENGINE 1.2L BSVI PHASE-2 34
FUEL INJECTION EQUIPMENT K. Fuel Injection Equipment SR NO DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (KGF-M) 1 Assembly Fuel Rail 2 Hex FL Bolt M8X30 (Common Rail) (2 Qty) 2.5 3 Clip Fuel Injector 4 Fuel Injector ENGINE 1.2L BSVI PHASE-2 35
LUBRICATION PUMP AND COMPONENTS L. ENGINE 1.2L BSVI PHASE-2 36
Lubrication Pump and Lines : SR 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 Oil Seal (Crankshaft) (Front) 4 Oil Pump 5 Hex FL Bolt M6X28 (13 Qty) 1.0 6 O-Ring (For Strainer assy) 7 Flanged Clinch Nut M6 (2 Qty) 1.0 8 Strainer Assembly (For Oil Pump) 9 Gasket (For Filter) 10 HEX FL BOLT M8X25 (For Filter) (3 Qty) 2.5 11 Adaptor (For Oil Filter Mounting) 12 Oil Filter Assembly ¾ th Turn 13 Oil Pressure Switch 3+1 ENGINE 1.2L BSVI PHASE-2 37
AIR INTAKE SYSTEM : M. ENGINE 1.2L BSVI PHASE-2 38
Air Intake System : SR NO DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (KGF-M) 1 Air Filter Housing Assembly 2 ETC to Intake Manifold (Hex.Nut AM6) (4 Qty) 3 ETC to Intake Manifold (STUD BM6X40) (4 Qty) 4 Blow by hose 5 Electronic Throttle Control 6 H/FL Bolt M8X28 (2Qty) 7 Intake Manifold 8 Snorkel Duct 2.5 9 Snorkel Bracket 10 H/FL Nut BM6 FOR Snorkel Bracket (1 Qty) ENGINE 1.2L BSVI PHASE-2 39
SPECIAL INSTALLATION : N. ENGINE 1.2L BSVI PHASE-2 40
Special Installation SR NO DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (KGF-M) 1 Belt 2 Bracket for Compressor Mounting 3 Hex FL Bolt M8X35 (Bracket to block) (Qty 4) 3.5 4 Compressor 5 H/FL Bolt M8X85 for Compressor (Qty 3) 2.2+0.2 6 Hex. FL Bolt M8X100 for Water Pump (Qty 2) 2.5 7 H/FL Bolt M8X55 for water pump (Qty 2) 8 Water Pump 9 Hex FL Nut AM6 to Thermostat 1.0 10 Bracket lambda sensor 11 Thermostat 12 Alternator 13 Alternator Cover Fitment Bracket: 14 Alternator Guard 15 Hex FL Nut AM6 for Guard (Qty 2) 1.0 16 Hex. FL Bolt M8X85 for alternator (Qty 2) 3.5 17 Hex flange bolt M8 X 55 (Qty 1) 3.5 18 Belt (Alternator Belt) 19 Water Temperature Sensor 1.8-2.5 ENGINE 1.2L BSVI PHASE-2 41
Special Installation : Special Installation : • SR NO DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (KGF-M) 20 Hex. FL Bolt M8X50 for Starter Motor (Qty 1 2.4+0.3 21 Hex. FL Bolt M8X45 for Starter Motor (Qty 1) 2.4+0.3 22 Starter Motor ENGINE 1.2L BSVI PHASE-2 42
ENGINE SUSPENSION O. ENGINE 1.2L BSVI PHASE-2 43
Engine Suspension SR NO DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (KGF-M) 1 Hex FL Nut AM12X1.5 For Mount 11 2 H/FL BOLT M8X28 TS17130 10.9SS8451S2-YH 3.2 3 B Mount Assembly 4 Nyloc Nut M8 5 FL Bolt M10X1.25x50 For Mount Bracket 5.8 6 B-Mount Bracket 7 SCR M10X1.25X30 At Bottom Of Bracket 8 H/FL Bolt M10X40 For Transaxle Side B-Mount 4.2 9 Stud For-B-Mount 10 B-Mount-Transaxle-Side 11 C-Mount 12 H/FL Bolt M10X80 C-Mount-LinkMount 5.4 13 H/FL Bolt M10X75 At Sleeve-CMount 5.4 14 C-Mount-Link-Mount 15 C-Mount-Brkt-BIW 16 Hex FL SCR M10X18 at C-MountBrkt-BIW 4.0 17 Bright Washer 18 Nyloc Nut M10 At Sleeve-C-Mount 19 Nyloc Nut M10 At C-Mount-LinkMount 20 Hex FL SCR M10X25 for C-Mount 5.4 21 A-Mount Bracket-BIW 22 SCR M10X1.25X30 At Bottom Of AMount Bracket-BIW 5.8 ENGINE 1.2L BSVI PHASE-2 44
SR NO DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (KGF-M) 23 A Mount 24 SCR M10X1.25X30 At Top Of AMount Bracket-BIW 5.8 25 A Mount Arm 26 BRIGHT WASHER 10.5 IS2016 ST SS8451S2-Y 27 Nyloc Nut M10 For A Mount Stud 6.3 28 Hex FL Nut AM10 At A Mount Arm 6.3 ENGINE 1.2L BSVI PHASE-2 45
ENGINE TESTS AND MAINTENANCE 4. PRELIMINARY INSPECTION A. GENERAL : • Check for leakage of Oil, fuel, and Coolant. 1. Check for overheating of engine. 2. Check for unusual smoke. 3. If there is any fault in the Engine Management 4. 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 Loss of power. 1. Excessive engine oil consumption. 2. Extremely low engine oil pressure. 3. Mechanical failures. 4. To know exact reason and general condition of engine, proceed as follows Loss of power. • Loss of engine power may be due to EMS is in limp-home mode due to some critical 1. fault. Clogged air filter / exhaust passage / catalytic 2. converter. Defective fuel system 3. Clutch slippage 4. Brake binding 5. EMS is in limp-home mode 1. 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) Clogged Air filter / Loss of Charge Air 2. 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. Defective Fuel System 3. Check the Fuel system for fuel flow. If the flow is restricted change the filter. Clutch Slippage 4. Clutch slipping can be confirmed by any of the following two methods: Method 1 : Drive the car in 1st or 2nd gear at a minimum 1. speed corresponding to that gear. With the accelerator pedal in a fully pressed 2. position, gradually apply brake with left foot. If the engine stalls, the clutch does not slip. 3. Method 2 : Drive the gear with weight equal to GVW in 3rd 1. gear on a level ground. Allow the speed to drop upto 15kmph. 2. Now press the accelerator pedal fully. 3. With slipping clutch the car will not pick up 4. speed, also a clutch burning smell could be noticed. If this does not occur, the clutch does not slip. 5. Brake Binding : 5. 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. 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. ENGINE 1.2L BSVI PHASE-2 46
ENGINE TESTS B. ENGINE COMPRESSION TEST : I. 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 : • If possible, bring the engine up to operating 1. temperature (approximately 80° - 90° C) by starting and driving the vehicle for several minutes. Make sure the vehicle battery is fully charged. 2. Remove the air filter element. 3. Label the spark plug coils and remove all spark 4. plugs from the engine. Install an engine compression test gauge (0 to 5. 25 bar) into the number one engine cylinder spark plug port. . (Remove fuel injector connections to avoid fuel injection). Depress the clutch and accelerator pedal fully 6. and crank the engine Have an assistant read and record the highest 7. pressure obtained on the gauge. Follow steps 5 through 7 for the three remaining 8. cylinders, recording the pressure obtained on the gauge. Compare the compression reading obtained for 9. each engine cylinder. The minimum compression is 12±1 bar. If the compression reading in a cylinder is 10. 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. If the compression improves after several 11. 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. If the compression between two adjacent 12. 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. CAUTION Use care not to damage the threads in the spark plug port when installing the compression test gauge adapter. ENGINE 1.2L BSVI PHASE-2 47
RkJQdWJsaXNoZXIy MTIwNTUz