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TIAGO TIGOR BS6 PHASE 2_SERVICE MANUAL

ENGINE 1.2L BSVI PHASE-2 1
TABLE OF CONTENTS 2
1. GENERAL INFORMATION 6
A. ENGINE INTRODUCTION 6
B. ELECTRONIC CONTROL 7
C. TECHNICAL SPECIFICATION 9
D. SPECIAL TOOLS 10
E. ASSEMBLY CLEARANCES 14
F. SEALANTS 15
G. LEAKAGE RATES 15
H. RECOMMENDED LUBRICANTS & COOLANTS 15
2. TROUBLESHOOTING 16
3. CONSTRUCTIONAL AND SERVICE DETAILS 23
A. ENGINE LIFTING 23
B. INTAKE MANIFOLD 24
C. CYLINDER HEAD COVER 26
D. CYLINDER HEAD-A 28
E. CYLINDER HEAD-B 30
F. CYLINDER BLOCK 31
G. OIL SUMP 33
H. MOVING PARTS 34
I. ENGINE TIMING 37
J. EXHAUST MANIFOLD 39
K. FUEL INJECTION EQUIPMENT 40
L. LUBRICATION PUMP AND COMPONENTS 41
M. AIR INTAKE SYSTEM 43
N. SPECIAL INSTALLATION 45
O. ENGINE SUSPENSION 48
4. ENGINE TESTS AND MAINTENANCE 51
A. PRELIMINARY INSPECTION 51
B. ENGINE TESTS 52
I. ENGINE COMPRESSION TEST 52
II. ENGINE OIL CONSUMPTION TEST 53
III. ENGINE OIL PRESSURE TEST 54
C. REGULAR MAINTENANCE 55
I. ENGINE OIL AND FILTER CHANGE 55
II. ENGINE COOLANT REPLACEMENT 56
III. AIR FILTER ELEMENT REPLACEMENT 57
IV. SPARK PLUG REPLACEMENT 58
V. AC COMPRESSOR AND ALTERNATOR BELT REPLACEMENT 60
5. REPAIR AND INSPECTION DETAILS 62
A. ACCESSORY DRIVING BELT 62
B. TIMING CHAIN 62
C. CYLINDER HEAD 62
D. VALVES 63
E. CYLINDER HEAD VALVE SEATS 65
F. ROLLER FINGER FOLLOWER 66
G. HYDRAULIC LASH ADJUSTER (HLA) 66
H. CAMSHAFTS (INTAKE & EXHUAST) 66
I. PISTON AND PISTON RINGS 68
J. CONNECTING RODS 69
K. CRANKSHAFT 71
L. CRANK CASE 73
M. FUEL TANK 74
N. CANISTER PURGE VALVE 74
O. CANISTER 75
6. ENGINE SYSTEM 76
A. AIR INTAKE SYSTEM 76
B. BLOW BY SYSTEM 78
C. LUBRICATION SYSTEM 79
D. EXHAUST SYSTEM 83
E. COOLING SYSTEM 85
F. FUEL SYSTEM 88
7. ON VEHICLE SERVICE PROCEDURE 91
A. ENGINE REMOVAL AND REFITMENT FOR MT VEHICLE 91
B. ENGINE REMOVAL AND REFITMENT FOR AMT VEHICLE 97
C. AIR FILTER ASSEMBLY 102
D. INJECTION SYSTEM 102
E. SPARK PLUG 103
F. EXHAUST SYSTEM REMOVAL 104
G. FUEL SYSTEM 107
H. COOLING SYSTEM 112
I. COMPRESSOR AND ALTERNATOR BELT REMOVAL 115
J. TIMING BELT REMOVAL 116
I. REMOVAL 116
II. TIMING CORRECTION / ADJUSTING PROCEDURE 119
K. WATER PUMP REMOVAL 120
L. SOLENOID REMOVAL 121
M. ELECTRONIC THROTTLE BODY REMOVAL 122
N. STARTER MOTOR REMOVAL 122
O. ALTERNATOR REMOVAL 123
P. COMPRESSOR REMOVAL 123
8. ENGINE OVERHAULING :( ON OVERHAUL STAND) 125
A. ENGINE DISASSEMBLY 125
I. REMOVAL OF INTAKE MANIFOLD 125
II. REMOVAL OF CCC 126
III. REMOVAL OF OIL SUMP 127
IV. REMOVAL OF SENSORS 127
V. REMOVAL OF ACCESSORIES 128
VI. REMOVAL OF TIMING CHAIN 131
VII. REMOVAL OF CYLINDER HEAD AND CAMSHAFT 132
VIII. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES 133
IX. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES 135
B. ENGINE ASSEMBLY 138
I. ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES 138
II. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES 140
III. ASSEMBLY OF CYLINDER HEAD SUB-ASSEMBLIES 143
IV. ASSEMBLY OF CYLINDER HEAD 144
V. ASSEMBLY OF ENGINE TIMING CHAIN 146
VI. ASSEMBLY OF ENGINE ACCESSORIES DRIVING BELT 150
VII. ASSEMBLY OF SENSORS AND PERIPHERALS 151
VIII. ASSEMBLY OF OIL SUMP 152
IX. ASSEMBLY OF CCC 153
X. ASSEMBLY OF INTAKE MANIFOLD 153
9. ENGINE MANAGEMENT SYSTEM 155
A. ABBREVIATIONS 155
B. AN OVERVIEW 156
C. ELECTRONIC CONTROL UNIT (ECU) 157
D. 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 168
VI. COOLANT TEMPERATURE SENSOR 170
E. ACTUATORS 172
I. IGNITION COIL 173
II. PURGE CONTROL VALVE 174
III. SOLENOID VALVE (OIL CONTROL VALVE) 175
IV. FUEL INJECTORS 176
V. ELECTRONIC THROTTLE BODY 177
F. SWITCH 179
I. OIL PRESSURE SWITCH 179
II. THROTTLE PEDAL SENSOR 180
III. CLUTCH SWITCH 181
IV. BRAKE SWITCH 182
V. VEHICLE SPEED SENSOR 183
VI. WHEEL SPEED SENSOR 184

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