SERVICE MANUAL BOOK - 1 SERVICE MANUAL PUNCH BSVI PHASE-2 SUPPLIMENT
Developed by: Technical Literature Cell
Developed by: Technical Literature Cell. Release Date : Mar 2023 / First Edition. The information provided in this manual is based on the latest product information available at the time of publication. . C Copyright 2023 TATA MOTORS All rights reserved. The information in this manual shall not be reproduced or copied, in whole or in part, in any form without written permission from TATA MOTORS PASSENGER VEHICLES LTD. Vehicles are subject to modification in design, specification and equipment. Also refer the Service Circulars released by Customer Support about product & procedures.
INTRODUCTION This Supplement Service manual provides information pertaining to technical Specifications, repair, maintenance and overhaul of different aggregates fitted on TATA PUNCH BSVI PHASE-2. 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. The contents which are not covered in this supplement service manual have to be read in conjunctions with “TATA PUNCH BSVI” Service manual. For ease of use, this workshop manual is divided into 4 volumes, comprising several sections. Each aggregate has a separate section. THE BOOK– 1 CONTAINS 1.2L REVOTRONNGNA BSVI PHASE 2 ENGINE THE BOOK– 2 CONTAINS DIAGNOSTIC TROUBLE SHOOTING CODES (DTC) THE BOOK– 3 CONTAINS SERVICE SCHEMATICS THE BOOK– 4 CONTAINS INFO. FITMENT DRAWINGS
PUNCH BSVI PHASE 2 SUPPLEMENT TABLE OF CONTENT SR. NO. AGGREGATE 1 1.2L REVOTRON NGNA BSVI PHASE 2 PETROL ENGINE
ENGINE 1.2L REVOTRON NGNA PHASE-2 ENGINE
1.2L REVOTRON ENGINE CONTENTS 1. GENERAL INFORMATION .................................................................................................................... 1 A ENGINE INTRODUCTION.....................................................................................................1 B ELECTRONIC FUEL INJECTION CONTROL .......................................................................2 C TECHNICAL SPECIFICATION ..............................................................................................3 2. CONSTRUCTIONAL AND SERVICE DETAILS ................................................................................. 4 A CYLINDER HEAD AND COVER ...........................................................................................4 B FUEL INJECTION EQUIPMENT ...........................................................................................6 C AIR INTAKE SYSTEM ...........................................................................................................7 D SPECIAL INSTALLATION .....................................................................................................9 3. ENGINE TESTS AND MAINTENANCE ............................................................................................. 12 A REGULAR MAINTENANCE…… ......................................................................................... 12 I ENGINE OIL AND FILTER CHANGE ..................................................................................12 II AIR FILTER ELEMENT REPLACEMENT............................................................................13 4. ENGINE SYSTEM .................................................................................................................................. 14 A BLOW BY SYSTEM.............................................................................................................14 B EXHAUST SYSTEM ............................................................................................................15 5. ENGINE ON VEHICLE SERVICE PROCEDURE ............................................................................. 17 A ENGINE REMOVAL AND INSTALLATION .........................................................................17 B AIR FILTER ASSY ...............................................................................................................23 C SPARK PLUG ......................................................................................................................24 D EXHAUST SYSTEM ............................................................................................................25 E FUEL SYSTEM ....................................................................................................................28 F COOLING SYSTEM ............................................................................................................33 G COMPRESSOR AND ALTERNATOR BELT REMOVAL.....................................................37 H TIMING BELT REMOVAL....................................................................................................38
1.2L REVOTRON ENGINE I WATER PUMP ....................................................................................................................41 J SOLENOID ..........................................................................................................................42 K ELECTRONIC THROTTLE BODY.......................................................................................43 6. ENGINE OVEHAULING (ON OVERHAUL STAND) ....................................................................... 44 A REMOVAL OF ACCESSORIES ..........................................................................................44 B ASSEMBLY OF ACCESSORIES DRIVING BELT...............................................................47 7. ENGINE MANAGEMENT SYSTEM .................................................................................................... 49 A ABBREVIATIONS ................................................................................................................49 B AN OVERVIEW....................................................................................................................50 C ELECTRONIC CONTROL UNIT..........................................................................................51 D SENSORS… ........................................................................................................................ 56 I T-MAP SENSOR..................................................................................................................57 II LAMBDA SENSOR ..............................................................................................................58 III CAMSHAFT POSITION SENSOR.......................................................................................60 IV KNOCK SENSOR ................................................................................................................61 V CRANKSHAFT POSITION SENSOR ..................................................................................62 VI COOLANT TEMPERATURE SENSOR ...............................................................................63 E ACTUATORS.. ..................................................................................................................... 65 I IGNITION COIL....................................................................................................................66 II PURGE CONTROL VALVE .................................................................................................67 III SOLENOID VALVE (OCV)...................................................................................................68 IV FUEL INJECTOR ................................................................................................................. 69 V ELECTRONIC THROTTLE BODY.......................................................................................70 F SWITCH.. ............................................................................................................................. 72 I OIL PRESSURE SWITCH ...................................................................................................72 II THROTTLE PEDAL SENSOR .............................................................................................73
1.2L REVOTRON ENGINE III CLUTCH SWITCH ...............................................................................................................74 IV BRAKE SWITCH .................................................................................................................75 V VEHICLE SPEED SENSOR ................................................................................................76 VI WHEEL SPEED SENSOR...................................................................................................77
1.2L REVOTRON ENGINE 1 1. GENERAL INFORMATION: A. ENGINE INTRODUCTION : Description: The “1.2L REVOTRON" is a 1200 CC, 3-Cylinder Gasoline Engine, with MPFI, VCTi and BS-VI Ph2 compliant. Features: Stiffened Aluminium Crankcase with Aluminium bed plate structure. Double Overhead Camshaft (DOHC) with 4 valves per cylinder. Variable cam timing - Dual VCT (VCTi) Timing chain drive system Three stage oil pump Weight optimized hollow cam shafts Drive by wire technology (Electronic Throttle Control). Plastic intake manifold and head cover Light weight piston assembly Auto tensioner auxillary belt drive system Engine is BSVI OBD-II compliant. Advance Engine Management System from M/s BOSCH providing precise control for performance and emissions. Multi Point Fuel Injection (MPFI) Graded bearing system for Main bearing and con-rod big end.
1.2L REVOTRON ENGINE 2 B. Electronic Control : The engine management software in the vehicle's Engine Control Unit (ECU) controls the fuel injection and ignition system using a variety of sensors that provides the engine operating conditions and operates input information. The ECU includes self-diagnosis to help pinpoint any system malfunctions. Refer to the "Engine Management System" portion of this section for additional information. The MPFI type of fuel injection offers many advantages over a single point fuel injection system or a carburetor engine. The following paragraphs describe the advantages of the electronic fuel injected engine. Improved Engine Performance : The ECU precisely and instantly controls optimum fuel delivery and spark timing according to the operating conditions, inputs from the engine sensors, and operator input. This control improves vehicle response and acceleration. Increased Fuel Economy : The electronic fuel injection system allows the REVOTRON 110 engine to be Bharat Stage VI (BS-VI) compliant. By electronically controlling the air/fuel ratio of the combustion process, the engine maintains an air/fuel closer to stoichiometric (14.7:1, air to fuel), the optimum ratio for complete combustion of the fuel mixture. Decreased Exhaust Emissions : The use of electronic fuel injection also decreases exhaust emissions because the air/fuel ratio is precisely controlled through the ECU for operating conditions and driver input. The catalytic convertor also helps reduce exhaust emissions and specially manufactured to the fuel injection system's operation. Improved Cold Starting and Operation : By detecting the atmospheric and engine conditions in which the operator is starting and driving the vehicle, the ECU can adjust fuel mixture and ignition timing to help the vehicle start more easily when cold and to warm up faster. The MPFI ECU achieves all of these advantages by instantly compensating for changes in operating conditions and sensors inputs. This compensation is faster and more efficient than a mechanical system or human input.
1.2L REVOTRON ENGINE 3 C. TECHNICAL SPECIFICATION : Model :- 1.2L NG NA REVOTRON Description REVOTRON 1.2L NA Gen1 Plus Engine, BSVI Phase - 2 Type :- Engine Configuration :- Transverse mounted inline 3-cylinder engine Engine Management System :- BOSCH Engine Management System Bore/Stroke :- 77 mm X 85.8 mm Engine Capacity :- 1199 cc Radiator Coolant :- Class II/JIS K2234 TATA SS7700, Coolant ratio 60:40 Compression Ratio :- 11.3 Maximum Engine Power Output :- 64.6 kw @ 6000 rpm Maximum Engine Torque Output :- 115 Nm @ 3250 ± 100 rpm Engine Firing Order :- 1-2-3 Oil Capacity :- 3.2 L Cooling System Capacity :- Spark Plug Type :- FM : RER8MC (0.8 to 0.9 mm gap) Air Filter :- Dry (paper) type Oil Filter :- Spin on Full flow Paper type Fuel Filter Not Applicable Timing :- VCT Intake VCT – Mikuni Exhaust VCT - Denso Emission Norms :- Bharat Stage VI Phase - 2 Compliance Ignition Coil Details :- Epoxy Molded Coil Type Ignition Coil (Supply Voltage 5-16V)
1.2L REVOTRON ENGINE 4 2. CONSTRUCTIONAL AND SERVICE DETAILS: A. Cylinder Head Cover :
1.2L REVOTRON ENGINE 5 Cylinder Head Cover : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Hex FL Bolt M6X25 for Ignition Coil (3Qty) 1.0 ±0. 2 2 Ignition Coil (3Qty) 3 Cylinder head Cover 4 Gasket (Cylinder Head Cover)** 5 Hex. Bolt (Cylinder Head) (8Qty)• 5 + 180˚ 6 Washer 7 Gasket (Cylinder Head) 8 Dipstick 9 'O' Ring (Oil Filler Cap) 10 Hex. FL Screw M6X22 (Head Cover) (13Qty) 1.0 11 Oil Filler Cap 12 Solenoid Valve 13 Hex FL Nut AM6 for Solenoid valve (1Qty) 1.0 14 Stud C M6X20 for OCV 1.0 Note:- • This Symbol indicates critical tightening torque.
1.2L REVOTRON ENGINE 6 B. Fuel Injection Equipment : Fuel Injection Equipment : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Hex FL Bolt M8X30 (Common Rail) (2 Qty) 2 + 0.3 2 Assembly Fuel Rail 3 Fuel Injector Clip 4 Fuel Injector 2.9 + 0.3
1.2L REVOTRON ENGINE 7 C. Air Intake System :
1.2L REVOTRON ENGINE 8 Air Intake System : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Air Filter Housing Assembly 2 Clamp (75mm Dia) 0.5 3 Clamp (60mm Dia) 0.5 4 Hose, Air Filter To Throttle body 5 Filter Element 6 Spr. BD Clamp 7 Reinforcement ,Battery Tray 8 Grommet, Air Filter 9 Hose, Blowby
1.2L REVOTRON ENGINE 9 D. Special Installation :
1.2L REVOTRON ENGINE 10 Special Installation : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TOQUE (Kgf.m) 1 Belt 2 Hex FL Bolt M8X30 for Tensioner (Qty 2) 3 3 Belt Tensioner 4 Bracket for Compressor Mounting 5 Hex FL Bolt M8X28 (Bracket to block) (Qty 4) 3.5 6 Compressor 7 H/FL Bolt M8X80 for Compressor (Qty 3) 2.2+0.2 8 Hex. FL Bolt M8X100 for Water Pump (Qty 4) 2.5 9 Water Pump 10 Gasket For Water Pump 11 Hex FL SCR M6X18 to Thermostat 1.0 12 Bright Washer 13 Thermostat Housing 14 Alternator 15 Alternator Cover Fitment Bracket: 16 Alternator Guard 17 Hex FL Nut AM6 for Guard (Qty 2) 1.0 18 Hex. FL Bolt M8X80 for alternator (Qty 3) 3.5 19 Water Temperature Sensor 1.8-2.5
1.2L REVOTRON ENGINE 11 Special Installation : Special Installation : No. DESCRIPTION NO REUSE SEALANT LUBRICA TION TOQUE (Kgf.m) 20 Hex. FL Bolt M8X50 for Starter Motor (Qty 1) 2.4 21 Starter Motor
1.2L REVOTRON ENGINE 12 3. ENGINE TESTS AND MAINTENANCE: A. REGULAR MAINTENANCE: NOTE Use clip removal tool to remove clips, pin where as necessary to avoid the damage. I. Engine Oil and Filter Change : Description : Change the engine oil and as per recommendation. If the vehicle is operated in sandy/dusty conditions, idled extensively, or subject to frequent short distance driving, change the engine oil and filter more frequently. CAUTION Always use the recommended grade and quality of motor oil. Never use reclaimed oil as this may not protect the engine components properly. NOTE To protect the environment, always recycle or dispose of oil at the proper outlets. Procedure WARNING Engine oil will be hot. Contact with hot engine oil will cause bums. Use care when handling hot engine oil. 1. Drive the vehicle so the engine oil is at normal operating temperature. 2. Raise the vehicle off the ground to access the oil sump drain plug and oil filter. Raise the vehicle with a lift hoist. Park the vehicle on flat, level surface and engage the parking brake. Place chocks at the rear wheels and raise the front of the vehicle with a floor jack. 3. Raise the vehicle bonnet/hood and remove the oil fill cap. 4. Place a suitable container under the oil sump pan and remove the drain plug. 5. Allow the oil to drain from the engine. 6. Wipe the sump drain plug clean and apply MAXIFIX sealant or equivalent to the drain plug threads. 7. Using a copper washer, re-install the oil sump drain plug into the sump pan. Tighten the plug to 34 Nm. 8. Using the oil filter spanner (5424 5890 18 02), remove the engine oil filter. 9. Apply a thin coating of fresh oil on the new oil filter sealing washer. 10. Carefully thread the new oil filter onto the engine block. Hand-tighten the filter by 7/8th turn to 1 turn until the filter is firm against the sealing surface.
1.2L REVOTRON ENGINE 13 CAUTION Use only the designated filter wrench to tighten the oil filter. Using any other means to tighten the filter may cause damage to the filter or engine. 11. Tighten the oil filter an additional threequarters of a turn (270°). 12. Lower the vehicle to the ground and add 3.5 liters of fresh oil through the oil fill hole on the cylinder head cover. 13. If the Oil cap is damaged then replace the oil fill cap and clean any spilled oil. 14. Start the engine, observing the oil pressure indicator on the instrument panel. Stop the engine immediately if the light fails to go out within a few seconds of starting the engine. 15. Allow the engine to run for two to three minutes before stopping. 16. Check the oil level using the engine dipstick to make sure the engine oil level is at the 'MAX' mark on the dipstick. 17. Check for oil leaks at the filter or drain plug. II. Air Filter Element Replacement: Description : Proper maintenance of the air filter is essential for vehicle performance and fuel economy. The air filter element removes foreign material such as dust, dirt, and other material from the intake air, thereby preventing the engine from damage due to contaminated air. Inspect and clean the air filter element at every routine service. Replace the air filter element every 45,000 km. Removal : 1. Park the vehicle on a level surface, engage the parking brake, and raise the hood. 2. Unscrew the top mounting bolts of air filter assembly. 3. Detach the cover through hinge action. 4. Remove the air filter element. 5. Lightly tap to remove any dirt or debris from the filter. Clean the housing and air ducts as well. Make sure not to allow dirt and debris to enter through the air inlet to the engine. Inspection : 1. Hold the air filter element up to a light source. Light should be visible through the element. There should be no holes or tears in the element. 2. The filter can also be cleaned using low pressure compressed air. 3. Replace the filter element if torn or light is not visible through the filter. Installation : 1. Place the air filter element. 2. For re-assembling the cover, please ensure that all the hinge lugs are properly assembled in the slot of the air filter housing body, before tightening the screws.
1.2L REVOTRON ENGINE 14 4. ENGINE SYSTEM: A. BLOW BY SYSTEM : Blow By Schematic Layout : 1 Cylinder Head Cover 4 Throttle body 2 Cylinder Head 5 Hose BlowBy 3 Intake Manifold Description : In order to reduce the blow by gas emission, the blow by gas is directed to the intake manifold. Blow by gases are drawn from cylinder head cover and crankcase.
1.2L REVOTRON ENGINE 15 B. EXHAUST SYSTEM : Exhaust System Schematic Layout : 1 Exhaust Manifold 4 Main Silencer 2 Lambda Sensor 5 Post Silencer 3 Close Coupled Catcon Description : The exhaust system consists of an Exhaust manifold, Close Coupled Catcon Assy (CCC) and Silencer. The exhaust pipes are supported using rubber hangers. A common flange is connected to the exhaust manifold. The Close Coupled Catcon (CCC) is provided to reduce the exhaust emission, whereas the silencer is provided to dampen the sound of the exhaust gases coming out of the engine. The exhaust system consist of the following components 1. Exhaust Manifold 2. Lambda Sensor 3. Close Coupled Catalytic Converter (CCC) 4. Main Silencer. 5. Post Silencer Components : 1. Exhaust Manifold : The exhaust manifold is connected to the cylinder head. The exhaust gases are trapped out from the engine through the exhaust manifold.
1.2L REVOTRON ENGINE 16 2. Lambda Sensor : The oxygen sensor operates on the principle of galvanic oxygen concentration cell (Nernst cell) with solid electrolyte (Nernst's principle). The ceramic sensing element is a conductor of oxygen ions from a temperature of 350°C. A heater is integrated on the sensing element. It is placed into the exhaust manifold. The sensing element compares the residual oxygen content in the exhaust gas with the oxygen content in the reference atmosphere (air surrounding the sensing element). This gives an output voltage between 100mV (lean exhaust gas) to 800mV (rich exhaust gas), depending on whether the exhaust gas is lean or rich. 3. Close Coupled Catalytic Converter (CCC) : The Close Coupled Catalytic Converter is a critical element of the system used to reduce vehicle exhaust emissions. The catalytically active element within the converter lowers the activation energy needed to selectively transform harmful combustion products into less harmful gases. The catalyst becomes active when it reaches a threshold temperature. Close coupled Catalytic Converter is physically positioned very close to the engine exhaust ports to enable quicker light-off. Benefits -: Positioned close to the engine exhaust ports for fast light-off and reduced cold start emissions. Internally insulated construction design enables improved durability, reduced heat rejection and lower noise. 4. Muffler Assembly : The main function of the silencer is to reduce the amount of noise emitted by the engine exhaust gases flow. It typically makes use of the change in the cross sectional area which can be made as a chamber to filter or reduce the sound waves which the engine produces. The silencers are divided into three main groups. i) Exhaust pipe front ii) Exhaust Pipe Assy. with Pre-silencer iii) Exhaust Assy., Rear (Main Silencer)
1.2L REVOTRON ENGINE 17 5. ON VEHICLE SERVICE PROCEDURE: A. ENGINE REMOVAL AND REFITMENT: Description In many cases, the engine can be repaired while still in the vehicle. The engine must be removed in cases where the engine has been severely damaged beyond repair or the type of repair necessitates removal. Use the following procedure as a guide to engine removal and installation. Engine Removal NOTE Access to an overhead hoist will ease removal of the engine. Use a vehicle lifting hoist, if available. 1. Place the vehicle on the two post lift and engage the parking brake. 2. Open the hood (bonnet) of the vehicle. 3. Disconnect the negative (-) cable and then the positive (+) cable from the engine. 4. Remove the air filter assembly and intake system hoses from the engine. 5. Remove Battery, Battery plate and ECU from the vehicle. 6. Remove the EMS protective cap and disconnect electrical connections.
1.2L REVOTRON ENGINE 18 7. Raise the vehicle off the ground and drain the engine oil by removing the drain plug into a suitable container. 8. Drain the engine coolant by removing drain plug into a suitable container. 9. Remove the bottom LH and RH guard. 10. Remove the drain bolt from the transaxle. Drain the transaxle oil from the vehicle. 11. Recover A/C compressed gas using suitable recovery unit. 12. Remove the battery tray. 13. Disconnect front harness electrical connection to engine wiring harness.
1.2L REVOTRON ENGINE 19 14. Disconnect the Radiator hoses. 15. Remove the refrigerant lines from the engine compressor. 16. Disconnect heater hoses from the engine. 17. Disconnect and remove vacuum hose connected between brake booster to intake manifold. 18. Disconnect the fuel lines connection to fuel rail and canister after relieving the fuel pressure. 19. To remove exhaust front pipe loosen the clamp near Catcon and clamp near pre silencer of exhaust pipe
1.2L REVOTRON ENGINE 20 20. Disconnect the gear shift cable and selector cable from the transaxle. 21. Disconnect the clutch cable connection from the transaxle. 22. Remove front two tyres. 23. Disconnect the left and right drive shafts from the vehicle. (For removal procedures refer Transaxle section). 24. Use suitable belt/chain to fix a zip crane to the engine lifting hooks located at front and rear of the engine. 25. Raise the crane slightly up until very light pressure is applied to the engine. 26. Remove the bolts on Engine 'B' mounting bracket. 27. Remove the “A”- mounting bracket nuts (3 nos) from engine side. 28. Remove the “C” mount.
1.2L REVOTRON ENGINE 21 29. Using hydraulic support stand lower the engine from engine bay and remove engine from vehicle. (Use a suitable wooden block or other support for additional height as necessary.) CAUTION Take care when lowering the engine off the vehicle. Verify all components and electrical connections are disconnected prior to raising the vehicle, or vehicle damage occurs. 30. Now slightly lower the lift until engine and transaxle assembly is securely placed / fix on the support stand. SPECIAL TOOL Engine Support stand -: 5424 5890 24 01 31. Disconnect the lifting crane from the engine. 32. Now carefully move the lift up. 33. Take out the engine and transaxle assembly along with support stand. 34. Remove the engine wiring harness and starter motor. Remove the engine wiring harness. 35. Remove the gearbox along with clutch from the engine. (Refer Gearbox and clutch section for removal procedure). 36. Fix the LH & RH mounting brackets to the engine with the help of adopter. SPECIAL TOOL LH Mounting Bracket - 2702 5890 24 03 SPECIAL TOOL Adopter - 5438 5890 2403
1.2L REVOTRON ENGINE 22 SPECIAL TOOL RH Mounting Bracket - 5424 5890 24 02 37. Safely lift the engine with the help of crane and fix it on overhaul stand. Engine Installation : 1. Engine installation is generally reverse of removal. Make certain all hardware is tightened to appropriate torque specification. 2. Prior to installing the engine, inspect the condition of the rubber on the engine mounts. Replace the engine mounts if the rubber is damaged. 3. Mount the transaxle back onto the engine. Tighten the bolts with specified torque. 4. Install the starter motor and engine wiring harness along with its mounting brackets. 5. With the vehicle raised on the vehicle lift hoist, place the engine underneath the vehicle, aligned with the engine compartment. CAUTION Use care when lowering the vehicle body to the engine and transaxle assembly. Verify all the engine and other components will not make direct contact or vehicle damage will occur. 6. Slowly and carefully raise engine into engine bay. 7. Connect the lifting crane to the engine with a chain / belt. Raise the hoist slightly to apply lifting tension to the engine. 8. Secure the engine in the vehicle by attaching A, B and then C mount in sequence along with brackets. NOTE While tightening of B mount, use 12 mm 3 no’s of sockets on consecutive 3 mounting bolts as shown in fig. 9. With the engine attached to the crane, remove the support stand. 10. Remove the chain / belt after engine mounts are secure. 11. Install the left and right driveshaft assemblies. 12. Connect the gearshift linkage, clutch cable to the engine and transaxle. 13. Connect the engine wiring harness. 14. Connect the cooling system reservoir hoses. Verify the cooling system drain is closed on the radiator. Install the cooling system hoses to the engine, radiator and heater core. 15. To connect the exhaust front pipe tighten the flange near Catcon and connect at rear end. 16. Install the air filter assembly and intake system hoses to the engine.
1.2L REVOTRON ENGINE 23 17. Connect the vacuum hose connected between brake booster to intake maniflod. 18. Connect all the hoses connected between radiator and engine. 19. Connect the fuel lines to the engine. 20. Install the Battery Plate, Battery and ECU. 21. Connect the engine wiring harness connection with ECU. 22. Add the appropriate quantity of Engine oil, Transaxle oil and coolant with respective systems. 23. Connect the battery positive cable and then the battery negative cable. 24. Crank the engine several times without allowing the vehicle to start. This allows the oil and coolant to flow through engine. 25. Start the engine and verify the oil pressure light on the instrument cluster goes out. Stop the engine immediately if the light fails to extinguish. 26. Allow the engine to run for several minutes, checking for fluid levels and leakage. B. AIR FILTER ASSEMBLY REMOVAL 1. Remove the air filter mounting bolt and clamp. 2. Remove air filter hose to throttle valve. FITMENT For fitment follow the removal procedure in reverse.
1.2L REVOTRON ENGINE 24 AIR FILTER ELEMENT REPLACEMENT 1. Remove the mounting bolts of the air filter cover. 2. Set the air filter aside along with the air filter hose. 3. Remove the filter element. 4. Inspect and replace filter element. FITMENT For fitment follow removal procedure in reverse. C. SPARK PLUG REMOVAL 1. Disconnect the battery negative terminal. 2. Disconnect electrical connections to the ignition coil. 3. Remove ignition coil from head cover by removing fasteners. 4. Remove Spark plugs. FITMENT Follow the reverse order of removal for fitment.
1.2L REVOTRON ENGINE 25 D. EXHAUST SYSTEM REMOVAL MAINTENANCE PRECAUTIONS WARNING To avoid the danger of being burned, do not touch exhaust system when the system is hot. Any service on the exhaust system should be performed when the system is cool. At every interval of periodic maintenance service and when vehicle is raised for other service, check exhaust system as follows: Check rubber mountings for damage, deterioration or out of position. Keep sufficient clearance between exhaust system component and underbody. Check exhaust system for leakage, loose connection, dent & damage. If bolts or nuts are loosened, tighten them to the specified torque. Check nearby body areas for damage, missing or mis-positioned part, open seam, hole, loose connection or any other defect which could permit exhaust fumes to seep into vehicle. PRECAUTIONS FOR CATALYTIC CONVERTER In the event of following symptoms, drive the vehicle at slow speed without rapid acceleration. Engine misfires or runs irregularly, following a cold start. A significant loss of power is noticed. In case MIL lamp remains ON even after engine has been started. If the vehicle continuously runs with misfiring, it may cause overheating of shell, carpet etc. resulting into fire. MAINTENANCE OF CLOSED COUPLED CATALYTIC CONVERTER Closed Coupled Catalytic Converter should be flushed by giving full throttle (4 to 5 times) in standing condition of vehicle on daily basis. In addition to this it is recommended to run the vehicle at high speeds (80 to 100 kmph) for few km as this will help to flush the carbon soot deposits from exhaust system and closed coupled catalytic converter. High speed running of the vehicle may be done periodically to avoid chocking of Closed Coupled Catalytic Converter. Alternative method for flushing operation for cleaning the catalytic converter is by directing dry compressed air draft (3 to 4 bar) in the direction of catalytic converter inlet, after removing it from the vehicle. AVOID Push start or tow-starting the vehicle. (Use jump leads). Long (not more than 10 seconds) repeat (not more than 3 times) starting of the vehicle. Investigate the cause for difficulty in starting and rectify the same. Long idling (to warm-up) if the engine is running rough, after a cold start. Switching “OFF” the ignition when driving down the hill. Fuel almost empty. Pre- Coating/Painting of Catalytic Converter WARNING Avoid parking of vehicle over inflammable materials, such as dry leaves; grass etc. as exhaust system is hot enough to initiate fire. CAUTION Ensure exhaust system and catalytic converter is not blocked and is free from obstruction. Blockages in the exhaust can create back pressure, low top speed, poor pick up, black smoke, carbon build up and low mileage. Excessive carbon build-up / sticky valve. Damaged vacuum lines. The Catalytic converter should not be dropped from a height. If dropped, it should not be used. CAUTION The Catalytic converter should not be dropped from a height. If dropped, it should not be used.
1.2L REVOTRON ENGINE 26 EXHAUST ASSY. REAR (MAIN SILENCER) REMOVAL 1. Loosen and remove the bolt of clamp and disconnect the two pipe assembly along with the main silencer from Intermediate pipe. 2. Remove the two rubber hanger. 3. Take out the main silencer assembly. FITMENT For fitment follow the reverse procedure of removal. INTERMEDIATE EXHAUST ASSY. REMOVAL 1. Remove the mounting bolts of the Intermediate exhaust pipe at front. 2. Loosen and remove the bolt of clamp and disconnect the two pipe assembly along with the main silencer from Intermediate pipe. 3. Remove all supporting rubber hangers on the silencer. 4. Remove the Intermediate exhaust assembly. FITMENT For fitment follow reverse procedure of removal. NOTE Use new gaskets every time while fitment and tighten nuts and bolts to specified torque.
1.2L REVOTRON ENGINE 27 FRONT PIPE WITH FLEXIBLE BELLOW REMOVAL 1. Remove the mounting bolts of exhaust front pipe and Catcone. 2. Remove the mounting bolts of exhaust front pipe and Intermediate pipe. 3. Remove mounting bolt of front pipe on C mount bracket. 4. Remove Front pipe with flexible bellow. FITMENT All joints to be hand tightened first and then follow above sequence 1,2,3. NOTE Use new gaskets every time while fitment and tighten nuts and bolts to specified torque. CLOSED COUPLED CATALYTIC CONVERTER 1. Remove the mounting bolts of the front exhaust pipe and disconnect front pipe. 2. Disconnect electrical connection to both lambda sensor. 3. Remove the heat shield of CCC.
1.2L REVOTRON ENGINE 28 4. Loosen and remove CCC mounting bracket bolts from both sides. ( one side each) 5. Loosen and remove the intake manifold nuts. 6. Remove the CCC. FITMENT For fitment follow the reverse procedure of removal. NOTE Use new gaskets every time while fitment and tighten nuts and bolts to specified torque. E. FUEL SYSTEM PRECAUTIONS Before attempting any service on fuel system, following precautions should be always followed for personal safety and to avoid system damages. a) Disconnect negative cable at battery. b) Do not smoke, and place ‘NO SMOKING” sign near work area make sure to have fire extinguisher handy. c) Make sure to perform work in well ventilated area and away from any open fire/flames. d) Wear Safety glasses e) Small amount of fuel may drip after the fuel lines are disconnected. In order to reduce the risk of personal injury, cover the pipe/ hose ends with suitable plugs with no rust or contamination. f) After servicing, make sure that the fuel hoses and clamps are properly connected. g) After servicing, check for fuel leakages at fuel hose joints. h) Relieve the fuel pressure from the system before disconnecting any fuel lines especially high pressure lines. If pressure is not relieve the fuel may splash on the technician and the components which is dangerous. PRESSURE RELIEVING PROCEDURE 1. Remove the fuel filler cap to relieve the fuel vapour pressure. 2. Disconnect the fuel delivery line from the tank unit. 3. Start the engine and allow the engine to stall. 4. Turn off the ignition switch and disconnect the battery negative terminal. FUEL RAIL REMOVAL ON VEHICLE For fuel rail removal procedure refer on vehicle injector removal procedure. FUEL FILLER AND BREATHER HOSE REMOVAL AND FITMENT Refer Body section for removal and fitment procedures.
1.2L REVOTRON ENGINE 29 FUEL TANK REMOVAL 1. Place the vehicle in a 2 poster lift. 2. Disconnect the electrical connections of the intank pump and the fuel lines. Refer In-tank pump removal process. 3. Disconnect the fuel filler hose and the breather hose. 4. Support the fuel tank from below. 5. Remove the four mounting bolts from tank and lower the tank carefully. INSPECTION Check all hoses and pipes connected to fuel tank for leaks, loose connections, deterioration or damage. Replace if necessary. Check fuel pump and fuel level gauge gaskets for leaks, cracks etc. Replace if necessary. Visually inspect fuel tank for leaks and damage. Replace if necessary. FITMENT Follow the reverse order of removal for fitment. TANK UNIT REMOVAL CAUTION Unless replacement is necessary, Tank unit, fuel level sensor should not be removed from the tank since the rubber parts i.e. gasket, seals etc. may harden when exposed to air and light. Never apply an excessive force to the tank unit nipple or lead wire. This may result in bent or poor contact. 1. Fold the 2nd row Seat and somersault it to access the in tank pump cut out. 2. Loosen and remove the four screws of the cutout cover and set cover aside.
1.2L REVOTRON ENGINE 30 3. Disconnect the electrical connection of the fuel pump module. 4. Disconnect the fuel delivery line and the hose connecting fuel pump module to the canister. 5. Loosen and remove the mounting fasteners. 6. Lift the in-tank pump carefully out from the tank. FITMENT For fitment follow reverse procedure for removal. INSPECTION Use multi-meter to confirm that the resistance of the fuel level sensor changes with the level of float position. FUEL LEVEL SENSOR REMOVAL 1. Remove the tank unit. (For Removal Refer Tank Unit removal process). 2. Disconnect the electrical connection and remove the fuel level sensor by releasing the snap. INSPECTION Use multimeter to confirm that the resistance of the fuel level sensor changes with the level of float position. Pin No Function A Fuel Pump (+) B Fuel Pump (−) C Fuel Level Sensor (+) D Fuel Level Sensor (−) `Measure the resistance in pins B and C. refer next page for values at different heights of the float.
1.2L REVOTRON ENGINE 31 The specified resistance values and calibration: CHECK POINTS FUEL LEVEL (MM) FUEL VOLUME (L) MEASURING HEIGHT (MM) RESISTANCE * EMS (Empty mech. Stop) 22.4 ( - ) 15.4 121.5 ** EMPTY LOW 24.9 +3.2 17.7 ± 2.0 121.5 ± 2.0 ** EMPTY HIGH 46.2 8.0 36.7 ± 2.0 104.5 ± 2.0 ** 1/4 54.1 9.9 43.9 ± 2.0 97.2 ± 2.0 ** 1/2 92.5 20.2 79.4 ± 2.0 63.1 ± 2.0 ** 3/4 127.6 29.4 112.0 ± 2.0 31.4 ± 2.0 **FULL 153.1 36 136.0 ± 2.0 9.0 ± 2.0 * FMS (Full mech. Stop) 156.1 ( - ) 138.8 9.0
1.2L REVOTRON ENGINE 32 CANISTER REMOVAL 1. Remove air filter assembly. 2. Relieve fuel pressure. 3. Disconnect canister hoses. 4. Slide the canister in upward direction and take out from firewall bracket. FITMENT For fitment follow reverse procedure for removal. CANISTER PURGE VALVE REMOVAL 1. Relieve fuel pressure. 2. Disconnect electrical connection of the canister purge valve. 3. Disconnect hoses to the canister purge valve. 4. Loosen the mounting brackets bolts and remove canister purge valve. FITMENT For fitment follow reverse procedure for removal.
1.2L REVOTRON ENGINE 33 F. COOLING SYSTEM COOLANT TANK REMOVAL 1. Drain the coolant, (For procedure refer “Coolant Replacement” in Engine maintenance section) 2. Disconnect hose to coolant tank. 3. Remove mounting bolts and take out coolant tank. FITMENT For fitment follow the reverse order of removal. RADIATOR REMOVAL 1. Drain the coolant and remove the Coolant tank. (For procedure refer “Coolant replacement” in Engine maintenance section). 2. Recover refrigerant from lines. 3. Disconnect coolant hose to radiator. 4. Remove the front bumper. (Refer front bumper removal procedure from Body section).
1.2L REVOTRON ENGINE 34 5. Disconnect overflow tube to radiator filler hose. 6. Remove mounting bolts of the radiator filler hose and aside the hose aside. 7. Disconnect the electrical connections of the cooling fan shroud. 8. Remove the center fastener of radiator support. 9. Disconnect refrigerant lines. 10.Remove the mounting bolts of the bottom member of radiator support. 11.Tilt inwards and slide out the radiator and condenser assembly from the vehicle. 12.Remove Sealing assemblies.
1.2L REVOTRON ENGINE 35 13.Remove the top mounting bolts and remove condenser assembly. 14.Remove the neck filler assembly of radiator. 15.Remove the fan shroud assembly by removing its mounting bolts. FITMENT For fitment follow the reverse order of removal. RADIATOR FAN SHROUD REMOVAL 1. Disconnect the electrical connections to the radiator fan. 2. Remove the six fasteners to separate fan shroud. 3. Pull out the shroud from the top. FITMENT For fitment slide the shroud into the mounts till it snaps at the top mounts.
1.2L REVOTRON ENGINE 36 THERMOSTAT REMOVAL 1. Drain the coolant. (Refer “Coolant Replacement Procedure). 2. Remove the Air Filter Assembly for Better Access. 3. Access the thermostat either from front right wheel side by removing the arch liner or from top by removing air filter assembly. 4. Remove the spring band clip and disconnect the hose. 5. Remove the cover mounting nuts. FITMENT For fitment follow the reverse order of removal. Tighten fasteners to the recommended torque. Thermostat cover mounting: M6 Bolt– (1 Kg-m) Checking procedure of thermostat: 1. Remove thermostat element from thermostat housing. 2. Mount thermostat element in a suitable fixture and place the fixture in a vessel filled with water. 3. Fix dial gauge with its spindle on valve surface with a pretension of 0.5mm 4. Heat the vessel and measure the water temperature with proper thermometer. 5. Note down the temperature when dial gauge needles starts moving indicating valve opening. 6. Note down the water temperature for needle movement (for valve fully open position). 7. The opening temperature and fully open temperature as measured should be as per the mentioned specifications. If they do not meet the specifications, replace the thermostat element.
1.2L REVOTRON ENGINE 37 G. COMPRESSOR AND ALTERNATOR BELT REMOVAL. The belt used in this vehicle is multi ribbed belt. This belt is pre-tensioned over Air conditioner compressor and crank shaft pulley and therefore do not require the tensioner as this is capable of efficient power transmission. CAUTION The belt is not interchangeable and should not be interchanged with normal multiribbed belts. 1. Remove front RH mud liner. (Refer Body section for removal procedure). 2. Rotate the tensioner point by using ring spanner opposite to belt tension to remove the belt 3. Remove the belt. FITMENT For fitment follow the reverse order of removal. CAUTION Ensure that the tool is correctly located during the belt fitment process. Make sure that while rotating the crank shaft pulley the belt should not slip away from AC Compressor pulley.
1.2L REVOTRON ENGINE 38 H. TIMING BELT REMOVAL 1. Drain and collect engine oil. 2. Remove RH side front tyre. 3. Remove RH side mud liner and wheel arch liner. (Refer Body section for removal procedure). 4. Remove compressor and alternator belt. 5. Disconnect and remove engine wiring harness mounted on head cover. Set the wiring harness aside. 6. Disconnect oil mist separator hose. 7. Remove engine head cover along with dipstick, solenoid valve and ignition coil. 8. Remove oil sump.
1.2L REVOTRON ENGINE 39 9. Lock the flywheel. 10. Remove damper pulley. 11. Remove belt tensioner. 12. Support engine using special tool. 13. Remove A-mount. 14. Remove timing cover and oil pump assembly.
1.2L REVOTRON ENGINE 40 16. Release tension and lock the timing chain tensioner using locking pin. 17. Pin-Timing chain tensioner plunger locking – 5424 5890 06 04 18. Remove movable and fixed guide rail. 19. Remove the camshaft carrier. 20. Remove the Timing chain from the gear train assembly. FITMENT For fitment follow the reverse order of removal. NOTE Place the chain over VCT, exhaust sprocket and crankshaft sprocket in such a way that the 3 copper color links of chain matches with the dimple marks of all the 3 sprockets respectively
1.2L REVOTRON ENGINE 41 TIMING CORRECTION / ADJUSTING PROCEDURE CAUTION If timing chain is removed when cylinder head is in assembled on block, Do not rotate the crankshaft and camshafts independently, It may damage the valves. 1. Rotate the crankshaft 90° so that the piston will not touch any of valve. 2. Rotate camshaft to face upward direction. 3. Tighten damper bolt and rotate crankshaft to adjust the marking at bottom most position. NOTE Ensure the flywheel is not locked. 4. Rotate both camshafts to align. Ensure the direction of the arrows opposite to each other 5. Now place the chain over on both VCT’s in such a way that the 3 copper color links of chain matches with the dimple marks of all the 3 sprockets respectively as shown.
1.2L REVOTRON ENGINE 42 I. WATER PUMP REMOVAL 1. Drain coolant. 2. Remove auxiliary belt. 3. Disconnect hose connecting water bypass tube. 4. Remove mounting bolts of the water bypass tube. 5. Disconnect the water bypass tube from water pump. 6. Remove mounting bolts and take out water pump. FITMENT For fitment follow the reverse order of removal.
1.2L REVOTRON ENGINE 43 J. SOLENOID REMOVAL 1. Disconnect battery. 2. Disconnect all electrical connections to solenoid valve. 3. Remove fasteners and take out solenoid valve. FITMENT For fitment follow the reverse order of removal. K. ELECTRONIC THROTTLE BODY REMOVAL 1. Remove Hose connecting air filter and throttle body. 2. Disconnect electrical connection to the throttle valve. 3. Remove electronic throttle valve. FITMENT For fitment follow the reverse order of removal.
1.2L REVOTRON ENGINE 44 6. ENGINE OVERHAULING (ON OVERHAUL STAND): A. REMOVAL OF ACCESSORIES. 1. Keep the piston at top dead centre by rotating crankshaft. 2. Remove dipstick from head cover. 3. Remove Solenoid valve of VCT. 4. Remove ignition coil from head cover by removing fasteners. 5. Remove Spark plugs. 6. Remove the Cylinder Head Cover from the engine & carefully placed the rubber gasket apart. 7. Rotate the tensioner point by using ring spanner opposite to belt tension to remove the belt 8. Remove alternator, compressor, and water pump driving common Belt.
1.2L REVOTRON ENGINE 45 9. Remove Belt tensioner. 10. Remove the Alternator by removing the four fasteners. 11. Remove the Starter Motor by removing the three fasteners. 12. Remove the Compressor by removing the three fasteners. 13. Remove the Compressor mounting bracket by removing the four fasteners. 14. Remove the water bypass tube by removing 2 bolts and pulling out by special tool.
1.2L REVOTRON ENGINE 46 15. Remove the water pump by removing the four fasteners. 16. Remove crankshaft Pulley. NOTE Ensure the flywheel in lock position during crankshaft pulley removal as given below.
1.2L REVOTRON ENGINE 47 B. ASSEMBLY OF ACCESSORIES DRIVING BELT 1. Assemble the Belt tensioner. 2. Rotate the tensioner point by using ring spanner anticlockwise to assemble the accessory driving belt easily. 3. Assemble the Cylinder Head Cover to the engine & carefully placed the rubber gasket apart. NOTE Ensure the Cylinder head cover gasket not to be reused. 4. Tighten the cylinder head bolts as per sequence. 5. Assemble the Solenoid valve of VCT. 6. Assemble the spark plugs.
1.2L REVOTRON ENGINE 48 7. Assemble ignition coil to head cover. 8. Assemble dipstick to head cover.
1.2L REVOTRON ENGINE 49 7. ENGINE MANAGEMENT SYSTEM A. Abbreviations : EMS Engine Management System ECU Electronic Control Unit OBD On Board Diagnosis DTC Diagnostic Trouble Code CKNL Check Lamp / MIL / Service Indicator T-MAP Temperature and Manifold Air Pressure HO2S1 Oxygen Sensor (Lambda Sensor) ADCs devices Analog To Digital Convertor devices I/O drivers Input Output drivers DG DG abbreviation is used for Crank Shaft Position Sensor RPM Revolution Per Minute LED Light Emitting Diode COM Computer Serial Port (RS-232) OCV Oil Control Valve (Solenoid Valve)
1.2L REVOTRON ENGINE 50 B. An Overview : Engine Management System Overview : Modern engine management systems do a fine job of ensuring that engines run cleanly and efficiently in a wide variety of conditions, they are for the most part reliable and require little or no maintenance. Engine management system Comprises of Electronic Control Unit (ECU), Sensors, Actuators, Wiring Harness and control algorithms, which determine the performance of the Engine as a whole and as part of the vehicle. Electronic Control Unit (ECU) : An engine control unit (ECU), now called the power train control module (PCM), is a type of electronic control unit that controls a series of actuators on an internal combustion engine to ensure optimal engine performance. It does this by reading values from a multitude of sensors within the engine bay or signals from other vehicle electronic control units through Controller Area Network (CAN), interpreting the data using multidimensional performance maps (called lookup tables), and adjusting the engine actuators accordingly. Modern ECUs use a microprocessor which can process the inputs from the engine sensors in real-time. An electronic control unit contains the hardware and software (firmware). The hardware consists of electronic components (ADC’s, H bridges, CAN Transceiver, MUX, Low side and High side drivers) on a printed circuit board (PCB), ceramic substrate or a thin laminate substrate. The main component on this circuit board is a microcontroller chip (CPU). The software is stored in the microcontroller or other chips on the PCB, typically in EPROMs or flash memory so the CPU can be re-programmed by uploading updated code or replacing chips. This is also referred to as an (electronic) Engine Management System (EMS). Engine control unit monitors/diagnoses the functionality of its Hardware I/O’s, Software algorithms & external interfaces and raises a Diagnostic trouble code (DTC) against a peripheral when it finds mal-functioning of that peripheral. Apart from logging a DTC, Engine Control Unit also alerts the user with MI Lamp / CE lamp Glowing/flashing. Engine Control Unit also conveys the information regarding Engine operating condition through Dynamic / Static Defined data identifiers. Sensors : A sensor is a device that measures a physical quantity and converts it into an electrical voltage which can be read by an instrument or used by some controller for its purpose. Actuators : An actuator causes an action (say injector open or close) based on command given by ECU. Wiring Harness: Engine Wiring Harness and Vehicle Wiring Harness interface the Engine and Vehicle components to Engine Control Unit.
1.2L REVOTRON ENGINE 51 C. Electronic Control Unit (ECU) : ECU description and operating conditions: The ECU is designed for 6000 h of operation, a lifetime of 15 years, and an average of 2 cold starts per day. Operating temperature: -40° to +85°C, The maximum air temperature inside the ECU is 105 °C. ECU Location : Electronic Control Unit (ECU) is mounted in engine compartment. Storage Temperature : Please store the ECU around 10°C - 40°C with relative room humidity: 25% - 75% Connector Images : Engine Connector : Vehicle Connector : Connector Pin out :
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