| ALTROZ BSVI PHASE-2 SUPPLIMENT |
1 |
| INTRODUCTION |
3 |
| TABLE OF CONTENT |
5 |
| 1.2L REVOTRON NGNA BSVI PHASE 2 PETROL ENGINE |
6 |
| TABLE OF CONTENTS |
8 |
| 1. GENERAL INFORMATION |
12 |
| A. ENGINE INTRODUCTION |
12 |
| B. ELECTRONIC FUEL INJECTION CONTROL |
13 |
| C. TECHNICAL SPECIFICATION |
14 |
| D. SPECIAL TOOLS |
15 |
| E. ASSEMBLY CLEARANCES |
18 |
| F. SEALANTS |
19 |
| G. LEAKAGE RATES |
19 |
| 2. TROUBLESHOOTING |
20 |
| 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 |
35 |
| I. ENGINE TIMING |
38 |
| J. EXHAUST MANIFOLD |
40 |
| K. FUEL INJECTION EQUIPMENT |
41 |
| L. LUBRICATION PUMP AND COMPONENTS |
42 |
| M. AIR INTAKE SYSTEM |
44 |
| N. SPECIAL INSTALLATION |
46 |
| O. ENGINE SUSPENSION |
49 |
| 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 |
57 |
| III. AIR FILTER ELEMENT REPLACEMENT |
61 |
| IV. SPARK PLUG REPLACEMENT |
62 |
| V. AIR CONDITIONER COMPRESSOR ANDALTERNATOR BELT REPLACEMENT |
63 |
| 5. REPAIR AND INSPECTION DETAILS |
65 |
| A. ACCESSORY DRIVING BELT |
65 |
| B. TIMING CHAIN |
65 |
| C. CYLINDER HEAD: |
65 |
| D. VALVES |
66 |
| E. CYLINDER HEAD VALVE SEATS |
67 |
| F. ROLLER FINGER FOLLOWER |
67 |
| G. HYDRAULIC LASH ADJUSTER (HLA) |
68 |
| H. CAMSHAFTS (INTAKE & EXHUAST) |
68 |
| I. PISTON AND PISTON RINGS |
69 |
| J. CONNECTING RODS |
70 |
| L. CRANK CASE |
72 |
| M. FUEL TANK |
73 |
| N. CANISTER PURGE VALVE |
73 |
| O. CANISTER |
74 |
| 6. ENGINE SYSTEM |
75 |
| A. AIR INTAKE SYSTEM |
75 |
| B. BLOW BY SYSTEM |
77 |
| C. LUBRICATION SYSTEM |
78 |
| D. EXHAUST SYSTEM |
82 |
| E. COOLING SYSTEM |
84 |
| F. FUEL SYSTEM |
87 |
| 7. ON VEHICLE SERVICE PROCEDURE |
90 |
| A. ENGINE REMOVAL AND REFITMENT |
90 |
| B. AIR FILTER ASSEMBLY REMOVAL |
96 |
| C. FUEL RAIL AND INJECTOR |
97 |
| D. SPARK PLUG REMOVAL |
98 |
| E. EXHAUST SYSTEM REMOVAL |
98 |
| F. FUEL SYSTEM |
103 |
| G. COOLING SYSTEM |
108 |
| H. COMPRESSOR AND ALTERNATOR BELT REMOVAL |
112 |
| I. TIMING CHAIN REMOVAL |
113 |
| J. WATER PUMP |
117 |
| K. SOLENOID |
118 |
| L. ELECTRONIC THROTTLE BODY |
119 |
| M. STARTER MOTOR |
119 |
| N. ALTERNATOR |
120 |
| O. COMPRESSOR |
120 |
| 8. ENGINE OVEHAULING (ON OVERHAUL STAND) |
122 |
| A. ENGINE DIS-ASSEMBLY |
122 |
| I. REMOVAL OF INTAKE MANIFOLD |
122 |
| II. REMOVAL OF EXHAUST MANIFOLD |
123 |
| III. REMOVAL OF OIL SUMP |
125 |
| IV. REMOVAL OF SENSORS |
125 |
| V. REMOVAL OF ACCESSORIES |
126 |
| VI. REMOVAL OF TIMING CHAIN |
129 |
| VII. REMOVAL OF CYLINDER HEAD AND CAMSHAFT |
131 |
| VIII. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES |
132 |
| IX. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES |
134 |
| B. ENGINE ASSEMBLY |
137 |
| I. ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES |
137 |
| II. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES |
142 |
| III. ASSEMBLY OF CYLINDER HEAD SUB-ASSEMBLIES |
145 |
| IV. ASSEMBLY OF CYLINDER HEAD |
146 |
| V. ASSEMBLY OF ENGINE TIMING CHAIN |
148 |
| VI. ASSEMBLY OF ACCESSORIES DRIVING BELT |
153 |
| VII. ASSEMBLY OF SENSORS AND PERIPHERALS |
154 |
| VIII. ASSEMBLY OF OIL SUMP |
155 |
| IX. ASSEMBLY OF EXHAUST MANIFOLD |
156 |
| X. ASSEMBLY OF INTAKE MANIFOLD |
158 |
| 9. ENGINE MANAGEMENT SYSTEM |
160 |
| A. ABBREVIATIONS |
160 |
| B. AN OVERVIEW |
160 |
| C. ELECTRONIC CONTROL UNIT (ECU) |
162 |
| D. SENSORS |
168 |
| I. MANIFOLD AIR PRESSURE SENSOR AND TEMPERATURE SENSOR (T-MAP) |
169 |
| II. LAMBDA SENSOR |
170 |
| III. CAMSHAFT POSITION SENSOR |
174 |
| IV. KNOCK SENSOR |
175 |
| V. CRANKSHAFT POSITION SENSOR |
176 |
| VI. COOLANT TEMPERATURE SENSOR |
178 |
| E. ACTUATORS |
179 |
| I. IGNITION COIL |
179 |
| II. SOLENOID VALVE (OIL CONTROL VALVE) |
181 |
| III. FUEL INJECTORS |
182 |
| IV. PURGE CONTROL VALVE |
183 |
| V. ELECTRONIC THROTTLE BODY |
184 |
| F. SWITCH |
186 |
| I. OIL PRESSURE SWITCH |
186 |
| II. THROTTLE PEDAL SENSOR |
187 |
| III. CLUTCH SWITCH |
188 |
| IV. BRAKE SWITCH |
189 |
| V WHEEL SPEED SENSOR |
190 |
| 1.2L REVOTRON NGNA DCT BSVI PHASE 2 PETROL ENGINE |
191 |
| CONTENTS |
192 |
| 1. GENERAL INFORMATION: |
195 |
| A. ENGINE INTRODUCTION |
195 |
| B. ELECTRONIC CONTROL |
196 |
| C. TECHNICAL SPECIFICATION |
197 |
| D. SPECIAL TOOLS |
198 |
| 2. CONSTRUCTIONAL AND SERVICE DETAILS: |
202 |
| A. Engine Lifting |
202 |
| B. Intake Manifold |
203 |
| C. Oil Sump |
205 |
| D. Exhaust Manifold |
206 |
| E. Fuel Injection Equipment |
207 |
| F. Lubrication Pump and Components |
208 |
| G. Air Intake System |
210 |
| H. Special Installation |
212 |
| 3. ENGINE TESTS AND MAINTENANCE |
213 |
| A. REGULAR MAINTENANCE |
213 |
| I. Air Filter Element Replacement: |
213 |
| 4. REPAIR AND INSPECTION DETAILS |
214 |
| A. Canister Purge Valve |
214 |
| 5. ENGINE SYSTEM |
215 |
| A. AIR INTAKE SYSTEM |
215 |
| B. LUBRICATION SYSTEM |
217 |
| C. EXHAUST SYSTEM |
221 |
| D. COOLING SYSTEM |
223 |
| E. FUEL SYSTEM |
226 |
| 6. ON VEHICLE SERVICE PROCEDURE |
229 |
| A. ENGINE REMOVAL AND REFITMENT |
229 |
| B. AIR FILTER ASSEMBLY REMOVAL |
235 |
| C. FUEL RAIL AND INJECTOR |
236 |
| D. SPARK PLUG REMOVAL |
237 |
| E. EXHAUST SYSTEM REMOVAL |
237 |
| F. FUEL SYSTEM |
241 |
| G. COOLING SYSTEM |
246 |
| H. COMPRESSOR AND ALTERNATOR BELT REMOVAL |
250 |
| I. TIMING BELT REMOVAL |
251 |
| J. WATER PUMP |
255 |
| K. SOLENOID |
256 |
| L. ELECTRONIC THROTTLE BODY |
256 |
| 7. ENGINE OVERHAULING (ON OVERHAUL STAND): |
257 |
| A. ENGINE DIS-ASSEMBLY |
257 |
| I. Removal of Intake Manifold |
257 |
| II. Removal of Exhaust Manifold |
259 |
| III. Removal of Oil Sump |
260 |
| B. ENGINE ASSEMBLY |
261 |
| I. Assembly of Oil Sump |
261 |
| II. Assembly of Intake Manifold |
262 |
| 8. ENGINE MANAGEMENT SYSTEM |
264 |
| A. Electronic Control Unit (ECU) |
264 |
| B. SENSORS |
269 |
| I. Manifold Air Pressure Sensor and Temperature Sensor (T-MAP) |
270 |
| II. Lambda Sensor |
271 |
| C. ACTUATORS |
273 |
| I. Ignition Coil |
274 |
| II. Purge Control Valve |
275 |
| III. Solenoid Valve (Oil Control Valve) |
276 |
| IV. Fuel Injectors |
277 |
| V. Electronic Throttle Body |
278 |
| D. SWITCH |
280 |
| I. Oil Pressure Switch |
280 |
| II. Throttle Pedal sensor |
281 |
| III. Clutch Switch |
282 |
| IV. Brake Switch |
283 |
| V. Brake Switch |
284 |
| 1.2L REVOTRON NGTC BSVI PHASE 2 PETROL ENGINE |
285 |
| CONTENTS |
286 |
| 1. GENERAL INFORMATION |
289 |
| A. ENGINE INTRODUCTION |
289 |
| B. ELECTRONIC CONTROL UNIT |
290 |
| C. TECHNICAL SPECIFICATION |
291 |
| D. SPECIAL TOOLS |
292 |
| E. ASSEMBLY CLEARANCES |
295 |
| 2. CONSTRUCTIONAL AND SERVICE DETAILS |
296 |
| A. Cylinder Head Cover |
296 |
| B. Lubrication Pump and Components |
298 |
| C. Turbocharger, Catcon and Components |
301 |
| D. Fuel Injection Equipment |
303 |
| E. Air Filter, Snorkel and Blow-by pipe |
305 |
| F. Water Pump, Thermostat and Components |
307 |
| G. Starter Motor and Alternator |
309 |
| H. Compressor, Auto-Tensioner and Belt |
310 |
| I. Engine Suspension |
311 |
| J. Intercooler and Hoses |
313 |
| 3. REPAIR AND INSPECTION DETAILS |
315 |
| A. Canister Purge Valve |
315 |
| B. Regular Maintenance |
315 |
| 4. ENGINE SYSTEM |
316 |
| A. LUBRICATION SYSTEM |
316 |
| B. EXHAUST SYSTEM |
320 |
| C. COOLING SYSTEM |
324 |
| D. FUEL SYSTEM |
327 |
| 5. ON VEHICLE SERVICE PROCEDURE |
330 |
| A. ENGINE REMOVAL AND REFITMENTDESCRIPTION |
330 |
| B. INJECTOR REMOVAL |
336 |
| C. SPARK PLUG REMOVAL |
337 |
| D. EXHAUST SYSTEM REMOVAL |
338 |
| E. FUEL SYSTEM |
343 |
| F. COOLING SYSTEM |
348 |
| G. COMPRESSOR AND ALTERNATOR BELT REMOVAL |
352 |
| H. TIMING COVER AND CHAIN REMOVAL |
353 |
| I. WATER PUMP REMOVAL |
358 |
| J. SOLENOID REMOVAL |
359 |
| K. ELECTRONIC THROTTLE BODY REMOVAL |
359 |
| L. STARTER MOTOR REMOVAL |
360 |
| M. ALTERNATOR REMOVAL |
360 |
| N. COMPRESSOR REMOVAL |
361 |
| 6. ENGINE OVERHAULING: (ON OVERHAUL STAND |
362 |
| A. ENGINE DISASSEMBLY |
362 |
| I. Removal of Intake Manifold |
362 |
| II. Removal of Closed Coupled Catcon and Turbocharger |
364 |
| III. Removal of Oil Sump |
366 |
| IV. Removal of Sensors |
367 |
| V. Removal of Accessories |
368 |
| VI. Removal of Timing Chain |
370 |
| VII. Removal of Cylinder Head And Camshaft |
373 |
| VIII. Removal of Cylinder Head Sub-Assemblies |
374 |
| IX. Removal of Cylinder Block Sub-Assemblies |
377 |
| B. ENGINE ASSEMBLY |
381 |
| I. Assembly of Cylinder Block Sub-Assemblies |
381 |
| II. Fitment of Piston and Connecting rod Sub-Assemblies |
385 |
| III. Assembly of Cylinder Head Sub-Assemblies |
387 |
| IV. Assembly of Cylinder Head |
389 |
| V. Assembly of Engine Timing Chain |
391 |
| VI. Fitment of cylinder head cover and peripherals |
395 |
| VII. Assembly of Sensors |
398 |
| VIII. Assembly of Oil Sump |
399 |
| IX. Assembly of Closed Coupled Catcon and Turbocharger |
400 |
| X. Assembly of Intake Manifold |
402 |
| 7. ENGINE MANAGEMENT SYSTEM |
404 |
| A. ABBREVIATIONS |
404 |
| B. AN OVERVIEW |
405 |
| C. ELECTRONIC CONTROL UNIT (ECU) |
406 |
| D. SENSORS |
413 |
| I. LAMBDA SENSOR |
414 |
| II. COOLANT TEMPERATURE SENSOR |
415 |
| E. ACTUATORS |
417 |
| I. IGNITION COIL |
418 |
| II. PURGE CONTROL VALVECOMPONENT DETAILS |
419 |
| III. SOLENOID VALVE (OIL CONTROL VALVE) |
420 |
| IV. FUEL INJECTORS |
421 |
| V. VACUUM MODULATOR OR ELECTRONIC VACUUM REGULATING VALVE (EVRV) |
423 |
| VI. Brake Switch |
424 |
| 1.5L REVOTORQ BSVI PHASE 2 DIESEL ENGINE |
426 |
| CONTENTS |
427 |
| 1. GENERAL INFORMATION |
432 |
| A. ENGINE INTRODUCTION |
432 |
| B. TECHNICAL SPECIFICATION |
433 |
| C. SPECIAL TOOLS |
434 |
| D. ASSEMBLY CLEARANCES |
438 |
| 2 TROUBLESHOOTING |
439 |
| 3. CONSTRUCTIONAL AND SERVICE DETAILS |
443 |
| A. Engine Lifting Hook |
443 |
| B. Intake Manifold and Fuel Injection System |
444 |
| C. Lubrication system |
446 |
| D. Air Filter, Snorkel, Blow By Pipe |
449 |
| E. Starter Motor, Compressor and Alternator |
451 |
| F. Timing Belt, Auto Tensioner, Water pump |
453 |
| G. Exhaust manifold, CATCON, Turbocharger |
455 |
| H. Cylinder head and Components |
458 |
| I. Piston, Crankshaft and Components |
461 |
| J. Engine Suspension |
463 |
| K. EGR Valve, Thermostat and Components |
465 |
| L. Crankcase and Components |
468 |
| 4. ENGINE TESTS AND MAINTENANCE |
470 |
| A. PRELIMINARY INSPECTION |
470 |
| B. ENGINE TESTS |
470 |
| C. REGULAR MAINTENANCE |
475 |
| i. ENGINE OIL AND FILTER CHANGE DESCRIPTION |
475 |
| ii. ENGINE COOLANT REPLACEMENT |
476 |
| iii. Wiring Harness Clip Removal |
479 |
| iv. AIR FILTER ELEMENT REPLACEMENT |
480 |
| v. FUEL FILTER REPLACEMENT |
480 |
| vi. DRAINING WATER FROM FUEL FILTER |
482 |
| vii. AC COMPRESSOR, ALTERNATOR BELT REPLACEMENT |
482 |
| 5. REPAIR AND INSPECTION DETAILS |
484 |
| A. TIMING BELT |
484 |
| B. FUEL TANK |
484 |
| C. CYLINDER HEAD |
485 |
| D. VALVES |
485 |
| E. VALVE SEATS |
487 |
| F. CRANKCASE |
488 |
| G. VALVE SEAT INSERT |
489 |
| H. HYDRAULIC LASH ADJUSTER |
489 |
| I. VALVE GUIDES |
490 |
| J. CAMSHAFT |
491 |
| K. PISTON AND PISTON RINGS |
492 |
| L. CONNECTING ROD |
493 |
| M. CRANK SHAFT |
495 |
| N. LEARNING PROCEDURE |
497 |
| 6. ENGINE SYSTEMS |
498 |
| A. AIR INTAKE SYSTEM |
498 |
| B. EXHAUST SYSTEM |
501 |
| C. LUBRICATION SYSTEM |
510 |
| D. EXHAUST GAS RECIRCULATION SYSTEM (EGR) |
513 |
| E. BLOW-BY VENTILATION SYSTEM |
515 |
| F. VACUUM MANAGEMENT SYSTEM |
516 |
| H. Fuel System |
519 |
| 7. ENGINE ON VEHICLE SERVICE PROCEDURE |
523 |
| A. FUSE BOX SHIFTING PROCEDURE: |
523 |
| B. ENGINE REMOVAL |
524 |
| C. ENGINE INSTALLATION |
530 |
| D. EXHAUST FRONT PIPE FITMENT PROCEDURE |
533 |
| E. COOLING SYSTEM |
534 |
| F. FUEL SYSTEM |
539 |
| G. TURBOCHARGER REMOVAL AND REFITMENT |
546 |
| H. TIMING BELT REMOVAL AND REFITMENT |
548 |
| I. STARTER MOTOR REMOVAL AND REFITMENT |
550 |
| J. ALTERNATOR MOTOR REMOVAL AND REFITMENT |
551 |
| K. COMPRESSOR MOTOR REMOVAL AND REFITMENT |
552 |
| L. HIGH PRESSURE PUMP REMOVAL AND REFITMENT |
553 |
| 8. ENGINE OVERHAULING |
556 |
| A. ENGINE DIS-ASSEMBLY |
556 |
| i. ON OVERHAUL STAND |
556 |
| ii. REMOVAL OF EGR VALVE & OIL FILTER |
560 |
| iii. REMOVAL OF INTAKE MANIFOLD |
561 |
| iv. REMOVAL OF EXHAUST MANIFOLD |
563 |
| v. REMOVAL OF VSV AND THERMOSTAT |
564 |
| vi. REMOVAL OF OIL SUMP |
565 |
| vii. REMOVAL OF TIMING BELT |
566 |
| viii. REMOVAL OF CYLINDER HEAD |
571 |
| ix. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES |
572 |
| x. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES |
575 |
| xi. PISTON CONNECTING ROD DISASSEMBLY |
577 |
| B. ENGINE ASSEMBLY |
583 |
| i. FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES |
583 |
| ii. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES |
584 |
| iii. FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES |
585 |
| iv. FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK |
587 |
| v. FITMENT OF TIMING BELT |
589 |
| vi. FITMENT OF ENGINE SUPPORT |
594 |
| vii. FITMENT OF OIL SUMP |
594 |
| viii. FITMENT OF EXHAUST MANIFOLD AND OTHER COMPONENTS |
595 |
| ix. FITMENT OF INTAKE MANIFOLD |
599 |
| x. FITMENT OF PERIPHERALS |
601 |
| 9. ENGINE MANAGEMENT SYSTEM |
604 |
| A. ABBREVIATIONS |
604 |
| B. AN OVERVIEW |
604 |
| C. ELECTRONIC CONTROL UNIT (ECU) |
605 |
| D. EMS SENSORS |
610 |
| i. CRANK POSITION SENSOR |
610 |
| ii. WHEEL SPEED SENSOR |
611 |
| iii. CAMSHAFT POSITION SENSOR |
612 |
| iv. AIR MASS FLOW SENSOR |
613 |
| v. VENTURI |
613 |
| vi. RAIL PRESSURE SENSOR |
614 |
| vii. THROTTLE PEDAL SENSOR |
614 |
| viii. WATER IN FUEL SENSOR |
615 |
| ix. CLUTCH SWITCH |
616 |
| x. OIL PRESSURE SWITCH |
617 |
| xi. BRAKE SWITCH |
618 |
| xii. COOLANT TEMPERATURE SENSOR |
618 |
| xiii. GLOW PLUG |
619 |
| xiv. VACUUM MODULATOR OR ELECTRONIC VACUUM REGULATING VALVE (EVRV) |
620 |
| xv. AIR TEMPERATURE SENSOR |
621 |
| xvi. START STOP SWITCH |
622 |
| xvii. AC PRESSURE SENSOR |
623 |
| BRAKE |
625 |
| CONTENTS |
627 |
| 1 REPAIRS |
629 |
| 1.1 REMOVAL AND REFITMENT OF TMC & BOOSTER ASSEMBLY |
629 |