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ALTROZ iCNG SERVICE MANUAL

ALTROZ iCNG SERVICE MANUAL 1
1.2L REVOTRON CNG PHASE-2 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 19
F. SEALANTS 20
G. LEAKAGE RATES 20
H. RECOMMENDED LUBRICANTS & COOLANTS 20
2. TROUBLESHOOTING 21
3. CONSTRUCTIONAL AND SERVICE DETAILS 27
A. ENGINE LIFTING 27
B. INTAKE MANIFOLD 28
C. CYLINDER HEAD COVER 30
D. CYLINDER HEAD-A 32
E. CYLINDER HEAD-B 34
F. CYLINDER BLOCK 35
G. OIL SUMP 37
H. MOVING PARTS 39
I. ENGINE TIMING 42
J. EXHAUST MANIFOLD 44
K. CNG FUEL INJECTION EQUIPMENT 45
L. FUEL INJECTION EQUIPMENT 46
M. LUBRICATION PUMP AND COMPONENTS 47
N. AIR INTAKE SYSTEM 49
O. SPECIAL INSTALLATION 51
P. ENGINE SUSPENSION 54
Q. CNG SYSTEM 56
4. ENGINE TESTS AND MAINTENANCE 58
A. PRELIMINARY INSPECTION 58
B. ENGINE TESTS 59
I. ENGINE COMPRESSION TEST 59
II. ENGINE OIL CONSUMPTION TEST 60
III. ENGINE OIL PRESSURE TEST 61
C. REGULAR MAINTENANCE 62
I. ENGINE OIL AND FILTER CHANGE 62
II. ENGINE COOLANT REPLACEMENT 64
III. AIR FILTER ELEMENT REPLACEMENT 68
IV. SPARK PLUG REPLACEMENT 69
V. AIR CONDITIONER COMPRESSOR AND ALTERNATOR BELT REPLACEMENT 70
VI. RECEPTACLE VALVE O RING REPLACEMENT ON VEHICLE 71
VII. RECEPTACLE VALVE FILTER MESH REPLACEMENT 72
VIII. CNG FILTER REPLACEMENT 73
IX. BI-FUEL AUTO SWITCH STRATEGY 76
5. REPAIR AND INSPECTION DETAILS 78
A. ACCESSORY DRIVING BELT 78
B. TIMING CHAIN 78
C. CYLINDER HEAD 78
D. VALVES 79
E. CYLINDER HEAD VALVE SEATS 80
F. ROLLER FINGER FOLLOWER 80
G. HYDRAULIC LASH ADJUSTER (HLA) 81
H. CAMSHAFTS (INTAKE & EXHUAST) 81
I. PISTON AND PISTON RINGS 82
J. CONNECTING RODS 83
K. CRANKSHAFT 84
L. CRANK CASE 85
M. FUEL TANK 85
N. CANISTER PURGE VALVE 86
O. CANISTER 86
6. ENGINE SYSTEM 88
A. AIR INTAKE SYSTEM 88
B. BLOW BY SYSTEM 90
C. LUBRICATION SYSTEM 91
D. EXHAUST SYSTEM 95
E. COOLING SYSTEM 97
F. FUEL SYSTEM 100
G. CNG FUEL SYSTEM LAYOUT 103
H. SCHEMATIC DIAGRAM OF CNG INJECTION SYSTEM 104
I. CNG FUEL SYSTEM COMPONENTS 109
7. ON VEHICLE SERVICE PROCEDURE 114
A. ENGINE REMOVAL AND REFITMENT 114
B. AIR FILTER ASSEMBLY REMOVAL 120
C. FUEL RAIL AND INJECTOR 121
D. SPARK PLUG REMOVAL 122
E. EXHAUST SYSTEM REMOVAL 122
F. FUEL SYSTEM 127
G. COOLING SYSTEM 132
H. COMPRESSOR AND ALTERNATOR BELT REMOVAL 136
I. TIMING CHAIN REMOVAL 137
J. WATER PUMP 141
K. SOLENOID 142
L. ELECTRONIC THROTTLE BODY 143
M. STARTER MOTOR 143
N. ALTERNATOR 144
O. COMPRESSOR 144
P. INJECTION SYSTEM 145
Q. CNG FUEL SYSTEM 148
R. MOON VALVE REMOVAL / REPLACEMENT PROCEDURE 156
S. HIGH PRESSURE LINE 165
T. FUEL FILLER BOWL 166
U. FUEL FLAP SWICTH 168
8. ENGINE OVEHAULING (ON OVERHAUL STAND) 170
A. ENGINE DIS-ASSEMBLY 170
I. REMOVAL OF INTAKE MANIFOLD 170
II. REMOVAL OF EXHAUST MANIFOLD 171
III. REMOVAL OF OIL SUMP 173
IV. REMOVAL OF SENSORS 173
V. REMOVAL OF ACCESSORIES 174
VI. REMOVAL OF TIMING CHAIN 177
VII. REMOVAL OF CYLINDER HEAD AND CAMSHAFT 179
VIII. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES 180
IX. REMOVAL OF CYLINDER BLOCK SUBASSEMBLIES 182
B. ENGINE ASSEMBLY 185
I. ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES 185
II. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES 190
III. ASSEMBLY OF CYLINDER HEAD SUB-ASSEMBLIES 193
IV. ASSEMBLY OF CYLINDER HEAD 194
V. ASSEMBLY OF ENGINE TIMING CHAIN 196
VI. ASSEMBLY OF ACCESSORIES DRIVINGBELT 201
VII. ASSEMBLY OF SENSORS AND PERIPHERALS 202
VIII. ASSEMBLY OF OIL SUMP 203
IX. ASSEMBLY OF EXHAUST MANIFOLD 204
X. ASSEMBLY OF INTAKE MANIFOLD 206
9. ENGINE MANAGEMENT SYSTEM 208
A. ABBREVIATIONS 208
B. AN OVERVIEW 208
C. ELECTRONIC CONTROL UNIT (ECU) 210
D. SENSORS 216
I. MANIFOLD AIR PRESSURE SENSOR AND TEMPERATURE SENSOR (T-MAP) : 217
II. LAMBDA SENSOR 218
III. CAMSHAFT POSITION SENSOR 222
IV. KNOCK SENSOR 223
V. CRANKSHAFT POSITION SENSOR 224
VI. COOLANT TEMPERATURE SENSOR 226
E. ACTUATORS 227
I. IGNITION COIL 227
II. SOLENOID VALVE (OIL CONTROL VALVE) 229
III. FUEL INJECTORS 230
IV. PURGE CONTROL VALVE 231
V. ELECTRONIC THROTTLE BODY 232
F. SWITCH 234
I. OIL PRESSURE SWITCH 234
II. THROTTLE PEDAL SENSOR 235
III. CLUTCH SWITCH 236
IV. BRAKE SWITCH 237
V. WHEEL SPEED SENSOR 238
ELECTRICAL 239
CONTENTS 240
1. INSTRUMENT CLUSTER 241
A. FEATURES 241
B. INSTRUMENT CLUSTER 242
C. BASIC ELECTRICAL SPECIFICATIONS 243
D. INSTRUMENT CLUSTER FEATURE DESCRIPTION 244
E. TELL TALES MATRIX 246
F. DRIVER INFORMATION SYSTEM 250
G. TEXT WARNINGS 252
H. SERVICE REMINDER IN BRIEF 253
I. REMINDER FEATURES 254
J. MAIN CONNECTOR PIN-OUTS 256
K. FUEL GAUGE DETAILS 257
L. CHIME TABLE 258
M. DISPLAY SCREEN FLOW AND SETTINGS 259
N. INSTRUMENT CLUSTER REPLACEMENT STRATEGY 260
O. ENGINEERING TEST MODE (ETM) 260
P. REMOVAL OF INSTRUMENT CLUSTER: 261

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