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PUNCH iCNG SERVICE MANUAL

PUNCH iCNG SERVICE MANUAL 1
1.2L REVOTRON NGNA CNG BSVI PHASE 2 ENGINE 6
TABLE OF CONTENTS 7
1. GENERAL INFORMATION 11
A. ENGINE INTRODUCTION 11
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 ANDALTERNATOR BELT REPLACEMENT 70
VI. RECEPTACLE VALVE O RINGREPLACEMENT 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. ENGINE 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 166
T. FUEL FILLER BOWL 167
U. FUEL FLAP SWICTH 169
8. ENGINE OVEHAULING (ON OVERHAUL STAND) 171
A. ENGINE DIS-ASSEMBLY 171
I. REMOVAL OF INTAKE MANIFOLD 171
II. REMOVAL OF EXHAUST MANIFOLD 172
III. REMOVAL OF OIL SUMP 174
IV. REMOVAL OF SENSORS 174
V. REMOVAL OF ACCESSORIES 175
VI. REMOVAL OF TIMING CHAIN 178
VII. REMOVAL OF CYLINDER HEAD AND CAMSHAFT 180
VIII. REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES 181
IX. REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES 183
B. ENGINE ASSEMBLY 186
I. ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES 186
II. FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES 191
III. ASSEMBLY OF CYLINDER HEAD SUB-ASSEMBLIES 194
IV. ASSEMBLY OF CYLINDER HEAD 195
V. ASSEMBLY OF ENGINE TIMING CHAIN 197
VI. ASSEMBLY OF ACCESSORIES DRIVING BELT 202
VII. ASSEMBLY OF SENSORS AND PERIPHERALS 203
VIII. ASSEMBLY OF OIL SUMP 204
IX. ASSEMBLY OF EXHAUST MANIFOLD 205
X. ASSEMBLY OF INTAKE MANIFOLD 207
9. ENGINE MANAGEMENT SYSTEM 209
A. ABBREVIATIONS 209
B. AN OVERVIEW 209
C. ELECTRONIC CONTROL UNIT (ECU) 211
D. SENSORS 217
I. MANIFOLD AIR PRESSURE SENSOR AND TEMPERATURE SENSOR (T-MAP) 218
II. LAMBDA SENSOR 219
III. CAMSHAFT POSITION SENSOR 223
IV. KNOCK SENSOR 224
V. CRANKSHAFT POSITION SENSOR 225
VI. COOLANT TEMPERATURE SENSOR 227
E. ACTUATORS 228
I. IGNITION COIL 228
II. SOLENOID VALVE (OIL CONTROL VALVE) 230
III. FUEL INJECTORS 231
IV. PURGE CONTROL VALVE 232
V. ELECTRONIC THROTTLE BODY 233
F. SWITCH 235
I. OIL PRESSURE SWITCH 235
II. THROTTLE PEDAL SENSOR 236
III. CLUTCH SWITCH 237
IV. BRAKE SWITCH 238
V. WHEEL SPEED SENSOR 239
ELECTRICAL 240
CONTENTS 241
1. INSTRUMENT CLUSTER 242
A. FEATURES 242
B. INSTRUMENT CLUSTER 243
C. BASIC ELECTRICAL SPECIFICATIONS 244
D. INSTRUMENT CLUSTER FEATURE DESCRIPTION 245
E. TELL TALES MATRIX 247
F. DRIVER INFORMATION SYSTEM 251
G. TEXT WARNINGS 253
H. SERVICE REMINDER IN BRIEF 254
I. REMINDER FEATURES 255
J. MAIN CONNECTOR PIN-OUTS 257
K. FUEL GAUGE DETAILS 258
L. CHIME TABLE 259
M. DISPLAY SCREEN FLOW AND SETTINGS 260
N. INSTRUMENT CLUSTER REPLACEMENT STRATEGY 261
O. ENGINEERING TEST MODE (ETM) 261
P. REMOVAL OF INSTRUMENT CLUSTER 262

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