SERVICE MANUAL BOOK - 1 SERVICE MANUAL TIAGO/TIGOR CNG BSVI PHASE-2 SUPPLIMENT
Developed by: Technical Literature Cell. Release Date : Sept 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 TIAGO/TIGOR CNG 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 TIAGO/TIGOR BSVI PHASE-2” 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 REVOTRON NGNA CNG BSVI PHASE 2 ENGINE ELECTRICAL THE BOOK– 2 CONTAINS DIAGNOSTIC TROUBLE SHOOTING CODES (DTC) THE BOOK– 3 CONTAINS SERVICE SCHEMATICS THE BOOK– 4 CONTAINS INFO. FITMENT DRAWINGS
ENGINE 1.2L REVOTRON BSVI TWIN CYLINDER CNG ENGINE
1.2L REVOTRON BSVI TWIN CYLINDER CNG ENGINE
Developed by: Technical Literature Cell. Release Date : Sept 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 Limited. 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 exclusive Changes for 1.2L REVOTRON BSVI TWIN CYLINDER CNG ENGINE. 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 conjunction with “TATA TIAGO / TIGOR CNG” Service manual.
1.2L REVOTRON TWIN CYLINDER CNG ENGINE CONTENTS 1. GENERAL INFORMATION ..................................................................................................................... 1 A ENGINE INTRODUCTION.................................................................................................................... 1 B ELECTRONIC CONTROL .................................................................................................................... 2 C TECHNICAL SPECIFICATION ............................................................................................................. 3 D SPECIAL TOOLS.................................................................................................................................. 4 E ASSEMBLY CLEARANCES ................................................................................................................. 9 F SEALANTS ........................................................................................................................................... 9 G LEAKAGE RATES ................................................................................................................................ 9 2. TROUBLESHOOTING............................................................................................................. 10 3. CONSTRUCTIONAL AND SERVICE DETAILS ................................................................................ 19 A ENGINE LIFTING ............................................................................................................................... 19 B INTAKE MANIFOLD ........................................................................................................................... 20 C CYLINDER HEAD COVER ................................................................................................................. 21 D CYLINDER HEAD-A ........................................................................................................................... 23 E CYLINDER HEAD-B ........................................................................................................................... 25 F CYLINDER BLOCK............................................................................................................................. 26 G OIL SUMP ........................................................................................................................................... 28 H MOVING PARTS ................................................................................................................................ 29 I ENGINE TIMING................................................................................................................................. 31 J EXHAUST MANIFOLD ....................................................................................................................... 33 K FUEL INJECTION EQUIPMENT ........................................................................................................ 34 L LUBRICATION PUMP AND COMPONENTS..................................................................................... 35 M AIR INTAKE SYSTEM ........................................................................................................................ 37 N SPECIAL INSTALLATION .................................................................................................................. 38 O ENGINE SUSPENSION...................................................................................................................... 41 P CNG SYSTEM .................................................................................................................................... 43
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 4. ENGINE TESTS AND MAINTENANCE ............................................................................................... 48 A PRELIMINARY INSPECTION............................................................................................................. 48 B ENGINE TESTS……………………… ....................................................... ……………………………..49 I ENGINE COMPRESSION TEST ................................................................................................... 49 II ENGINE OIL CONSUMPTION TEST ............................................................................................ 50 III ENGINE OIL PRESSURE TEST ................................................................................................... 51 C REGULAR MAINTENANCE…… ........................................................................................................ 52 I ENGINE OIL AND FILTER CHANGE ............................................................................................ 52 II ENGINE COOLANT REPLACEMENT........................................................................................... 53 III AIR FILTER ELEMENT REPLACEMENT ..................................................................................... 56 IV SPARK PLUG REPLACEMENT .................................................................................................... 57 V FUEL FILTER REPLACEMENT .................................................................................................... 58 VI AIR CONDITIONER COMPRESSOR BELT REPLACEMENT ..................................................... 59 VII RECEPTACLE VALVE O-RING REPLACEMENT ........................................................................ 61 VIII RECEPTACLE VALVE MESH REPLACEMENT........................................................................... 62 IX CNG FILTER REPLACEMENT...................................................................................................... 63 5. REPAIR AND INSPECTION DETAILS ................................................................................................ 67 A ACCESSORY DRIVING BELT ........................................................................................................... 67 B TIMING CHAIN ................................................................................................................................... 67 C CYLINDER HEAD ............................................................................................................................... 67 D VALVES .............................................................................................................................................. 68 E CYLINDER HEAD VALVE SEATS ..................................................................................................... 69 F ROLLER FINGER FOLLOWER.......................................................................................................... 70 G HYDRAULIC LASH ADJUSTER......................................................................................................... 70 H CAMSHAFT (INTAKE AND EXHAUST) ............................................................................................. 70 I PISTON AND PISTON RINGS ........................................................................................................... 72 J CONNECTING RODS ........................................................................................................................ 73 K CRANKSHAFT.................................................................................................................................... 75 L CRANK CASE..................................................................................................................................... 77 M FUEL TANK ........................................................................................................................................ 78 N CANISTER PURGE VALVE ............................................................................................................... 78
1.2L REVOTRON TWIN CYLINDER CNG ENGINE O CANISTER .......................................................................................................................................... 79 6. ENGINE SYSTEM ................................................................................................................................... 80 A AIR INTAKE SYSTEM ........................................................................................................................ 80 B BLOW BY SYSTEM ............................................................................................................................ 82 C LUBRICATION SYSTEM .................................................................................................................... 83 D EXHAUST SYSTEM ........................................................................................................................... 87 E COOLING SYSTEM............................................................................................................................ 89 F FUEL SYSTEM ................................................................................................................................... 92 7. ENGINE ON VEHICLE SERVICE PROCEDURE ............................................................................ 106 A ENGINE REMOVAL AND INSTALLATION FOR MT VEHICLE....................................................... 106 B AIR FILTER ASSY ............................................................................................................................ 112 C INJECTION SYSTEM ....................................................................................................................... 112 D SPARK PLUG ................................................................................................................................... 115 E EXHAUST SYSTEM ......................................................................................................................... 115 F FUEL SYSTEM ................................................................................................................................. 118 G CNG FUEL SYSTEM ........................................................................................................................ 122 H MOON VALVE REMOVAL / REPLACEMENT PROCEDURE ......................................................... 133 I HIGH PRESSURE LINE ................................................................................................................... 140 J FUEL FLAP SWITCH........................................................................................................................ 141 K COOLING SYSTEM.......................................................................................................................... 142 L REMOVAL OF STARTER MOTOR .................................................................................................. 145 M REMOVAL OF ACCESSORIES ....................................................................................................... 146 8. ENGINE OVEHAULING (ON OVERHAUL STAND) ...................................................................... 151 A ENGINE DIS-ASSEMBLY................................................................................................................. 151 I REMOVAL OF INTAKE MANIFOLD............................................................................................ 151 II REMOVAL OF EXHAUST MANIFOLD........................................................................................ 152 III REMOVAL OF OIL SUMP ........................................................................................................... 153 IV REMOVAL OF SENSORS ........................................................................................................... 155
1.2L REVOTRON TWIN CYLINDER CNG ENGINE V REMOVAL OF ACCESSORIES .................................................................................................. 156 VI REMOVAL OF TIMING CHAIN.................................................................................................... 157 VII REMOVAL OF CYLINDER HEAD AND CAMSHAFT.................................................................. 159 VIII REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES............................................................... 160 IX REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES ............................................................ 162 B ENGINE ASSEMBLY ........................................................................................................................ 165 I ASSEMBLY OF CYLINDER BLOCK SUB-ASSEMBLIES .......................................................... 165 II ASSEMBLY OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES.................................. 167 III ASSEMBLY OF CYLINDER HEAD SUB-ASSEMBLIES............................................................. 169 IV ASSEMBLY OF CYLINDER HEAD ............................................................................................. 171 V ASSEMBLY OF TIMING CHAIN.................................................................................................. 172 VI ASSEMBLY OF ACCESSORIES DRIVING BELT ...................................................................... 176 VII ASSEMBLY OF ENGINE SENSORS AND PERIPHERALS ....................................................... 177 VIII ASSEMBLY OF OIL SUMP .......................................................................................................... 178 IX ASSEMBLY OF EXHAUST MANIFOLD ...................................................................................... 179 X ASSEMBLY OF INTAKE MANIFOLD .......................................................................................... 180 9. ENGINE MANAGEMENT SYSTEM ................................................................................................... 183 A ABBREVIATIONS ............................................................................................................................. 183 B AN OVERVIEW................................................................................................................................. 183 C ELECTRONIC CONTROL UNIT....................................................................................................... 184 D SENSORS… ..................................................................................................................................... 189 I T-MAP SENSOR.......................................................................................................................... 190 II LAMBDA SENSOR ...................................................................................................................... 191 III CAMSHAFT POSITION SENSOR (INTAKE / EXHAUST) .......................................................... 193 IV KNOCK SENSOR ........................................................................................................................ 194 V CRANKSHAFT POSITION SENSOR .......................................................................................... 195 VI COOLANT TEMPERATURE SENSOR ....................................................................................... 196 VII OIL PRESSURE SWITCH ........................................................................................................... 197
1.2L REVOTRON TWIN CYLINDER CNG ENGINE VIII CNG RAIL PRESSURE / TEMPERATURE SENSOR................................................................. 198 IX CNG HIGH PRESSURE SENSOR (NON SERVICEABLE) ........................................................ 199 E ACTUATORS.. .................................................................................................................................. 200 I IGNITION COIL............................................................................................................................ 201 II PURGE CONTROL VALVE ......................................................................................................... 202 III SOLENOID VALVE (OCV)........................................................................................................... 203 IV GASOLINE FUEL INJECTOR ..................................................................................................... 204 V CNG FUEL INJECTOR ................................................................................................................ 205 VI ELECTRONIC THROTTLE BODY............................................................................................... 206 F SWITCH.. .......................................................................................................................................... 207 I THROTTLE PEDAL SENSOR ..................................................................................................... 207 II CLUTCH SWITCH ....................................................................................................................... 208 III BRAKE SWITCH.......................................................................................................................... 209 IV VEHICLE SPEED SENSOR ........................................................................................................ 210 V WHEEL SPEED SENSOR ........................................................................................................... 211
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 1 1. GENERAL INFORMATION: A. ENGINE INTRODUCTION Description: The “1.2L REVOTRON" is a 1199 CC, 3-Cylinder Bi-Fuel CNG Engine, with MPFI, VCTi and BS-VI compliant. Features: Stiffened Aluminium Crankcase with Aluminium bed plate structure. Double Overhead Camshaft (DOHC) with 4 valves per cylinder. Dual VCT 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 Engine is BSVI OBD-II compliant. Multi Point Fuel Injection (MPFI) Graded bearing system for Main bearing and con-rod big end. Fuel Type: Bi-Fuel (Gasoline + CNG)
1.2L REVOTRON TWIN CYLINDER CNG 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. Single ECU for Bi-Fuel action. 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 (Gasoline14.7:1 Air to Fuel, CNG-17.2:1 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. To keep gasoline engine injection system in healthy condition and to have good start-ability engine start in gasoline and switched to CNG in auto mode.
1.2L REVOTRON Bi FUEL CNG ENGINE_FEAD_OAP 3 C. TECHNICAL SPECIFICATION : Model :- 1.2 L REVOTRON Description 1.2 NA NG REVOTRON Bi-fuel CNG110 377 DOHC VCT BS-VI Type :- Bi-fuel CNG 4-stroke MPFI, inline 3 cylinder with 4 valves per cylinder. Engine Configuration :- Transverse mounted inline 3-cylinder engine Engine Management System :- BOSCH Engine Management System / Cube Lite Bore/Stroke :- 77 mm X 85.8 mm Engine Capacity :- 1199 cc Radiator Coolant :- Water + Ethylene Glycol 60:40 Compression Ratio :- (11.3 ±0.3) :1 Maximum Engine Power Output :- Petrol: 63 kw @ 6000 rpm (85ps @ 6000 rpm) CNG : 54 kw @ 6000 rpm (72.5ps @ 6000 rpm) Maximum Engine Torque Output :- Petrol :113 Nm @ 3300 +/- 200 RPM CNG: 95 Nm @ 3500 +/ -100 RPM Engine Firing Order :- 1-2-3 Oil Capacity :- 3.5 L Cooling System Capacity :- 4 liters Spark Plug Type :- FM : RER8MC (0.8 to 0.9 mm gap) Air Filter :- Engine Mounted, Dry Paper Cartridge type. Oil Filter :- Spin on Full flow Paper type Fuel Filter In line filter (Integrated with Fuel pump in tank ) + CNG Filter Timing :- Chain Drive VCT DENSO Controller Assy Emission Norms :- Bharat Stage VI Phase-2 Compliance Ignition Coil Details :- Epoxy Molded Coil Type Ignition Coil (Supply Voltage 5-16V) CNG tank capacity :- 60 liters Water capacity CNG Filter :- Maximum pressure : 450kPa Nominal gas pressure : 400kPa
1.2L REVOTRON Bi FUEL CNG ENGINE_FEAD_OAP 4 D. SPECIAL TOOLS SR NO. TOOL DESCRIPTION TOOL PART NUMBER APPLICATION 1 Stand-Engine Support 5424 5890 24 01 2 Fixture (Stand) assembly aggregate repair 5425 5890 0605 3 Adaptor for engine mounting bracket LH (Petrol) 5438 5890 2403 4 Bracket LHEngine Overhauling stand 5424 5890 24 03 5 Bracket RHEngine Overhauling stand 5424 5890 24 02
1.2L REVOTRON Bi FUEL CNG ENGINE_FEAD_OAP 5 SR NO. TOOL DESCRIPTION TOOL PART NUMBER APPLICATION 6 Pin-Flywheel locking On vehicle 2871 5890 06 75 7 Pin-Flywheel locking In Standalone Condition 2702 5890 06 04 8 Pin-Timing chain tensioner plunger locking 5424 5890 06 04 9 Wedge-Oil Sump sealant cutting 5424 5890 06 09 10 CompressorValve spring 2829 5890 06 05
1.2L REVOTRON Bi FUEL CNG ENGINE_FEAD_OAP 6 SR NO. TOOL DESCRIPTION TOOL PART NUMBER APPLICATION 11 Rail - Valve spring compressor 5424 5890 06 06 12 Tool-Water pipe installation 5424 5890 20 02 13 Drift-Crank shaft front cover oil seal 2654 5890 05 08 14 Drift-Crank shaft rear oil seal 2699 5890 18 03 15 Spanner-Oil filter 5424 5890 18 02
1.2L REVOTRON Bi FUEL CNG ENGINE_FEAD_OAP 7 SR NO. TOOL DESCRIPTION TOOL PART NUMBER APPLICATION 16 Guide pin for VCT 5424 5890 06 14 17 Alternator belt stopper 5424 5890 0619 18 Outer Stretch Belt removal tool 5427 5890 0602 19 Inner Stretch Belt removal tool 5424 5890 0616 20 Inner stretch belt installation tool 5424 5890 0603
1.2L REVOTRON Bi FUEL CNG ENGINE_FEAD_OAP 8 SR NO. TOOL DESCRIPTION TOOL PART NUMBER APPLICATION 21 Outer stretch belt installation tool 5424 5890 0615 22 Injector Puller 23 Engine adaptor for Compression Test Refer tool ITCC7337 24 CNG cylinder valve removal 287358904701 25 NO GO Gauge for HP tube joint inspection 287358904703
1.2L REVOTRON Bi FUEL CNG ENGINE_FEAD_OAP 9 E. ASSEMBLY CLEARANCES Group Description Values (mm) 01 Crankshaft Axial Play 0.1 To 0.3 Main Bearing Clearance (Cold Condition) 0.013 To 0.046 Cylinder Head Gasket Compression 0.7 THK (In assembled condition) 03 Connecting Rod Axial Play (Big End) 0.05 To 0.35 Piston Play Clearance On Skirt (Bore To Piston Stamp Size) 0.055 To 0.075 Connecting Rod Bearing Clearance (Small End) (Cold Condition) 0.005 To 0.025 Connecting Rod Bearing Clearance (Big End) (Cold Condition) 0.027 To 0.066 Piston Topping (Piston Is Above Block Top Face) 0.64 ± 0.1 05 Camshaft Axial Play 0.1 To 0.3 Camshaft Bearing Clearance 0.04 To 0.082 Valve Stem Clearance, Inlet 0.017 To 0.043 Valve Stem Clearance, Exhaust 0.027 To 0.053 F. SEALANTS Sealant No. Sealant Type Use 56506005162 Adhesive Sealant Loctite 5188 Henkel For Sealing Block To Bed Plate 56506005162 Adhesive Sealant Loctite 5188 Henkel For Plug Mc 10x1 56506002350 Adhesive Bearing Retainer Hs Ts25408 For Core Plug 570501995303 Sealant Loctite 5910 (50 Ml. Tube Pack) For Oil Sump To Bedplate G. LEAKAGE RATES Region Pressure Leakage (Max.) Air Side 0.2 bar < 200 cc/min Water Side 0.7 bar < 20 cc/min
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 10 2. TROUBLESHOOTING: 1. Starting Problems Condition Possible Cause Remedy Engine does not crank Insufficient battery voltage/charge test battery and charging system. Clean and tighten battery connections. Jump start engine. Battery or charging system component faulty. Replace as necessary. Engine starter motor defective. Repair or replace starter as necessary. Immobilizer system defective. (as equipped) Inspect system and repair as necessary. Engine components seized. Inspect engine components for seizure. Attempt to rotate crankshaft by hand. Overhaul engine as necessary. Engine cranks but does not start Obstructed air filter or air inlet. Clean or replace air filter or inlet. Incorrect valve/ignition timing or timing belt broken. Check timing system components and repair or replace as necessary. Faulty spark plugs, wires or ignition coil. Check ignition system components for proper operation. Replace as necessary. Malfunctioning engine management system component. Perform engine management system diagnostic test as described in this section of the manual. Defective Engine Control Unit (ECU) Replace as necessary. Malfunctioning emissions system component Check tank pressure valve, purge canister valve and charcoal canister. Repair or replace as necessary. Clogged or faulty fuel filter, fuel regulator, fuel line or fuel pump. Check fuel system components, repair or replace as necessary Clogged or faulty fuel injectors Check fuel injector operation. Replace as necessary. Improper firing order Check ignition system and fuel injector connections. Rectify as necessary. Inertia switch tripped or defective. Reset or replace as necessary.
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 11 2. Engine Idle Problems Condition Possible Cause Remedy Engine Starts but does not idle Faulty ETC unit. Perform Diagnosis test. Replace as necessary. Fuel filter if clogged. Replace the fuel filter. fuel lines are pinched or clogged Correct the routine to avoid pinch, or allow shop air to clear the clog in the fuel lines. Improper Electrical supply at pump connector If electrical supply is in proper check electrical system. In adequate fuel pump pressure IF fuel pump does not built pressure then replace. Incorrect manifold absolute pressure (MAP) sensor signal input. Check for leakage at sensor. Perform diagnostic test. Engine idles erratically Disconnected or leaking vacuum line or vacuum leak at inlet manifold. Inspect all vacuum lines and connections. Repair or replace as necessary. Faulty ETC unit. Perform diagnostic test. Replace as necessary. Incorrect valve / ignition timing. Check timing system components and repair or replace as necessary. Fuel filter if clogged. Replace the fuel filter. fuel lines are pinched or clogged Correct the routine to avoid pinch, or allow shop air to clear the clog in the fuel lines. Improper Electrical supply at pump connector If electrical supply is in proper check electrical system. In adequate fuel pump pressure IF fuel pump does not built pressure then replace. 3. Poor Engine Performance Condition Possible Cause Remedy Maximum RPM -low Insufficient battery voltage/charge - test battery and charging system. Clean and tighten battery connections Jump start engine. Battery or charging system component faulty. Replace as necessary. Obstructed air filter or air inlet Clean or replace air filter or inlet. Improper grade or contaminated fuel Rush fuel system with fresh, clean, fuel of the correct type. Replace fuel filter. Faulty spark plugs, wires, or ignition coil Check ignition system components for proper operation. Replace as necessary.
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 12 Malfunctioning engine management system component Perform engine management system diagnostic test as described in this section of the manual. Fuel filter if clogged. Replace the fuel filter. fuel lines are pinched or clogged Correct the routine to avoid pinch, or allow shop air to clear the clog in the fuel lines. Improper Electrical supply at pump connector If electrical supply is in proper check electrical system. In adequate fuel pump pressure IF fuel pump does not built pressure then replace. Incorrect crank angle signal Check sensor gap and adjust to 1.0 ± 0.4mm Clogged or faulty fuel injector(s) Check fuel injector operation. Replace as necessary. Improper firing order Check ignition system and fuel injector connections. Rectify as necessary. Poor acceleration or low power Insufficient battery voltage/charge - test battery and charging system Clean and tighten battery connections Battery or charging system component faulty. Replace as necessary. Obstructed air filter or air inlet Clean or replace air filter or inlet. Disconnected or leaking vacuum line or vacuum leak at inlet manifold Inspect all vacuum lines and inlet manifold. Repair or replace as necessary. Improper grade or contaminated fuel Flush fuel system with fresh, clean, fuel of the correct type. Replace fuel filter. Faulty spark plugs, wires, or ignition coil Check ignition system components for proper operation. Replace as necessary. Malfunctioning engine management system component Perform engine management system diagnostic test as described in this section of the manual. Defective Engine Control Unit (ECU) Replace as necessary. Malfunctioning emissions system component Check tank pressure valve, purge canister valve, and charcoal canister. Repair or replace as necessary. Fuel filter if clogged. Replace the fuel filter. fuel lines are pinched or clogged Correct the routine to avoid pinch, or allow shop air to clear the clog in the fuel lines.
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 13 Improper Electrical supply at pump connector If electrical supply is in proper check electrical system. In adequate fuel pump pressure IF fuel pump does not built pressure then replace. Clogged or faulty fuel injector(s) Check fuel injector operation. Replace as necessary. Incorrect valve/ignition timing Check timing system components and repair or replace as necessary. Improper firing order Check ignition system and fuel injector connections. Rectify as necessary. Engine misfires Disconnected or leaking vacuum line or vacuum leak at inlet manifold Inspect all vacuum lines and inlet manifold. Repair or replace as necessary. Improper grade or contaminated fuel Rush fuel system with fresh, clean, fuel of the correct type. Replace fuel filter. Faulty spark plugs, wires, or ignition coil Check ignition system components for proper operation. Replace as necessary. Incorrect crank angle signal. Check sensor gap and adjust to 1.0 ± 0.4mm Improper firing order Check ignition system and fuel injector connections. Rectify as necessary. Fuel filter if clogged. Replace the fuel filter. fuel lines are pinched or clogged Correct the routine to avoid pinch, or allow shop air to clear the clog in the fuel lines. Improper Electrical supply at pump connector If electrical supply is in proper check electrical system. In adequate fuel pump pressure IF fuel pump does not built pressure then replace. 4. Engine Noise Condition Possible Cause Remedy Engine 'pings' or 'knocks' while accelerating or travelling uphill. Improper grade of fuel Fill fuel tank with a minimum BSIV Fuel Spark plugs excessively worn or gapped improperly. Inspect spark plugs. Replace if worn. Incorrect valve/ignition timing Check timing system components and repair or replace as necessary. Excessively worn camshaft Inspect camshaft lobes and run-out for excessive wear. Replace as necessary Fuel filter if clogged. Replace the fuel filter.
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 14 fuel lines are pinched or clogged Correct the routine to avoid pinch, or allow shop air to clear the clog in the fuel lines. Improper Electrical supply at pump connector If electrical supply is in proper check electrical system. In adequate fuel pump pressure IF fuel pump does not built pressure then replace. 'Squeal' or 'chirping' while engine is running. Worn, oil-fouled, or improperly adjusted engine accessory belt. Check engine accessory belt condition. Adjust or replace. 'Clunking' or 'rapping' noise from bottom end of engine Defective piston wrist pin, rod, or main bearings If noise occurs after taking foot off accelerator pedal, inspect piston wrist pins. If noise is constant inspect rod bearings and main bearings for proper clearance and condition Replace bearings as necessary. 'Tapping' or 'ticking' noise from the top end of the engine Fuel injectors worn excessively Fuel injectors will make some ticking noise. Replace fuel injectors if not putting out enough fuel to cylinders. Excessively worn camshaft Inspect camshaft. lobes and runout for excessive wear. Replace as necessary. Valve springs, tappets, or rocker arms worn Inspect valve train components; replace as necessary. 5. Exhaust System Condition Possible Cause Remedy Engine emits white smoke from tailpipe. Obstructed air filter or air Inlet Clean or replace air filter or Inlet. Head gasket leaking coolant into combustion chamber Inspect engine oil for coolant and perform engine compression test. Engine cylinder head or block cracked Inspect engine oil for coolant and perform engine compression test. Engine oil or other substance on exhaust manifold Inspect exhaust manifold for foreign material. Improper grade or contaminated fuel Rush fuel system with fresh, clean, fuel of the correct type. Replace fuel filter. Engine emits blue smoke from tailpipe. Worn or damaged valve guide seals Remove rocker arm cover and inspect valve guide seals. Replace as necessary. Engine crankcase overfilled with oil Check oil level; drain oil as necessary. Worn I damaged piston ring(s) or cylinder bore, permitting oil blow-by Perform engine compression test and/or leak-down test. Head gasket leaking oil into combustion chamber Inspect engine coolant for oil and perform engine compression test.
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 15 Engine emits black smoke from tail pipe. Excess carbon deposits in combustion chamber Remove carbon deposits in combustion chamber using a commercially available cleaner Excess fuel entering cylinder(s) Check lambda/O2 and other engine sensors for proper operation. Test fuel injectors for proper operation or leakage. Check the fuel and emissions system for proper operation. Exhaust rubber hanger wear / crack. Ageing of rubber hanger Check the Exhaust rubber hangers & replaced if found crack / damage or wear. 6. Cooling System Condition Possible Cause Remedy Overheating Low coolant level/ Cooling system leaking Check coolant level in reservoir and inspect system for leaks. Add coolant as necessary. Defective thermostat Remove thermostat and seek support from thermostat supplier. Defective water pump Inspect and replace water pump as necessary. Defective temperature sending unit Check coolant temperature sending unit Replace as necessary. Engine cooling fan malfunctioning Test operation of engine cooling fan. Repair or replace as necessary. Engine overloading Make sure vehicle brakes are not dragging. Vehicle overloaded. Make sure vehicle does not exceed weight limit with cargo. Engine lean condition Verify proper operation of fuel system components. Repair system or replace components as necessary. Head gasket leaking Test engine compression. Replace head gasket as necessary. Over cooling Defective thermostat Remove thermostat and seek support from thermostat supplier. Defective temperature sending unit Check coolant temperature sending unit. Replace as necessary.
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 16 7. Engine Lubrication System Condition Possible Cause Remedy Engine consumes oil Obstructed air filter or air Inlet Clean or replace air filter or inlet Worn piston rings Perform compression or leak-down test Worn valve guide seals or other valve train component. Inspect valve train components. Repair or replace as necessary Mechanical oil seal, O-ring, or gasket leaking Inspect engine oil seals and gaskets for visual signs of leakage. Replace seals or gaskets as necessary. Engine does not develop oil pressure Low oil level or Incorrect grade of oil Add proper grade of oil until level is at the 'MAX' mark on dipstick Faulty oil pressure sending unit Replace faulty sending unit as needed. Defective engine oil pump/oil pump relief valve stuck open Inspect oil pump operation. Repair or replace as necessary. Excessive wear of connecting rods, main bearings and journals, or other internal engine components. Repair/replace engine components. Oil Filter clogged strainer clogged Clean or replace.
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 17 CNG SYSTEM TROUBLE SHOOTING Sr. No. Problem Cause Solution 1 Engine missing on CNG and runs well on petrol. Inadequate CNG supply. Check if filter is blocked or high pressure line is blocked. Ignition System faulty. Check spark plug and ignition coil Air filter dirty. Clean air filter Wiring harness Check injector wiring harness connections for proper latching, terminal loosening. Rectify Regulator Vacuum port blocked. Clear regulator vacuum port. 2 Poor pick up. (CNG Mode) Air filter dirty. Clean air filter Ignition system faulty Check and Rectify CNG Injector faulty Replace injector Pressure Regulator Faulty Check gas delivery, replace regulator if needed 3 Under-filling/no filling of gas into cylinder` Manual valve closed Open manual valve 4 CNG regulator not delivering gas Manual valve closed Open manual valve Solenoid not operating. Check operation. Replace regulator if found faulty HP line blocked Check for blockage. Clean using compressed air if blockage is found. Pressure Regulator Faulty Check and Replace 5 CNG Leakage Leakage from joints/components due to inadequate or no sealing Check and tighten the joints 6 CNG smell in passenger cabin Leakage at filler valve joint Check and tighten the joint. Venting system blocked Check and clear blockage 7 Pressure Regulator freezing Inadequate coolant circulation Check the coolant circuit for damage or leakage. Blockage in coolant circuit Check and rectify CNG leakage Check and Rectify 8 Leakage from end connection High pressure connection not proper. Tighten the fitting nut as per the standard instruction for the high pressure connection. 9 O-ring found damage condition Dirt particles in gas or damage due to continuous usage. Change the O-ring as per the maintenance procedure.
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 18 Sr. No. Problem Cause Solution 10 Leakage from Cylinder valve threads Over Tightening In case of over tightening the valve threads will be damaged. Replace the valve with a new one and install as per given instructions Teflon tape is not properly wrapped Unwrap the Teflon tape and clean the threads. Wrap a new Teflon tape as per given instructions .Always check the Cylinder valve and Cylinder threads at the time of installation of new valve. 11 Pressure Release Device/Valve Activated Cylinder subjected to high pressure/temperature Replace the Cylinder valve with a new one. Do not attempt to repair or re-use the faulty valve. 12 Gas is not coming from Cylinder Excess flow device activated due to pressure difference 1. Close the manual valve and wait for a few minutes. 2. Open the knob of the manual valve slowly. 13 CNG level show erratic reading on cluster /Gasoline to CNG mode not converting Pressure regulator sensor failure. Replace the pressure regulator sensor. Both or One of the Manual shut off valve may be closed. Open the manual shut off valve/s if found in closed condition. Check CNG Level on instrument cluster is it shows empty. Refill CNG if level shows empty. Pressure regulator freezing due to inadequate coolant circulation, coolant hose damage, blockage or leakage. Check the coolant circuit for damage, blockage or leakage CNG gas leakage. Check all joints and rectify.
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 19 3. CONSTRUCTIONAL AND SERVICE DETAILS: A. Engine Lifting : Engine Lifting : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Lifting Hook (Front) 2 Hex FL SCREW M8X18 (4 Qty.) 2.5
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 20 B. Intake Manifold: Intake Manifold : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 ETC to Intake Manifold (HEX FL NUT AM6) (4 Qty.) 1.0 2 ETC to Intake Manifold (STUD BM6X40) (4 Qty.) 1.0 3 Electronic Throttle Control 4 Grommet on intake manifold for air filter (Top) 5 MAP Sensor 6 Hex FL screw m6x12 1.0 7 Intake Manifold 8 HEX FL NYLOC NUT M8 (4 Qty.) 2.0+0.3 9 HEX FL BOLT M8X30 at bottom of intake manifold on block (1 Qty.) 2.5 10 Grommet on intake manifold (Bottom) 11 Intake Manifold Stud (4 Qty.)
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 21 C. Cylinder Head Cover :
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 22 Cylinder Head Cover : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Hex FL Bolt M6X35 for Ignition Coil (3 Qty.) 1.0 ±0. 2 2 Ignition Coil (3 Qty.) 3 Cylinder head Cover 4 Gasket (Cylinder Head Cover)** 5 Hex. Bolt (Cylinder Head) (8 Qty.)• 4.0+0.5 185˚+5˚ 6 Washer 7 Gasket (Cylinder Head) 8 Dipstick 9 'O' Ring (Oil Filler Cap) 10 Oil Filler Cap 11 Hex. FL Screw M6X22 (Head Cover) (13 Qty.) 1.0 12 Solenoid Valve 13 Hex FL Nut AM6 for Solenoid valve (1 Qty.) 1.0 14 Stud C M6X20 for OCV 1.0 15 Hex FL Bolt M6X65 (1 Qty.) 1.0 Note:- • This Symbol indicates critical tightening torque.
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 23 D. Cylinder Head-A :
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 24 Cylinder Head-A : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Hex FL Bolt M6X60 for ITG Bearing Cap Upper (4 Qty.)• 1.5±0.15 2 ITG Bearing Cap Upper 3 Camshaft 4 ITG Bearing Cap Lower 5 Cylinder Head 6 Exhaust Valve 7 Intake Valve 8 Camshaft Bearing Cap (Inner) 9 H/FL Bolt M6X35 for Camshaft Brg. Cap (12 Qty.)• 1.5±0.15 10 Dowel Bolt M6X35 for Camshaft Brg. Cap (12 Qty.)• 1.5±0.15 11 Spring Seat 12 Valve Guide Seal 13 Valve Spring 14 Valve Spring Retainer 15 Lock Half 16 HLA RFF Assembly Note:- • This Symbol indicates critical tightening torque.
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 25 E. Cylinder Head-B : Cylinder Head-B : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Cam Phase Sensor (2 Qty.) 2 H/FL Screw M6X14 for Cam Sensor (2 Qty.) 1.0 3 Thermostat Housing
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 26 F. Cylinder Block :
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 27 Cylinder Block : Note:- • This Symbol indicates critical tightening torque. No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Seal Plug M20x1.5 for oil gallery crankcase 2.5 2 Crankcase 3 Knock Sensor 4 Hex FL Screw M8X30 2.0+0.5 5 Sealing Plug M24X1.5 3.5 6 Crankshaft Oil Seal (Rear) 7 Bolt main bearing cap torx M10x1.5 e14 8 Bed plate Hex/Fl bolt M8X70 (10 Qty.) • 3.2±0.6 9 Bed Plate 10 Rotational Speed Sensor 11 H/FL Screw M6X16 for Crank Angle Sensor 1.0+0.2 12 Deflector Plate Cyl. Block
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 28 G. Oil Sump Oil Sump No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Oil Sump 2 Sealing Washer 3 Drain Plug 3.5 4 H/FL Screw M6X14 for Oil Sump (18 Qty.) 1.0 5 Pipe seal 6 Water Bypass Assembly 7 H/FL Screw M6X14 (2 Qty.) 1.0
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 29 H. Moving Parts : Note:- • This Symbol indicates critical tightening torque.
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 30 Moving Parts : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Top Ring 2 Taper Faced Ring 3 Oil Ring 4 Piston Pin 5 Round Wire Circlip 6 Connecting Rod 7 Bearing Half (Connecting Rod) 8 Bolt (Connecting Rod) (M8 X 1) (6 Qty.)• 2.2+0.5 90˚ ± 5˚ 9 Woodruff Key 10 Crank Sensor Target Wheel 11 Assembly Vibration Damper Pulley 12 Washer (Damper Pulley) 13 Hex. Bolt M16x1• 14.5+0.3 90˚ ± 5˚ 14 CSK SOC Screw M6X20 for crank sensor wheel 1.7+0.3 15 Bearing Shell Half Lower (Crankshaft) 16 Bearing Shell Half Upper (Crankshaft) 17 Thrust Washer 18 Crankshaft 19 Flywheel 20 Hex. Bolt For Flywheel (M10 X 1.5) (6 Qty.)• 3.5+0.5 25˚ ± 5˚ 21 Piston
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 31 I. Engine Timing :
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 32 Engine Timing : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Fixed Blade 2 Sprocket Crankshaft 3 Hex Pivot Bolt for Chain Guide (Movable) 2.5 4 Chain 5 Hex bolt (Exhaust Camshaft VVT)• ˚9 ± 5 % 6 Hex FL Bolt M6x25 (2 Qty.) 1.0 7 Cam Guide Valve 8 Hex Bolt (Intake Camshaft VVT)• ˚6 ± 0.5 9 Controller Assy. Valve Timing 10 Variable Cam Timing 11 Tensioner Guide Rail 12 H/FL Screw M6 x14 (2 Qty.) 1.0 13 Hex FL SCR M6X30 (2 Qty.) 1.0 14 Tensioner Note:- • This Symbol indicates critical tightening torque.
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 33 J. Exhaust Manifold : Exhaust Manifold : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Exhaust Manifold 2 Gasket (Exhaust Manifold)) 3 Stud C M8X25 for Exhaust (4 Qty.) 2.5 4 M8X1.25 Flange P/T Nut. (4 Qty.) 2.0+0.3 5 Lambda Sensor 5.0+1.0 6 Lambda Sensor 5.0+1.0 7 H/FL Screw M8X20 (2 Qty.) 2.5
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 34 K. Fuel Injection Equipment : Fuel Injection Equipment : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Assembly Fuel Rail 2 Hex FL Bolt M8X30 (Common Rail) (2 Qty) 2.5 3 Clip Fuel Injector (3 Qty) 4 Fuel Injector (3 Qty) 5 Fuel Rail Assy (CNG) 6 Fuel Injector (CNG) (3 Qty) 7 Pressure/Temperature Sensor 0.9 ± 0.2 8 Hex Fl Scr.M6X14 (3 Qty) 1.3 9 CNG fuel injector clip (3 Qty)
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 35 L. Lubrication Pump and Components :
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 36 Lubrication Pump and Lines : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Oil Pump Assy. Complete 2 Hex FL Bolt M8X55 for Oil Pump Assy. (6 Qty.) 2.5 3 Oil Seal (Crankshaft) (Front) 4 Oil Pump 5 Hex FL Bolt M6X28 (13 Qty.) 1.0 6 O-Ring (For Strainer assy.) 7 Flanged Clinch Nut M6 (2 Qty.) 1.0 8 Strainer Assembly (For Oil Pump) 9 Gasket (For Filter) 10 HEX FL BOLT M8X25 (For Filter) (3 Qty.) 2.5 11 Adaptor (For Oil Filter Mounting) 12 Oil Filter Assembly ¾ th Turn 13 Oil Pressure Switch 3+1
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 37 M. Air Intake System : Air Intake System : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TORQUE (Kgf.m) 1 Air Filter Housing Assembly 2 ETC to Intake Manifold (Hex.Nut AM6) (4 Qty.) 1.0 3 ETC to Intake Manifold (STUD BM6X40) (4 Qty.) 4 Blow by hose 5 Electronic Throttle Control 6 H/FL Bolt M8X28 (2Qty) 7 Intake Manifold 8 Snorkel Duct 9 Snorkel Bracket 10 H/FL Nut BM6 FOR Snorkel Bracket (1 Qty.) 1.0
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 38 N. Special Installation :
1.2L REVOTRON TWIN CYLINDER CNG ENGINE 39 Special Installation : No. DESCRIPTION NO REUSE SEALANT LUBRICATION TOQUE (Kgf.m) 1 Belt 2 Bracket for Compressor Mounting 3 Hex FL Bolt M8X35 (Bracket to block) (4 Qty.) 3.5 4 Compressor 5 H/FL Bolt M8X85 for Compressor (3 Qty.) 2.2+0.2 6 Hex. FL Bolt M8X100 for Water Pump (2 Qty.) 2.5 7 H/FL Bolt M8X55 for water pump (2 Qty.) 8 Water Pump 9 Hex FL Nut AM6 to Thermostat 1.0 10 Bracket lambda sensor 11 Thermostat 12 Alternator 13 Alternator Cover Fitment Bracket: 14 Alternator Guard 15 Hex FL Nut AM6 for Guard (2 Qty.) 1.0 16 Hex. FL Bolt M8X85 for alternator (2 Qty.) 3.5 17 Hex flange bolt M8 X 55 (1 Qty.) 3.5 18 Belt (Alternator Belt) 19 Water Temperature Sensor 1.8-2.5
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