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TIAGO/TIGOR ICNG TWIN CYLINDER - SERVICE MANUAL

TIAGO/TIGOR ICNG TWIN CYLINDER - SERVICE MANUAL 1
1.2L REVOTRON BSVI TWINCYLINDER CNG ENGINE 6
CONTENTS 9
1. GENERAL INFORMATION 14
A. ENGINE INTRODUCTION 14
B. Electronic Control 15
C. TECHNICAL SPECIFICATION 16
D. SPECIAL TOOLS 17
E. ASSEMBLY CLEARANCES 22
F. SEALANTS 22
G. LEAKAGE RATES 22
2. TROUBLESHOOTING 23
3. CONSTRUCTIONAL AND SERVICE DETAILS 32
A. Engine Lifting 32
B. Intake Manifold 33
C. Cylinder Head Cover 34
D. Cylinder Head-A 36
E. Cylinder Head-B 38
F. Cylinder Block 39
G. Oil Sump 41
H. Moving Parts 42
I. Engine Timing 44
J. Exhaust Manifold 46
K. Fuel Injection Equipment 47
L. Lubrication Pump and Components 48
M. Air Intake System 50
N. Special Installation 51
O. Engine Suspension 54
P. CNG System 56
4. ENGINE TESTS AND MAINTENANCE 61
A. PRELIMINARY INSPECTION 61
B. ENGINE TESTS 62
I. Engine Compression Test 62
II. Engine Oil Consumption Test 63
III. Engine Oil Pressure Test 64
C. REGULAR MAINTENANCE 65
I. Engine Oil and Filter Change 65
II. Engine Coolant Replacement 66
III. Air Filter Element Replacement 69
IV. Spark Plug Replacement 70
V. Fuel Filters Replacement 71
VI. Air Conditioner Compressor andAlternator Belt Replacement 72
VII. Filler Receptacle Assembly Filter & ValveO-Ring Replacement 74
VIII. Receptacle Valve Filter MeshReplacement 75
IX. CNG filter Replacement 76
5. REPAIR AND INSPECTION DETAILS 80
A. Accessory Driving Belt 80
B. Timing Chain 80
C. Cylinder Head 80
D. Valves 81
E. Cylinder Head Valve Seats 82
F. Roller Finger Follower 83
G. Hydraulic Lash Adjuster (HLA) 83
H. Camshafts (Intake & Exhuast) 83
I. Piston and Piston Rings 85
J. Connecting Rods 86
K. Crankshaft 88
L. Crank case 90
M. Fuel Tank 91
N. Canister Purge Valve 91
O. Canister 92
6. ENGINE SYSTEM 93
A. AIR INTAKE SYSTEM 93
B. BLOW BY SYSTEM 95
C. LUBRICATION SYSTEM 96
D. EXHAUST SYSTEM 100
E. COOLING SYSTEM 102
F. FUEL SYSTEM 105
7. ON VEHICLE SERVICE PROCEDURE 119
A. ENGINE REMOVAL AND REFITMENT FORMT VEHICLE 119
B. AIR FILTER ASSEMBLY 125
C. INJECTION SYSTEM 125
D. SPARK PLUG 128
E. EXHAUST SYSTEM REMOVAL MAINTENANCE 128
F. FUEL SYSTEM PRECAUTIONS 131
G. CNG FUEL SYSTEM 138
H. MOON VALVE REMOVAL / REPLACEMENT PROCEDURE 149
I. HIGH PRESSURE LINE 156
J. FUEL FLAP SWITCH 158
K. COOLING SYSTEM 158
L. REMOVAL OF STARTER MOTOR 162
M. REMOVAL OF ACCESSORIES 162
8. ENGINE OVERHAULING ( ON OVERHAUL STAND) 168
A. Engine Dis-assembly 168
I. Removal of Intake Manifold 168
II. Removal of Exhaust Manifold 169
III. Removal of Oil Sump 170
IV. Removal of Sensors 172
V. Removal of Accessories 173
VI. Removal of Timing Chain 174
VII. Removal of Cylinder Head and Camshaft 176
VIII. Removal of Cylinder Head Sub-Assemblies 177
IX. Removal of Cylinder Block Sub-Assemblies 179
B. ENGINE ASSEMBLY 182
I. Assembly of Cylinder Block Sub-Assemblies 182
II. Fitment of Piston and Connecting rod Sub-Assemblies 184
III. Assembly of Cylinder Head Sub-Assemblies 186
IV. Assembly of Cylinder Head 188
V. Assembly of Engine Timing Chain 189
VI. Assembly of Engine Accessories driving Belt 193
VII. Assembly of Sensors and Peripherals 194
VIII. Assembly of Oil Sump 195
IX. Assembly of Exhaust Manifold 196
X. Assembly of Intake Manifold 197
9. ENGINE MANAGEMENT SYSTEM 200
A. ABBREVIATIONS 200
B. AN OVERVIEW 200
C. ELECTRONIC CONTROL UNIT (ECU) 201
D. SENSORS 206
I. MANIFOLD AIR PRESSURE SENSOR AND TEMPERATURE SENSOR (T-MAP) 207
II. LAMBDA SENSOR 208
III. CAMSHAFT POSITION SENSOR (INTAKE/ EXHAUST) 210
IV. KNOCK SENSOR 211
V. CRANKSHAFT POSITION SENSOR 212
VI. COOLANT TEMPERATURE SENSOR 213
VII. OIL PRESSURE SWITCH 214
VIII. CNG RAIL PRESSURE / TEMPERATURE SENSOR 215
IX. CNG HIGH PRESSURE SENSOR (NonServiceable) 216
E. ACTUATORS 217
I. IGNITION COIL 218
II. SOLENOID VALVE (OIL CONTROL VALVE) 219
III. GASOLINE FUEL INJECTORS 220
IV. PURGE CONTROL VALVE 221
V. ELECTRONIC THROTTLE BODY 222
VI. CNG Fuel Injectors 223
F. SWITCH 224
I. THROTTLE PEDAL SENSOR 224
II. CLUTCH SWITCH 225
III. BRAKE SWITCH 226
IV. VEHICLE SPEED SENSOR 227
V. WHEEL SPEED SENSOR 228
ELECTRICAL 229
CONTENTS 230
1. INSTRUMENT CLUSTER 231
A. FEATURES 231
B. INSTRUMENT CLUSTER VARIANTS 232
C. BASIC ELECTRICAL SPECIFICATIONS 233
D. INSTRUMENT CLUSTER FEATUREDESCRIPTION 234
E. BASIC FUNCTIONAL MATRIX 236
F. TELL TALES MATRIX 237
G. DRIVER INFORMATION SYSTEM 243
H. REMINDER FEATURES 252
I. MAIN CONNECTOR PIN-OUTS 254
J. FUEL GAUGE DETAILS 255
K. CHIME TABLE 256
L. DISPLAY SCREEN FLOW AND SETTINGS 257
M. REMOVAL OF INSTRUMENT CLUSTER 258
2. FUSE AND RELAY BOX DETAILSCHECKING FUSES 259
A. FUSE AND RELAY BOX LAYOUT 261
B. BATTERY MOUNTED FUSE BOX (BDU) 262
C. ENGINE FUSE AND RELAY BOX 263
D. CABIN FUSE AND RELAY BOX 268
E. FUSE AND RELAY REPLACEMENT 271
3. TYRE PRESSURE MONITORING SYSTEM (TPMS) 272
A. GENERAL INFORMATION 272
B. ON VEHICLE PROCEDURE 275
C. TPMS ECU LEARNING PROCEDURE 277
D. TPMS SENSOR REPLACEMENT PROCEDURE USING LF TOOL 279
E. TIRE REPLACEMENT 280
F. MOUNTING OF THE TIRE 281

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