TATA Indica Manual de Taller
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Descripción: TATA Indica Manual de Taller...
Description
ENGINE 475 SI MPFI
ENGINE
INTRODUCTION :
Tata Indica (Petrol) is available in 4 versions namely LEi, LSi, LX & LXi. LX & LXi are powered by 475 MPFI engine which produces 85 PS @5500 rpm and a torque of 115 Nm @3000 rpm. LEi & LSi are powered by 475 MPFI engine which produces 75 PS @5500 rpm and a torque of 110 Nm @3000 rpm. Tata 475 SI MPFI is a spark ignition multipoint fuel injection water cooled, petrol engine with SOHC (Single OverHead Cam) valve mechanism in ‘V’ t ype arrangement. All inlet valves on one side & all exhaust valves on other side.
SULIN SULIN
475 MPFI engine is fitted with 16 Bit inbuilt microprocessor intelligence into the engine control system. 475 MPFI engine provides better engine performance, better cold starting and warm up, better fuel economy, quick response and confirms the EURO II emission norms.
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MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI CONTENTS Sr. No.
Description
Page No.
1.
Technical specifications
1
2.
List of special tools
2
3.
Tightening torques
3
4.
Carburetted engine vs MPFI engine
6
5.
MPFI engine advantages
7
6.
MPFI schematic circuit diagram
8
7.
Features of MPFI engine
9
8.
MPFI sensors / actuators
12
9.
Intank fuel pump
26
10.
Ignition Coil Assembly
27
11.
ECU
30
12.
Trouble shooting of MPFI sensors
32
13.
ECU Handling & care
36
14.
Preliminary inspection of engine
37
15.
Exploded Views
40
16.
Removal & installation of engine from the car
58
17.
Radiator, removal and installation
60
18.
Alternator/Power steering pump & A. C. compressor belts removal, inspection, & fitment a. For 85 PS Engine b. For 75 PS Engine
61 63
19.
Timing belt Removal / Fitment
64
20.
Cylinder Head Sub-assembly a. Disassembly, inspection of Rocker shafts & arms, spark plug camshaft, valves, valve guides, valve seats and valve seat inserts b. Assembly of cylinder head c. Valve clearance adjustment
67 82 84
21.
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Cylinder block sub assembly a. Disassembly, inspection & assembly of : Pistons & piston rings, Connecting rods, Crankshaft, cylinder block, oil pump, water pump, thermostat assembly b. Removal, installation & machining of cylinder liners
101
22.
Lubrication system
103
23.
Cooling system
105
24.
Air intake system
113
25.
Air cleaner
114
26.
Accelerator Cable
115
27.
Assembly Foot Control
116
ENGINE
87
28.
Engine Testing
117
29.
Evaporative Emission Circuit
118
30.
Trouble Shooting
119
Note : This section is common for both 85 PS & 75 PS engines, but following pages are exclusive for respective engines: l
For 85 PS : 41, 51, 56 & 61
l
For 75 PS : 42, 50, 57 & 63. Please also check page no. 65 for selection of camshaft.
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ENGINE 475 SI MPFI TECHNICAL SPECIFICATION ENGINE
ENGINE
Model
:
TATA 475 SI MPFI
Type
:
Water cooled Multi Point Fuel Injection Petrol Engine
No. of cylinders
:
4 inline
Bore / Stroke
:
75 mm x 79.5 mm
Capacity
:
1405 cc
(For LX & LXi)
:
85 PS (62.5 kw) at 5500 rpm as per ISO : 1585
(For LEi & LSi)
:
75 PS (55.2 kw) at 5500 rpm as per ISO : 1585
(For LX & LXi)
:
115 Nm at 3000 rpm as per ISO : 1585
(For LEi & LSi)
:
110 Nm at 3000 rpm as per ISO : 1585
Compression ratio
:
9.5 : 1
Firing order
:
1-3-4-2
Fuel system
:
Grouped Injection with close loop Air / Fuel control supported by Hitachi EMS
Ignition system
:
Grouped Ignition supported by Hitachi EMS
Emission compliance
:
EURO II
Engine oil capacity
:
4 Litres
Cooling system capacity
:
6 Litres
Air filter
:
Dry (paper) type
Oil filter
:
Spin on full flow paper type
Max. engine output
Max. torque
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1
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ENGINE 475 SI MPFI LIST OF SPECIAL TOOLS ENGINE
Sr. No.
Description
Part No.
1.
Box spanner (16 A/ F) for spark plug
2702 5890 06 01
2.
Extended socket (10mmA/ F) for oil sump mounting screw
2702 5890 06 03
3.
Camshaft Locking Pin
2702 5890 06 04
4.
Flyw heel locking pin
2702 5890 06 05
5.
Lock plate for camshaft gear washer
2702 5890 06 07
6.
Drift for crankshaft oil seal in rear cover
2702 5890 06 08
7.
Drift for removal / fitment of valve guide
2702 5890 06 11
8.
Spacer for valve guide fitment
2702 5890 06 12
9.
Drift for fitment of oil seal on valve guide
2702 5890 06 14
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10.
Valve spring com pressor
2702 5890 06 15
11.
Support rail
2702 5890 06 16
12.
Drift for valve guide seal fitment
2702 5890 06 17
13.
Drift for oil pump oil seal
2702 5890 18 01
14.
Spanner for oil filter
2702 5890 18 02
15.
Bracket (LH) for mounting engine on stand
2702 5890 24 02
16.
Bracket (RH) for mounting engine on stand
2702 5890 24 03
17.
Engine repair stand
2573 5890 24 01
18.
Drift for fitment of camshaft oil seal
2654 5890 05 08
19.
Engine support stand
2702 5890 24 01
20.
Hitachi HDM 2000 diagnostic monitor w ith accessories and Telco cartridge 1.20
2932 9900 60 54
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ENGINE 475 SI MPFI TIGHTENING TORQUES : The fasteners should be tightened to specified torque at recommended intervals (km). If various fasteners are not t ight ened t o specified t orques, t hat is eit her over t ight ened or let loose, it w ill result in leakage at joint s and dam age t o t he part s/ t hreads. It w ill also adversely affect t he perform ance of t he part s/ syst em s as clearances/ bearing plays in the aggregates are governed by the tightening torques of the fasteners. When choosing the torque wrench, remember that it should not be subjected to torque exceeding three fourths of its capacit y. Before tightening, clean the threads and apply a little oil.
Serial No.
Description
Torque in mkg.
1.
Main Bearing Cap bolt M10 x 1
5.5 #
2.
Cylinder head bolts M10 x 1.1
3, 5, 7.5 (Ref. Note) #
3.
Spark plug in cylinder head M14 x 1.5
4.
Cylinder head cover bolts M6
5.
Oil sump Screw M6 x 1
6.
Sealing plug for oil gallery block rear M14 x 1.5
3.5
7.
Oil sump drain plug M12 x 1.5
3.5
8.
Rear timing cover to block M6 x 1
1.0
9.
Rear timing cover to head cover M6 x 1
1.0
10.
Timing belt cover M6 x 1
1.0
11.
Rear cover crank case on cylinder block screw M6 x 1
1.0 #
12.
Connecting rod cap Nut M9 x 1
5.25 #
13.
Flywheel mounting screw M10 x 1
5.0 #
14.
Crankshaft gear to crankshaft bolt M14 x 1
15.
Vibration damper / 4 groove A/C pulley to crankshaft gear
2.5
16.
Belt tensioner adjuster bolt M10 x 1.5
3.0
17.
Cam thrust plate
1.0
18.
Timing belt idler to cylinder block bolt M10 x 1.5
19.
Camshaft gear to camshaft screw M12 x 1.25
8.0
20.
Lock Nut (Rocker adjusting screw) M9 x 1
3.5
21.
Assembly Fuel feed pump on cylinder head screw M8 x 1.25
2.0 #
22.
Exhaust manifold mounting bolts on cylinder head M8 x 1.25
2.0 #
23.
Starter motor on Transaxle bolt M8 x 1.25
2.4
24.
Alternator bracket to cylinder crankcase M8 X 1.25
2.0
25.
Alternator to bracket M10
2.0
2.5 1.0 # 0.6 to 0.7 #
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4+60 0 #
4.5 #
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ENGINE
ENGINE 475 SI MPFI Serial No. ENGINE
Description
Torque in mkg.
26.
Adapter to cylinder head Stud M6 x 1
2.0 #
27.
Alternator tensioner bracket to block M8 x 1.25
2.0
28.
Alternator to tensioner bracket screw M8 x 1.25
1.5
29.
Oil pump on cylinder block
30.
Assembly Strainer to oil pump M6 x 1
31.
Assembly oil filter to cylinder crankcase M12 x 1.5
32.
Oil pressure switch on cylinder crankcase M20 x 1.5
33.
Water pump to cylinder crankcase screw M6 x 1
1.0 #
34.
Water outlet elbow to intake manifold Nut M6 x 1
1.0 #
35.
Water inlet elbow to cylinder crankcase screw M8 x 1.25
2.0
36.
Temperature Transducer on cylinder head M14 x 1.5
1.5
37.
Water inlet elbow to intake manifold nut M6 x 1
1.0
38.
Thermostat cover to intake manifold nut M6 x 1
1.0
39.
Lifting hooks to cylinder head screw M8 x 1.25
2.5
40.
Engine mounting bracket to block M10 x 1.5
4.5
41.
Engine mounting bracket to arm
4.0
42.
Power steering pump mounting on bracket screw M8 x 1.25
2.5
43.
A/ C Compressor bracket to cylinder block screw M8 x 1
2.5
44.
A/C Compressor to A/C compressor bracket bolt M8 x 1.25
2.5
45.
Power steering pulley to power steering pump Nut M12 x 1.25
8.0
46.
Assembly Idler to Slider (A/ C compressor belt tensioner) Nut M8 x 1.25
2.5
1.0 # 1.0
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Ref. Note @# 3.0
Tolerance on Torque values + 5% for those marked # and + 10% for others Note @ Apply oil on seal face and screw in until seal touches face. Tighten further by 3/ 4 turn. Do not over tighten.
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Cylinder Head Cover
Inlet Manifold Exhaust Manifold
Oil Filling Cap
Cylinder Head Cover
Oil Filling Cap
Inlet Manifold Exhaust Manifold
Throttle Body
Throttle Body
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Timing Cover
Timing Cover
AC Compressor
AC Compressor
Cylinder Block
Vibration Damper
Alternator
GROUP INDEX
Power Steering Pump
85 PS ENGINE
Cylinder Block
Vibration Damper
Alternator
Power Steering Pump
75 PS ENGINE
ENGINE 475 SI MPFI
ENGINE 475 MPFI - EURO II
5 ENGINE
ENGINE 475 SI MPFI
ENGINE
CARBURETTED ENGINE V/s MPFI ENGINE
Prim ary m ain jet
Typically a carburetted engine differs from petrol injected engine in following aspects.
Slow air hole no. 1
l
Fuel Metering
l
Ignition System
l
Cold Start
l
Ch an g e in At m osp h eric Con d it ion Resp on se (Alt it ude, Tem perat ure et c.)
Prim ary slow jet
Carburetted Engine : (Fig 1). l
l
In this case fuel metering is done by carburettor i.e. fuel quantity is controlled by fuel jet and air flow into the engine due to the vacuum available at the venturi. Fuel quantity is a continuously variable function with respect to air flow. Ignition system consists of a Distributor driven by a camshaft. The Distributor timing is a continuously variable function as engine speed and load changes. Due to Mechanical make/break system, the Ignition energy is low (low dwell time) at high speeds.
Petrol Injected Engine : l
l
Bypass p ort Prim ary m ain jet Id le p ort
Fig. 1 Carburettor system - illustration 2 1. Fuel 2. Air 3.Throttle valve 4. Intake manifold 5. Injector 6. Engine
1
3
SULIN
In this case fuel delivery to the engine is through one or more than one Injectors. (See illustration for Single p oint and Mult ip oint fuel inject ion System Fig. 2). The amount of fuel going into the engine is controlled by an ECU depending upon engine speed and load. The fuel delivery is not a cont inuously variab le funct ion b ut a d iscret e function as ECU calculates optimum fuel quantity required for any speed and load condition of the engine. The correction in fuel quantit y is almost instantaneous (less than one cycle time).
Ignition system of Petrol Injection engine consists of Ignit ion Coil w it h built in Pow er Sw it ch and t he spark t im ing is cont rolled by ECU. Ignit ion timing is varied discretely, depending upon the engine sp eed and load. This syst em m aint ains optimum Ignition energy levels for a good spark in bot h low and high speed of t he engine. No w ear part s like point s, Dist ribut or cap et c., and hence bet t er reliabilit y.
5
4
6
SINGLE POINT FUEL INJECTION (THROTTLE BODY INJECTION) 2 1. Fuel 2. Air 3.Throttle valve 4. Intake manifold 5. Injectors 6. Engine
3
4
1
5
6
M U LTI POINT FUEL INJECTION Fig. 2 6
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ENGINE 475 SI MPFI
Manifold pressure sensor
ENGINE
Throt t le body Cylinder head cover
LTRS arrangem ent
Blow by hose
ISC Valve
Canist er purge valve
Fuel rail
Cylind er head
Int ake manifold
SULIN Ignit ion coil
Fig. 3 Intake Manifold with throttle body
475 SI MPFI ENGINE ADVANTAGES 475 MPFI engine uses HITACHI multipoint fuel injection system. Seven sensors located at various points in the engine, sense important parameters of the engine operation & send signals to a ECU located under dashboard. Based on predetermined engine mapping, the ECU precisely controls the fuel delivery injection t im ing t o ensure op t im um fuel ut ilisat ion w it h minimum emission.
MPFI engine provides the following advantages :
speed is increased as a function of Water and Air temperature inputs to the ECU. l Emission :
The petrol injection engine has low emissions because the air fuel ratio is controlled to stoichiometric using lambda sensor.Faster warm up from cold start ensures early operation of catalytic converter in turn reducing the emission. l Fuel Economy :
The petrol injection engine has a better fuel economy because the engine is optimised at each operating point,discretly.
l Better Engine Performance :
Optimum fuel quantity and Spark timing is calculated by ECU for any operating condition.
l Quick Response :
l Better Cold Starting and Warm up :
ECU identifies cranking condition and quick starting is ensured by providing sufficient fuel quantity and optimum spark timing. For quicker warm up, idling
Th e p et ro l in ject io n en g in e w ill h ave a b et t er driveability and better acceleration since the fuel delivery and spark t im ing are cont rolled by ECU, which quickly responds to engine/ Driver demands.
7
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GROUP INDEX
ENGINE 475 SI MPFI
MPFI SCHEMATIC CIRCUIT DIAGRAM
ENGINE
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8
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ENGINE 475 SI MPFI FEATURES OF MPFI FEATURE
HOW ACHIEVED
USER BENEFIT
CRANKING MODE :
ENGINE
Variable Injected Quantity
Injector pulse width starts with very high value and drops as cranking rpm, Air & Water t em perat ure increases.
Good Cold starting
Divided fine injection pulse w idth method
Further total pulse width is divided into fine pulse w idths for efficient mixture formation
Low Emissions
Fuel is cut if Throttle valve is opened
When throttle valve is opened more than 700 ECU cuts the fuel by reducing pulse width to very low value
Good startability in all conditions (both hot & cold)
Ignition timing for starting is calculated
ECU identifies cranking m ode and calculates spark timing depending upon water t em perat ure and engine speed.
Good startability in all conditions (both hot & cold)
A/ C Compressor is kept ‘OFF’
SULIN ECU identifies cranking mode and sw itches ‘OFF’ the A/ C relay.
Good startability due to reduced engine load
Fuel pump is kept ‘ON’ during Cranking only NOT OTHERWISE
If the engine is not started or stalls due to absence of rpm signal, Fuel pump is cut ‘OFF’.
Safet y
Canister Purge Valve is kept ‘OFF’
ECU identifies cranking m ode and sw itches ‘OFF’ CPV
Good startability
Based on inputs to ECU
Bet t er Idle st abilit y
ISC Valve position (steps) is continuously memorised and renewed in memory.
Bet t er Idle st abilit y w henever Idle st at e changes.
IDLING MODE : Idle speed is dependent on l Water t em perat ure l Engine Load (A/ C) l Battery Voltage l Manifold Vacuum. and speed is maintained by Closed Loop control ISC Valve memorises the previous position (Learned Function)
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ENGINE 475 SI MPFI
ENGINE
FEATURE
HOW ACHIEVED
USER BENEFIT
‘LIMP HOME’ Idle Speed
When the following sensors are ‘No Good’, then idle speed assum es default value for Throttle position sensor, MAP Sensor,Vehicle speed sensor, air temperature sensor, water temperature sensor.
Flexibility and user convenience
‘LIMP HOME’ ISC Valve
When ISC Valve fails in closed condition, open throttle marginally to start the engine.
User convenience
Engine Stall protection
When engine rpm is as low as 650 rpm, ECU cuts A/C relay.
Better Idle stability and user convenience
High Engine Speed Control
Fuel is cut beyond 6500 rpm
Engine safety
High Vehicle Speed Control
Fuel is cut beyond 165 Kmph
Vehicle Safety
Fuel is cut if ‘no load acceleration’ is sustained beyond certain time say, 180 sec.
Better fuel economy
Variable Acceleration Enrichm ent
Four levels of acceleration is det ect ed depending upon throttle position and vehicle speed and injected quantity is varied.
Better Fuel economy Bet t er Em issions Better Overt aking abilit y
Anti Surge Function
Ignition timing is varied to dampen sudden torque variations.
Driving comfort
High w at er t em perat ure A/ C cut ‘OFF’ beyond 1100c.
ECU cuts A/ C relay when the w at er t em pet ure increases
Engine Safety
A/ C compressor is kept ‘OFF’ during ‘rapid’ accelerat ion
A/ C relay is cut-off depending upon vehicle speed and throttle position .
Better over taking ability
ACCELERATION MODE :
Zero Vehicle Speed Fuel cut
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DECELERATION MODE : Fuel Cut during deceleration
ECU cuts the fuel depending upon Better fuel economy throttle position and rate of change of rpm.
10
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GROUP INDEX
ENGINE 475 SI MPFI FEATURE
HOW ACHIEVED
USER BENEFIT
Anti-Surge Function
Ignition timing is varied to dam pen sudden torque variat ions.
Driving comfort
Accurate Basic Map Data for efficient Injection and Ignition cont rol
High resolution data on a 16 x 16 matrix
Best compromise for Driveabilit y and Fuel econom y
Closed Loop Air/ Fuel ratio control
Lambda sensor input to ECU maintains Stoichiometric Air/ Fuel ratio
‘LIMP HOME’ mode When one or many sensors fails to function (Except crank angle sensor) the vehicle will run in default and the engine check lamp on the instrument cluster will glow continuously. The car can be driven to the nearest w orkshop for rect ificat ion.
ECU assumes default values
ENGINE
STEADY STATE MODE :
Emission Compliance
Safety and Comfort
SULIN
Inertia Switch (Fig. 4).
When the Vehicle collision occurs, inertia sw itch cuts ‘OFF’ fuel pump
Safety (Fire Protection)
Immobiliser (If fitted)
Rem ot e operat ed Immobiliser cuts supply to Main Relay and Fuel Pump.
Safety (Anti-theft device)
Fig. 4 Inertia switch under driver’s seat 11
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ENGINE 475 SI MPFI MPFI SENSORS / ACTUATORS CRANK ANGLE SENSOR : (Fig.5 & 6). ENGINE
Type : RS 313 B Inductive pick up (Variable reluctance) 2 Pin connector
Working Principle An A.C. voltage is induced in sensor coil when flywheel holes pass t hrough t he sensor by rot at ion. This A.C. vo lt ag e is d irect ly p ro p o rt io n al t o t h e sp eed o f rot at ion.
System Integration : This sensor p rovid es sp eed and crank angle inp ut signals t o ECU w hen p laced over rot at ing flyw heel with 7 holes, located at different angular dispositions.
Fig. 5 Crank angle sensor
Fitment Data : This sensor is mounted on the cylinder block over the flyw heel (Fig. 5). Sensor Gap = 1.5 + 0.5 mm
SULIN
Stand Alone Diagnosis : Use Mult im et er Coil resistance = 1200 W + 15% @ 200 C Check gap between flywheel and sensor tip Sensor end
Pin assignment ECU 20 = (CR+)
20
21
ECU 21 = (CR-) Measure resistance across pin 20 & 21
Fig. 6 Crank angle sensor
System Diagnosis : Use Hitachi Diagnostic Test er Check for crankshaft position signal “ON” during cranking.
Electrical Circuit : SENSOR SHIELD EWH
W 0.75
CRANK ANGLE SENSOR 21 (CR+)
CRANK ANGLE SENSOR 20 (CR-)
EWH
B 0.75
[ MAKE HITACHI ]
FWH FWH
CRANK ANGLE SENSOR SHIELD 19 (CRS)
CRANK ANGLE SENSOR
FWH
W/Y
EWH
AV 0.75
ECU
12
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ENGINE 475 SI MPFI AIR & WATER TEM PERATURE SENSOR : (Fig. 7 & 8) Type :
ENGINE
TT-20 Negat ive Tem perat ure Coefficient (NTC) 2 Pin connector
Working Principle A semiconductor material changes its resistance when exposed t o variable t em perat ure source. Resist ance decreases as t em perat ure increases.
System Integration : Th is sen so r p ro vid es air t em p erat u re o r w at er t em perat ure input t o ECU w hen placed in air/ w at er st ream .
Fig. 7 Air temperature sensor
Fitment Data : (ATS = AIR TEMPERATURE SENSOR) (WTS = WATER TEMPERATURE SENSOR) ATS is fitted on air filter (Clean side of air filter) (Fig. 7) WTS is f it t ed o n t h erm o st at h o u sin g (Bef o re thermostat) (Fig. 8)
SULIN
Stand Alone Diagnosis (See Illustration) : for both ATS & WTS Use Mult im et er Therm ist er resist ance
W+ 0.25 k W @ 200 + 10C 0.84 k W+ 0.10 k W @ 500 + 10C W
2.5 k
Air temperature sensor : Sensor end Pin assignment ECU 18 TA 18
26
ECU 26 TAG Measure the resistance across pins 18 & 26
Fig. 8 Water temperature sensor
Electrical Circuit : EWH
Water temperature sensor : Sensor end 24
Pin assignment 32
ECU 24 TW
ECU 32 TWG Measure the resistance across pins 24 & 32
System Diagnosis :
WATER TEMP. SENSOR 24 SIGNAL (TW)
WATER TEMP. SENSOR 32 GND. (TWG)
R/G FWH
BR/W
Check for ‘Air Tem p’ or ‘Wat er Tem p’ values d uring Idling.
EWH
0.75
FWH
AIR TEMP. SENSOR
BR/B
Use Hitachi Diagnostic Monitor
0.75
FWH
W/P
AIR TEMP SENSOR 18 SIGNAL (TA)
WATER TEMP. SENSOR [ MAKE HITACHI ]
0.75
AIR TEMP.SENSOR 26 GND. (TAG)
0.75
[ MAKE HITACHI ]
FWH
ECU
13
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ENGINE 475 SI MPFI MANIFOLD AIR PRESSURE SENSOR (MAP) (Fig. 9 & 10) Type :
ENGINE
PS-60-01 Peizo - Resistive type 3-Pin Connector
Working Principle A DC signal volt is produced by t his sem iconduct or device when varying manifold air pressure acts on the semiconductor diaphragm. To produce this output the sem iconductor device has t o be excit ed. This signal out put increases w it h increase in absolut e m anifold vacuum .
Fig. 9 Manifold air pressure sensor
System Integration : This provides manifold vacuum (abs.) signal input to ECU. The sensor is act ivat ed by excit at ion volt ag e supplied by ECU.
Fitment Data : This sensor is a part of Integrated Throttle Body which is fitted on Inlet manifold upstream side (Fig. 9)
SULIN
Stand Alone Diagnosis : Use Mult im et er With ignition “ON”. Supply volt » 5.12 vdc ~ ~ ~ ~
Signal volt
» 4.2 vdc @710 mmHg of Atm pr. (abs) Fig.10 Manifold air pressure sensor (Top view)
= 4.6 vdc @760 mmHg of Atm pr.(abs) Sensor end
31
22
112
Pin assignment ECU 31 supply, VCC ECU 22 signal, PM ECU 112 ground, GNDS
M easu re sig n al vo lt at p in 22 & 112 w it h sen so r connected to w iring harness.
System Diagnosis : Use Hitachi Diagnostic tester Ch eck for ‘In t ake m an ifold p ressure’ value d urin g cranking.
Electrical Circuit : EWH W/Y
SENSOR POWER SUPPLY 31 (+5V)(VCC) PRESSURE SENSOR 22 SIGNAL (PM) SENSOR GND. 112 (GNDS)
AV 0.75 EWH
FWH W/O
0.75 EWH
FWH BR/R
PRESSURE/MAP SENSOR [ MAKE HITACHI ]
0.75
FWH
EWH 0.75
ECU To Throttle Position Sensor
14
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GROUP INDEX
ENGINE 475 SI MPFI THROTTLE POSITION SENSOR (TPS) Fig. 11 & 12 Type :
ENGINE
SERA 483-06 Linear Pot ent iom et er t ype 3-Pin Connector
Working Principle : A fixed input DC volt to a potentiom eter provides a variable output DC volt when the circuit resistance is varied externally. Ou t p u t vo lt ag e in creases w h en circu it resist an ce red uces.
System Integration :
Fig.11 Throttle Position Sensor (TPS)
Sensor provides variable signal Input t o ECU w hen t h ro t t le lever is o p erat ed (o p en ed / clo sed ). Th is requires a supply volt of 5.12 VDC from ECU.
Fitment Data : This sensor is a part of Integrated Throttle Body which is fitted on inlet manifold upstream side. Throttle lever shaft is extended to a crank lever which operates the sensor (varies the circuit resistance). Fig. 11
SULIN
Stand Alone Diagnosis : Use Mult im et er With ignition “ON”. Supply volt » Signal volt
» =
Sensor end
31
23
5.12 vdc 0.5 vdc at Idle position 4.5 + 0.15 vdc at WOT position Pin Assignment
30
Fig. 12 Throttle Position Sensor (Side view)
ECU 31 Supply VCC ECU 23 Signal THS ECU 30 Ground THSG
Measure signal voltage across pin 23 & 30 with sensor connected to w iring hamess.
System Diagnosis :
Electrical Circuit :
Use Hitachi Diagnostic tester From Pressure/Map Sensor
Check for ‘Throttle sensor’ voltage by pressing the accelerator pedal in and out. THROTTLE SENSOR 23 SIGNAL (THS) THROTTLE SENSOR GND 30
V/R
0.75
EWH
0.75
EWH
FWH BR/G
THROTTLE POSITION SENSOR [ MAKE HITACHI ]
FWH
ECU
15
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GROUP INDEX
ENGINE 475 SI MPFI LAMBDA SENSOR (O2 Sensor) Fig. 13 & 14 Type : ENGINE
LSH 24
Heated Ceram ic Oxygen Sensor 3 Pin Connector
Working princple (See Illustration) : A special ceramic body with gas permeable platinum electrodes on it s surface, operates, depending upon ceramic material’s porosity which allows oxygen in the air t o diffuse w hen t he ceram ic body is exposed t o t em p erat u res ab o ve 350 0 C. Vo lt ag e is g en erat ed across the electrodes w hich are exposed to gas w ith different levels of oxygen contents.
System Integration :
Fig. 13 Lambda sensor fitted ON Exhaust pipe
This sensor provides Air/ Fuel ratio signal in the form of mV to ECU as a function of varying Air/ Fuel ratio Typical values at 3500C: = 0.95 = 1.05
840 + 70mv (rich) 20 + 50mv (lean)
Fitment Data : Fitted on the exhaust pipe as shown in Fig. 13
Stand Alone Diagnosis :
SULIN
Use Mult im et er Heater function (Coil resistance : 4.2 Wat 300C) Sensor end Pin assignment A
B 17
A Heater (+) B Heater (_)
Fig. 14 Lambda sensor (O2sensor)
ECU 17 Signal w.r.t. engine ground. Measure the signal volt - m V, across ECU pin no. 17 and engine ground w ith sensor connected to w iring harness.
Electrical Circuit :
System Diagnosis : Use Hitachi Diagnostic tester Check for ‘Front O2 Sensor’ value at idling.
LAMBDA SENSOR (A +ve)
(200mv to 600mv continuously varying due to lambda control function).
(B -ve)
GY/O
17 LAMBDA SENSOR(O2)
0.75
GND(ENGINE)
25 LAMBDA SENSOR SHIELD
ECU
16
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI LAMBDA SENSOR : l
Lambda oxygen sensor located in exhaust pipe Fig. 15. 1. 2. 3. 4. 5. 6. 7. 8.
5
Special ceramic coat Electordes Cont act Housing Exhaust pipe Ceramic Shield (porous) Exhaust gas. Air
7
6
4
8
ENGINE
3
1
2
Fig. 15 Lambda Sensor Lambda (oxygen) sensor voltage curve at 6000C operating temperature Fig. 16 a) Rich mixture (air deficiency) b) Lean mixture (excess air)
mV a
1000
Oxygen-sensor voltage
l
b
800
SULIN
600 400 200
0
0.8 0.9 1 1.1 Excess-air factor
1.2
Fig.16 Lambda Sensor Voltage Curve l
Heated Lambda (oxygen) sensor Fig. 17 1. Probe housing 2. Ceramic Shield tube
1
2
3
3. Electrical connections 4. Shield tube with slits 5. Active ceramic sensor layer 6. Contact 7. Shield 8. Heating lement 9. Clamp connections for heater element
5
6
7 8 9
Fig. 17 Heated Lambda Sensor 17
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI VEHICLE SPEED SENSOR (VSS) Fig. 18 & 19 Type : ENGINE
VDO Reed Switch Part of Instrument Cluster
Working Principle : This reed sw itch in a circuit provides ON/ OFF pulses by m aking/ b reaking t he cont act s. The cont act s are made/ broken by a rotating magnet.
System Integration : This provides vehicle speed input signal to ECU in the form of ON/ OFF pulses. When a reed switch is driven t hrough speedom et er cable. Specification : 4 pulses per revolution & 2550 contacts per km .
Fig. 18 Instrument cluster (rear view)
Fitment Data : This reed switch is integral part of instrument cluster and is driven by Speedometer cable Fig. 18.
Stand Alone Diagnosis :
SULIN
Use Mult im et er
Manually rotate the speedometer cable and check for contact make & break pulses 4 times/ rev.
VSS
With Ignition ‘ON’, Pulse volt in ‘ON’ condition = 4.5 Volt DC Measure pulse volt across ECU pin no. 6 and car body as ground with wiring harness connected to ECU.
System Diagnosis :
Fig. 19 Vehicle Speed Sensor (VSS)
Use Hitachi Diagnostic tester Check for Vehicle speed sensor ‘Value’ during driving. NG condition : 2 km/ hr irrespective of vehicle speed.
Electrical Circuit : R/Y
VEHICLE SPEED PULSE 6 (SPD)
PIN NO:1 INST CLUST [ MAKE PRICOL/VDO ]
FWH
ECU TO VEHICLE SPEED SENSOR
18
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI ISC VALVE (IDLE SPEED CONTROL VALVE) Fig. 20 Type :
ENGINE
AEP 125-1 Stepper motor type 6 Pin connector
Working Principle : Fig. 22 & 23 A linear flow pneumatic valve allows accurate flow control by varying flow cross section area.This is done by a moving spindle in bot h open/ close direct ions operat ed by a st epper m ot or.
System Integration : ECU provides drive signal to the stepper motor of ISC valve to allow m ore/ less air depending upon engine dem and to m aintain target speed of 750 rpm ( N = 50 rpm) in hot condition. Also, the input from various ot her sensors helps ISC valve t o m aint ain t he t arget Idle Speed for various engine loads
Fig. 20 Throttle Body showing Idle Speed control valve fitted ISC Valve in inset
0.75
e.g. : A/ C idle speed = 800 rpm Engine water temp dependent Speed, say at 300C = 1100 rpm.
0.75
Fitment Data :
P1
P2 LG/B
This actuator is part of Integral Throttle Body which is fitted on inlet manifold upstream side. Fig. 20
0.75 FWH
G/R
Stand Alone Diagnosis :
SULIN
Use Multimeter Single Phase coil resistance = 49 W Actuator end 2 9
P1 P2
3 10
R/L
3 ISC S/M ØA (ISCA)
0.75
FWH W/V
Pin assignment ECU 2 Coil A P1 Supply (+) ECU 3 Coil A’ P2 Supply (+) ECU 10 Coil B’
0.75 FWH
M
2 ISC S/M ØA (ISCA)
0.75 FWH
9 ISC S/M ØB (ISCB)
10 ISC S/M ØB (ISCB)
ECU STEPPING MOTOR TYPE ISC VALVE [ MAKE HITACHI ]
Measure coil resistance across pins = P1 & 2, P1 & 3, P2 & 9, P2 & 10
Fig. 21 Electric Circuit of ISC Valve
System Diagnosis : Use Hitachi Diagnostic tester Check for ISC valve steps For normal idling at hot condition
Throttle Body
ISC valve steps = 20 + 3 steps.
AIR FLOW (L/min) Illustration of graph showing air flow and step number on ISC valve. 600 500
Air Cleaner
400
Air Outlet
300
Stepper Motor
200
Air Inlet
100
Throttle Plate
Intake Manifold
0 0
20
40 60 80 Step Num ber
100
120
Fig. 22 ISC valve illustration 19
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI INTEGRAL THROTTLE BODY ENGINE
Type : RTT 38 Æ 38 mm throttle valve, integrated with MAP sensor Throttle position sensor & ISC valve Air flow control valve. Working Principle : Air flow into the engine is varied by varying the cross sect ion area. In addit ion, flow rat e is dependent on engine speed.
System Integration : This Integral Throttle Body is with a throttle valve (See Illustration) in the air flow path (of ø 38 mm). The throttle is actuated by the lever and the shaft assembly w hich in t urn op erat es Throt t le p osit ion sensor t o provide engine load signal.
Fig. 23
Manifold air p ressure sensor fit t ed on t he air flow passage dow nst ream of t he t hrot t le valve provides m anifold pressure signal. An ISC valve fitted on the throttle body allows the air flow into the engine by-passing the main air flow path.
SULIN
Ho t w at er p assag e is p ro vid ed f o r co ld clim at ic operat ions (de-iceing).
Fitment Data : Fitted on the upstream of the inlet manifold. Fig. 24
Stand Alone Diagnosis : Use Mult im et er
Fig. 24 Integral throttle body
Refer to MAP sensor, TPS sensor and ISC valve.
System Diagnosis : Use Hitachi Diagnostic tester 2000 Refer to MAP sensor, TPS sensor and ISC Valve.
20
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI CANISTOR PURGE VALVE Fig. 25 & 26 Type : ENGINE
TEV 2 BOSCH Solenoid valve 2 Pin connector
Working Principle : Fig. 27 & 28 A solenoid valve opens and closes t he gas passage depending upon ECU signal to the solenoid valve. Gas (petrol vapour) flows into manifold from canistor and the flow rate varies depending upon valve duty cycle ratio (open time to close time ratio) and pressure differential between canistor and inlet manifold. System Integration : ECU provides drive signal to this solenoid valve to purge the petrol vapour from canistor into the engine (inlet manifold) at appropriate speed and load of engine as decided by ECU. This valve is kep t op en (t o p urge) depending upon the duty cycle ratio drive signal from ECU.
Fig. 25 Location of purge valve
Fitment Data :
SULIN
This valve is mounted on the engine block. In petrol vapour circuit this valve connects canister purge line to intake manifold, downstream side of integrated throttle body. Fig. 25
Stand Alone Diagnosis : Use Multimeter Solenoid coil resistance = 26 W @200 C Actuator end P
11
Pin assignment
Fig. 26 Purge valve
P supply (+) main relay ECU 11
CP
Measure the resistance across pin P & 11
System Diagnosis :
Electrical Circuit :
Use Hitachi Diagnostic tester Check for CPC solenoid ‘ON/ OFF’ condition by freely accelerating the engine from idle to 4000 rpm.
CANISTER PURGE VALVE 0.75 EWH
EWH [ MAKE HITACHI ]
Y/L
FWH
11 CANISTER PURGE (CP)
ECU
21
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
CANISTER PURGE VALVE - ILLUSTRATION : ENGINE
1.
HOSE CONNECTION
2.
NON RETURN VALVE
3.
LEAF SPRING
4.
SEALING ELEMENT
5.
SOLENOID ARMATURE
6.
SEALING SEAT
7.
SOLENOID COIL.
1 2 3 4 5 6 7
1
SULIN
Fig. 27
3.5
3.0
FLOW IN M 3 / H
2.5 0.2 2.0
0.1
1.5
1.0
0.5
0.0 0
-100
-200
-300
-400
-500
-600
-700
-800
-900
DIFFERENTIAL PRESSURE PE IN MBAR
Fig. 28 22
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI FUEL INJECTOR Fig 29 & 30 Type : ENGINE
JS 2J - 3 Ball valve and Top feed 2 Pin Connector
Working Principle : Fig. 31 A solenoid valve, normally closed by a ball and cone seat, opens when the electromagnetic core is energised. Fuel under pressure flows through swirler and metering orifice on t he b all seat . This ensures fine at om isat ion and consistent flow rate for a given Injector opening time.The ball type seating valve acts as a good anti-deposit.
Inject ors
System Integration : ECU provides drive signal to Injector (normally closed valve) to open and remain in open condition (pulse widthms) depending upon the engine operating conditions (speed/ load). Also the pulse width is compensated for low battery voltage condition. The concept of Grouped injection means when ECU provides drive signal, two injectors (either for cyl 1&4 or cyl 2&3) are simultaneously opened, one in end of compression and one in end of exhaust. This means approximately half of the required quantity of fuel for one power output is provided in two stages.This enables efficient control of Air/ Fuel ratio by modifying injected fuel quantity in the second half of the injection.
Fig. 29 Fuel Injectors location in the engine
SULIN
Fitment Data : Four numbers of injectors are fitted on inlet manifold and fuel is fed by a common fuel rail so that the fuel spray from each injector is directed towards the inlet valve, inside the inlet port. Fig. 29
System Diagnosis : Use Hitachi Diagnostic tester. Check for ‘Fuel injection 01 pulse Values during idling : 2.0 to 2.5 ms
Stand Alone Diagnosis : Use multimeter Injector coil resistance 8.6 W Actuator end Pin assignment supply, m ain
relay
101
ECU 101 or ECU 102
Injector 1 & 4 Injector 2 & 3
Electrical Circuit : 1.0
Measure the resistance across the pin P and ECU101
1 CYL
R/B
L/G
0.75
EWH
EWH
4 CYL
(or ECU 102). With ignition ON, measure the supply voltage w.r.t.engine ground at the wiring harness end by removing all injector connectors.
FWH
0.75
Pow er
NOTE : Pu lse w id t h w ill co n t in u o u sly vary t o m ain t ain stoichiometric Air/Fuel ratio.
2 CYL
EWH
3 CYL
101 INJECTOR (IJ1) 1CYL, 4CYL.
Y/G
0.75
0.75
1 1
Fig. 30 Fuel Injector
FWH
102 INJECTOR (IJ2) 2CYL, 3CYL
ECU
INJECTOR 8.6_ X 4 [ MAKE HITACHI ] (+ ve)
23
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
FUEL INJECTOR - ILLUSTRATION : ENGINE
FILTER
FUEL IN
(1) TERMINAL (Driving Signal) from E.CU.)
(3) CORE
(2) COIL (COPPER)
SULIN
(5) YOKE A
(4) PLUNGER ROD (6) SWIRLER
(7) BALL VALVE (8) NOZZLE
ORIFICE
FUEL OUT
Fig. 31 24
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI FUEL PRESSURE REGULATOR Fig. 32 & 33 Type : ENGINE
MPDB 20 6A Diaphragm type valve (variable pressure) Pneumatic Regulator
Working Principle : Fig. 34 A diaphragm operated valve regulates pressure at fuel inlet and returns the excess fuel back to the tank. The d iap h rag m is o p erat ed b y d if f eren t ial p ressu re between fuel rail and intake manifold.
System Integration : Intank fuel pump provides fuel at very high flow rates t o co m m o n f u el rail w h ere p ressu re reg u lat o r regulates according to the position of diaphragm. This diaphragm is held in an equilibrium position as a result of fuel p ressure act in g on on e sid e an d m an ifold vacuum act ing on t he ot her side of t he diaphragm . The excess fuel, aft er regulat ion is ret urned back t o fuel tank. This ensures a constant operating pressure of 3 bar across Injector inlet and outlet, at all engine operat ing condit ions.
Fitment Data :
Fig. 32 Fuel pressure regulator
SULIN
This regulator is fitted on the Fuel rail. Fig. 32
Stand Alone Diagnosis : Check for leaking diaphragm. Leakage is confirmed if fuel traces are noticed on vacuum side.
System Diagnosis : Fig. 33 Fuel pressure regulator
Use Hitachi Diagnostic tester Check for ‘Front O2 sensor’ value for variat ions since lam b d a co n t ro l is in p ro g ress t o m ain t ain stoichiometric Air / Fuel ratio.
AIR CHAMBER
VC PIPE
FUEL IN
DIAPHRAGM VALVE
TO FUEL TANK
OUTLET PIPE
Fig. 34 Fuel pressure regulator illustration 25
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI INTANK FUEL PUMP Fig. 35 & 36 Type : ENGINE
F002 KIA 004, BOSCH / PENTADEWA Intank - Electric Fuel Pump 2 Pin connector
Working Principle : A p osit ive d isp lacem ent p um p assy. is d riven b y a m ot or t o p rovid e con t in uous flow of fuel t o h ig h pressure fuel system from fuel tank. This Intank pump provides continuous flow of fuel to fuel rail w here a variable fuel pressure is m aintained by a fuel regulator as a function of varying manifold vacuum .
Fig. 35
Fitment Data : This Intank pump is fitted inside the fuel tank by immersing the pump’s suction end in the fuel. Fig. 35
Stand Alone Diagnosis : Use Multimeter Motor armature resistance = 20W @200C Actuator end (Pump) 2
1
Pin assignment
SULIN
from relay 2 car body 1
Measure the coil resistance across Pin 1&2 Actuator end (Relay) P
108
Pin assignment P Supply (+) ECU 108 FP
Fig. 36 Intank Fuel Pump
System Diagnosis : Use Hitachi Diagnostic tester Check for Fuel pump relay ‘ON/ OFF’ condition.
NOTE : With ignition ON, Fuel pump is switched off after 1 sec. if engine is not cranked.
26
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI IGNITION COIL ASSEMBLY Fig. 37 & 38 Type : ENGINE
CM12 - 100D Duel Spark Coil with built in Power Switch 4 Pin Connector
Working Principle : This ignition coil operates on conventional principle of second ary (high) volt age generat ion b y ind uct ion. However,primary current switching (ON/OFF) is triggered by an electronic circuit on ECU w hich also maintains constant dwell time (time required to energise primary coil) throughout the engine operating conditions.
System Integration : ECU provides the trigger pulse to switch ON/OFF the power sw it ch b u ilt in t h e co il w h ich p ro vid es 2 sp arks simultaneously in cylinders 1& 4 or 2&3 as both the ends of the secondary coil is ending with sparkplugs. This concept called Grouped Ignition, means two sparks occur for one useful power output (i.e. one spark in the end of compression & one spark at the end of exhaust). This enables maintenance of optimum dwell time at very high engine speeds.
Fig. 37 Ignition coil with built in power switch
SULIN
Fitment Data :
The ignition coil is fitted beneath the inlet manifold to have the shortest possible length for High tension cable to connect Sparkplugs.This is done to reduce the level of electromagnetic radiation from HT cables and possible interferance w.r.t. the functioning of ECU. Fig. 37
Stand Alone Diagnosis (See Illustration) : Fig. 38
Use Multimeter Check for 12 V power supply P/ G on wiring harness Firing ord er (1,3,4,2) & HT cab le connect ions (See Illustration) Secondary coil resistance = 13 k W Actuator end
Pin assignment ECU 16
15 G 16
P
G ECU 15 P
supply (use for cyl. 2&3) ground (engine) signal (use for cyl. 1&4) Power supply
Measure supply volt across pin P and G on wiring harness with Ignition ON. Measure secondary coil resistance across High tension terminals of cyl. 1 & cyl. 4 (or cyl. 2 & cyl. 3).
System Diagnosis : Use Hitachi Diagnostic tester Check for ‘Ignition timing value’ during idling.
27
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Electrical Circuit :
FROM IGNITION
ENGINE
H.T. CABLE 0.75
H.T. CABLE
H.T. CABLE AV 0.75
[ MAKE ANU/DELTRONIX ]
SPARK PLUGS
1
2
BODY EARTH [MAKE MICO]
15 IGNITION1(IG1) 1CYL, 4CYL
EWH
H.T. CABLE
H.T. CABLE
0.75 AV 0.75
3
16 IGNITION2(IG2)
4
EWH
2CYL, 3CYL
ECU IGNITION COIL [ MAKE HITACHI ]
ENIGNE GND
GND (ENGINE)
SULIN
28
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI IGNITION COIL ILLUSTRATION : ENGINE
PRINCIPLE OF OPERATION OF IGNITION COIL
VCC
IGN RELAY
91 W
IGNITION COIL
91 W
1g. Key S. W. CURRENT LIMIT CIRCUIT
POWER TRANSISTOR UNIT ENG. CONTROL UNIT
SULIN
Fig. 39
FIRING ORDER (1,3,4,2) HEAT SINK & CONNECTOR FACING ‘UP’
4 - RS
CYL. 4 CYL. 1
ENGINE FRONT SIDE
CYL. 2 CYL. 3
Fig. 40 29
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI ENGINE CONTROL UNIT (ECU) Fig. 41 & 42 ENGINE
Type : H8 536 16 Bit, 16 MHz CPU with 62k ROM & 2k RAM 48 pin connector Working Principle : Microprocessor based Engine Control System .
System Integration (See Illustration) : All sen sors (e.g. Wat er t em p erat ure sen sor), in p ut sig n als are p rocessed b y t h e m icrop rocessor an d control signals are provided for various actuators (e.g. ISC Valve) for satisfactory engine performance. Various control Algorithms (software) are used in conjunction w it h M ap / t ab le d at a t o p ro vid e vario u s co n t ro l functions for optimum functioning of the engine, which in turn provides best fuel consumption/ Emissions.
Fig. 41
Fitment Data : ECU is fitted below the steering column in the driver cabin. Fig. 41
Stand Alone Diagnosis (See Illustration) : Use Mult im et er.
SULIN
Perform continuit y check only on ECU connection at wiring harness end to any sensor/ actuator depending upon engine symptom.
System Diagnosis : Use Hitachi Diagnostic tester Check for all dat a w hen engine st art ing and idling normally (typical data for normal idling are given on page no. 34)
Fig. 42 Electronic control unit
30
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI ENGINE CONTROL UNIT - ILLUSTRATION : Block Diagram : ENGINE
Input
Control Unit
Output
Injector * 4
Crank angle sensor Speed sensor
CPU : H8
Air temp.Sensor Throttle Position Sensor Water temp. sensor
Ignition Coil * 1 ISC solenoid
CPU Signal Condi-
ROM
tioner
A/D
RAM
Fuel pump relay Buffer
Diagnosis Lamp
I/O
Others
Battery Oxygen Sensor D/N Switch A/C switch Others
Voltage Regulator
Watch dog timer
SULIN
* D/N Switch - applicable for AUTOTRANSMISSION only.
Fig. 43
SPECIFICATIONS : Type : H8 536
Data Line : 16 Bit
Clock Speed :
Intelligent Driver ICs : 1. Idle Speed control 2. Diagnostic line
Diagnosis level :
16 MHz
3 levels
Memory :
a) Test switch (Actuators)
62k ROM
b) Read Memory switch (Blink code)
2K RAM
c) Diagnostic Monitor (HDM 2000)
A/D Convertor : 10 Bit (high accuracy)
FEATURES : Grouped Ignition Grouped Injection
Note : For MPFI ECU Schematic circuit refer electrical group.
31
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI TROUBLE SHOOTING OF SENSORS USED IN MPFI : ENGINE
Pow er Monitor Lamp
Method No. 1
HITACHI DIAGNOSTIC MONITOR ( HDM 2000 ) should be loaded with the cartridge TATA Indica Version 1.2. Fig. 44
Display Screen
Rub b er Jacket
Key Pad
Pow er Switch
This is an user – friendly diagnostic kit, makes the Trouble Shooting simpler. This HDM 2000 can also be used as :
Wrist Strap
Cart rid ge LED Display
1. A multimeter St rap Hook
2. An Oscilloscope The monitor provides the diagnostic data for efficient trouble shooting.
Fig. 44
Connecting the Diagnostic Equipment : Not e : Connect t he HDM only wit h t he Ignit ion switch in “OFF” position. HDM 2000 is given w it h an int erm ediat e cable,one end of it is connected to HDM 2000 and the other end to the female socket below the co-driver's seat Fig. 45. The power supply for it is taken from the battery of the vehicle through the same cable. No need of separate power supply.
SULIN
During diagnosis this instrument provides data in graphical form. Also allows measurement and recording of data for analysis and efficient trouble shooting. Stores‘No Good’ conditions of Sensors/Actuators as listed in Read Memory Switch’s diagnostic mode.That is in E C U’s memory.
Fig. 45 Female socket below co-driver seat
The error codes are stored in two areas : 1.
Current Error Codes – to diagnose exiting faults.
2.
History of Error Codes – to diagnose previous stored faults.
NOTE :
At the end of each diagnosis and rectification of the fault,‘HISTO RY CODES’isto be erased by opting ‘CLEAR MEMORY’ option in the menu and check for normal functioning of Engine/Vehicle
32
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI EXPLANATION OF BUTTONS : On this instrument, you can select each mode from the menu display screen using the cursor.The following table shows the main functions of the keys.These key functions vary depending on the selected mode.
ENGINE
Moves up the cursor, and scrolls up the display screen. Increments a numeric value.
Moves down the cursor, and scrolls down the display screen. Decrements a numeric value.
Moves left the cursor, and scrolls left the display screen. Increments a numeric value.
Moves right the cursor, and scrolls right the display screen. Decrements a numeric value.
Use this key for item selection, deselection, execution, confirmation, etc.,
SULIN
Use this key for item deselection, function turn-off, etc.
Goes back to the previous display screen or function.
Provides the shift function.
These keys for carrying out individual functions on each display screen.
Fig. 46 33
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI TEST SWITCH MODE : Method No. 2 ENGINE
This mode is used to check the functioning of the following components. 1.
Canister Purge Valve
2.
Fuel pump relay
3.
A/C Compressor
TROUBLE SHOOTING PROCEDURE : 1.
Turn the ignition ‘ON’
2.
Short the terminals of the connector (Test Switch connector) below co-drivers seat using a suitable connector. Fig. 47
Fig. 47 Test switch mode connector in shorted condition (Black Socket)
3. Switch ‘ON’ the blower and A/ C Switch 4. Ph ysically ascert ain t h e f u n ct io n in g o f A/ C compressor, intank fuel pump and canister purge valve b y h earin g t h e resp ect ive relay so u n d , ot herw ise t hat part icular com ponent should be checked .
N OTE:
SULIN
At the end of each diagnosis and rectification of the fault, ‘HISTORY CODE’ is t o be erased by opting for “CLEAR MEMORY” it in HDM 2000 or by removing the battery supply for atleast 3 minutes. Method No. 3
READ MEMORY SWITCH MODE (BLINK CODE) : Read m em o ry sw it ch m o d e m et h o d (Blin k co d e method) is a manual diagnostic method used to check the malfunctioning of the following parts.
Fig. 48 Read memory switch mode white connector in shorted condition. DIAGNOSTIC TESTER
1. Water t em p erat ure sensor 2. Air t em perat ure sensor 3. Manifold air pressure sensor READ MEMORY
4. Idle speed control valve
TEST SWITCH
5. Throttle position sensor 6. Lam bada sensor 7. Vehicle speed sensor To check t hrough t his m ode, w e have t o short t he terminals of the Read Memory Switch mode connector which is situated below the co-driver’s seat as shown in Fig. 48. Blink Code checks t he funct ioning of t he Sensors/ Actuators as indicated in the Blink code table.
WHITE CONNECTOR
BLACK CONNECTOR
Fig. 49
34
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI TROUBLE SHOOTING PROCEDURE :
HITACHI DIAGNOSTIC MONITOR DATA :
1. Short the terminals of the connector using suitable connector and OBSERVE the following :
TYPICAL DATA DURING NORMAL IDLING : Value changes in accordance with the change in engine temperature.
2. Turn the ignition ‘ON’ a. If the ‘CHECK ENGINE’ lamp on the dash board blinks cyclically at every 0.5 secs, Then there is ‘NO TROUBLE’ with the engine sensors.
SR. NO.
PARAMETER
VALUE
1.
Battery Voltage
14.0 V
b. Ot h erw ise t h e lam p b lin kin g f req u en cy is correlated to a trouble code and corresponding sensor/ actuator is indicated to be fault y.
2.
Vehicle Speed
0.0 kmph
3.
Engine Speed
750 rpm
4.
Coolant Temperature
85 0C
BLINK CODE TABLE :
5.
Ignition Timing
9-100 BTDC
Read m em ory sw it ch m ode connect or in follow ing shorted condition.
6.
Throttle Position Sensor Volt
0.50 V
7.
Fuel Injection # 1 Pulse
2.30ms
Code
8.
ISC Valve Step
23.5 Step
Water temperature Sensor
31
9.
Engine Load
34.4%
Pressure Sensor
33
10.
Front O2 Sensor
0.24 to 0.68V
ISC Valve
34
11.
Max. Value of O2 Sensor
0.76v
Air Temperature Sensor
36
12.
Min. value of O2 Sensor
0.10v
Throttle Sensor
41
13.
A/F Correction # 1
-2.3 to -3.9%
O2 Sensor
42
14.
CPC Valve Duty Ratio
0%
Vehicle Speed Sensor
43
15.
Manifold Absolute Pressure
280/300 mm Hg
16.
Intake Air Temperature
28o C
17.
Ignition Switch
ON
18.
Test Mode Signal
OFF
19.
Read Memory Signal
OFF
20.
Idle Switch
ON
21.
A/C Switch
OFF
22.
A/C Relay
OFF
23.
Fuel Pump Relay
ON
24.
CPC Solenoid Valve
OFF
25.
Front O2 Rich Signal
OFF/ON
26.
Crank Shaft Position Signal
ON
Item
SULIN
For Example : If the “Check Engine” lamp gives 3 slow blinks (of 1.2 Secs each) representing the first digit of the failcode viz.,”3" followed by 1 fast blink (of 0.16 Secs each) representing the second digit of the failcode viz.,”1" in a cyclic fashion, thus flashing the code “3 1” indicating that the water Temp Sensor is faulty (from the table below). If there are t wo or more sensors fault y, then the blink codes are repeated cyclically. For example, if the water temperature sensor and lambda sensor are faulty then t h e b lin kin g co d es w ill b e rep eat ed like ..31… .42… .31… .42… .
N OTE: At the end of each diagnosis and rectification of the fault, ‘HISTORY CODE’ is to be erased by opting ‘CLEARMEMORY’ option in HDM 2000 or by removing the battery supply for atleast 3 minutes.
35
MAIN INDEX
GROUP INDEX
ENGINE
ENGINE 475 SI MPFI
ENGINE
ECU HANDLING CARE :
l
Do not try to repair the ECU.
Earth (Ground) Connection
l
Use standard harness for circuit connections.
l
Connect GND - P, GND - I, GND - C each to the engine block.
l
Ensure that Do not try to insert any thing into the ECU case.
l
The above mentioned GND should be connected firmly using screws.
l
l
Ensure that the ignition coil GND and ECU GND - C are connected firmly together to the engine block b y screw s; an d en su re t h at even if t h ese are d et ached from t he eng ine b lock, t hey are not detached from each other.
The installation should be done in such a way as to keep the connector side down and the wiring done accordingly (to avoid water penetration into the ECU through the wiring).
l
Take care to avoid any bending of the connector pins while inserting the connector.
l
Ensure that the connector is inserted in the end after all the installation is complete.
l
To carry out welding job on the car the ECU should be disconnected.
Power Supply l
The power for the ECU should be taken through the Main Relay. Do not take out the connector from the ECU for at least 5 sec after IGNITION OFF. Never take out the connector from the ECU during IGNITION ON.
l
Ensure that key SW is in OFF position while plugging - in the connector to the ECU.
l
Do not plug - in the connector again to the ECU for at least 100 sec after disconnecting it.
Input
SULIN
l
Ensure that the Input signal line is as far as possible from noise sources such as High Tension Cable, Horn relay,Motor etc.
l
Ensure that sealed wire are used for input line of O2 Sensor and Crank Angle Sensor, and the wiring is as far as possible from the noise sources similar to the ones above (Unsealed wire may be used for O2 sensor if the noise level is small enough so as not to affect the Air/Fuel control).
Output l
Take care to avoid dead - short (solenoid short - circuit etc.) and similar circuit misconnection while checking ( to avoid any damage to the Output Power Transistor). Use a solenoid which does not use a fly - back diode (reverse polarity m ay dam age the Output Pow er Transistor).
Installation l
Ensure that the ECU is secured firmly to the body using screws.
l
Ensure that there is no water seepage into the ECU.
l
Do not use an ECU which has been dropped once.
36
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI PRELIMINARY INSPECTION OF ENGINE :
gradually with left foot. If the engine stalls, it means that clutch does not slip.
Before proceeding to carry out actual overhauling of engine it is desirable to have a preliminary inspection of engine to ascertain whether an engine overhaul is necessary and to w hat extent.
OR Drive the car with weight equal to GVW in 3rd gear on level ground and let the speed drop down to approximately 15 kmph. Now press accelerator pedal fully.With slipping clutch,the car speed will not pick up and also clutch burning smell will be noticed. If t his does not occur and car picks up speed, it indicates that clutch does not slip.
Most common reasons for which engine is overhauled are : 1.
Loss of power
2.
Excessive engine oil consumption
3.
Extrem ely low engine oil pressure
4.
Mechanical failures
e.
LOSS OF POWER
BRAKE BINDING During driving apply brake number of times and then shift the gear to neutral position Check brake drums for over-heating and if necessary jack up the car and check the wheels for free rotation.
To know exact reason and general condition of engine, proceed as follow s :
1.
ENGINE
f.
Loss of engine power may be due to :
CHECKING ENGINE COMPRESSION PRESSURE If loss of power is not on account of defective fuel system, lack of air, choked exhaust silencer, clutch slip p in g an d b rake b in d in g . ch eck en g in e compression as follows :
a.
Defective Ignition system
b.
Defective Fuel system
c.
Clogged air cleaner/ choked cat alyt ic convert er exhaust silencer
1.
Warm up engine preferably by road drive to get a temperature of about 75 to 85 0C.
d.
Clut ch slippage
2.
Remove all spark plugs.
e.
Brake binding
3.
Rem ove air cleaner filter elem ent.
f.
Loss of engine compression
4.
a.
IGNITION SYSTEM
Install Compression gauge (Range about 0 to 25 kg/ cm 2) into one of the spark plug hole.
SULIN
Note : Use adaptor w hich is available com m ercially to suit the size of the spark plug threads.
Check all the sensors for proper function by using diagnostic m onitor. Replace defective sensors.
b.
FUEL SYSTEM Check condit ion of fuel filt er. If found blocked replace fuel filt er.
c.
CLOGGED AIR CLEANER/ CHOKED EXHAUST SILENCER Check air filter element If found choked clean or rep lace.
d.
CLUTCH SLIPPAGE Clutch slipping can be confirmed by any of the following two methods : Drive t he car in 1st or 2nd gear at m axim um sp eed co rresp o n d in g t o t h at g ear. Wit h accelerat o r p ed al fu lly p ressed , ap p ly b rake
Fig. 50 37
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI 5.
Disengage clutch (to reduce starting load on engine) and depress accelerator pedal all the way to make throttle valve open fully.
6.
Crank engine with fully charged battery, and read the highest pressure on compression gauge.
7.
Carry out steps 5 to 7 on each cylinder to obtain co m p ressio n p ressu res. Th e sp ecif ied compression pressure is 9.5 bar minimum.
ENGINE
8.
Variation in compression pressure between cylinders should not be more than 0.5 bar.
9.
Low compression pressure may be due to leakage past valves / piston rings/blown cylinder head gasket. To ascertain the point of leakage,spray small quantity of clean engine oil in to the cylinder showing low pressure and re-check compression pressure. If it im proves, w ear in pist on rings/ cylinder bore is indicated. If it does not, leakage past the valves is indicat ed. If com pression pressure of adjacent cylinder is also on lower side, it may be due to blown cylinder head gasket.
2.
EXCESSIVE ENGINE OIL CONSUMPTION
High engine oil consumption may also lead to overhauling of the engine but before proceeding to overhauling, check following points :
4.
Take a clean vessel, place it below the drain plug of oil sump.
5.
Drain the hot oil into the clean vessel. Drain it fully.
6.
Screw in oil sump drain plug and tighten it.
7.
Weigh the vessel along with oil let this weight be ‘w1’, gms.
8.
Refill the weighed oil into the oil sump. Do not spill any oil. The vessel used for draining should not be used for any other purposes.
9.
Drive the vehicle approx. 200 - 300 km. This drive should include at least 30 - 40 kms. of highway or similar road, vehicle running at about 60 kmph. Let this drive distance be ‘D’ kms.
10.
Immediately after the test drive, place the vehicle at the same spot from where it started.
11.
Place the same previously used vessel below the oil sum p, unscrew t he drain plug and drain off oil into the vessel. Drain the sump fully.
12.
Weig h t h e vessel alon g w it h oil, n ow for t h e second t im e. Let t his w eight be ‘w 2’ gm s.
SULIN
1.
2.
Make sure that there is absolutely no external oil leak (i. e. from the camshaft oil seal, crankshaft oil seal, oil sump gasket, oil pump gasket, cylinder head cover gasket etc.)
13.
Find out standard oil consumption as -
Std. oil consumption ‘C’ (litres/ 1000km)
If no external leakage is found, determine the exact engine oil consumption, as per following procedure.
=
(w1 - w2)(wt. of oil consumed, gms) x 1000 sp. wt. of oil (gm/ cm 3) x ‘D’ (drive dist. in km.)
w1 - w2 0.88 x D
‘C’
=
litres/ 1000km
3.
EXCESSIVE LOW OIL PRESSURE EXTREMELY
Check the following :
DETERMINING EXACT ENGINE OIL CONSUMPTION :
a.
Ext ernal leakages.
CAUTION :
b.
Oil level in su m p u p t o m axim u m m ark o n dip st ick.
c.
Oil pressure transducer for proper functioning.
d.
Functioning of pressure relief valve on oil pump.
e.
Oil pump performance using a suitable pressure gauge.
Do not make a rough estimate of engine oil consumption by noting the kilometerscovered by the car at any random stage and finding oil consumed from the topped up position taking into consideration dipstick level and oil sump capacity.
PROCEDURE : 1.
Once it is doubted that engine oil consumption is higher, place the car on a level ground.
2.
Top up oil sump to its capacity of 4 litres.
3.
Warm up the engine so that oil temperature is 75 800 C.
Oil pressure found to be less than 2.8 bar at maximum sp eed and 1.2 b ar at id ling sp eed , m ay b e d ue t o im p rop er funct ioning of oil p um p or d efect ive oil pum p relief valve. If low oil pressure is not on account of above factors, w ear o f j o u rn als/ b earin g s is in d icat ed f o r w h ich overhaul of engine may be considered.
38
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Checking oil pressure : Procedure for checking ENGINE
Before conducting the test ensure : 1.
Engine oil level is at high mark on dipstick, otherwise top up.
2.
No leakage.
3.
Correct grade of engine oil is used.
Remove electrical connection from oil pressure transducer. Remove oil pressure transducer from cylinder block. In st all Oil p ressure g aug e in p lace of oil p ressure t ransducer. St art eng ine and w arm it up t o norm al op erat ing t em p erat ure. Warm up t h e en g in e an d m easure oil p ressure. It should be w ithin specified limits. After checking oil pressure, stop engine and remove oil pressure gauge. Before reinstalling oil pressure transducer, be sure to apply sealant on screw threads and tighten transducer t o specified t orque.
SULIN
Tighten oil pressure switch to 1.2 - 1.5 mkg torque.
4.
MECHANICAL FAILURES
Metallic knocking sound from an engine may be due to faulty ignition, excessive clearance in main and big end bearings, sm all end bush, t appet s, pist on slap, seizin g o f p ist o n rin g s, sco red cylin d er b o re o r breakage of any moving parts. Defective alternator can also be a source of mechanical noise. Defect can be located by replacing alternator or pow er steering pum p (if fitted) or AC com pressor (if fitted) or belt tensioner pulley with a new one. Dismantling of engine may be considered if still noise o ccu r even af t er at t en d in g all ab o ve m en t io n ed p rob lem s.
39
MAIN INDEX
GROUP INDEX
ENGINE
PART DESCRIPTION
01
ASSY.ENGINE COVER
02
ASSY.RUBBER GROMMET (ENGINE COVER MTG)
03
CR CSK SCREW M6X16
04
ASSY.ENGINE COVER MTG.BKT. (FRONT)
05
PAN HD SCR M6X8
06
ASSY.BUFFER (FOR ENG.COVER MTG.)
07
HEX FL NUT
08
ASSY.LIFTING HOOK REAR
09
HEX.FL.SCREW M8X18
ENGINE 475 SI MPFI
40 SR. NO.
SULIN
MAIN INDEX GROUP INDEX
2.5
ENGINE COVER MOUNTING (same for 85 PS & 75 PS engines)
ENGINE 475 SI MPFI
- Specified Torque in Kgm
MOVING PARTS (For 85 PS engine)
# Allowed Tolerance of ±5%
®
-Non Reusable Part
®
MAIN INDEX
SULIN
®
5.5 #
GROUP INDEX
SR. NO.
PART DESCRIPTION
01
ASSY.CRANKSHAFT WITH PIN - NORMAL
01-a
CRANKSHAFT-NORMAL
08
KEY
01-b
CYL PIN 8m6X16
09
ASSY.FLYWHEEL COMPLETE.
13
ASSY.CONNECTING ROD
02
ASSY.GEAR (FOR CRANKSHAFT) (SINTERED)
09-a
DOWEL (FOR CLUTCH ON FLYWHEEL)
13-a
BOLT (FOR CONNECTING ROD)
10
HEX.BOLT (FOR FLYWHEEL)
11
SET MAIN BEARING SHELLS NORMAL (BIMETAL)
41
03
PULLEY CRANKSHAFT-ALT.DRIVE (4-GROOVES)
04
PULLEY (4 GROOVE)(ON CRANKSHAFT FOR AC)
05
HEX FL BOLT M8X38
06
HEX.BOLT (FOR CRANKSHAFT GEAR)
07
WASHER (FOR CRANKSHAFT GEAR)
12
SET THRUST WASHERS (BIMETAL)
13-b
NUT (FOR CONNECTING ROD)
13-c
SET BRG.HALF NORMAL (CON.ROD) (BIMETAL)
14
PISTON SET WITH RINGS GRADE A (IP)
14-a
PISTON SET WITHOUT RINGS GRADE A (IP)
14-b
SET PISTON RINGS ABC STD (IP)
ENGINE
ENGINE
ENGINE 475 SI MPFI
42 - Specified Torque in Kgm
MOVING PARTS (For 75 PS engine)
# Allowed Tolerance of ±5%
®
-Non Reusable Part
®
MAIN INDEX
SULIN
®
5.5 #
GROUP INDEX
SR. NO.
PART DESCRIPTION
01
ASSY.CRANKSHAFT WITH PIN - NORMAL
01-a
CRANKSHAFT-NORMAL
08
KEY
01-b
CYL PIN 8m6X16
09
ASSY.FLYWHEEL COMPLETE.
13
ASSY.CONNECTING ROD
02
ASSY.GEAR (FOR CRANKSHAFT) (SINTERED)
09-a
DOWEL (FOR CLUTCH ON FLYWHEEL)
13-a
BOLT (FOR CONNECTING ROD)
10
HEX.BOLT (FOR FLYWHEEL)
11
SET MAIN BEARING SHELLS NORMAL (BIMETAL)
03
PULLEY CRANKSHAFT-ALT.DRIVE (4-GROOVES)
04
PULLEY (4 GROOVE)(ON CRANKSHAFT FOR AC)
05
HEX FL BOLT M8X38
06
HEX.BOLT (FOR CRANKSHAFT GEAR)
07
WASHER (FOR CRANKSHAFT GEAR)
12
SET THRUST WASHERS (BIMETAL)
13-b
NUT (FOR CONNECTING ROD)
13-c
SET BRG.HALF NORMAL (CON.ROD) (BIMETAL)
14
PISTON SET WITH RINGS GRADE A (IP)
14-a
PISTON SET WITHOUT RINGS GRADE A (IP)
14-b
SET PISTON RINGS ABC STD (IP)
ENGINE 475 SI MPFI
ENGINE TIMING (same for 85 PS & 75 PS * engines) * View is same for 85 PS & PS engines, but for 75 PS engine camshaft is different
GROUP INDEX
PART DESCRIPTION
1
TIMING BELT
2
OIL SEAL (CAMSHAFT-FRONT)
3
TIMING GEAR (CAMSHAFT)
4
WASHER (FOR CAMSHAFT GEAR)
5
HEX BOLT (CAMSHAFT GEAR MTG.)
6
ASSY.TENSIONER (TIMING BELT)
7
SPACER(TIMING BELT TENSIONER)
8
HEX FL BOLT M10X65
9
ASSY.IDLER (FOR TIMING BELT)
10
SPACER
11
HEX FL BOLT M10X65
12
CAM SHAFT *
13
ROCKER ARM
14
ADJUSTING SCREW (FOR ROCKER ARM)
15
ROCKER NUT
16
.ASSY.ROCKER SHAFT WITH SEALING CAP
17
SPRING (ROCKER ARM SHAFT)
18
ROCKER SPRING SEAT
19
SCREW-ROCKER SHAFT HOLDER.
20
CAM THRUST PLATE (FRONT)
21
CAP SCREW M6X20
SULIN
MAIN INDEX
SR. NO.
1.0
®
4.5
®
-Non Reusable Part - Specified Torque in Kgm
43 ENGINE
ENGINE
PART DESCRIPTION
01
ASSY.FUEL RAIL (CASTING)
02
HEX FL SCREW M8X18
03
HOSE (PR.REGULATOR TO I.MANIFOLD)205
04
SPRING CLIP (10)
05
SUPPORT BRACKET - CANISTER PURGE VALVE
06
HEX FL SCREW M8X16
GROUP INDEX
07
CANISTER PURGE VALVE
08
RUBBER SLEEVE (CANISTER PURGE VALVE)
09
CLAMP - CANISTER PURGE VALVE
10
HEX FL SCREW M6X10
11
RUBBER HOSE-CARBON CANISTER TO CPV (380)
12
RUBBER HOSE-CPV TO INTAKE MANIFOLD (240)
13
SPRING CLAMP (14)
14
SPRING CLIP (10)
15
ASSY.ACT.CARBON CANISTER (KOEL)
16
ASSY.BRACKET (FOR CARBON CANISTER MTG.)
17
HEX FL SCREW M6X16
SULIN
MAIN INDEX
SR. NO.
- Specified Torque in Kgm
ENGINE 475 SI MPFI
44
FUEL INJECTION EQUIPMENT (same for 85 PS & 75 PS engines)
ENGINE 475 SI MPFI
CYLINDER BLOCK ASSY. (same for 85 PS & 75 PS engines) - Specified Torque in Kgm
# Allowed Tolerance of ±5%
®
1.0 #
®
-Non Reusable Part
3.5
® 5.5 #
®
1.0
® 2.0
SULIN
1.0 #
MAIN INDEX
®
1.0
® 1.0
1.0
®
GROUP INDEX 45
SR. NO. 01 01-a 01-b 01-c 01-d 01-e 01-f 01-g 01-h 01-i 02 02-a 02-b 03 04 05
® 3.5
1.0
PART DESCRIPTION ASSY.CYLINDER CRANKCASE HOLLOW DOWEL 14h6x10.5x14L DOWEL SLEEVE (FRONT HALF TO INT.PLATE (2) ) HOLLOW DOWEL 10h6x8.4x8L HOLLOW DOWEL 8h6x6.5x8L SEALING PLUG M14X1.5 SEALING WASHER 14X20 IS3175-CU HEX.BOLT (FOR M.B.CAP) DOWEL 6h6x10 (1-no screw behind) HOLLOW DOWEL 8h6X6.5X8L (6) .ASSY.REAR COVER CRANKCASE WITH OIL SEAL REAR COVER - CRANKCASE (HOLLOW DOWEL) 0IL SEAL-CRANKSHAFT (REAR) GASKET (REAR COVER CRANKCASE) ASSY HEX SCREW M6X20 (6-for rear cover) ASSY.DIPSTICK TUBE
0.6 to 0.7#
06 07 07-a 07-b 07-c 08 09 10 11 12 13 14 15 16 17 18 19
ASSY.DIPSTICK ASSY.OIL SUMP COMPLETE ASSY.OIL SUMP W/O DRAIN PLUG MAGNETIC DRAIN PLUG SEALING WASHER (OIL SUMP DRAIN PLUG) OIL SUMP GASKET HEX FL SCREW M6X14 (for oil sump) ASSY.TIMING COVER - REAR (LH BOTTOM) ASSY.TIMING COVER - REAR (RH BOTTOM) HEX FL SCR M10X14 (for timing cover) ASSY.FRONT COVER(LOWER)(TIMING COVER) HEX FL SCREW M6X14 COVER (TIMING BELT-FRONT) SEALING STRAP SHOULDER BOLT (FOR TIMING COVER) BRIGHT WASHER 10.5 RUBBER BUSH (TIMING COVER)
20 21 22 23 24 25 26 27 28 29 30 31 32 33
HEX SCREW M6X20 WASHER A6.4 IS5370 RUBBER BUFFER (FOR MTG.TIMING COVER) INSERT TUBE (FOR MTG.TIMING COVER) ASSY.OIL PUMP GASKET (FOR OIL PUMP) ASSY HEX SCREW M6X25 OIL SEAL-CRANKSHAFT (FRONT) ASSY.STRAINER (FOR OIL PUMP) GASKET (FOR OIL PUMP STRAINER) STUD CM6X16 HEX FL NUT BM6 ADAPTOR (OIL FILTER) ASSY.OIL FILTER
ENGINE
ENGINE
ENGINE 475 SI MPFI
46
CYLINDER HEAD & COVER (same for 85 PS & 75 PS engines)
16 17
6.5
1.0
08
1-i-d
1.0
09
07 11
10
®
19 20 21 22
1.0
12
®
22
®
®
GROUP INDEX
18
ASSY.CYL.HEAD COMP(WITH VAL,RO.ARM,SP.PL VALVE GUIDE SEAL INTAKE VALVE EXHAUST VALVE SPRING SEAT VALVE SPRING VALVE SPRING RETAINER LOCK HALF SPARK PLUG ASSEMBLY.(M/S CHAMPION) ASSY.CYLINDER HEAD (WITHOUT VALVES) CYLINDER HEAD STUD CM8X25 (FOR INTAKE MANIFOLD) STUD CM8X20 (FOR PURGE VALVE MTG. BRACKET.) STUD CM8X25 (FOR EXHAUST MANIFOLD) GASKET (FOR CYL.HEAD)(1.1THK.) HEX BOLT (FOR CYL.HEAD) WASHER (FOR CYL.HEAD BOLT) ASSY.CYLINDER HEAD COVER COMPLETE (LMM) BAFFLE GASKET BAFFLE PLATE SCREW RUBBER HOSE (BLOWBY) (HEADCOVER-AIR FIL) HOSE CLAMP 25 HOSE CLAMP 16 'T' - CONNECTOR RUBBER HOSE-BLOW BY-HD.COVER TO MANIFOLD HOSE CLAMP 25 HOSE CLAMP 20 GASKET (FOR CYL.HEAD COVER) STUD (FOR CYL.HD.COVER) SPACERTUBE (FOR CYL.HD.COVER) ASSY.RUBBERBUSH (FOR CYL.HD.COVER) DOMED CAP NUT (FOR CYL.HEAD COVER MTG.) SEALING WASHER (FOR CYL.HEAD COVER) OIL FILLER CAP GASKET 21 VALVE GUIDE VALVE INSERT
®
11 12 13 14 15
PART DESCRIPTION
SULIN
MAIN INDEX
SR. NO. 01 01-a 01-b 01-c 01-d 01-e 01-f 01-g 01-h 01-i 01-i-a 01-I-B 01-I-C 01-I-D 02 03 04 05 05-a 05-b 05-c 06 07 08 09 10
®
-Non Reusable Part - Specified Torque in Kgm
ENGINE 475 SI MPFI
GASKET KIT (same for 85 PS & 75 PS engines)
® ®
® ®
Cylinder Head Cover Gasket
5
Oil Filler Cap Gasket
6
Throttle Body Gasket
Front Cover Gasket
10
Oil Pump Strainer Gasket
11
Water Pump Gasket
47
12
Gasket
13
Gasket Elbow
14
Rear Crankshaft Oil Seal (Rear Crankcase Cover)
15
Camshaft Front Oil Seal
16
Front Crankshaft Oil Seal
®
9
®
Exhaust Manifold Gasket
®
Inlet Manifold Gasket
8
®
GROUP INDEX
7
®
Cylinder Head Gasket
4
®
Oil Sump Gasket
3
®
2
®
Rear Gasket
®
1
SULIN
®
PART DESCRIPTION
®
MAIN INDEX
SR. NO.
®
-Non Reusable Part
ENGINE
ENGINE
ENGINE 475 SI MPFI
48
AIR INTAKE SYSTEM (same for 85 PS & 75 PS engines)
® ®
GROUP INDEX
PART DESCRIPTION
01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
ASSY AIR FILTER MPFI ASSY.FILTER ELEMENT ASSY.ISOLATOR (FOR AIR FILTER) ISOLATOR (FOR AIR FILTER) ASSY.ADAPTER (BLOWBY CONN.ON AIR FILTER) SEALING WASHER 14X18 CU SEALING WASHER 12X15.5 CU ASSY.BRACKET FRONT (FOR AIR FILTER MTG.) BRACKET REAR (A/ F MTG.ON BATTERY TRAY) HEX FL SCREW M8X12 HEX FL BOLT M8X25 ASSY.BRACKET (FOR RESONATOR BOX MTG.) HEX FL SCREW M6X10 RESONATOR BOX ASSY.ISOLATOR (FOR RESONATOR) RUBBER GROMMET (FOR RESONATOR BOX) HEX FL BOLT M8X25 AIR INTAKE SNORKEL ASSY.CLAMP (FOR SNORKEL MTG.) HEX FL SCREW M6X14 (FOR SNORKEL MOUNTING) HOSE (RESONATOR BOX) HOSE CLAMP (42 DIA.) INTAKE DUCT (FROM AIR INTAKE SYSTEM) HOSE (AIR FILTER TO INTAKE DUCT) HOSE CLAMP (72 DIA.) HEX FL NUT AM6 8C (FOR SNORKEL MOUNTING) PLUG (ON THROTTLE BODY) GASKET (FOR INTEGRATE THROTTLE BODY) HEX FL NUT AM6 8C RUBBER BELLOW (AIR FILTER TO THRO.BODY) HOSE CLAMP ( 53 DIA.) HOSE CLAMP (72 DIA.)
®
SULIN
MAIN INDEX
SR. NO.
®
-Non Reusable Part
ENGINE 475 SI MPFI
INTAKE & EXHAUST MANIFOLDS (same for 85 PS & 75 PS engines)
01
ASSY.INTAKE MANIFOLD COMPT (FOR LTRS)
02
BRACKET (FOR ACC.CABLE MTG) (LTRS)
03
CYL PIN 4m6X8 IS2393
04
HEX FL SCREW M6X12 ASSY.CABLE LEVER COMPLETE (FOR LTRS)
06
STICKER (FOR SPARK PLUG CONNECTION)
07
STUD CM6X45 (FOR THROTTLE BODY)
08
GASKET (FOR INLET MANIFOLD)
49
09
SELF LOCKING NUT
10
EXHAUST MANIFOLD
11
GASKET EXHAUST MANIFOLD
12 13
.ASSY.HEAT SHIELD (FOR EXHAUST MANIFOLD) HEX FL SCREW M6X10
14
STUD CM8X32
2.0
®
GROUP INDEX
05
®
PART DESCRIPTION
SULIN
MAIN INDEX
SR. NO.
®
4 3 21 4 3 4 32 21 1 4 43 32 21 1
06
®
-Non Reusable Part - Specified Torque in Kgm
ENGINE
ENGINE
-Non Reusable Part
ENGINE ELECTRICAL EQUIPMENT (75 PS)
- Specified Torque in Kgm 2.0
2.0
3.0
2.5
SULIN
®
MAIN INDEX
4.0
1.5
2.0 8.0
GROUP INDEX
SR. PART DESCRIPTION NO. 01 02 03 04 05 06 07 08
BRACKET (FOR 75 AMP ALT.& PSTG.) STUD (FOR A.C. & ALT. BRACKET) HEX FL SCREW M8X18 HEX FL NUT AM8 HEX FL BOLT M8X125 BRIGHT WASHER 8.4 NYLOC NUT M8 ASSY.CLAMP ROD COMP.WITH BRACKET (172mm)
08-a ASSY.CLAMP ROD (COMPLETE) 172 mm 08-a-a ASSY.CLAMP ROD WITH SILENT BLOCK 08-a-b ASSY.CLAMPING PIECE 08-a-b-a CLAMPING PIECE 08-a-b-c CYL PIN 8m6X25 IS2393 08-b ASSY.BRACKET (ALTERNATOR - UPPER) 08-c HEX FL BOLT M10X40 9 HEX FL SCREW M8X18 1 0 HEX FL BOLT M8X45
11 12 13 14 22 23 24 25
HEX THIN NUT M12 LOW OIL PRESSURE SWITCH POLY-V BELT (4 GROOVES-875) ALTERNATOR 12V 75A W/ IEM W/ O VP-OFFER POWER STEERING PUMP HEX FL SCREW M8X18 PULLEY (POWER STG.PUMP) 4 GROOVES HEX FL.NUT AM12X1.25
ENGINE 475 SI MPFI
50
®
ENGINE 475 SI MPFI
ENGINE ELECTRICAL EQUIPMENT (85 PS) SR. NO.
PART DESCRIPTION
01
BRACKET (ALTERNATOR,IDLER & PSTG.MTG.)
02
HEX FL SCREW M8X18
03
HEX FL BOLT M8X25
04
SUPPORT BKT.(FOR ALT.BKT.& TOP SUPPORT)
05
HEX FL SCREW M8X18
06
BRACKET (FOR ALT.TOP SUPPORT)
07
HEX FL BOLT M8X25
2.0
SLIDER (FOR TENSIONER MTG.) (ALUMINIUM)
09
WASHER (FOR AC COMPRESSOR IDLER)
10
SLIDER SCREW (FOR TENSIONER)
11
ASSY.SHAFT W/ H DUST SHIELDFOR TENSIONER
12
ASSY.TENSION PULLEY. (FOR A/ C COMP.)(INA)
13
HEX.NUT(FOR MTG.70 DIA.INA-TENSIONER)
14
POLY VEE BELT (5 PK-1095)
15
ALTERNATOR 12V 90A W/ VP W/ IEM
16
PULLEY-PSTG.PUMP (5-GROOVES)
SULIN
MAIN INDEX
08
2.0
2.0
2.0 2.3
GROUP INDEX
4.0 2.3
- Specified Torque in Kgm
51 ENGINE
ENGINE
ENGINE 475 SI MPFI
52
ENGINE ELECTRICAL/A.C. EQUIPMENT (same for 85 PS & 75 PS engines)
MAIN INDEX
SULIN
2.4
5.0
®
2.5 2.5
GROUP INDEX
®
-Non Reusable Part - Specified Torque in Kgm
Sr. No.
Part Description
02-a-a
ASSY.TENSION PULLEY(FOR A/ C COMP)INA.
02-a-b
SPACER(FOR A/ C BELT TENSIONER)-M/ S INA.
02-d
HEX.NUT(FOR MTG.70 DIA.INA-TENSIONER)
02-e
DUST CAP
15
STARTER MOTOR 0.8KW. MALE TER.-M/ S LTVS
16
SET ASSY.COMPRESSOR MTG.(HALLA-110CC)DLX
16-a
BRACKET(MTG.A/ C COMPRESSOR)(HALLA-110CC)
16-b
ASSY.AIR COMPRESSOR (w ith sealed connector)
16-c
HEX FL SCREW M8X30
17
STUD (FOR A.C. & ALT. BRACKET)
18
HEX FL NUT AM8
19
HEX FL SCREW M8X18
20
POLY-V BELT (4-GROOVES-730)
21
SET ASSY.IDLER (AUTOLEC)
21-a
ASSY.IDLER (FOR A/ C COMP.) (AUTOLEC)
21-b
DUST CAP
21-c
SLIDER (FOR MTG.OF A/ C IDLER)
21-d
SCREW (FOR A/ C COMP TENSIONER)
21-e
NYLOC NUT M8
EMS KIT COMPONENTS (same for 85 PS & 75 PS engines)
ENGINE 475 SI MPFI
- Specified Torque in Kgm
1.0
12
11
MAIN INDEX
SULIN
1.0
09
08
10
GROUP INDEX
1.4 NOTE : Vehicles speed sensor, one of EMS component, is a part of instrument cluster. (not shown)
SR. NO.
PART DESCRIPTION
53
01 KIT-EMS BHARAT STAGE-II FE (HITACHI) 01-a ASSY.COIL WITH IGNITOR (HITACHI) 01-b ENGINE CONTROL UNIT (BS-II) FE (HITACHI) 01-b ENGINE CONTROL UNIT (BS-II) FE (HITACHI) 01-c CRANK ANGLE SENSOR (HITACHI) 01-d WATER/ AIR TEMP.SENSOR (HITACHI) 01-e ASSY.FUEL INJECTOR (HITACHI) 01-e-a O-RING (FOR FUEL INJECTOR)
01-e-b INSULATOR (FOR FUEL INJECTOR) 01-e-c RUBBER RING (FOR FUEL INJECTOR) 01-f INTEG.THROTTLE BODY(HITACHI) NEW PR.SEN. 01-g ASSY.PRESSURE REGULATOR (HITACHI). 01-g-a O-RING (FOR PR.REGULATOR) 02 HEX FL SCREW M5X12 03 ASSY HEX SCREW M6X25 (Ignition coil)
04 05 06 07 08 09 10 11 12
BRACKET (FOR CRANK ANGLE SENSOR) CR CSK SCREW M6X16 CYL PIN 6m6X14 HEX FL BOLT M6X20 MANIFOLD AIR PRESSURE SENSOR THROTTLE POSITION SENSOR ISC VALVE WATER TEMPERATURE SENSOR LAMBDA SENSOR
ENGINE
ENGINE
-Non Reusable Part - Specified Torque in Kgm
NOTE : Please read this view in conjunction with view of Radiator (next page), as both are related.
®
1.0 1.0
®
®
®
FROM RADIATOR TOP
2.0
® ®
® 1.5
®
®
MAIN INDEX
48
SULIN
1.5
TO AUX. TANK
2.0 1.0
GROUP INDEX
TO HEATER
SR. PART DESCRIPTION NO. 10 11 12 13 14 15 16 36 37 38
ASSY.ADAPTER (FOR HEATER CONNECTION) WASHER (18X22X2-Cu) ASSY.BANJO BOLT WITH NIPPLE (FOR HEATER) HOSE (FROM CYL.HEAD TO HVAC UNIT) SPRING BAND CLAMP FORM A 12X23D TS17665 ASSY.TUBE(CYL.HEAD VENT) SPRING BAND CLAMP FORM A 12X14D TS17665 ASSY.WATER PUMP (OFFER DRG.) GASKET (FOR WATER PUMP) ASSY HEX SCREW M6X20
39 40 41 42 43 44 45 46 47 48
THERMOSTAT HOUSING O-RING 42.52X2.62 A NITRILE HEX FL NUT AM8 STUD CM6X25 ASSY.COVER (THERMOSTAT) ASSY.THERMOSTAT (82 DEG.SOT ) SEAL THERMOSTAT HEX FL NUT AM6 SEALING WASHER 12X15.5 TEMPERATURE TRANSDUCER-M/ S PRICOL
49 50 51 52 53 54 55 56 57 58
SEALING WASHER 14X18 STUD CM6X16 ASSY.TUBE WATER BYPASS GASKET (FOR WATER BYPASS TUBE) HEX FL NUT BM6 ASSY.HOSE (WATER BYPASS) (SPR.BAND) HOSE CLAMP 35 ASSY.ELBOW (FOR WATER INLET GASKET (FOR WATER INLET ELBOW) HEX FL SCREW M8X18
ENGINE 475 SI MPFI
54
®
ENGINE COOLING SYSTEM (same for 85 PS & 75 PS engines)
TO WATER ELBOW
08
FROM HEATER
06
*
07
1.0
17
Fitted on Body
18
08
Fitted on Body
1.0
19
1.5 09
*
To Heater
TH ER M
OS TA T
1.5
1.5
TO
MAIN INDEX
SULIN
OCK TO BL
GROUP INDEX
SR. PART DESCRIPTION NO.
55
01 02 03 04 05 06 07 08 09 14 15 16 17
ASSY.INT.RUBBER HOSE RUBBER HOSE (INTEGRAL HOSE TO AUX.TANK) HOSE CLAMP (53 DIA.) SPRING BAND CLAMP FORM-A 12X28D SPRING CLIP (25) HOSE CLAMP (26 DIA.) HEX FL NUT BM6 ASSY.CLAMP (FOR INT.HOSE AUX.TANK BR.) HEX FL SCREW M6X10 SPRING BAND CLAMP FORM A 12X23D ASSY.TUBE(CYL.HEAD VENT) SPRING BAND CLAMP FORM A 12X14D HEX FL SCREW M6X10
18 19 20 21 22 23 24 25 26 27 28
CLAMP FRONT (CYL.HEAD VENT HOSE) HEX FL SCREW M8X12 RUBBER HOSE (RADIATOR VENT)TOYO RAD.ONLY SPRING BAND CLAMP FORM A 12X14D SPRING BAND CLAMP FORM A 12X19D RUBBER HOSE-COVER THERMOSTAT TO RADIATOR SPRING BAND CLAMP FORM A 15X49D ASSY.AUX.WATER TANK W/ H PR.CAP ASSY.BRACKET-REAR (FOR AUXILLIARY TANK) HEX FL SCREW M6X12 ASSY HEX SCREW M6X16
29 29-a 29-b 30 31 32 33 34 35 59
ASSY.RADIATOR W/ H TH.SW.(AC/ NON AC) TOYO ASSY.THERMOSWITCH DRAIN PLUG WITH WASHER ASSY.SHROUD WITH FAN & MOTOR HEX FL SCREW M6X14 RUBBER GROMET (RAD MOUNT) ASSY.BKT.RAD.MTG.TOP RH COMPL ASSY.BKT.RAD.MTG.TOP LH COMPL HEX FL SCREW M6X12 SCREW FOR TOP MOUNTING BRACKET (AUX. TANK)
ENGINE 475 SI MPFI
RADIATOR (same for 85 PS & 75 PS engines) NOTE : Please read this view in conjunction with view of Engine Cooling System (previous page), as both are related.
ENGINE
ENGINE 475 SI MPFI
ENGINE SUSPENSION (85 PS) ®
ENGINE
- Specified Torque in Kgm
®
1.5
-Non Reusable Part
4.0
2.5
2.5
c b
®
a
4.5
2.5
2.5
3.5
SULIN 2.0
a
®
b
3.0 SR. NO.
PART DESCRIPTION
01 02 03 03-a 03-b 03-c 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18
LIFTING HOOK (FRONT) HEX FL SCREW M8X18 ASSY.BRACKET ENG MTG. WITH STUDS BRACKET (FOR ENG.MTG.ARM) STUD BM10X50 STUD BM10X60 HEX FL BOLT M10X40 HEX FL BOLT M10X70 ENGINE MTG.ARM (FRONT) HEX FL NUT AM10 ASSY.ENGINE MOUNT-A(HYDRAULIC) NYLOC NUT M10 BRIGHT WASHER 10.5 ASSY.MOUNTING PLATE (B-MOUNT) ASSY.STOPER(ON B-MOUNT PLATE) HEX FL BOLT M8X25 ASSY.ENG.MOUNT-B (ON GEAR BOX) NYLOC NUT M12X1.5 WASHER (FOR B-MOUNT) .HEX FL NUT BM8 ASSY.ENGINE MOUNT-C (TC)
8.0
SR. NO.
PART DESCRIPTION
19 20 21 22 23 24 24-a 24-b 25 26 27 28 29
ASSY.BRACKET ENGINE STOPPER (FABRICATED) HEX FL SCR M12X30 HEX FL BOLT M8X38 ASSY.RUBBER STOPPER HEX NUT M12 ASSY.C LINK & BODY MTG BKT COMPLETE ASSY.MOUNT INTERMEMEDIATE LINK (REAR) ASSY.BODY MTG.BRACKET (FOR C-MOUNT) HEX FL BOLT M10X55 NYLOC NUT M10 ASSY HEX SCR M12X1.25X30 HEX FL BOLT M10X75 HEX FL NUT AM10
56
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
ENGINE SUSPENSION (75 PS) ® ENGINE
- Specified Torque in Kgm
®
1.5
-Non Reusable Part
4.0
2.5
2.5
c b
®
a
4.5
2.5
2.5
3.5
SULIN 2.0
a
®
b
3.0 SR. NO.
PART DESCRIPTION
01 02 03 03-a 03-b 03-c 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18
LIFTING HOOK (FRONT) HEX FL SCREW M8X18 ASSY.BRACKET ENG MTG. WITH STUDS BRACKET (FOR ENG.MTG.ARM) STUD BM10X50 STUD BM10X60 HEX FL BOLT M10X40 HEX FL BOLT M10X70 ENGINE MTG.ARM (FRONT) HEX FL NUT AM10 ASSY.ENGINE MOUNT-A(HYDRAULIC) NYLOC NUT M10 BRIGHT WASHER 10.5 ASSY.MOUNTING PLATE (B-MOUNT) ASSY.STOPER(ON B-MOUNT PLATE) HEX FL BOLT M8X25 ASSY.ENG.MOUNT-B (ON GEAR BOX) NYLOC NUT M12X1.5 WASHER (FOR B-MOUNT) .HEX FL NUT BM8 ASSY.ENGINE MOUNT-C (TC)
8.0
SR. NO.
PART DESCRIPTION
19 20 21 22 23 24 24-a 24-b 25 26 27 28 29
ASSY.BRACKET ENGINE STOPPER (FABRICATED) HEX FL SCR M12X30 HEX FL BOLT M8X38 ASSY.RUBBER STOPPER HEX NUT M12 ASSY.C LINK & BODY MTG BKT COMPLETE ASSY.MOUNT INTERMEMEDIATE LINK (REAR) ASSY.BODY MTG.BRACKET (FOR C-MOUNT) HEX FL BOLT M10X55 NYLOC NUT M10 ASSY HEX SCR M12X1.25X30 HEX FL BOLT M10X75 HEX FL NUT AM10
57
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI REMOVAL OF 475 MPFI ENGINE FROM THE CAR : It is recommened to used two post hoist for removing engine from the car. ENGINE
Remove bonnet Disconnect electrical cable connections for : Fig. 51 l Battery (-ve first) l Starter motor l Alternator l Electrical connections of all sensors and actuators l Oil pressure switch l Water temperature transducer l Electric fan transducer l Reversing switch l A/C Compressor Disconnect cables for Accelerator, Speedometer drive, Clut ch. Disconnect exhaust pipe from exhaust manifold
Fig.51
Drain coolant from cooling system Disconnect hoses from and to radiator and heater coil. Disconnect pipe from radiat or t o auxilliary t ank and cylinder head to aux. tank. Remove AC pipe lines (if AC is fitted) Remove following sub assemblies :
SULIN
l
Air filter
l
Gear shift linkages from transaxle Fig. 52
l
Radiator (if required)
Drain transaxle oil, Fig. 53.
Fig. 52
Fig. 53 58
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Remove drive shafts (for procedure, see suspension group) Fix chain to front and rear engine lifting hooks and hold chain in position with crane. Fig. 54
ENGINE
Unscrew and remove nut on ‘B’ mount bracket. Fig. 55 Remove ‘A’ mount support arm. Fig. 55 Remove ‘C’ mount bracket. Fig. 55 Lift engine slightly on car with the help of crane. Place support stand under the engine & lower the engine along with transaxle assembly. Remove the chain. Lift the front end of the car till the engine is clear ( It is recommended to use two pole hoist to lift the car) Remove the engine alongwith transaxle. Remove starter motor. Disconnect transaxle Assembly from engine. (Ref. transaxle group)
2702 5890 24 01
Fig. 54
Remove alternator and its mounting bracket.
‘C’ MOUNT
Mount the engine on work stand with mounting bracket Pt. No. 2702 5890 24 02 & 2702 5890 2403 Drain engine oil. Fig. 56
INSTALLATION OF ENGINE ON THE CAR :
SULIN
l
Check engine mounting pads for wear.Replace them if necessary.
l
Install the engine in reverse sequence of removal
l
Tighten engine mounting bolts to specified torque
l
Connect all pipes, hoses and electrical connections
l
Fill sp ecif ied q u an t it y o f o il in en g in e o f recommended brand.
l
Fill coolant in the cooling system through aux. tank
l
Crank the engine momentarily. Let oil and coolant circulate through the system. Remove air trapped in cooling system with the air venting screw provided on outlet hose from cylinder head to radiator top.
l
Confirm whether engine oil pressure indicator light is switching off when engine is started.
l
Check for leakage, rectify if any.
l
Top up coolant upto FULL mark in auxiliary tank, if necessary.
FRONT
‘A’ MOUNT
‘B’ MOUNT
Fig. 55
Fig. 56 59
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI REMOVAL OF RADIATOR FROM CAR (Front bum p er, Splash guard already rem oved - For procedure refer Body group of this manual) ENGINE
1.
Drain the coolant.
2.
Remove all the hose connections i. e. i. From the thermostat ii. From the auxiliary tank. iii. To the outlet elbow.
3.
4.
1. 2.
3.
Disconnect the electrical connections, i. To the condenser fan (For AC version) ii. To the temperature sensor of cooling fan.
1. ASSY. RADIATOR COMPLETE 2. CROSS MEMBER RADIATOR MOUNTING
i.
Unscrew the 2 M8 bolts & remove the radiator bottom m ounting m em ber along w ith the radiator.Fig 57
ii.
Remove upper support bracket.
3. RUBBER GROMET
Fig. 57
SPECIFICATIONS Leakage testing pressure
AUXILLIARY TANK
:
1.5 bar
: :
1 bar 0.05 bar (max)
AUXILLIARY TANK CAP
Auxillary Tank Cap Fig. 58 Pressure valve opening Vacuum valve opening (suct ion)
INSPECTION
SULIN
Check radiat or for dam ages / leakages. St raight en bent fins if any.
CLEANING Clean radiator frontal cores.
Installation : 1.
i.
ii.
Fit the radiator along with the radiator bottom mounting member on to the car & tighten the mounting bolts. Fit upper mounting bracket.
2.
Fit back the 3 hose connections.
3.
Connect the electrical connections for temperature sensor & condenser fan (For AC version)
Fig. 58 a.
Fill branded premixed ready to use coolant in the auxiliary tank after ensuring all the hoses are secured and leak proof.
b.
Du rin g fillin g , keep t h e h ose clam p loose at thermostat housing.
c.
During coolant filling, ensure that the air in the system is removed from this then tighten the hose, using a screwdriver.
d.
Start the engine & slowly raise the engine speed & wait for the temperature to reach 850 C to 900 C to allow the thermostat to open up. Engine running at idling speed, open the bleeding screw by using a screwdriver to allow any trapped air in the system to escape. Tighten the bleeding screw & top up with coolant to max. level.
Fill branded coolant as per specification. Top up coolant through auxiliary tank cap upto ‘Full” mark. Fit Auxillary tank cap. Run engine for short durat ion and t op up coolant if necessary. Rem ove t he t rap p ed air t hough vent ing screw .
Bleeding procedure for cooling system : (For refilling or during reconditioning after complete draining)
60
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI ALTERNATOR / POWER STEERING PUMP BELT (specific to 85 PS engine) Removal :
ENGINE
l
Lo o sen b o t h t h e slid er m o u n t in g screw s o n alternator bracket.
l
Slide the slider to reduce the belt tension by rotating the slider screw at the bottom. Fig. 59.
l
Remove the alternator belt.
Inspection : l
Inspect the alternator belt for wear,cracks and signs of failure. Replace, if necessary.
Fitment : l
Adjust the slider at the higher most position and keep the screws loose but engaged.
l
Install alternator belt over Crankshaft, Alternator, Power Steering pump and the tensioner pulley.
l
Slide the slider by rotating the bottom slider screw till correct belt tension is set.
l
Retighten the slider screws.
l
The belt tension to be adjusted such that on the spans shown in the Fig. 60. 180+10/ 5 Hz. (For only Alternator configuration) and 200 +10/ -5 Hz. ( For Alternator and pow er steering configuration) is measured by CLAVIS gauge. Alternately belt can be depressed by 11 to 13 mm (for only Alternator configuration) & 9 to 11 mm (for alternator and power steering configuration) with thumb pressure applied.
SULIN SLIDER SCREWS
Fig. 59
A.C. COMPRESSOR BELT REMOVAL 1.
Loosen b elt t ensioner b olt (Fig. 61) on idler / tensioner.
2.
Release tension load on the belt and remove the belt from the pulleys.
INSPECTION 1.
Inspect the A. C. compressor belt for wear, cracks, and signs of failures. Replace if necessary.
2.
Inspect pulley grooves.
SPAN
ALTERNATOR BELT TENSIONER BOLT
Fig. 60 61
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI FITMENT 1.
Install the belt over crankshaft and A. C. compressor pulleys.
2.
Press the tensioner against the belt and tight the tension bolt to specified torque.
3.
Check belt tension.
4.
The belt tension to be adjusted such that on the span shown in Fig. 12, 200 +10/-5 Hz is measured by CLAVIS gauge. Alternately belt can be depressed by 11 to 13 mm with thumb pressure applied.
ENGINE
SPAN
BELT TENSIONER ROLLER
BELT TENSION ADJUSTING SCREW
Fig. 61
SULIN
62
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI ALTERNATOR / POWER STEERING PUMP BELT (specific to 75 PS engine) ALTERNATOR / POWER STEERING PUMP BELT Removal : l Loosen alternator upper mounting Bolt and bottom m ount ing bolt Fig. 61a. For vehicles w it h pow er steering please refer 61b. l Slightly loosen banjo bolt connections on vacuum pump l Reduce alternator belt tension by loosening of tension adjust ing nut and by pushing alt ernat or t ow ards engine. l Remove alternator belt. Inspection : l Inspect alternator belt for wear, cracks and signs of failure. Replace, if necessary. Fitment : l Install alternator belt over crank shaft, power steering pully and alternator pulleys (Fig. 61b). Note : incase of vehicle without power steering, power steering pulley will not be there Fig-61a). l Pull alternator away from engine for specified tension & tighten the nut to specified torque. l ALTERNATOR BELT TENSION IS CORRECT IF IT CAN BE DEPRESSED BY 10-11 mm (for engine with alternator) & 8-9 mm (for engine with A.C., Alternator and Power steering) WITH THUMB PRESSURE (1O KG APPROX.) APPLIED IN THEMIDDLEOF ITSLENGTH Fig.61a & 61b. l Tighten alternator top mounting screw and bottom mounting bolt. l Tighten banjo bolt connections on vacuum pump A.C. COMPRESSOR BELT REMOVAL 1. Loosen b elt t ensioner b olt . (Fig. 61b ) on id ler / tensioner. 2. Release tension load on the belt and remove the belt from the pulleys. INSPECTION 1. Inspect the A. C. compressor belt for wear cracks, and signs of failures. Replace if necessary. 2. Inspect pulley grooves. FITMENT 1. Install the belt over crankshaft and A. C. compressor pulleys. 2. Press the tensioner againsts the belt and tight the tension bolt to specified torque. 3. Check belt tension. 4. A. C. Compressor belt tension is correcrt if it can be depressed by 8-9 mm with thumb pressure applied in the middle of its length between compressor and crankshaft pulleys.
3
Crankshaft Pulley
4
5
ENGINE
6
2
10 -1 1mm
Alternator
1
Engine with Alternator (without power steering) 1. Alternator mounting bottom bolt 2. Alternator mounting upper bolt 3. Clamping piece 4. Clamping bolt 5. Adjusting nut 6. Lock nut
Fig. 61a
SULIN
Alt ern at or Crankshaft Pulley
8-9 mm
Com pressor Tensioner
Tensioner Bo lt Pow er St eering Pum p
8 -9
mm
Fig. 61b
63
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI TIMING BELT : Removal : ENGINE
Remove alternator and AC belt Unscrew the mounting screws & remove front timing gear train cover Fig. 62. Keep cran k sh af t ro t at in g w it h so cket sp an n er simultaneously pressing camshaft timing pin till it locks camshaft Fig. 63.
Fig. 62 Check at this position whether timing pin 2702 5890 0605 in crankcase locks the flywheel or not Fig. 64. Remove timing pin locking the camshaft & now ensure that flywheel is in locked position.
SULIN Fig. 63
Fig. 64 64
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Fit lock plate for camshaft gear washer on cylinder head as shown in Fig.65 Slacken the camshaft gear fixing bolt.
ENGINE
Slacken t he m ount ing b olt of b elt t ensioner roller assembly and rotate the belt tensioner in anticlockwise direction to loosen the belt. Fig. 66 Remove timing belt.
Inspection : Check belt in detail. If following flaws are evident, replace belt with new one. l
Back surface glossy,non elastic and so hard that even if finger nail is forced into it, no mark is produced.
l
Cracked back surface rubber
l
Cracked or exfoliated canvas
l
Cracked tooth bottom
l
Side of belt cracked
l
Side of belt excessively worn
l
Excessively worn teeth
l
Missing tooth
NOTE :
Fig. 65
SULIN
Normal belt should have clear cut sides, as if cut with a sharp knife. In the initial stage of wear, load side tooth flank will look like fluffy canvas fibre, rubber gone and colour changed to white. In the last stage of wear, canvas on load side tooth flank will be totally worn out exposding rubber.
Fig. 66
Fitment : Ensure that timing pin is in flywheel locked position. Check that the cam gear is “Just ” freely rotating on the cam sh af t w it h m o u n t in g b o lt in h an d lo o se condit ion. Slacken all valve t appet clearance set t ing screw s t o such an ext ent t hat t he screw bot t om radius is just riding on the valve tips & tighten the locknuts.
Slacken the camshaft gear fixing bolt so that the camshaft gear is“Just ” freely rotating on camshaft.Fit the camshaft gear washer lock plate as shown in Fig. 65 Check now that both the flywheel and camshaft are in locked in timing position. Fit timing belt on Crank shaft gear,water pump, tensioner roller and camshaft gear.
NOTE : This is to reduce the valve spring load on Camshaft, while rotating the camshaft. Using appropriate spanner on camshaft gear fixing bolt, rotate camshaft in clockwise direction with timing pin placed on the cylinder head reference hole, until the camshaft is locked in timing position. (Fig. 116)
Adjust the timing belt tension, by rotating tensioner roller clockw ise an d t ig ht en t h e m oun t in g screw, w h ile t ig ht ening t he m ount ing screw ensuring t hat t he t ensioner roller does not rot at e furt her in clockw ise direct ion. This w ill prevent overtensioning of t im ing b elt . Tighten the cam shaft gear fixing bolt to a lower tightening torque of 1 mkg.
65
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Remove cam shaft timing locking pin. Re-tighten the cam gear fixing bolt to the specified torque. ENGINE
Remove camshaft gear washer lock plate and flywheel locking pin. Set valve tappet clearance on the following rocker arms. Fig. 67 Tappet Cylinder valves :
Inlet = 30 Exhaust = 20
Inlet - 1 & 2 and Exhaust - 1 & 3 Rotate crank shaft in clockwise direction by one revolution and lock the flywheel. Set the valve tappet clearance on the reamaining rocker arms i. e., Inlet - 3 & 4 and Exhaust - 2 & 4 Rot at e cran ksh aft in clockw ise d irect ion b y m ore revolution and check whether flywheel and camshaft are in locked timing position.
NOTE : In t his procedure t im ing pin locking t he cam shaft is rem oved from t he cylind er head t im ing reference hole, w henever cam shaft is sub ject ed t o very high looserning and tightening torque through the gear fixing
Fig. 67 bolt. This is to prevent severe damage to cylinder head, camshaft timing slot and subsequent problem of very low oil pressure (due to increased bearing clearance on bearing No. 5 of cylinder. head). Special ‘C’ tool should be used whenever cam gear fixing bolt is to be tightened or loosened.
SULIN
Never use the timing pin in locked timing position to hold the camshaft during tightening or loosening process.
LOCK NUT (VALVE TAPPET CL. SCREW) ROCKER SCREW
Cylinder Head Exploded
ROCKER ARM
SPRING RETAINER LOCK HALF SPRING VALVE GUIDE SEAL
VALVE GUIDE ROCKER SHAFT
CYLINDER HEAD CAM SHAFT TIMING GEAR INTAKE VALVE
EXHAUST VALVE
Fig. 68 66
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI CYLINDER HEAD : (Engine on workstand) Disassembly: Remove electrical cable connections for : l
ENGINE
Spark plug leads. Fig. 69
Fig. 69 Remove l
Fuel pressure regulator
l
Canister purge valve
l
Bracket supporting fuel lines. Fig. 70
SULIN Fig. 70 l
Coolant bypass line. Fig. 71
Fig. 71 67
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI l
Blowby hose connection to cylinder head cover. Fig. 72
ENGINE
Fig. 72 l
Vacuum pipe from intake manifold to brake booster.
l
Vacuum pipe to canister purge valve Fig. 73.
SULIN Fig. 73 l
Inlet manifold with throttle body Fig. 74.
Fig. 74 68
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI l
Exhaust manifold Fig. 75
l
Timing Cover ENGINE
Fig. 75 l
Cylinder head cover Fig. 76
SULIN Fig. 76 Keep crankshaft rotating by socket spanner simultenously, Insert flywheel locking pin and lock fly wheel. Fit lock plate for camshaft gear washer & loosen cam shaft gear mounting bolt. (Fig. 77)
Fig. 77 69
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Also remove l ENGINE
l
Timing belt Fig. 78 Dip stick clamping screw
Fig. 78 Unscrew and remove cylinder head mounting screws in reverse order of tightening Fig. 79 Slightly lift cylinder head to clear locating hollow dowel in crank case and remove it. l
Cam shaft gear Fig. 80
SULIN Fig. 79 l
Rocker arm shaft locking grub screws and rocker arm shafts. Fig. 81
Fig. 80 70
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI NOTE : 1) To ease the dismantling of rocker shaft relieve the valve spring load by slackening the tappet setting screws. In this condition do not attempt to rotate the cam shaft, if you do so valve tips will be damaged. (Fig. 81)
ENGINE
2) While pulling out Rocker arm shafts, take out t he rocker arm w it h springs & spring seat s carefully one by one. (Fig. 82)
Fig. 81
SULIN Fig. 82
INLET MANIFOLD WITH THROTTLE BODY (Removed from cylinder head)
Disassembly : Rem ove ignit ion coil assem b ly from inlet m anifold Fig. 83 (Four bolt)
Fig. 83 71
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Disconnect the tube from inlet manifold to fuel pressure regulator ENGINE
Remove the fuel rail mtg. bolt on inlet manifold Fig. 84
Fig. 84 Remove fuel rail alongwith injectors Fig. 85
SULIN Fig. 85 Detach injectors from fuel rail Fig. 86
Fig. 86 72
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Remove fuel pressure regulator from fuel rail Fig. 87
ENGINE
Fig. 87 Rem ove int egral t hrot t le body from inlet m anifold. Fig. 88
Assembly of inlet manifold For assembling the MPFI system component proceed in reverse order of disassembly of component.
SULIN Fig. 88
SPARK PLUG l
Remove Spark plugs Fig. 89
Spark Plug
-
Champion
Spark Plug no.
-
C9YC
Spark Plug Gap
-
0.7 mm to 0.8 mm
You should inspect the spark plugs periodically for carbon deposits. When carbon accumulates on the spark plug, a strong spark will not be produced. Remove carbon deposits using a spark plug cleaner.
Spark Plug Replacement : 1.
Clean up any dirt or oil that is collected around the spark plug caps.
Fig. 89 73
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
ENGINE
2.
Pull out the spark plug cables by gripping at the connector.
3.
Remove the spark plug with the help of box spanner 2702 5890 06 01 (Fig. 89)
4.
Check and adjust the gap, it should be 0.7 mm to 0.8 mm. Fig. 90
5.
Replace the spark plug if the gap is more than 0.8 mm.
6.
Fix the spark plug and tighten it to the specified torque (dry.)
7.
Fit the spark plug cable.
Repeat the procedure for the other spark plugs. Tighten the spark plug carefully. Overtightening can damage the threads in the cylinder head. A loose spark plug can affect combustion and cause engine damage.
Fig. 90
SPARK PLUG DEFECTS The condit ion of spark plug firing ends can act as a guide t o t he st at e of t une and general condit ion of t he engine.
NORMAL Fig. 91
SULIN
Core nose light ly coat ed w it h grey-brow n deposit s. Electrodes not burning unduly - gap increasing about 0.01 mm per 2000 km (with the use of unleaded fuel). Spark plugs ideally suited to engine.
HEAVY DEPOSITS Fig. 92 Possible causes : Fuel or oil additives. Oil in combustion ch am b er. Wo rn valve g u id es. Unvar yin g sp eed (stationary engine). Replace spark plugs.
Fig. 91
Fig. 92
CARBON FOULING Charact erised by dull black soot y deposit s alt hough unleaded fuel carb on fouling can ap p ear as glossy deposits similar in appearance to oil fouling. Deposits can sh o rt circu it t h e f irin g en d ; w eaken in g o r elim inat ing t he spark. Check for : Over-rich m ixt ure setting, fault y choke mechanism or clogged air filt er. Replace spark plugs.
OIL FOULING Deposits can short-circuit the firing end, weakening or eliminating the spark. May be caused by worn valve guides,
Fig. 93 74
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI bores or piston rings, or whilst a new or overhauled engine is running-in.Cure the oil problem, if possible.Temporary use of the next hotter grade of spark plug may stop the misfire. Replace spark plugs.
ENGINE
OVERHEATING Likely causes are : Over-advanced ignition timing. incorrect distributor advanced curve. Use of fuel with insufficient octance rating. Weak mixture. Discard spark plugs showing signs of overheating, and cure the cause.
INITIAL PRE-IGNITION Caused by serious overheating. Causes are those listed for overheat ing but m ay be m ore severe. Correct ive measures are urgently needed before engine occurs. Discard plugs in this condition.
Fig. 94
SPLIT CORE NOSE Fig. 93 M ay ap p ear in it ially as a h air-lin e crack. Prob ab ly cau sed b y d et o n at io n w aves, in d icat in g : Overad van ced ig n it io n t im in g . In co rrect d ist rib u t o r advance curve, use of fuel w it h insufficient oct ance rat in g, Weak m ixt u re, M an if o ld air-leaks, Co o lin g system problems, Incorrect gap setting technique, etc.
Cylinder head disassembly continued
SULIN
Remove : l
Cyl. head cover mounting studs and spacer tubes. (replace if required) Fig. 94
Fig. 95 l
Cam shaft locking plate from cam shaft bearing cap at the front
Push the cam shaft from rear and pull out from front, with oil seal Fig. 95 & 96 For Camshaft inspection go to Page No. 81
Fig. 96 75
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Fit sup p ort rail, (2702 5890 0616) t o cylinder head Fig. 97 ENGINE
Fig. 97 With spring compressor (2702 5890 06 15) compress valve springs and remove valve lock halves Fig. 98 Remove valve lock retainers, valve springs, valve spring seats and valves. Place them in correct sequence.
SULIN Fig. 98
Mating Surface : Using a straight edge and feeler gauge, check cylinder head mating surface with crank case, Fig. 99 & 100. If unevenness exceeds, replace cylinder head.
Fig. 99 76
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI CYLINDER HEAD TOP AND BOTTOM SURFACE REMACHINING, IN SERVICE IS NOT PERMITTED. Permissible unevenness of cyl. head overall mating surface (150 x 150) : cross wise 0.015 mm lengt h w ise 0.030 mm.
ENGINE
VALVES Fig. 101 Check valve leakages by pouring gasoline on valve head. Gasoline must not seep past valve seat. Valves with burnt heads, excessive scoring and wear on stem should be replaced.
Fig. 100
ROCKER SHAFT
SULIN
ROCKER SCREW ROCKER ARM
CAM SHAFT
VALVE RETAINER LOCK HALF
VALVE GUIDE SEAL
SPRING VALVE GUIDE
INTAKE PORT CYLINDER HEAD
VALVE
VALVE SEAT VALVE SEAT INSERT (external fitment)
Fig. 101 Valve Arrangement 77
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
ENGINE
Check valve seat run out with respect to valve stem. Fig. 102. If it exceeds specified limit (0.030 mm both inlet & exhaust) replace valve. No attempt should be made to straighten bent valves. If valve is free from any other d efect s excep t w orn out seat , t hen only it can b e rematched on valve grinding machine as follows. l
Clamp valve on grinding machine jaws as close as possible to valve head.
l
Adjust grinding angle on graduated scale to achieve correct valve seat angle.
l
Feed valve slowly towards grinding wheel until wheel just touches valve head.
l
Grind at low feed until valve seat is just clean all around.
NOTE :
After grinding, valve head thickness should not be less than 0.85 mm.
Fig. 102
EXHAUST VALVE
INLET VALVE VALVE STEM
B
SULIN
B VALVE SEAT C
C
45
0
A
VALVE SEAT ANGLE
C
C
D
A
VALVE HEAD
Fig. 103
VALVE GUIDES : In case of valve stem sticking in valve guide before or excessive clearance between them, remove valve guide from cylinder head using drift (2702 5890 0611) Fig. 104
Fig. 104 78
MAIN INDEX
GROUP INDEX
D
ENGINE 475 SI MPFI Valve dimensions : Fig. 101 INLET
EXHAUST ENGINE
Valve head dia. A mm
36.6/36.8
30.9/31.1
Valve seat angle
450 +15'
450+15'
Valve stem dia B mm
6.97-0.015
6.96-0.015
Maximum run out of valve face with respect to valve steam mm
0.2
0.2
Valve seat dia C mm
35
29.2
2.65+0.1
2.82+0.1
Maximum run out of valve seat with respect to valve steam
0.030
0.030
Valve seat dia in cylinder head mm
34
28.0
Valve seat end distance from valve face D mm
SULIN
Distance between cylinder head mating surface with crank case to valve seat in cylinder head mm
Maximum run out of valve seat in cylinder head with respect to valve guide axis mm
14.4+0.05
14+0.05
0.030
0.030
Remove valve guide seals. Check condition and replace if required with drift 2702 5890 0617 Fig. 105 Check valve guide bore diameter in cylinder head and if necessary,ream valve guide bore in cylinder head to next over size. (Refer table on next page)
Fig. 105 79
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Install matching size valve guide in cylinder head using d rift 2702 5890 0611 an d sp acer, 2702 5890 0612 Fig. 106. ENGINE
Ream valve guide inside diameter to specified size. Fit valve guide oil seals.
VALVE SEATS OF VALVES Check valve seat (this is the position on valve seat insert, where valve face rest) height with respect to cylinder head mating surface. Replace valve seat inserts if they are worn out byond specified limit. Cut exhaust and inlet valve seat s w it h a 45 0 cut t er Fig. 107.
Fig. 106
Size
Valve guide bore in cyl. head
Valve guide OD,mm
Valve guide ID,mm
Normal
12.99+0.008/-0.01
13.0 + 0.046 + 0.028
7 7
+ 0.015 - 0 + 0.016 + 0.004
(Inlet) (Exhaust)
13.1 + 0.046 + 0.028
7 7
+ 0.015 - 0 + 0.016 + 0.004
(Inlet) (Exhaust)
Normal 1
13.09+0.008/-0.01
SULIN
VALVE SEAT MUST BE ABSOLUTELY FAULTLESS AND WITHOUT ANY CHATTERMARKS
Valve guide length, mm 39.5 (Inlet) 46 (Exhaust)
suitable puller. In order to avoid damaging machined cylinder head mating surface with crank case, place any soft protective sheet metal under supports of puller.
If necessary lap valve seats to a smooth and even finish by using suitable hand pump grinder or a lapping paste and valve itself.
Measure valve seat insert bore in cylinder head & then select suitable insert after referring table on next page.
Smear valve seat with carbon blue. Install valve in guide and turn it slowly under axial pressure. CONTACT LINE ON VALVE SEAT MUST BE AROUND ENTIRE CIRCUMFERENCE AT EQUAL WIDTH Dist ance bet w een narrow diam et er of valve face t o contact line should be minimum 0.5 mm Check for leakages t hrough valve seat b y p ouring gasoline on valve head. Gasoline must not seep past valve seat.
VALVE SEAT INSERTS : For removing valve seat inserts from cylinder head use a suitable boring machine. Bore old insert thin (about 0.5 mm thickness) and then pry it out. Alternatively use a suitable turning tool to cut an annular groove into valve seat insert and then pull it out with a
Fig. 107 80
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI If boring and prying is done carefully without damaging valve seat insert bore in cylinder head, fitment of an over size valve seat insert will not be necessary. ENGINE
Re-machined valve seat insert bore in cylinder head must be exactly at right angle to cylinder head mating surface with crank case. All specified dimensions should be strictly maintained to ensure proper interference of valve seat insert in its bore. Clean the valve seat insert and its bore in cylinder head thoroughly. Just before installation : l Place valve seat insert in a mixture of Methanol and d ry ice fo r ab o u t 20-30 m in u t es t o b rin g it s temperature down to -150 deg. C.
Fig. 108
Heat cylinder head to approximately 80 deg. C in water bath.
l
Install valve seat insert in cylinder head bore quickly by using mallet. Machine valve seat in cylinder head.
Valve seat insert :
SULIN
Valve seat insert thickness Inlet Exhaust
Valve seat inside dia in insert
- 6.5
+ 0.05
- 6.5
+ 0.05
mm
Inlet
mm
Exhaust
- 32
+ 0.1
- 26
+ 0.1
mm mm
Valve seat insert & bore dia. in cyl. head Stage
Valve seat insert bore diameter in cyl. head (mm)
Valve seat insert out side diameter (mm)
38/ 38.03
38.13/ 38.155
38.23/ 38.28
38.43/ 38.455
INLET -
Normal
-
Normal 1
EXHAUST -
Normal
32.99/ 33.021
33.13/ 33.155
-
Normal 1
33.29/ 33.321
33.43/ 33.455
CAM SHAFT INSPECTION Carry out visual inspection of cam shaft for : l
Overall heating of journals, which is indicated by bluish/brown colour
l
Deep scoring marks on journals and cam lobes
l
Cracks, which should be checked on a magnetic crack detector.
Check hardness of cam shaft journals and cam lobes. It should be 40 HRC min. Check cam shaft runout at 2nd, 3rd & 4th journal by supporting it on V-block at 1st and 5th journal. Fig. 108 Check cam shaft journal dimensions. 81
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Cam shaft journal & bearing bore dimensions (mm) : Journal No.
Cam shaft bearing journal bore diameter in cylinder head
1
42.000 - 42.025
41.925 - 41.950
2
41.500 - 41.525
41.425 - 41.450
3
41.000 - 41.025
40.925 - 40.950
4
40.500 - 40.525
40.425 - 40.450
5
40.000 - 40.025
39.925 - 39.950
ENGINE
Cam shaft bearing journal diameter.
Maximum permissible run out of cam shaft bearing journal
0.025 mm
Maximum permissible axial play of cam shaft in installed condition Runout of oil seal mating diameter.
0.1/ 0.25 mm 0.02 mm
Cylinder head cover: Remove the baffle plate in the cylinder head cover by removing the screws Fig. 109. Check the baffle plate gasket if it is torn/damage, replace if necessary otherwise it might result in high engine oil consumption.
SULIN Fig. 109
Assembly of cylinder head : Install valves in their respective positions Install spring seat, valve springs and valve retainers. Fit sup p ort rail (2702 5890 0616) on cylind er head Fig. 110.
Fig. 110 82
MAIN INDEX
GROUP INDEX
ENGINE 475 SI M PFI With spring compressor,(2702 5890 0615),compress valve springs and install valve lock halves Fig. 111. (Note : Camshaft for 85 PS engine & 75 PS engine are different).
ENGINE
Smear cam shaft journals and cam lobes with moly paste grease Install cam shaft and lock it by lock plate at the front Fig. 81 & Fig. 112. Insert the rocker arm shaft with rocker arm spring and spring seat one by one CAREFULLY. Rocker arm and rocker shaft dimensions: Rocker shaft dia. :15 Rocker bore dia. : 15
- 0.016 + 0.011
mm mm
Fig. 111
CAUTION :
While inserting rocker arm shaft on inlet valves, ensure that tapped hole on the shaft is at the front end and for rocker arm shaft on exhaust valves the tapped hole - 0.027 on the shaft is at the rear end. - 0.000
Ch eck cam sh af t axial p lay. It sh o u ld b e w it h in specified limits (0.1/ 0.25 mm) Fig. 113
SULIN
Check camshaft for rotation.
Fit camshaft oil seal with drift (Pt. No. 2654 5890 0508) Fit camshaft gear and hand tighten the mounting bolt. Measure piston projection above crank case and select correct thickness of cylinder head gasket PISTON PROJECTION mm
GASKET THICKNESS, mm
0.04 - 0.26
1.1
Fig. 112
MAXIMUM DIFFERENCE BETWEEN PISTON PROJECTIONS OF ANY TWO PISTONS IN CRANK CASE SHOULD NOT EXCEED SPECIFIED VALUE.
Fig. 113 83
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Ensure that cylinder head locating hollow dowel is in position on crank case (Block). ENGINE
Ensure t hat flyw heel locking pin 2702 5890 0605 is installed in position Fig. 114. Place cylinder head gasket of pre-determined thickness. Install cylinder head and tighten cylinder head mounting screws to 3 mkg torque in the correct sequence i.e. from
9
5
1 10
1
2 6
4
3 2
8
4 3
7 Fig. 114
centre to outwards.Then retighten screws to 5 mkg torque in the same sequence - Then loosen each screw by quarter turn and retighten to 7.5mkg. torque Fig. 115.
Valve clearance adjustment. VALVE CLEARANCES SHOULD BE CHECKED ONLY WHEN ENGINE IS COLD. l
Fit camshaft gear
SULIN
Fitment : Ensure that timing pin is in flywheel locked position. Check that the cam gear is “Just ” freely rotating on the camshaft with mounting bolt in hand loose condition. Slacken all valve tappet clearance setting screws to such an extent that the screw bottom radius is just riding on the valve tips & tighten the locknuts. (Refer fig. 68)
Fig. 115
NOTE : This is to reduce the valve spring load on camshaft, while rotating the camshaft. Using an appropriate spanner on camshaft fixing bolt, rotate in camshaft in clock direction with timing pin placed on the cylinder head reference hole, until the camshaft is locked in timing position. Fig. 116 Slacken the fixing bolt so that the camgear is“Just ” freely rotating on camshaft. Fit the camshaft gear washer locking plate. (Fig. 65) Check now that both the flywheel and camshaft are in locked timing position.
Fig. 116 84
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Fit timing belt on crank shaft gear, water pump tensioner roller and camshaft gear. Adjust the timing belt tension, (Fig. 117) by rotating tensioner roller clockwise and tighten the mounting screw, ensuring that the tensioner roller does not rotate further in clockwise direction.This will prevent overtensioning of timing belt.
ENGINE
Fig. 117 Tighten the cam gear fixing bolt to a lower tightening torque of 1 mkg Fig. 118. Remove cam shaft timing locking pin. Re-tighten the cam gear fixing bolt to the specified torque.
SULIN Fig. 118 l
Set the flywheel and cam shaft in No.1 cylinder firing position by inserting cam shaft timing locking pin.
l
Adjust the valve clearances of cylinder No. 1 & 2 on inlet valves and cylinder No. 1 & 3 on exhaust valves Fig. 119
l
Remove the camshaft locking pin and fly wheel locking pins.
Fig. 119 85
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI l
Rot at e t h e cran ksh aft b y on e rot at ion in t h e clo ckw ise d irect io n an d in sert t h e f lyw h eel locking pin.
l
Adjust the valve clearances of cylinder No. 3 & 4 on inlet valves and cylinder No. 2 & 4 on exhaust valves Fig. 120
ENGINE
Specified
INLET
EXHAUST
0.20
0.30
Assemblies
l
Fig. 120
Spark plug. Fig. 121
SULIN Fig. 121 l
Exhaust manifold Fig. 122
Fig. 122 86
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI l
Inlet m anifold w it h t hrot t le b od y and gasket . Fig. 123
l
Spacer tube on cylinder head cover mtg. studs.
l
Cylinder head cover along with camshaft gear rear cover. Replace the gasket if required.
l
Timing belt gear cover Fig. 124.
l
Thermostat cartridge
l
Thermostat cover with gasket
l
Bypass line
l
Dip stick clamp screw
l
Vacuum pipe canister purge valve to intake manifold.
l
Hoses from intake manifold to cylinder head cover and brake booster.
l
Bracket supporting fuel lines.
l
Spark plug leads.
ENGINE
Fig. 123
Fill recommended quantity of oil.
SULIN Fig. 124
CYLINDER BLOCK (Cylinder head assembly removed) Disassembly Uniform ly and evenly unscrew clut ch pressure plat e mounting screws and remove clutch pressure plate and clutch disc Fig. 125.
Fig. 125 87
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Remove : l
Vibration damper Fig. 126.
ENGINE
Fig. 126 l
Crankshaft gear Fig. 127.
l
Water pump
l
Timing belt tensioner
l
Timing belt rear cover
SULIN Fig. 127 l
Oil filter by using spanner (2702 5890 1802) Fig. 128
l
Engine mtg. bkt. (intermediate)
Fig. 128 88
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI l
Oil sump by extended socket (2702 5890 0603) Fig. 129 ENGINE
Fig. 129 l
Oil pump strainer Fig. 130a
l
Oil pump Fig. 130b
Carefully remove combustion residues towards top end of cylinder bores, preferably by a broken piston ring or by a ridge cutter.
SULIN
Turn the crank shaft and bring a pair of piston to BDC
Unscrew connecting rod bearing cap mounting nuts Fig. 131
Fig. 130a
Fig. 130b
Fig. 131 89
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Remove connecting rod bearing caps with bearing shells.
ENGINE
Push these piston assemblies out of cylinders using the wooden handle of the mallet. Remove connecting rod bearing shells and duly mark them with paint on their backs in case these are to be reused. IT ISESSENTIAL TO ASSEMBLECONNECTING ROD BEARING CAPSTO THEIR RESPECTIVE CONNECTING RODS Verify serial numbers on connecting rod bearing caps and connecting rods. Remove remaining pistons in same manner Rem ove p ist on p in sp ring clip s w it h suit ab le p lier. Fig. 132
Fig. 132 Remove piston pins from piston by pushing them out using soft drift. Fig. 133 Remove connecting rod
SULIN Fig. 133
KEEP PISTONS AND PISTONS PIN IN SETS : Insert flywheel locking pin. Fig. 134
Fig. 134 90
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Unscrew flywheel mounting screws Fig. 135a Remove flywheel locking pin. Remove flywheel.
ENGINE
Unscrew and remove crankcase rear cover with oil seals. Fig. 135b
Fig. 135a
Fig. 135b Removal o f Crankcase rear cover
SULIN Unscrew main bearing cap mounting bolts and remove main bearing caps. Fig. 136 Remove crank shaft main bearing shells and thrust washers from crank case. Duly mark the main bearing shells with paint on their backs, in case these are to be reused.
Fig. 136 Remove crankshaft Fig. 137 IT IS ESSENTIAL TO ASSEMBLE MAIN BEARING CAPS TO THEIR RESPECTIVE POSITIONS IN CRANK CASE.
Fig. 137 91
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI PISTON AND PISTON RINGS : PISTON AND CYLINDER BORE SIZES : ENGINE
Type
Grade
Cylinder bore Diameter mm
Piston Diameter mm
A
75.00/ 75.01
74.96
B
75.01/ 75.02
74.97
C
75.02/ 75.03
74.98
Standard
PISTON RINGS : Type of ring
Axial clearance in piston groove
Butt clearance in cylinder bore
1st Compression ring
0.03 / 0.07 mm
0.15 / 0.3 mm
2nd Compression ring
0.02 / 0.06 mm
0.2 / 0.35 mm
-
0.2 / 0.6 mm
3rd Oil control ring
Fig. 138
Remove piston rings from piston using ring expander.Fig. 138 Remove the carbon deposits from the piston
SULIN
Clean the piston and piston rings thoroughly In case t he cylinder bore t aper and ovalit y is w it hin specified limit, then same piston and piston rings may be reused. Examine the pistons for cracks, scoring, other damages, ring groove wear, piston pin bore wear, spring clip groove wear/damage etc.
Fig. 139
In case of any one piston with any one of this defect, com plete piston set should be replaced. Exam ine piston rings for scoring, lateral clearance in piston ring groove and butt clearance in cylinder bore. Fig. 139 & 140
Piston pin dia. Piston Pin length Piston Pin bore in piston Height of Piston Piston to bore clearance Max. permissible difference in weights of pistons with pin & rings of an engine
20.00/ 19.996 mm 59.00/ 58.7 mm 19.998/ 20.003 mm 52.5 mm 0.040 - 0.050 mm
3 gm s.
Fig. 140 92
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI BUTT CLEARANCEOF PISTON RING SHOULD BEMEASURED IN UNWORN PORTION OF CYLINDER BORE. In case of any piston ring with any one of this defect, com plete ring set should be replaced.
ENGINE
When cylinder bores are re-bored or honed, pistons and rings of appropriate size should be used. Piston size is stamped on piston crown. Install piston rings in their respective position on piston using ring expander,with “TOP” marking upward.Fig.141 Ensure that piston & rings are clean. Assemble the expander of the oil ring in the 3rd groove & then the bottom & top rails. Do not wind in the rails on to the groove. AssembleTaper compression ring in the 2nd groove using ring plier.Ensure‘TOP’marking istowardsthe piston crown.
Fig. 141
Assemble the Gas nitrided steel ring in the top groove using a ring plier. Stagger the ring gap. Light ly oil t he rings and use ring com pressor, w hile inserting into the cylinder.
CONNECTING RODS
SULIN
In sp ect co n n ect in g ro d sm all en d b u sh an d if necessary, replace it .
Ch eck co n n ect in g ro d sm all en d p aren t b o re dimension Fig. 142 If necessary machine connecting rod small end parent bore to next over size.
NOTE : Ensure that the Connecting rod big end & small end axes are parallel to each other within specified limits. Ensure that centre distance between small end & big end is maintained within specified limit.
Fig. 142
Oil the parent bore in connecting rod. Install a new bush in such a way that slit is positioned approximately in vertical axis. Drill oil hole in the new bush Fin ish co n n ect in g ro d sm all en d b u sh b o re o n a co n n ect in g ro d b o rin g m ach in e. Alt ern at ely connecting rod small end bush may be reamed. Inst all connect ing rod bearing caps w it hout bearing shells on connecting rod. Tighten connecting rod bearing cap mounting nuts to specified torque. Fig. 143
Fig. 143 93
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI CONNECTING ROD (DIMENSIONS) : Connecting rod small end ENGINE
Stage
parent bore diameter mm
bush outside diameter mm
Norm al
23.021/ 23.000
23.086/ 23.111
Normal I
23.221/ 23.200
23.286/ 23.311
Maximum permissible taper and ovality of connecting rod small end parent bore and cylindricity
0.004 0.008
mm mm
20.0+ 0.020/ 0.007
mm
Maxim um perm issible out of parallelism (bend) betw een connecting rod small end and big end parent bores.
0.050
mm
Centre to centre distance betw een connecting rod sm all end and big end parent bores.
141.65+ -0.3
mm
0.050
mm
48.655 / 48.671
mm
0.005 0.01
mm mm
0.024 to 0.075
mm
0.013-0.051
mm
5
gms
0.05 - 0.35
mm
Connecting rod small end bush inside diameter finished after installation) (Piston pin oiled has thumb push fit in small end bush).
Maximum permissible tw ist of connecting rod
SULIN
Connecting rod big end parent bore diameter
Maximum permissible taper and ovality of connecting rod big end parent bore and cylindricity
Bearing shells to be selected such that clearance is maintained as Pre-tension of connecting rod big end bearing shells Maxim um perm issible difference in w eight of connecting rods in one engine Connecting rod big end axial play
94
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI NOTE : Ensure that the identification numbers for connecting rod & connecting rod bearing cap are matched & notches for bearing shells are on same side.
ENGINE
Check twist and bend of connecting rod by using new piston pin in connecting rod small end bush. Measure twist and bend of connecting rod with feeler gauge with respect to vertical face of connecting rod alignment gauge in vertical and horizontal plane at a dist ance of 50 m m from t he line joining cent res of connecting rod small end and big end bosses. Fig. 144 & 145 If necessary, st raight en t he connect ing rod in cold cond it ion. Since a slight clearance exist s b et w een connecting rod bolts and corresponding connecting rod bearing cap holes, it is possible that connecting rod bearing cap once rem oved m ay be inst alled off centre, by which dimension of connecting rod big end parent bore w ill be different in different directions.
Fig. 144
If d ifference is not iced in connect ing rod b ig end parent bore dim ension, connect ing rod bearing cap can be centralised by lightly tapping it with mallet in required direction after slightly loosening connecting rod bearing cap mounting nuts.
SULIN
Check connecting rod big end parent bore dimension. Fig. 146 If connecting rod big end parent bore is slightly more t han m axim um p erm issib le lim it s, it is p ossib le t o reclaim connecting rod provided the wear is confined only to connecting rod bearing cap.
Fig. 145
Connect ing rod bearing cap m at ing surface m ay be slightly faced. Parent bore should then be finished on a connecting rod boring machine. ENSURE THAT CONNECTING ROD BIG END AND SMALL END AXES ARE PARALLEL TO EACH OTHER WITHIN SPECIFIED LIM ITS. CENTRE TO CENTRE DISTANCE BETWEEN CONNECTING ROD SMALL END AND BIG END IS MAINTAINED WITHIN SPECIFIED LIMITS. If one or more connecting rods are to be replaced, ensure that difference in weight of connecting rod in an engine is within permissible limits. Install new pair of connecting rod bearing shell according to size of crank pin journal diameter, making sure that securing lugs of bearing shells are properly seated in grooves of connecting rod and its bearing cap.
Fig. 146 95
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Install connecting rod bearing cap with bearing shell on connecting rod. ENGINE
Tighten connecting rod bearing cap mtg. nuts to specified torque Fig. 147
Fig. 147 Measure connecting rod bearing bore Fig. 148 IF CONNECTING ROD BIG END PARENT BORE DIMENSION IS MAINTAINED WITHIN SPECIFIED LIMITS. PROPER BEARING BOREDIMENSION ISAUTOMATICALLY ACHIEVED. However, it must be physically measured and confirmed . Measure pre-tension of connecting rod bearing shell with a feeler gauge after loosening connecting rod bearing cap mounting nut on opposite side of bearing shell lug.
SULIN
CONNECTING ROD BEARING SHELLS ARE PRECISION FINISHED AND SHOULD NOT BE BORED OR SCRAPED.
Fig. 148
96
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Crank shaft (dimensions) Stage
Crank case main bearing bore diameter with bearing shell mm
Crank shaft main bearing journal diameter mm
Normal
50.026 / 50.065
50.0/ 49.98
Normal 1
49.926/ 49.965
49.900/ 49.880
Repair 1
49.786 / 49.815
49.760/ 49.730
Repair 2
49.526 / 49.565
49.500/ 49.480
Stage
Connecting rod big end bore diameter with bearing shell (mm)
Crank pin journal diameter mm
Normal
45.007 / 45.043
44.995/ 44.980
Normal 1
44.907 / 44.943
44.895/ 44.880
Repair 1
44.757 / 44.793
44.745 / 44.730
Repair 2
44.507 / 44.543
44.495 / 44.480
Stage
Width of 4th main bearing journal (mm)
Thickness of 4th main bearing thrust washers, mm
Normal
24.052 / 24.000
2.62(2.60-2.65)
Standard 1
24.152 / 24.100
2.57(2.55-2.60)
Repair 1
24.252 / 24.200
2.52(2.50-2.55)
End play of crank shaft
SULIN
0.06 - 0.226 mm
Fillet radius of main bearing journals
2.5-0.5 mm
Fillet radius of crank pin journals
2.5-0.5 mm
Pre-tension of main bearing shells Hardness of crank shaft main bearing and crank pin journals
ENGINE
0.018-0.040 mm 50-60 HRC
Width of 1st, 2nd, 3rd and 5th main bearing journals
24.0+0.2 mm
Main bearing parent bore dia in crank case
Width of crank pin journals
24.0+0.2 mm
Maximum permissible taper of main bearing parent bore
0.005 mm
Maximum permissible ovality of main bearing parent bore.
0.005 mm
Maximum permissible cylindricity
0.0025 mm
Ovality of main brg. journal
0.005 mm
Max. permissible ovality of crank pin
0.005 mm
Maximum permissible run out of 2nd, 3rd and 4th main bearing journals when supported at 1st and 5th main bearing journals Maximum permissible out of parallelism between crank pin and main bearing journal axis
0.02 mm
Crank shaft journal to main bearing clearence
53.8 +0.019 mm + 0.00 mm
0.026 / 0.085 mm
0.010 m m
97
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI 4th main bearing journal
CRANK SHAFT : ENGINE
Clean and carry out visual inspection of crankshaft for the following l
Overheating of journals, which is indicated by bluish brown colour.
l
Scoring marks on journals.
l
Cranks, which should be checked on magnetic crack detector.
Check crank shaft run out by supporting it on V-block at 1st and 5th main bearing journals. Fig. 149 If run out exceeds permissible limits, straighten crank shaft in cold condition on press carefully. Similarly check lateral and radial run outs of flywheel mounting flange.
Fig. 149
Check crank shaft main bearing and crank pin journal dimension. If necessary,grind crank shaft main bearing and crank pin journals to next under size. MAINTAIN CORRECT FILLET RADII FOR JOURNALS Care must be taken during grinding to ensure that width of journals is not increased.
SULIN
Should it be necessary to grind sides of 4th main bearing journal, grind it to next over size. Re-chamfer oil holes on journals to avoid scoring of new bearing shells.
Finish journals by lapping them with 320 grit lapping cloth of suitable width. After grinding recheck main bearing and crank pin journal dimensions.
Fig. 150
Also recheck run out of crank shaft. Thoroughly clean crank shaft with kerosene. Use wire brush for cleaning oil holes. IT IS ESSENTIAL TO RECHECK CRANK SHAFT FOR CRACKS AND BALANCE AFTER GRINDING Apply grease to all machined surfaces, if crank shaft is t o b e st ored. Crank shaft m ust alw ays b e st ored in vert ical posit ion.
CYLINDER BLOCK Check cylinder block for cracks by pressure t est ing m et hod. Check crank case m at ing surface w it h cylinder head for unevenness with help of straight edge and feeler gauge. Fig. 150 & 151
Fig. 151 98
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI If necessary grind this surface just to clear unevenness. Ensure that the minimum height of crank case is not less than the specified minimum height.
ENGINE
Th o ro u g h ly clean t h e m ain b earin g cap s an d corresponding m achined surfaces of crank case. Install main bearing caps without bearing shells in their respective positions of crank case. ENSURETHATTHESERIAL NUMBERSON CRANK CASEAND MAIN BEARING CAPS ARE MATCHING. ALSO CAPS ARE IN SERIAL ORDER AND NOTCHES FOR BEARING SHELLS ARE ON SAME SIDE. Tighten main bearing cap mounting bolts to specified torque. Fig. 152 Check crank case main bearing parent bore dimensions. Fig. 153 Rem ove cap s. Select m ain b earing shells according to size of crank shaft main bearing journal diameter, making sure that securing lugs of bearing shells are properly seated in grooves of crank case and main bearing caps.
Fig. 152
SULIN Fig. 153 Install main bearing caps w ith bearing shells in their respective position on crank case. Tighten main bearing cap mounting bolts in specified sequence to specified torque. Fig. 154
Fig. 154 99
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Measure the main bearing bore.
BOLT LOOSENED
However,it must be physically measured and confirmed. Measure pre tension of main bearing shell with a feeler gauge after loosening main bearing cap mounting bolt on opposite side of bearing shell lug (This is to be done on a flat surface plate as it can not be measured on engine cylinder block because the main bearing caps are guided) Fig. 155. If pre tension is not in range (0.018 - 0.040 mm), change & select new shell. MAIN BEARING SHELLS ARE PRECISION FINISHED AND SHOULD NOT BE BORED OR SCRAPED. Select a new pair of thrust washer according to crank shaft 4th main journal width. Refer Fig. 149
PRETENSION GAP
ÞÞ
ENGINE
BOLT TIGHTENED
IF M AIN BEARING PARENT BORE DIM ENSION IS MAINTAINED WITHIN SPECIFIED LIMITS, PROPER MAIN BEARING BOREDIMENSION ISAUTOMATICALLY ACHIEVED.
SURFACE PLATE
Schematic Sketch : Main bearing shell pretension checking
Fig. 155
Cylinder bores Clean cylinder bores thoroughly Check cylind er b ore d im ension, t ap er and ovalit y. Fig. 156a If taper and ovality is found to exceed specified limit or bore is excessively worn out machine cylinder bore as given below to fit the liners.
SULIN
Record the readings in Engine inspection sheet no. 2 given in this manual. Rebore all the cylinders to 78+0.02 mm size and fit the liners as per the procedure.
Fig. 156a
100
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI REM OVAL, INSTALLATION AND M ACHINING OF CYLINDER LINERS REMOVAL 1. Keep cylinder block upside down on hydraulic press such that bore from which liner is to be removed lies clear in machine table slot. 2. Ensure that the block is resting squarely on machine bed. 3. Press out liners individually using drift, (Pt. No. 2702 5890 0201 and a suitable distance piece between press ram and the drift. Make sure that the distance piece is also seating squarely between the drift and the ram.
INSTALLATION OF LINERS IN CYLINDER BLOCK Thoroughly clean bores of the cylinder block. Thoroughly clean liners. Place cylinder block on hydraulic press ensuring that oil sump mating face is resting evenly and squarely on the horizontal bed.
DO NOT SMEAR CYLINDER BORE OF BLOCK OR LINER OUTSIDE SURFACE WITH OIL.
approximately at 100-120 rpm and approx. 50 double strokes per minute. Under these conditions leave about 0.02 mm materials for second stage honing. Anticlock wise direction of rotation of tool will be prefered if possible.
Stage II Base honing The honing should be approx. 50-60 rpm & 25 double strokes per minute.The opration should be completed in 5 to 8 double strokes with low pressure of 2.0 to 3.0 kg/cm 2. Anticlock wise rotation will be preferred if possible.
Note : Adjust honing stick travel project by approx. 20-25 mm from top and bottom of bore during honing. Use plenty of kerosene during honing operation. At bottom 20 mm overtravel, care must be taken that stick holder will not hit to MB faces. Clean cylinder block thoroughly and if engine assembly is not to be taken up immediately,apply grease on machined surface of cylinder block.
Special Tools Required : Drift for installation of cylinder liner - 2702 5890 02 01 Drift for removal of cylinder liner - 2702 5890 02 02
Place liner with proper orientation (matching minimum / maximum ovality axis) in the cylinder bore and make it at right angles to cylinder block top surface in longitudinal and crosswise directions using precision tri-square.
SULIN
78+0.02 22.50+2.50
Press liner using drift 2702 5890 0202. Use a wooden spacer about 100 mm thick between press ram and drift. Pressing force should be within 4 to 6 tonnes.
75+0.01
Similarly,press all other liners. Liners damaged during installation should be removed and replaced with new ones.
FINISHING OF CYLINDER BLOCK WITH LINER Process of boring & honing is already explained in manual. Machine all the bores to 74.96 +0.0/-0.045 mm diameter. Note : It is very important that the axes of the bores are parallel to each other and are at right angles to the axis of crankshaft. Therefore, we recommend the use of pillar type boring and honing machines. If portable bar is used, check and clean mating surface have boring bar and cylinder block and centralise the boring bar as accurately as possible in the bore. Finish bore by honing to 75.00 mm diameter. Honing should be done in three stages as follows.
Stage I Rough honing Use honing st one of grit 60. The honing should b e
Fig. 156b 101
MAIN INDEX
GROUP INDEX
ENGINE
ENGINE 475 SI MPFI Cylinder Block (Dimensions) - in mm C ENGINE
Height of crank case (Dimension A&B) Fig. 157
D
265.8/ 265.6
Maximum permissible unevenness of crank case mating surface with cylinder head 150x150 : cross wise ‘D’ Fig. 157
0.015
: length wise ‘C’ Fig. 157
0.030
Maximum permissible out of parallelism between crank case top and bottom machined surface Maximum permissible shift in perpendicularity of cylinder bore from crank shaft axis when checked from crank shaft centre line Maximum permissible taper and ovality of cylinder bore
B A
0.2
0.25 mm
Fig. 157
0.007
SULIN
102
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI LUBRICATION SYSTEM :
Pump rpm
Minimum flow rate in Ipm
OIL PUMP
4000
28
Unscrew screws holding oil pump to cyl. block and remove the oil pump assembly Check oil pump for flow rate at specified rpm. Check for any leakage at sealing plugs.
2000
14
800
5.6
Ch eck fu n ct io n in g o f Pressu re relief valve. If t h e performance of the pump is not satisfactory, then replace the oil pump assembly. Fit oil pump assembly with new gasket. Flow rate measured against back pressure of 3kg/ cm 2 should be as follows using SAE-30 oil.
ENGINE
Engine oil pressure with coolant temperature of 700 C at idling speed 800+50 rpm - 1 bar at 5000 rpm - 3 bar
Oil Pressure Switch NC contact opening pressure : 0.9 / 0.6 bar
ENGINE LUBRICATION COMPONENTS
SULIN MAINOIL GALLERY
OILFILTER
OILPUMP
GASKET
OILSUMP
STRAINER DRAINPLUG
Fig. 158
103
MAIN INDEX
GROUP INDEX
ENGINE
RADIATORVENT HOSE AUXILIARYWATERTANK
SULIN
MAIN INDEX
RADIATOR
INTEGRAL HOSE
WATERINLET ELBOW HEATER RETURN HOSE
GROUP INDEX
CYLINDER HEAD VENT LINE
BYPASSLINE
UPPERCOOLINGLINE
THERMOSTATCOVER WATERTEMP.SENSOR THERMOSTATHOUSING
CAB HEATER FEEDER HOSE
ENGINE 475 SI MPFI
Fig. 159
104
COOLING CIRCUIT
ENGINE 475 SI MPFI COOLING SYSTEM : Fig.159
THEMOSTATE CLOSED
WATER PUMP ENGINE
Check water pump for free rotation. Check water pump for flow rate at specified rpm. Check for coolant leakage through leakage hole. It indicatesthat the seal isdamaged and leaking. Replace the water pump if necessary. Water pump characteristics :
ENGINE RPM
PUMP RPM
FLOW RATE AT BACK PRESSURE=0.3 BAR (LITRES PER MINUTE)
2000
2100
40
3000
3150
60
4000
4200
80
5000
5250
100
5500
5775
110
Fig. 160
THEMOSTATE OPEN
Thermostat l
Start opening temperature - 87 0C ± 2
l
Full open temperature - 93 0C ± 2
l
By pass port closed at or before
l
Leakage through main valve (including seepage hole) at room temperature and pressure of 1 kg/ cm 2 : 150-250 ltrs/ hr
l
Maximum leakage through by pass at full open t em p erat u re or m ain f lo w rat e of 130 + 5 lpm : 1.5 lpm
SULIN
Thermostat is installed in cooling system between cyl. head & radiator inlet tank. The working principle of thermostat : 1.
For cold engine (im m ed iat ely aft er st art ing) : Thermostat does not allow coolant to flow to radiator (Thermostat valve in closed position) instead coolant flows through thermostat by-pass outlet to engine. Thus short circuiting of radiator which helps for attaining engine working temperature in very short period. Fig. 160
2.
As soon as the coolant temperature reaches opening temperature of thermostat, the thermostat valve starts opening gradually and water flow starts to radiator.At the same time thermostat by pass starts closing gradually.
Fig. 161 3.
As t h e en g in e co o lin g t em p erat u re reach es thermostat full open temperature, thermostat valve opens fully and thermostat by-pass valve closes completely.Under such condition maximum quantity of engine coolant flows to radiator Fig. 161.
105
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Satisfactory operation of thermostat is very much essential for : ENGINE
l
Efficient engine operation
l
Longer engine life.
Defective thermostat may cause l
Over cooling due to thermostat valve sticking in full open position
l
Over heating due to thermostat valve sticking in partial/ full closed condition
When above defects are observed, thermostat needs checking.
Checking of thermostat element 1.
Rem ove t herm ost at elem ent from t herm ost at housing Fig. 162
2.
Mount therm ostat elem ent in a suitable fixture and place the fixture in a vessel filled with water.
3.
Fix dial gauge w ith its spindle on valve surface with a pretension @ 0.5 mm
4.
Heat t h e vessel an d m easu re t h e w at er t em perat ure w it h proper t herm om et er
5.
Not e dow n t he t em p erat ure w hen dial gauge needle starts moving indicating valve opening.
6.
Not e dow n t he w at er t em p erat ure for needle movement of 8mm (valve fully open position)
7.
The opening temperature (Sl.No.5) and fully open temperature (Sl.No.6) as measured should be as m ent ioned.
Fig. 162
SULIN
If t hey do not m eet t he sp ecificat ions, rep lace t he t herm ost at elem ent .
Fig. 163
Cylinder block Assembly : Install main bearing shells, in the block. Install thrust washers in crank case at their respective location on 4th main bearing sides. Apply light coat of engine oil to m ain bearing shells and main journals. Install crank shaft Fig. 163 Install 4th main bearing cap with thrust washers. Install 1st, 2nd, 3rd and 5th main bearing caps with shells in their respective position on crank case. Tighten main bearing cap mounting bolts evenly and uniformly to specified torque (first 3rd cap, next 4th and 2nd, lastly 5th and 1st) Fig. 164
Fig. 164
106
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Check that end float of crank shaft is within specified limits. Fig. 165 ENGINE
Fig. 165 Install rear oil seal using drift 2702 5890 0608 in crank case rear cover. Fig. 166 Clean the mating surfaces of crank case & rear cover.
SULIN Fig. 166 Fit crank case rear cover with new gasket Fig. 167 Locate flywheel on crank shaft rear flange. Screw-in flywheel mounting screws. Insert flywheel locking pin Tighten flywheel mounting screws to specified torque. Remove flywheel locking pin. Remove the connecting rod bearing cap with shell.
Fig. 167 107
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Assemble the connecting rod in piston such that when you hold the piston in your hand, the arrow mark on the piston crown is towards left. ENGINE
Insert the piston pin. Fit piston pin spring clip. Fig. 168 Apply oil on piston, piston rings, cylinder bore and bearing shells. Turn the crank shaft and bring crank pin journal to top most position into which connecting rod with piston is to be fitted. Insert the connecting rod with piston upto piston rings into cylinder bore with arrow on piston crown pointing towards front. Stagger the piston ring gaps such that they are 1200 apart. Clamp piston ring compressor over piston rings such that piston with piston rings can slide inside it. Fig. 169
Fig. 168
Push the piston gradually inside cylinder bore using wooden handle of mallet till connecting rod locates on cran k p in j o u rn al. Slo w ly ro t at e t h e cran k sh af t , simultaneously pushing piston till crank pin journal reaches BDC position.
SULIN Fig. 169 Install connecting rod bearing cap with bearing shell on connecting rod ensuring that bearing shell lugs are on same side Fig. 170.
VALVE POCKETS
JET
LUGS
Fig. 170 108
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Tighten connecting rod bearing cap mounting nuts to specified torque. Fig. 171 Assemble other connecting rods with piston in same manner.
ENGINE
Fig. 171 Check end play of connecting rods Fix oil pump gasket Install oil pump Assembly with gasket.
SULIN Fig. 172 Tighten the oil pump mtg. screws to specified torque. Fig. 173
Fig. 173 109
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Fit oil pump strainer with gasket. Fig. 174
ENGINE
Fig. 174 Fit water pump with new gasket. Fig. 175
SULIN Fig. 175 Install - Oil sump Fig. 176 - Timing gear rear covers - Timing belt tensioner - Crankshaft gear Install crank shaft pulley assembly (An additional multi groove p ulley p rovid ed for d eluxe version, for AC compressor drive) in position.
Fig. 176 110
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Lock flywheel with timing pin Fig. 177
ENGINE
Fig. 177 Screw in crankshaft pulley mounting bolt with spacer and tighten it to specified torque. Fig. 178 Fit l
Alternator top mounting bracket
l
Alternator bottom mounting bracket
l
Alternator
SULIN Fig. 178
l
NEW oil filter Fig. 179
l
Fit coolant inlet elbow with gasket.
Fig. 179 111
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Fit clutch disc using mandrel (2702 5890 2501) Fig.180.
ENGINE
Fig. 180 Assemble Clutch pressure plate Fig. 181. FOR ASSEMBLY OF CYLINDER HEAD ON BLOCK,TIMING BELT FITMENT ETC. PLEASE REFER RESPECTIVE SECTIONS OF THISMANUAL.
SULIN 2702 5890 250 Mandrel for Clutch Disc
Fig. 181
112
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
Fig. 182
AIR INTAKE SYSTEM
AIRTEMPRATURESENSOR
SNORKEL
MAIN INDEX
SULIN
T- HOSE
AIRFILTER
RESONATORBOX
GROUP INDEX
INTAKEMANIFOLD
CYLINDERHEAD
113 ENGINE
ENGINE 475 SI MPFI AIR CLEANER Fig. 182 For regular cleaning as per maintenance schedule : ENGINE
l
Unscrew and remove housing cover, and remove element. Fig. 183
l
Clean it gently by tapping on clean table.
l
Use com pressed air, at a very low pressure, for cleaning the element
l
Check the condition of rubber sealing
l
Check element for major rupture or puncture of paper pleats.
l
Replace elem ent if any rupt ure or punct ure is observed.
l
Check condition of air hose / resonator box
l
Check condition of rubber cuff on air filter and replace it if necessary.
l
Always use GENUINE air filter element to ensure long engine life.
l
Install paper filter element
l
Fit housing cover and clamp it firmly with the screws.
Fig. 183
SULIN
114
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
ACCELERATOR CABLE ENGINE
8
9
11
10
1
SULIN
ASSY.ACC.CABLE-RHD
2
CLIP
3
HOSE
4
GROMMET
5
HEX FL SCREW M6X10
6
CABLE TIE 4.7X110
7
BRACKET ACC. CABLE
8
TOP SIDE NUT
9
ACCELERATOR PEDAL
1 0 ACCELERATOR CABLE PLASTIC END 1 1 INNER CABLE END
Fig. 184
Removal :
Installation :
1.
Loosen the top side nut (8) from threaded end of accelerator cable at throttle body end.
1.
Insert accelerator cable plastic end (10) inside the firewall hole.
2.
Remove Hex FL screws (5) & remove cable from clip (2).
2.
Insert inner cable end (11) in accelerator pedal.
3.
3.
Remove inner cable end from throttle body sector after disengaging the threaded end of the cable in throttle body bracket (7).
Locate accelerator cable in clip (2). Ensure that rubber sleeve (3) on accelerator cable are located inside the clip.
4.
4.
Remove inner cable end (11) from accelerator pedal (9).
5.
Remove accelerator cable plastic end (10) through firewall hole.
Loosen the top side nut (8) from threaded end of the cable. Engage the threaded end of the cable in body bracket (7). Insert inner cable end in throttle body sector.
5.
Ensure tightness in inner cable by adjusting the nuts on threaded end of cable.
6.
Ensure t hat w hen accelerat or cab le (9) is fully depressed, full travel of throttle sector is achieved.
115
MAIN INDEX
GROUP INDEX
ENGINE
ENGINE 475 SI MPFI
116
ASSY. FOOT CONTROL ®
4.0
GROUP INDEX
PART DESCRIPTION
1 2
ASSY FOOT CONTROL MODULE -RHD ASSY.CONTROL MOUNTING BRACKET (WELDED) ASSY CLUTCH PEDAL LEVER COMPLETE. ASSY ACC PEDAL (RHD) SLEEVE (FOR BRAKE & CLUTCH) CLUTCH PEDAL ASSISTANCE SPRING BRIGHT WASHER 10.5 HEX BOLT M10X125 ASSY BRAKE PEDAL LEVER COMPLETE TORSION SPRING (FOR BRAKE PEDAL RETURN) NYLOC NUT M10 TORSION SPRING FOR ACC.PEDAL RETURN. BUSH CIRCLIP E9X1.1 STOP LIGHT SWITCH CLUTCH PEDAL STOPPER HEX SCREW M8X45 HEX NUT M8 RUBBER COVER (PEDAL PLATE) RUBBER COVER (ACC.PEDAL)
3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
SULIN
MAIN INDEX
SR. NO.
®
- Specified Torque in Kgm
Fig. 185
®
-Non Reusable Part
ENGINE 475 SI MPFI ENGINETESTING After assembly of the engine, mount engine on test bed, prepare engine for starting and testing in the following manner. Connect oil pressure gauge and temperature gauge.
Allow engine to cool down for about 3 hours.Then remove cylinder head cover. Loosen cylinder head mounting bolt by quarter turn and retighten immediately to 7 mkg torque in the correct sequence. Complete cylinder head tightening operation in the same sequence and with the same torque.
Connect coolant hose to and from radiator. Fill coolant in the cooling system. Fit radiator cap.
Start the engine and check for any fuel leakages.Rectify, if necessary.
Fill required quantity of recommended running-in oil in the oil sump. Mount air cleaner assembly on test bed suitably.Connect air cleaner outlet to engine intake using suitable hoses. Make suitable linkage for controlling accelerator lever. Connect exhaust pipe to exhaust manifold. Connect battery cables to starter motor. Ensure that -ve terminal is earthed. Crank engine with accelerator lever in idling position. Allow oil to be circulated through the system. Check and ensure t hat oil p ressure indicat ed b y gauge is sat isfact ory.
SULIN
Slightly raise the engine speed and check for any oil, fuel, coolant and air leakages. Rect ify if any. Check colour of the exhaust gas. Check for any unusual noise from the engine. Connect engine to dynamometer and run for running in test as per schedule.
Engine running in test schedule : Engine Speed (rpm)
Tim e (m inutes)
Torque (m kg)
800
5
0.0
2000
5
2.3
2500
5
4.6
3000
5
5.8
3500
5
4.9
2500
5
8.2
After running in test of the engine, reduce dynamometer load to zero and allow engine to run at idling speed for about 5 minutes and then stop it.
117
MAIN INDEX
GROUP INDEX
ENGINE
ENGINE 475 SI MPFI
EVAPORATIVE EMISSION CIRCUIT : ENGINE
SULIN
Fig. 186 118
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI 8. TROUBLE SHOOTING NOTE : BEFORE CHANGING ANY SENSOR PLEASE CHECK THE WIRING HARNESS CAREFULLY. Sr. Problem Observed no. 1.
Engine not cranking
Probable Cause
ENGINE
Action to be taken
Low battery voltage
Clean and tighten the connectors Jump start using another battery Get battery charged or changed
2.
Engine cranks but doesnot start
Faulty starter
Rectify or replace
Worn out piston rings/seized pistons
Overhaul & replace affected parts
Faulty immobiliser
Check and rectify
Clogged air filt er
Clean as per the instructions
Incorrect valve timing
Set valve timing / check & reset
Fault y spark plugs
Clean, check gap/ replace if necessary
Fault y crank angle signal
Check & correct the gap
Faulty water tem p erature sensor
Check & replace if necessary
Fault y MAP signal
Check & replace if necessary
Fault y throttle position signal
Check & replace if necessary
Fault y ISC valve
Check & replace if necessary
Clogged inject ors
Check & replace if necessary
Fault y fuel regulator
Check & replace if necessary
Clogged fuel filt er
Rep lace
SULIN
3.
Erratic idling
Fault y ignition coil
Check and replace
Fault y firing order/ injector (connect ion) order
Check and replace
Fault y E C U
Rep lace
Fault y inertia switch
Reset if tripped off or replace
Fault y Fuel Pump
Check and replace if necessary
Inlet manifold leakage/ vacuum connections
Check and rectify
Valve timing incorrect
Set valve timing / check & reset
Vehicle speed signal fault y
Check & replace
ISC valve faulty
Check & replace
Vacuum line to presure regulat or connect ions
Check & t ight en/ replace
Fault y firing order/
4.
Does not idle
inject or(connect ion) order
Check and rectify
Fault y MAP signal
Check & replace
Fault y ISC Valve
Check & replace
Fault y fuel regulator
Check & replace 119
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Sr. Problem Observed no.
Probable Cause
Action to be taken
5.
Battery voltage low
Check and tighten connections Jump start using good battery Get battery charged/changed Clean as per instruction set valve timing / check & reset
Maximum RPM low
ENGINE
Clogged air filt er Valve timing incorrect Spark plugs defect ive
Clean an d necessary
ch eck g ap / rep lace if
Adult erat ed fuel
Flush the system and refill
Fault y crank angle signal
Check and rectify the gap 1.5 + 0.5 mm
Clogged inject ors
Check and Replace
Fuel pump fault y
Check and Replace
Clogged fuel filt er
Rep lace
Fault y firing order/
6.
Poor acceleration/Power
injector (connection) order
Check and rectify
Low battery voltage
Check and tighten connections Jump start using good battery Get bat t ery charged/ changed
Clogged air filt er
Clean as per instructions
Inlet manifold leakage/ vacuum connections
Check and rectify
SULIN
Fault y ISC valve
Check & replace
Clogged inject ors
Check & replace
Fault y fuel regulator
Check and replace
Clogged fuel filt er
Rep lace
Fault y ignition coil
Check and replace
Fault y firing order/ injector (connect ion) order
Check and replace
Incorrect t appet clearances
Check and reset
Valve timing incorrect
Set valve timing / check & reset
Inlet manifold leakage/ vacuum connections
Check and rectify
Valve timing incorrect
Set valve timing / check & reset
Worn out piston rings/ seized pistons
Overhaul / replace affect ed part s
Spark plugs defect ive
Clean an d necessary
Adult rat ed fuel
Flush the system and refill
Clogged inject ors
Check and Replace
Fault y fuel regulator Fuel pump fault y
Check and Replace Check and Replace
Clogged fuel filt er
Rep lace
Fault y firing order/ inject or(connect ion) order
Check and rectify
ch eck g ap / rep lace if
120
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Sr. Problem Observed no. 7.
8.
9.
Knocking
Misfiring
Whitish/Bluish smoke
Probable Cause
Action to be taken
Spark plugs defective
Clean and check gap/replace if necessary
Adultrated fuel
Flush the system and refill
Vacuum line to presure regulat or connect ions
Check and t ight en/ replace
Incorrect valve timing
Check and adjust.
Inlet manifold leakage/ vacuum connections
Check and Replace Check and rectify
Incorrect t appet clearances
Check and reset
Valve timing incorrect
Set valve timing / check & reset
Spark plugs defect ive
Clean an d necessary
Adult rat ed fuel
Flush the system and refill
Faulty crank angle signal
Check and rectify the gap
Clogged inject ors
Check and Replace
Fault y firing order/ inject or(connect ion) order
Check and Rectify
Clogged air filt er
Clean as per instructions
Worn out piston irings/ seized pistons
SULIN
10. High fuel consumption
ch eck g ap / rep lace if
Overhaul / replace affected parts
Valve guide seals leaking
Check and Replace
Adult et at ed fuel
Flush the system and refill
Low battery voltage
Check and tighten connections Jump start using good battery Get bat t ery charged/ changed
11. High oil consumption
Inlet manifold leakage/ vacuum connections
Set valve timing / check & reset Check and rectify
Incorrect t appet clearances
Check and reset
Valve timing incorrect
Set valve timing / check & reset
Worn out piston rings/ seized pistons
Overhaul / replace affect ed part s
Spark plugs defect ive
Clean and check gap/ replace if necessary
Adult rat ed fuel
Flush the system and refill
Faulty lambada signal Clogged inject ors
Check and Replace Check and Replace
Fault y fuel regulator
Check and Replace
Vacuum line to presure regulat or connect ions
Check and t ight en/ replacet
Fault y firing order/ injector (connect ion) order
Check and rectify
Clogged Air Filter
Clean/ replace
Worn out piston rings/ siezed pistons
Overhaul / replace affect ed part s
Valve guide seals leaking
Check and Replace
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ENGINE
ENGINE 475 SI MPFI
INTRODUCTION :
Indica MPFI - Euro III is powered by 475 MPFI engine which produces 85 PS @ 5500 rpm and a torque of 120 Nm @ 3500 rpm. Tata 475 SI MPFI is a spark ignition multipoint fuel injection water cooled, petrol engine with SOHC (Single OverHead Cam) valve mechanism in ‘V’ type arrangement. All inlet valves on one side & all exhaust valves on other side.
SULIN SULIN
475 MPFI engine is fitted with 32 Bit inbuilt microprocessor intelligence into the engine control system. 475 MPFI engine provides better engine performance, better cold starting and warm up, better fuel economy, quick response and confirms the EURO III emission norms.
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ENGINE 475 SI MPFI CONTENTS Sr. No.
Description
Page No.
1.
Technical specifications
1
2.
List of special tools
2
3.
Tightening torques
3
4.
475 MPFI Euro III engine
5
5.
475 SI MPFI engine advantages
6
6.
475 MPFI Euro III system : Schematic representation
7
7.
Exploded view of : EMS Kit Components
8
8.
Engine Management System (EMS) Overview
9
9.
MPFI sensors / actuators
11
10.
Integrated Intank fuel pumpwith pressure regulator
31
11.
Ignition Coil Assembly
32
12.
ECU
34
13.
ECU Handling & care
40
14.
Schematic wiring diagram of power relay
41
15.
Schematic wiring diagram of some other EMS components
42
16.
Preliminary inspection of engine
45
17.
Exploded Views:
SULIN
a.
Engine cover mounting
48
b.
Air - Intake system
49
c.
Engine suspension
50
d.
Inlet & exhaust manifold
51
e.
Engine Timing - Petrol (Euro III)
52
f.
Moving parts - block
53
g.
Engine cooling
54
h.
Fuel injection
55
i.
Cylinder Head & Cover - Petrol EURO III
56
j.
Gaskets
57
k.
Engine electrical equipment
58
18.
Removal & Installation of 475 MPFI engine from the car
59
19.
Removal and Installation of Radiator from the car
61
20.
Alternator/Power steering pump belt & A.C. compressor belts removal, inspection,
62
& fitment
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ENGINE 475 SI MPFI Sr.No.
Description
Page No.
21.
Timing belt Removal / Fitment
63
22. 23. 24.
Cylinder Head (Engine on Workstand) Cylinder block sub assembly Lubrication system
66 86 100
25.
Cooling system
102
26.
Air intake system
111
27.
Accelerator Cable
113
28.
Engine Testing
115
29.
Trouble Shooting
116
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ENGINE 475 SI MPFI TECHNICAL SPECIFICATION ENGINE Model
:
TATA 475 SI MPFI
Type
:
Water cooled Multi Point Fuel Injection Petrol Engine
No. of cylinders
:
4 inline
Bore X Stroke
:
75 mm x 79.5 mm
Capacity
:
1405 cc
Max. engine output
:
85 PS at 5500 rpm as per ISO : 1585
Max. torque
:
120 Nm (12 Kgm) @ 3500 rpm
Compression ratio
:
10 : 1
Firing order
:
1-3 - 4-2
Fuel system
:
Sequential Injection with close loop Air / Fuel control
Ignition system
:
Grouped Ignition
Emission compliance
:
EURO III with EOBD
Engine oil capacity
:
4.5 Litres
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Cooling system capacity :
6 Litres
Air filter
:
Dry (paper) type
Oil filter
:
Spin on full flow paper type
Valve train
:
SOHC, 2V/cylinder
EMS
:
JCAE EMS, S 2000 PL4
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ENGINE 475 SI MPFI LIST OF SPECIAL TOOLS Sr. No.
Description
Part No.
1.
Box spanner (16 A/F) for spark plug
2702 5890 06 01
2.
Extended socket (10mmA/F) for oil sump mounting screw
2702 5890 06 03
3.
Camshaft Locking Pin
2702 5890 06 04
4.
Flywheel locking pin
2702 5890 06 05
5.
Lock plate for camshaft gear washer
2702 5890 06 07
6.
Drift for crankshaft oil seal in rear cover
2702 5890 06 08
7.
Drift for removal / fitment of valve guide
2702 5890 06 11
8.
Spacer for valve guide fitment
2702 5890 06 12
9.
Drift for fitment of oil seal on valve guide
2702 5890 06 14
10.
Valve spring compressor
11.
Support rail
2702 5890 06 16
12.
Drift for valve guide seal fitment
2702 5890 06 17
13.
Drift for oil pump oil seal
2702 5890 18 01
14.
Spanner for oil filter
2702 5890 18 02
15.
Bracket (LH) for mounting engine on stand
2702 5890 24 02
16.
Bracket (RH) for mounting engine on stand
2702 5890 24 03
17.
Engine repair stand
2573 5890 24 01
18.
Drift for fitment of camshaft oil seal
2654 5890 05 08
19.
Engine support stand
2702 5890 24 01
20.
Tata Diagnostic Tool
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2702 5890 06 15
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ENGINE 475 SI MPFI TIGHTENING TORQUES : The fasteners should be tightened to specified torque at recommended intervals (km/m). If various fasteners are not tightened to specified torques, that is either over tightened or let loose, it will result in leakage at joints and damage to the parts/threads. It will also adversely affect the performance of the parts/systems as clearances/ bearing plays in the aggregates are governed by the tightening torques of the fasteners. When choosing the torque wrench, remember that it should not be subjected to torque exceeding three fourths of its capacity. Before tightening, clean the threads and apply a little oil. Note: For tightening torque of EMS components, refer to respective sections. Serial No.
Description
Torque in mkg.
1.
Main Bearing Cap bolt M10 x 1
5.5 #
2.
Cylinder head bolts M10 x 1.1
3, 5, 6.5 (Ref. Note) #
3.
Spark plug in cylinder head M14 x 1.5
4.
Cylinder head cover bolts M6
5.
Oil sump Screw M6 x 1
6.
Sealing plug for oil gallery block rear M14 x 1.5
3.5
7.
Oil sump drain plug M12 x 1.5
3.5
8.
Rear timing cover to block M6 x 1
1.0
9.
Rear timing cover to head cover M6 x 1
1.0
10.
Timing belt cover M6 x 1
1.0
11.
Rear cover crank case on cylinder block screw M6 x 1
1.0 #
12.
Connecting rod cap Nut M9 x 1
5.25 #
13.
Flywheel mounting screw M10 x 1
5.0 #
14.
Crankshaft gear to crankshaft bolt M14 x 1
15.
Vibration damper / 5 groove A/C pulley to crankshaft gear
2.5
16.
Belt tensioner adjuster bolt M10 x 1.5
3.0
17.
Cam thrust plate
1.0
18.
Timing belt idler to cylinder block bolt M10 x 1.5
19.
Camshaft gear to camshaft screw M12 x 1.25
20.
Lock Nut (Rocker adjusting screw) M9 x 1
21.
Assembly Fuel feed pump on cylinder head screw M8 x 1.25
2.0 #
22.
Exhaust manifold mounting bolts on cylinder head M8 x 1.25
2.0 #
23.
Starter motor on Transaxle bolt M8 x 1.25
2.4
24.
Alternator bracket to cylinder crankcase M8 X 1.25
2.0
25.
Alternator to bracket M10
2.0
2.5 1.0 # 0.6 to 0.7 #
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4+60 0 #
4.5 # 8.0 2 Kgm
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ENGINE 475 SI MPFI Serial No.
Description
Torque in mkg.
26.
Adapter to cylinder head Stud M6 x 1
2.0 #
27.
Alternator tensioner bracket to block M8 x 1.25
2.0
28.
Alternator to tensioner bracket screw M8 x 1.25
1.5
29.
Oil pump on cylinder block
30.
Assembly Strainer to oil pump M6 x 1
31.
Assembly oil filter to cylinder crankcase M12 x 1.5
32.
Oil pressure switch on cylinder crankcase M20 x 1.5
33.
Water pump to cylinder crankcase screw M6 x 1
1.0 #
34.
Water outlet elbow to intake manifold Nut M6 x 1
1.0 #
35.
Water inlet elbow to cylinder crankcase screw M8 x 1.25
2.0
36.
Temperature Transducer on cylinder head M14 x 1.5
1.5
37.
Water inlet elbow to intake manifold nut M6 x 1
1.0
38.
Thermostat cover to intake manifold nut M6 x 1
1.0
39.
Lifting hooks to cylinder head screw M8 x 1.25
2.5
40.
Engine mounting bracket to block M10 x 1.5
4.5
41.
Engine mounting bracket to arm
4.0
42.
Power steering pump mounting on bracket screw M8 x 1.25
2.5
43.
A/C Compressor bracket to cylinder block screw M8 x 1
2.5
44.
A/C Compressor to A/C compressor bracket bolt M8 x 1.25
2.5
45.
Power steering pulley to power steering pump Nut M12 x 1.25
8.0
46.
Assembly Idler to Slider (A/C compressor belt tensioner) Nut M8 x 1.25
2.5
47.
Lambda Sensor on Front exhaust pipe & Catalytic Convertor
1.0 # 1.0 Ref. Note @ # 3.0
SULIN
3.5 - 4.5
Tolerance on Torque values + 5% for those marked # and + 10% for others Note @ Apply oil on seal face and screw in until seal touches face. Tighten further by 3/4 turn. Do not over tighten.
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ENGINE 475 SI MPFI
475 MPFI EURO III ENGINE
OIL FILLER CAP IGNITION COIL INTAKE MANIFOLD
EXHAUST MANIFOLD
THROTTLE BODY
PHASE SENSOR
AC COMPRESSOR
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ENGINE RPM SENSOR MAP SENSOR OIL FILTER DIPSTICK TUBE
ALTERNATOR
POWER STEERING PUMP
5
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ENGINE 475 SI MPFI
INTAKE MANIFOLD WITH THROTTLE BODY
IAC VALVE
MAP SENSOR
THROTTLE BODY
CYLINDER HEAD COVER BLOWBY HOSE
CYLINDER HEAD
FUEL RAIL
CANISTER PURGE VALVE
INTAKE MANIFOLD
SULIN 475 SI MPFI ENGINE ADVANTAGES 475 MPFI engine uses JCAE multipoint fuel injection system. Various sensors located at various points in the engine, sense important parameters of the engine operation & send signals to a ECU located in egine compartment.Based on predetermined engine mapping, the ECU precisely controls the fuel delivery injection timing to ensure optimum fuel utilisation with minimum emission. MPFI engine provides the following advantages
• Better Engine Performance : Optimum fuel quantity and Spark timing is calculated by ECU for any operating condition.
• Better Cold Starting and Warm up : ECU identifies cranking condition and quick startingis ensured by providing sufficient fuel quantity and optimum spark timing. For quicker warm up, idling speed is increased as a function
of Water and Air temperature inputs to the ECU.
• Emission : The petrol injection engine has low emissions because the air fuel ratio is controlled to stoichiometric using lambda sensor. Faster warm up from cold start ensures early operation of catalytic converter in turn reducing the emission.
• Fuel Economy : The petrol injection engine has a better fuel economy because the engine is optimised at each operating point, discretly.
• Quick Response : The petrol injection engine will have a better driveability and better acceleration since the fuel delivery and spark timing are controlled by ECU, which quickly responds to engine/Driver demands.
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ENGINE 475 SI MPFI
475 MPFI EURO III SYSTEM: SCHEMATIC REPRESENTATION
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7
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ENGINE 475 SI MPFI EMS KIT COMPONENTS 1
7
1 2
1
8
2
6
1.4 0.8
SULIN 4
11
3 10
5 1
9
1.5
- SPECIFIED TORQUE IN Kgm
Sr.No. 1 2 3 4 5
PART DESCRIPTION Crank Angle and Shaft RPM Sensor Bracket (Crank Angle Sensor) Cam Sensor Bracket (for Cam Sensor) Rubber Grommet (Dust seal)
Sr.No. 6 7 8 9 10 11
PART DESCRIPTION Sensor Plate (Cam Shaft Gear) Knock Sensor MAP Sensor Coolant Temperature Sensor Throttle Body Ignition Coil
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ENGINE 475 SI MPFI ENGINE MANAGEMENT SYSTEM (EMS) OVERVIEW : Indica MPFI - Euro III is powered with 475–SI Multi Point Fuel Injected (MPFI) engine, which generates 85Hp. The JCAE (Johnson Controls Automotive Electronics) S2000 Engine Management System combined with the suitable hardware meets the EURO – III regulations. The Engine Management System is modular with a basic core group of essential sensors, actuators and strategies(refer block diagram below). The strategies are derived from physical modeling of the engine and vehicle. The S 2000 PL 4 is dedicated for EURO III / Engine On Board Diagnostics(EOBD) Engine management systems. It benefits from new technologies includes a 256Kbit flash memory, allowing a downloading of the engine parameters and has a 12MIPS (Million Inputs Per Second) processing capability. The following matrix identifies the features used on Indica MPFI - Euro III application • • •
• •
Distributorless Grouped Ignition ( Wasted Spark Ignition) Sequential Multi point (MPI) Injection engine control Engine Phase detection Dual (Up stream & Downstream) O2 Sensor Interfaces with independent monitoring and heater drivers Idle Speed Control by Stepper motor EOBD Functions (Catalyst Monitoring, Mis-fire detection ,Oxygen sensors, Fuel system etc)
• • • • • •
Canister Purge Control Valve Integrated Fault –tolerant System Immobilizer (Anti theft) management Air Conditioning and Fan Control Keyword 2000 (ISO 9141)interface Electrical diagnostic and protection (Short and open circuits, signals)
Additional Features • Warm Up Corrections • Model Based transient injection control • Model based transient ignition control • Model based air/water temperature compensation • Limp home and recovery • Adaptive fuel injection control • Catalyst light-off control during engine warm up • Altitude compensation • Deceleration fuel cut-off • Engine Knock Control • Fuel Pump relay Control • Post Ventilation – Fan control • Accessory Load based Idle Speed regulation GENERAL SYSTEM OVERVIEW Refer page No. 7 + Block Diagram of JCAE EMS (below)
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» Starting: The Idle Air Control Valve is opened to allow the correct amount of extra air into the engine for starting. The Ignition timing and the amount of the fuel are adjusted according to the engine temperature, giving quick starts regardless of the different ambient conditions.
INPUTS OUTPUTS
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ENGINE 475 SI MPFI » Idle Air Control: Proper Idling of the engine is ensured irrespective of different operating conditions with help of closed loop control. The Idle Air control valve (IACV) that allows air to bypass the throttle controls idle air. The activation of the IACV occurs in three strategies: 1. 2.
3.
During Starting to provide correct amount of air to the engine During engine Idle. Depending upon the engine coolant temperature, the amount of the air inducted through the valve is varied by the varying the position of the valve, ensuring a closed loop control to a target Idle Speed. During engine running to enhance driveability by controlling engine torque changes on closing throttle (depression limiting).
» Engine Load Determination: Fuelling and Ignition timing requirements of the engine are dependent on the Engine load. The Load determination is done using the Model Based Fuelling (MBF) strategy. The strategy uses the estimated temperature and pressure at the intake port together with the engine speed to estimate the amount of air entering the cylinder at the next induction stroke. To calculate the airflow as precisely as possible, a thermal model of the Intake manifold is used, which is a correction factor applied to the load equation to determine the correct amount of the fuel to deliver to the engine. This model also serves as a backup strategy if either the Throttle Position or Manifold Absolute Pressure Sensors fails. The MBF model or Thermo model is a heat transfer model, which use the heat exchange between the air and the manifold walls. The manifold also takes into account of all temperature variations (E.g.: purging) that will occur during the running.
depends largely on the engine load and speed. Further adjustments are to account for the variations in the operating conditions (e.g. Engine temperature). To maximise the engine performance the fuelling is enriched to give maximum power at wide-open throttle (WOT) conditions. Not all the fuel injected by the Injectors enters the engine directly, some amount is deposited on the Inlet port walls as a puddle whose size varies with the throttle position, engine speed and engine temperature. The puddle evaporates over the time and its effect is particularly significant during transients. To account for these transient effects, the puddle dynamics are modelled and the fuelling is adjusted accordingly. Overrun fuel cut-off is provided for fuel economy and improved emissions performance. A closed loop fuelling system is used – a further correction is applied to the open loop pulse time to maintain a stoichiometric air fuel ratio under certain operating conditions. The closed loop system also provides adaptive (‘Learning’) fuelling to compensate for the wear of the intake system, component tolerances and vehicle to vehicle variations.
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» Fuelling: The Fuel is injected into the Inlet ports (Port Fuel Injection) by the solenoid operated Fuel Injectors which are driven by ECU. The amount of the fuel delivered during each engine cycle is proportional to duration of the Injector open time. Injector timing (phasing) is controlled to optimise performance. The injection is sequential i.e., each injector is opened relative to its own cylinder timing. Amount of the fuel required (i.e. the Injector pulse time)
» Ignition: The optimum ignition timing depends largely upon the engine speed and load. Further small corrections are applied to improve driveability and to account for the variations in the operating conditions (e.g. engine temperature, Inlet air temperature). The ignition timing is also adjusted in conjunction with the Idle Air Control Valve to control the idle speed of the Engine. » Throttle Position and Adaptation: The throttle position potentiometer output may differ between vehicle and can also change over time due to component aging. A corrective term is applied to compensate for this effect; this is an adaptive (‘learning’) value that is updated throughout the vehicle’s life. » Knock Control: A sensor mounted on the engine detects when the knock occurs and allows the ECU to determine on which cylinder knock is occurred. Then the Ignition and fuelling corrections are applied to prevent further knock and thus protecting the engine from any damages. Further an intelligent software strategy enables a ‘Cylinder selective’ knock control, despite the ignition is ‘grouped’.
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ENGINE 475 SI MPFI » Gear Ratio Determination: Employing different calibrations for open loop Idle control and fuel cut off depending on which gear is currently selected can enhance Driveabilty. Gear ratio, and hence the gear engaged, is calculated from the vehicle’s measured engine speed and road speed. This input is further synchronised with the ‘Anti- surge’ functions for a smoother driveability during the transients (accelerations and decelerations). » Purge Control: Fuel vapours generated in the fuel tank is stopped in a canister, in order to limit the hydrocarbon emissions into the atmosphere. The vapours stored in the canister are purged into the engine under controlled conditions via a Purge valve to minimise any detrimental effects on driveability or on the emissions. » Engine Speed Limiting: A rev-limiter protects the engine from over revving. The cut off is introduced progressively to make the operation smooth to the driver. » Vehicle Speed Limiting: The vehicle speed is limited from over speeding to provide safety and protection. A smooth vehicle speed cut off is applied in order to have a better driveability feel.
SULIN
» Cooling Fan Control: Cooling Fans are switched ‘ON’ if the engine temperature is too high, and remains on until the temperature falls to an acceptable level.This operation controls fan speed in two stages.The fans also runs even after the ignition is switched off. if the engine is hot. » Auxiliary load Input Information: Auxiliary drive like power steering, Air-conditioning and Alternator load information are taken into consideration in order to have a better Idle speed control and the driveability » Fuel Level Sensor A fuel level sensor provides the necessary information for the low-level inputs for the EOBD strategies activation.
11
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ENGINE 475 SI MPFI MPFI SENSORS / ACTUATORS CRANK ANGLE SENSOR : (Fig.1 & 2). Type : 03VR Inductive pick up (Variable reluctance) 3 Pin connector Working Principle : The sensor is positioned near the flywheel mounted toothed wheel. An A.C. voltage is induced in sensor coil, when the flywheel tooth projection pass through the sensor. This A.C. voltage is directly proportional to the speed of rotation. This sensor signal is first processed by an ASIC and then by the ECU.
Fig. 1 Crank angle sensor
System Integration : The sensor provides the speed and crank angle input to the ECU. The system uses a 60 -2 = 58 tooth spaced at 6º intervals. The tooth wheel (target wheel) is integral part of the flywheel. This wheel has 2 tooth missing (at 114º ATDC of cylinder1) to allow the engine position to be determined.
SULIN
The sensor signal is used to calculate engine speed & crank angle position.(Fig. 3 & 4). Fitment Data : This sensor is mounted on the cylinder block over the flywheel (Fig. 1). Sensor Gap = 1.5 ± 0.75 mm Installation Guideline :
Sensor to be fitted in a suitable bracket and secured by use of a bolt tightened to a torque of 6 to 10 Nm.
Fig. 2 Crank angle sensor System Diagnosis :
Stand Alone Diagnosis : (At NTP conditions)
Use Tata Diagnostic Tool.
Use Multimeter
Check for engine RPM during cranking.
Coil resistance = 300ohm - 420 ohm (between pin 1 and pin 2) Check gap between flywheel and sensor tip Sensor end
Pin assignment 1 : ECU pin M2B1: +ve 2 : ECU pin M2B2: -ve 3 : Shield
12
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ENGINE 475 SI MPFI PMH 1-4 Physical Teeth
VR sensor signal
Processed Signal 1
PMH 2-3
3
1
PMH = TDC, Top Dead Centre
Fig. 4
Fig. 3 SCHEMATIC WIRING DIAGRAM :
+ VE
- VE
M2B1
SULIN
M2B2
CRANK ANGLE SENSOR
13
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ENGINE 475 SI MPFI WATER TEMPERATURE SENSOR(Fig.5) Type : 16TT Negative Temperature Coefficient (NTC) 2 Pin connector Working Principle A semiconductor material changes its resistance when exposed to variable temperature source. Resistance decreases as temperature increases. System Integration : This sensor provides water temperature input to ECU when placed in water stream.
Fig. 5 Water temperature sensor
Fitment Data : WTS is fitted on thermostat housing (before thermostat) which is in contact with the engine coolant.(Fig. 5) Installation Torque : 8Nm Stand Alone Diagnosis (See Illustration) : Use Multimeter Nominal Thermister resistance values 2500 ohm @ 20º C 833.9 ohm @ 50º C Sensor end Pin assignment 1 : ECU M1D4: -ve
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2 : ECU M1E4: +ve Measure the resistance across pins 1 & 2. System Diagnosis : Use Tata Diagnostic Tool. Check for ‘Water Temp’ values. SCHEMATIC WIRING DIAGRAM :
SIG
M1E4
- VE
M1D4
14
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ENGINE 475 SI MPFI MAP & T SENSOR (Manifold Air Pressure & Temperature Sensor) (Fig. 6 & 7) Type : 05 BP001 Peizo - Resistive type / NTC 4-Pin Connector Working Principle : MAP : A DC signal volt is produced by this semiconductor device when varying manifold air pressure acts on the semiconductor diaphragm. To produce this output the semiconductor device has to be excited. This signal output increases with increase in absolute manifold vacuum.
Fig. 6Manifold air pressure sensor
Air temp : Semiconductor material changes resistance when exposed to variable temperature source. System Integration :
SULIN
4 3 2 1 PIN Nos.
This provides manifold vacuum (abs.) signal & air temperature input to ECU. The sensor is activated by excitation voltage supplied by ECU. Fitment Data
:
This sensor is fitted on Inlet manifold pleanum.(Fig. 6) Installation Torque : 1Kgm Stand Alone Diagnosis :
Fig. 7Manifold air pressure sensor
Use Multimeter Characteristic of MAP Sensor
With ignition “ON”. Supply volt = 5.00 vdc
5 4.65
Output Voltage Uout in V
Signal volt = 0.4 V @ 10 kpa (abs) = 4.65 V @ 115 kpa (abs) Pin assignment (Fig.7) 1 : M2A2 : Ground 2 : M1A2 : Temp. Signal 3 : M2E1 : Supply 5V
0.4 0
0
10
4 : M2C1 : Pressure Signal
115 Absolute Pressure Pabs in kPa
Measure signal volt at pin1 and pin3 with sensor
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ENGINE 475 SI MPFI connected to wiring harness.
Characteristic of Temperature Sensor
System Diagnosis :
100000
Resistance R in ohm
Use Tata Diagnostic Tool Check for ‘Intake manifold pressure’ and air temperature value.
10000
1000
100
10 -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 Temperature t in ºC
SCHEMATIC WIRING DIAGRAM :
2 + SIG -
3 4
M1A2
SULIN
1
M2E1 M2C1 M2A2
MAP & T
16
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ENGINE 475 SI MPFI THROTTLE POSITION SENSOR (TPS) Fig. 8 & 9. Type : 06TP Linear Potentiometer type 2 Pin Connector Blade drive with integral 3-way connector Working Principle : A fixed input DC volt to a potentiometer provides a variable output DC volt when the circuit resistance is varied externally. Output voltage increases when circuit resistance reduces. System Integration :
Fig. 8 Throttle Position Sensor (TPS)
Sensor provides variable signal Input to ECU when throttle lever is operated (opened / closed). This requires a supply volt of 5.00 Vdc from ECU. Fitment Data : This sensor is a part of Integrated Throttle Body which is fitted on inlet manifold upstream side. Throttle lever shaft is extended to a crank lever which operates the sensor (varies the circuit resistance). Fig. 8
SULIN
Installation Guidelines : Diameter of screws used to fix potentiometer = 12mm Tightening Torque = 2.5 + 0.5 Nm Stand Alone Diagnosis : Use Multimeter With ignition “ON”. Supply volt = Signal volt
= =
Fig. 9 Throttle Position Sensor 5.00 vdc Sensor Characteristics
0.5 vdc at Idle position 4.5 + 0.15 vdc at WOT position 4.25 + 0.225
Sensor end
Pin Assignment
2 : ECU pin M1B4 : Signal 3 : ECU pin M2C3 : 5V supply Measure signal voltage across pin 2 and pin 3 with sensor connected to wiring hamess. System Diagnosis : Use Tata Diagnostic Tool. Check for ‘Throttle sensor’ voltage by pressing the accelerator pedal in and out.
Volts
1 : ECU pin M1A3 : Gnd.
0.68 + 0.1
0
91
5
98
Degrees
Note : The broken lines represent acceptable divergence limits
17
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ENGINE 475 SI MPFI SCHEMATIC WIRING DIAGRAM :
+ VE SIG
3
M2C3
2
M1B4
1
M1A3
- VE
THROTLE POSITION SENSOR FROM POWER RELAY (BASE PIN NO 8) FUSE 15A + VE - VE SIG - VE
SULIN
1 2
M1E2
4
M2A3
3
M2B3
UPSTREAM LAMBDA (O2 )SENSOR
FROM POWER RELAY (BASE PIN NO 8) FUSE 15A + VE - VE SIG - VE
1 2
M1D2
4
M1E3
3
M1D3
DOWNSTREAM LAMBDA (O2 )SENSOR 18
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ENGINE 475 SI MPFI LAMBDA SENSOR (O2 Sensor) Fig. 10 & 11 Type : Heated Ceramic Oxygen Sensor 4 Pin Connector 08LS Down Stream Oxygen Sensor 09LS Up Stream Oxygen Sensor Working princple (See Illustration) : A special ceramic body with gas permeable platinum electrodes on its surface, operates, depending upon ceramic material’s porosity which allows oxygen in the air to diffuse when the ceramic body is exposed to temperatures above 3500C. Voltage is generated across the electrodes which are exposed to gas with different levels of oxygen contents. System Integration :
Fig. 10 Lambda sensor fitted ON Exhaust pipe
This sensor provides Air/Fuel ratio signal in the form of mV to ECU as a function of varying Air/Fuel ratio Typical values at 3500C: = 0.95’ 840 + 70mv (rich) = 1.05’ 200 + 50mv (lean) Fitment Data :
SULIN
Fitted on the exhaust pipe as shown in Fig. 10 (Down stream O2 Sensor).
Fig. 11 Lambda sensor (O2sensor) Installation And Handling : • Do not store lambda sensors under high temperatures and/or high humiding condition. • Do not use impact wrench for installing the sensor. • Reject the sensor in case of dropping. • Anti-seize compound should be painted on thread portion. • Avoid lambda sensor cable touching exhaust pipes. • Do not splash oily liquid on the sensor surface. Installation Torque : 34.3 to 44.1 Nm
19
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GROUP INDEX
ENGINE 475 SI MPFI Stand Alone Diagnosis : Use Multimeter Heater function Heater Resistance
For Pin nos. please refer to marking on casing.
08LS : 6.0 ± 1ohm ( 23 ± 5º C) 09LS : 3.3 (+0.7ohm/-0.3ohm) ( 23 ± 5º C) Pin assignment (Fig. 12) Up Stream Oxygen Sensor (Green colour) 1 : Supply 12V 2 : ECU pin M1E2 : Heater 3 : ECU pin M2B3 : Signal -ve 4 : ECU pin M2A3 : Signal +ve Down Stream Oxygen Sensor (Blue colour) 1 : Supply 12V 2 : ECU pin M1D2 : Heater 3 : ECU pin M1D3 : Signal -ve 4 : ECU pin M1E3 : Signal +ve Measure heater resistance across pin 1 & 2. System Diagnosis : Use Tata Diagnostic Tool.
Fig. 12
SULIN
Check for the signal voltages. ●
For Upstream O2 sensor : Voltage > 0.500V or < 0.400V & Switching frequency > 0.2Hz
●
Downstream O2 sensor : Voltage > 0.500V or < 0.400V
20
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI LAMBDA SENSOR :
•
Lambda oxygen sensor located in exhaust pipe Fig. 13.
5
1. Special ceramic coat 2. Electordes 3. Contact 4. Housing 5. Exhaust pipe 6. Shield (porous) 7. Exhaust gas. 8. Air
7
6
4
8
3
1
2
Fig. 13 Lambda Sensor Lambda (oxygen) sensor voltage curve at 6000C operating temperature Fig. 14 a) Rich mixture (air deficiency) b) Lean mixture (excess air)
mV a
1000
Oxygen-sensor voltage
•
b
800
SULIN
600 400 200 0
0.8 0.9 1 1.1 Excess-air factor
1.2
Fig. 14 Lambda Sensor Voltage Curve
•
Heated Lambda (oxygen) sensor Fig. 15 1. Probe housing 2. Ceramic Shield tube
5
1
2
3. Electrical connections
3
4. Shield tube with slits 5. Active ceramic sensor layer 6. Contact 7. Shield 8. Heating lement 9. Clamp connections for heater element
4
6
7 8 9
Fig. 15 Heated Lambda Sensor 21
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GROUP INDEX
ENGINE 475 SI MPFI VEHICLE SPEED SENSOR (VSS) Fig. 16 & 17 Type : VDO - Hall Effect sensor Working Principle : This sensor is a semiconductor device, employing Hall Effect switches. It provides On/Off pulses, when a rotating metallic object interupts the magnetic field. System Integration : This provides vehicle speed input signal to ECU with respect to the vehicle speed, driven via speedo cable. Specification : 8 pulses per revolution. Fitment Data : This vehicle speed sensor is mounted on the gearbox on speedo output location.Fig. 16.
Fig. 16 Location of VSS on Transaxle
Stand Alone Diagnosis : Use Multimeter Pin assignment 1 : Supply
SULIN
2 : Ground 3 : ECU pin CPG2 : Signal
Manually rotate the speedometer cable and check for contact make & break pulses 8 times/rev. With Ignition ‘ON’, Pulse volt in ‘ON’ condition = 12 Volt DC
3
Measure pulse volt across ECU pin no. 6 and car body as ground with wiring harness connected to ECU.
2
PIN NOS.
1
Fig. 17 Vehicle Speed Sensor (VSS)
System Diagnosis : Use Tata Diagnostic Tool. Check for Vehicle speed sensor ‘Value’ during driving. SCHEMATIC WIRING DIAGRAM :
FROM POWER RELAY (BASE PIN NO 8) FUSE 15A
+ VE 1
CPG2
SIG 3 2 - VE
VEHICLE SPEED SENSOR 22
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI KNOCK SENSOR Fig. 18 & 19 Type : Piezo electric Sagem Working Principle : Knock sensor is directly mounted on the cylinder block. When knock occurs due to the uncontrolled combustion, vibrations are generated on the block. These vibration forces cause a charge transfer and a voltage is generated by the sensor element. This is tapped off by contact discs and passed to the ECU where it is processed.
Fig.18
System Integration : Sensor is fitted on to block directly so that the structure borne vibrations generated by the ‘knocking’ can be detected effectively. This will enable the ECU to limit the Ignition timing (advance) for optimum efficiency, without the knock damaging the engine.
SULIN
Fitment Data : Mounted on the cylinder block. Installation Guidelines :
The sensor is fixed with screws and without washer. Screw sizes:Cast Block: M8X25 & M10X1.5 -30 Tightening Torque: 20 + 5 Nm Stand Alone Diagnosis : Sensor end
Pin assignment
Fig.19
1 : ECU pin M1C3 : +ve 2 : ECU pin M1B3 : -ve SCHEMATIC WIRING DIAGRAM :
1
M1C3
2
M1B3
KNOCK SENSOR
KNOCK SENSOR 23
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GROUP INDEX
ENGINE 475 SI MPFI CAM PHASE SENSOR Fig. 20 & 21 Type : AAC K9 Hall Effect Sensor Working Principle : A signal voltage is generated by the sensor when the ‘target’ wheel pass through the sensor supplied with 12V supply. The position of the ‘target’ indicates the phase of the engine. System Integration : Sensor provides the information to ECU to determine the phasing. The software reads the state of the Camshaft sensor on each engine revolution, by the signal provided by the sensor.
Fig.20
Fitment Data : This sensor is mounted near the Camgear on the cylinder head. Sensor Gap : 1.5 ± 0.5mm
SULIN PIN Nos. 1 2
3
Installation Guidelines : 6 - 10 Nm Stand Alone Diagnosis : Pin Assignment 1 : Ground 2 : ECU pin M1F3 : Signal
Fig.21
3 : Supply 12V (From relay - pin 8 of base) SCHEMATIC WIRING DIAGRAM :
FROM POWER RELAY (BASE PIN NO 8) FUSE 10A
+ VE 3
M1F3
SIG 2 1 - VE
CAM SHAFT POSITION SENSOR
24
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GROUP INDEX
ENGINE 475 SI MPFI IAC VALVE(IDLE AIR CONTROL VALVE)Fig.22& 23 Type : 01SM003 Stepper motor type 6 Pin connector Working Principle : Fig. 24 A linear flow pneumatic valve allows accurate flow control by varying flow cross section area. This is done by a moving spindle in both open/close directions operated by a stepper motor. System Integration : ECU provides drive signal to the stepper motor of IAC valve to allow more/less air depending upon engine demand to maintain target speed of 750 rpm ( N = 50 rpm) in hot condition. Also, the input from various other sensors helps IAC valve to maintain the target Idle Speed for various engine loads e.g. :A/C idle speed = 800 rpm Engine water temp dependent Speed, say at 300C = 1100 rpm. Fitment Data : This actuator is part of Integral Throttle Body which is fitted on inlet manifold upstream side. Fig. 22 & 23. Installation Guidelines : Screws to be used for fastening M5X0.8X14. Torque : 4+ 0.4 Nm - Thread locking adhesives can be used to prevent loosening. Stand Alone Diagnosis : Use Multimeter Single Phase coil resistance = 53 ± 5.3 ohm Actuator end Pin assignment A ECU pin M2E3 : Coil A B ECU pin M2D2 : Coil B C ECU pin M2D3 : Coil B D ECU pin M2D1 : Coil A Measure the coil resistance across pins M2E3 & M2D1, M2D2 & M2D3. System Diagnosis :
Fig. 22 Throttle Body showing Idle Air control valve fitted
SULIN Fig. 23 Idle Air control valve (IAC)
Throttle Body
Use Tata Diagnostic Tool. Check for IAC valve steps For normal idling at hot condition IAC valve steps = 12 ± 3 steps. (typical value) SCHEMATIC WIRING DIAGRAM :
M2D1 M2D3 M2D2 M2E3
D C B A
Air Cleaner
Air Inlet
Air Outlet
Throttle Plate
Stepper
Intake Manifold
Fig. 24 IAC valve illustration 25
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GROUP INDEX
ENGINE 475 SI MPFI INTEGRAL THROTTLE BODY Type : 09TB Ø 44 mm throttle valve, integrated with throttle position sensor, IACV (Idle Air Control Valve). Working Principle : Air flow into the engine is varied by varying the cross section area. In addition, flow rate is dependent on engine speed. System Integration : This Integral Throttle Body is with a butterfly valve (See Illustration) in the air flow path (of ø 44mm). The throttle is actuated by the lever (Fig.27)and the shaft assembly which in turn operates Throttle position sensor to provide engine load signal.
Fig. 25
Fitment Data : Fitted on the upstream of the inlet manifold. Fig. 25 Installation Guidelines : Manifold mounting flange screw torque : 6Nm Tightening Torques : Item Throttle Screw
Dimension
SULIN
Torque(NM)
M4 x 0.7
2.2 + 0.5
Idle actuator fastening M5SPIRALOCK 4.5 + 0.5 screws TPS fastening screws M4SPIRALOCK
2.5 + 0.5
Cable bracket screw
M5SPIRALOCK 5.5 + 1.0
Idle adjusting screw
M5 x 0.5
---
Fig. 26 Integral throttle body
Stand Alone Diagnosis : Refer to IAC, TPS section. System Diagnosis : Use Tata Diagnostic Tool. Serviceability : The following parts can be replaced in service : a) Idle Air Control Valve (Stepper Motor) b) Throttle Position Sensor
Fig. 27 26
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GROUP INDEX
ENGINE 475 SI MPFI CANISTOR PURGE VALVE Fig. 28 & 29 Type : Sagem make purge value 2 Pin connector Working Principle : Fig. 30 A solenoid valve opens and closes the gas passage depending upon ECU signal to the solenoid valve. Gas (petrol vapour) flows into manifold from canistor and the flow rate varies depending upon valve duty cycle ratio (open time to close time ratio) and pressure differential between canistor and inlet manifold. System Integration : ECU provides drive signal to this solenoid valve to purge the petrol vapour from canistor into the engine (inlet manifold) at appropriate speed and load of engine as decided by ECU. This valve is kept open (to purge) depending upon the duty cycle ratio drive signal from ECU.
Fig. 28 Location of purge valve
Fitment Data : This valve is mounted on the engine block. In petrol vapour circuit this valve connects canistor purge line to intake manifold, downstream side of integrated throttle body. Fig. 28
SULIN
Stand Alone Diagnosis : Use Multimeter Solenoid coil resistance = 26 ohm ± 4 ohm @ 200 C Actuator end
Pin assignment 1 : ECU pin M2F2
Fig. 29 Purge valve
2 : Supply
Measure the resistance across pin 1 and 2. System Diagnosis : Use Tata Diagnostic Tool.
27
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GROUP INDEX
ENGINE 475 SI MPFI CANISTER PURGE VALVE - ILLUSTRATION : 1. HOSE CONNECTION
1
2. NON RETURN VALVE 3. LEAF SPRING
2
4. SEALING ELEMENT
3
5. SOLENOID ARMATURE
4
6. SEALING SEAT
5
7. SOLENOID COIL. 6 7
1
SULIN
Fig. 30
SCHEMATIC WIRING DIAGRAM :
M2B1
1
2
FUSE 10A
FROM POWER RELAY (BASE PIN NO 5) PURGE VALVE
28
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GROUP INDEX
ENGINE 475 SI MPFI FUEL INJECTOR Fig. 31, 32 & 33 Type : F type short 2 Pin Connector Working Principle : A solenoid valve, normally closed, opens when the electromagnetic core is energised. Fuel under pressure flows through metering orifice.This ensures fine atomisation and consistent flow rate for a given Injector opening time. The ball type seating valve acts as a good anti-deposit. System Integration : ECU provides drive signal to Injector (normally closed valve) to open and remain in open condition (pulse width-ms) depending upon the engine operating conditions (speed/load). Also the pulse width is compensated for low battery voltage condition. The concept of Sequential injection means when ECU provides drive signal to each injector separately at the end of compression. Fitment Data :
Fig. 31 Fuel Injectors location in the engine
SULIN
Four numbers of injectors are fitted on inlet manifold and fuel is fed by a common fuel rail(Fig.32) so that the fuel spray from each injector is directed towards the inlet valve, inside the inlet port. Stand Alone Diagnosis :
Injectors
Use multimeter Injector coil resistance 12.25 ohm ± 0.50 ohm Actuator end Pin assignment Injector 1 1 : ECU pin : M2H2 : Signal 2 : Supply Injector 2 1 : ECU pin : M2G3 : Signal 2 : Supply Injector 3 1 : ECU pin : M2G2 : Signal 2 : Supply Injector 4 1 : ECU pin : M2H3 : Signal 2 : Supply
Fig.32 Fuel Injectors
System Diagnosis : Use Tata Diagnostic Tool.
Fig. 33 Fuel Injector 29
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GROUP INDEX
ENGINE 475 SI MPFI SCHEMATIC WIRING DIAGRAM : FROM POWER RELAY (BASE PIN NO 5) FUSE 15A 2 1
INJECTOR CYLINDER 1
2 1
INJECTOR CYLINDER 2
2
SULIN 1
INJECTOR CYLINDER 3
2 1
INJECTOR CYLINDER 4
INJECTORS
30
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GROUP INDEX
ENGINE 475 SI MPFI INTEGRATED INTANK FUEL PUMP WITH PRESSURE REGULATOR FIG. 34 & 35. Type : PENTADEWA Intank - Electric Fuel Pump with inbuilt pressure regulator 2 Pin connector Working Principle : A positive displacement pump assy. is driven by a motor to provide continuous flow of fuel to high pressure fuel system from fuel tank. This Intank pump provides continuous flow of fuel to fuel rail where a constant fuel pressure is maintained by a fuel regulator which is integrated with the pump return line.
Fig. 34
The pressure regulator is a diaphragm operated valve which regulates pressure in the system (at fuel rail) to 3.5 bar and returns the excess fuel back to the tank. The diaphragm is operated by differential pressure between the system (fuel rail & lines) and the atmosphere.
SULIN
Fitment Data :
This Intank pump is fitted inside the fuel tank by immersing the pump’s suction end in the fuel. Pressure regulator is fitted on the return line of the pump. Stand Alone Diagnosis : Use Multimeter
Fig. 35 Intank Fuel Pump
Motor armature resistance = 20ohm @ 200C Actuator end (Pump)
Pin assignment 1 : from relay 2 : car body
Measure the coil resistance across pin 1 and 2 System Diagnosis : Use Tata Diagnostic Tool. Check for Fuel pump relay ‘ON/OFF’ condition. NOTE : With ignition ON, Fuel pump is switched off after 1 sec. if engine is not cranked.
31
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI SCHEMATIC WIRING DIAGRAM :
M FUSE 15A
FROM POWER RELAY (BASE PIN NO 5) FUEL PUMP
FROM POWER RELAY (BASE PIN NO 5)
FUSE 15A
3
2
4
1
4 3 2 1
SULIN M1H3 M1G3
IGNITION COIL
IGNITION COIL ASSEMBLY Type : BAE04 Four output Ignition Coil 4 Pin Connector Working Principle : This ignition coil operates on conventional principle of secondary (high) voltage generation by induction. However, primary current switching (ON/OFF) is triggered by an electronic circuit on ECU which also maintains constant dwell time (time required to energise primary coil) throughout the engine operating conditions.
32
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ENGINE 475 SI MPFI System Integration : ECU provides the trigger pulse to switch ON/OFF the power switch built in the coil which provides 2 sparks simultaneously in cylinders 1& 4 or 2&3 as both the ends of the secondary coil is ending with sparkplugs. This concept called Grouped Ignition, means two sparks occur for one useful power output (i.e. one spark in the end of compression & one spark at the end of exhaust). This enables maintenance of optimum dwell time at very high engine speeds. Fitment Data : The ignition coil is fitted on the thermostat housing to have the shortest possible length for High tension cable to connect Sparkplugs. This is done to reduce the level of electromagnetic radiation from HT cables and possible interferance w.r.t. the functioning of ECU. Fig. 36 & 37
Fig. 36 Ignition coil
Stand Alone Diagnosis (See Illustration) : Use Multimeter Check for 12 V power supply P/G on wiring harness Firing order (1,3,4,2) & HT cable connections (See Illustration)
SULIN
Primary coil resistance = 0.6 ohm Actuator end
Pin assignment 1 : ECU pin M1G3 : cylinder1&4 2 : ECU pin M1H3 : cylinder 2&3 3 : Supply
4 : Ground (through supressor) Measure supply volt across pin 3 and 4 on wiring harness with Ignition ON. Measure secondary coil resistance across High tension terminals of cyl. 1 & cyl. 4 (or cyl. 2 & cyl. 3).
Fig. 37
System Diagnosis : Use Tata Diagnostic Tool. Check for ‘Ignition timing value’ during idling.
Cylinder nos. marked for HT cable fitment.
Fig. 38 33
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GROUP INDEX
ENGINE 475 SI MPFI ENGINE CONTROL UNIT (ECU) : Fig. 39,40 & 41. Type : S2000PL4 12 MIPS CPU Processor with 256KB ROM & 4KB RAM 84 PIN connector Working principle : Microprocessor based engine control system. System Integration :
Fig. 39 ECU Mounting location All sensors (e.g. water temperature, air temperature, etc.) input signals are processed by the microprocessor and control signals are provided for various activators (e.g. ISC valve, Injectors etc.) for satisfactory engine performance. Various control algorithms (software) are used in conjuction with the map/table data to provide various control functions for optimum functioning of the engine, which in turn provides best fuel consumption/emissions.
SULIN
Fitment Data : (Fig. 39) ECU is fitted inside the engine compartment between battery and the suspension tower. Stand Alone Diagnosis : Note : Please also refer to ECU Handling Care section,page no. 42 Use multimeter. Perform continuity check on the ECU connection at wiring harness end to any sensor/actuator depending upon engine symptom.
Fig. 40
SPECIFICATIONS : Type : S2000PL4 CPU Make : SIEMENS CPU Type : SAK 167 Processor Speed : Over 12 MIPS
Fig. 41 34
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GROUP INDEX
ENGINE 475 SI MPFI CPU Data Processing size :
36.2 mm
32 bits CPU Clock Speed : 20 Mhz CPU Data Communication Size : 16 bits Memory : RAM - 4KB ROM - 256KB FEATURES : •
Grouped Ignition
•
Sequential Injection
204 mm
SULIN
35
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ENGINE 475 SI MPFI CONNECTOR CLM1(BLACK) :
(VIEW SEEN FROM CABLE ENTRY SIDE)
PIN NO M1 A1 M1 A2 M1 A3 M1 A4 M1 B1 M1 B2 M1 B3 M1 B4 M1 C1 M1 C2 M1 C3 M1 C4 M1 D1 M1 D2 M1 D3 M1 D4 M1 E1 M1 E2 M1 E3 M1 E4 M1 F1 M1 F2 M1 F3 M1 F4 M1 G1 M1 G2 M1 G3 M1 G4 M1 H1 M1 H2 M1 H3 M1 H4
PIN ASSIGNMENT NOT USED AIR TEMPERATURE SENSOR SENSOR GROUND 2 Vbatt SWITCH NOT USED NOT USED KNOCK SENSOR THROTTLE POSITION NOT USED NOT USED KNOCK SENSOR + ALTERNATOR CURRENT NOT USED DOWNSTREAM LAMBDA SENSOR HEATER DOWNSTREAM LAMBDA SENSOR WATER TEMPERATURE INPUT NOT USED UPSTREAM LAMBDA HEATING DRIVER DOWNSTREAM LAMBDA SIGNAL INPUT + WATER TEMPERATURE INPUT + NOT USED MAIN RELAY DRIVER CAM SENSOR INPUT NOT USED NOT USED NOT USED COILS 1 AND 4 NOT USED NOT USED NOT USED COILS 2 AND 3 POWER GROUND n3
CABLE CODE(Please Refer Page 39) BR LgW BR B BrG W BrY BrG B Rg PB W BrW P W WL G BR
SULIN
36
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GROUP INDEX
ENGINE 475 SI MPFI CONNECTOR CLM2 (GREY) :
(VIEW SEEN FROM CABLE ENTRY SIDE)
PIN NO M2 A1 M2 A2 M2 A3 M2 A4 M2 B1 M2 B2 M2 B3 M2 B4 M2 C1 M2 C2 M2 C3 M2 C4 M2 D1 M2 D2 M2 D3 M2 D4 M2 E1 M2 E2 M2 E3 M2 E4 M2 F1 M2 F2 M2 F3 M2 F4 M2 G1 M2 G2 M2 G3 M2 G4 M2 H1 M2 H2 M2 H3 M2 H4
PIN ASSIGNMENT NOT USED MAP SENSOR GROUND 1 UPSTREAM LAMBDA SENSOR + NOT USED ENGINE SPEED SENSOR + ENGINE SPEED SENSOR UPSTREAM LAMBDA SIGNAL INPUT NOT USED INLET AIR PRESSURE NOT USED SENSOR +5V_2 NOT USED ICS STEPPER DRIVER OUTPUT D ICS STEPPER DRIVER OUTPUT B ICS STEPPER DRIVER OUTPUT C NOT USED SENSOR +5V_1 NOT USED ICS STEPPER DRIVER OUTPUT A NOT USED NOT USED PURGE CANISTER POWER RELAY NOT USED CHECK ENGINE LAMP INJECTOR CYLINDER 3 INJECTOR CYLINDER 2 NOT USED POWER GROUND n4 INJECTOR CYLINDER 1 INJECTOR CYLINDER 4 NOT USED
CABLE CODE(Please Refer Page 39) BrR B W B W WO VR LGO WV RL WY GR YL WG LR YL YL Br LG LgP -
SULIN
37
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI CONNECTOR CP (BROWN) :
AC PRESS SW
FUEL LEVEL
FAN2 LO SPEED
(VIEW SEEN FROM CABLE ENTRY SIDE)
PIN NO CP A1 CP A2 CP A3 CP A4 CP B1 CP B2 CP B3 CP B4 CP C1 CP C2 CP C3 CP C4 CP D1 CP D2 CP D3 CP D4 CP E1 CP E2 CP E3 CP E4 CP F1 CP F2 CP F3 CP F4 CP G1 CP G2 CP G3 CP G4 CP H1 CP H2 CP H3 CP H4
PIN ASSIGNMENT NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED L-LINE IGNITION SWITCH INPUT NOT USED NOT USED AIR CON O/P (Relay Driver) ONBOARD DIAGNOSTIC FAULT INDICATOR(MIL) NOT USED NOT USED AC REQUEST INPUT NOT USED NOT USED COOLING FAN - HIGH SPEED POWER STEERING STOP INPUT NOT USED NOT USED NOT USED ANTI THEFT LINK NOT USED NOT USED VEHICLE SPEED SENSOR INPUT NOT USED NOT USED NOT USED K LINE NOT USED NOT USED
CABLE CODE(Please Refer Page 39) RG GR GP WP BY GY GrW WG V YR -
SULIN
38
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI PIN NO CP J1 CP J2 CP J3 CP J4 CP K1 CP K2 CP K3 CP K4 CP L1 CP L2 CP L3 CP L4 CP M1 CP M2 CP M3
PIN ASSIGNMENT NOT USED NOT USED NOT USED COOLING FAN 1 (RELAY DRIVER) NOT USED NOT USED NOT USED FAN 2 RELAY DRIVER NOT USED NOT USED NOT USED POWER GROUND1 NOT USED NOT USED LOW FUEL LEVEL INPUT
CP M4
POWER GROUND2
CABLE CODE Y YB Br VR Br
2. FOR VERSION : NON AC WITH POWER STEERING ALL PINOUT ARE AS PER REFERENCE VERSION EXCEPT CP D3 CP C3 CP E2
AC REQUEST INPUT AC COMPRESSOR DRIVER COOLING FAN HIGH SPEED
BY GP GY
NOT CONNECTED 12 V SUPPLY NOT CONNECTED
SULIN
3. FOR VERSION : NON AC WITHOUT POWER STEERING ALL PINOUT ARE AS PER REFERENCE VERSION EXCEPT CP CP CP CP
D3 C3 E2 E3
AC REQUEST INPUT AC COMPRESSOR DRIVER COOLING FAN HIGH SPEED POWER STEERING STOP INPUT
CABLE CODE B Br G Gr L O P R W Y V Lg Sb
BY GP GY GrW
NOT CONNECTED 12 V SUPPLY NOT CONNECTED NOT CONNECTED
CABLE COLOUR BLACK BROWN GREEN GREY BLUE ORANGE PINK RED WHITE YELLOW VIOLET LIGHT GREEN SKY BLUE
39
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI ECU HANDLING CARE :
•
Ensure that the connector is inserted in the end after all the installation is complete.
•
To carry out welding job on the car the ECU should be disconnected.
Earth (Ground) Connection •
Ensure all the ground connections are fixed correctly.
•
DO NOT leave any grounded wire loose or open.
Power Supply •
The power for the ECU should be taken through the Main Relay. Do not take out the connector from the ECU for at least 1 minute after IGNITION OFF. Never take out the connector from the ECU during IGNITION ON.
•
Ensure that key SW is in OFF position while plugging - in the connector to the ECU.
Input •
Ensure that the Input signal line is as far as possible from noise sources such as High Tension Cable, Horn relay, Motor etc.
•
Ensure that sealed wire are used for input line of O2 Sensor, Crank Angle Sensor and Knock Sensor and the wiring is as far as possible from the noise sources similar to the ones above (Unsealed wire may be used for O2 sensor if the noise level is small enough so as not to affect the Air/Fuel control).
SULIN
Output •
Take care to avoid dead - short (solenoid short circuit etc.) and similar circuit misconnection while checking (to avoid any damage). Use a solenoid which does not use a fly - back diode (reverse polarity may damage the Output Power Transistor).
Installation •
Ensure that the ECU is secured firmly to the body using screws.
•
Ensure that there is no water seepage into the ECU.
•
Do not use an ECU which has been dropped once.
•
Do not try to repair the ECU.
•
Use standard harness for circuit connections.
•
Do not try to insert any thing into the ECU case.
•
Take care to avoid any bending of the connector pins while inserting the connector.
40
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI SCHEMATIC WIRING DIAGRAM OF POWER RELAY : BAT
30A (EMS ECU MAXI FUSE)
MAIN RELAY
NO
M1F2
NC 2
4 P
INERTIA SWITCH
M1A4
6
M2F3
POWER RELAY (2 NO CONTACTS)
SULIN
8
5
IMMOBILISER 6 5
26
IMMOBILISER PIN
15A FUSE
FUEL 15A FUSE PUMP
• IGNITION COIL • INJECTORS • UPSTREAM O2 SENSOR • DOWNSTREAM 02 SENSOR • STEPPER MOTOR • CAMSHAFT POS SENSOR • PURGE VALVE • VEH SPEED SENSOR NOTE :
If a group of sensors like upstream O2 sensor, downstream O2 sensor, camshaft sensor, vehicle speed sensor, are not functioning, first check for conditions of fuses and power relay.
41
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI SCHEMATIC WIRING DIAGRAM OF SOME OTHER EMS COMPONENTS :
MIC4
SULIN
CPE3
42
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
3 CAN_H 11 CAN_L
0.5 mm
CPB4
7 ISO 9141k 15 ISO 9141L 16 12V+ve 1 GND
SULIN 10A FUSE IGN SUPPLY IGNITION KEY
CEL (1.4W) M2G1 10A FUSE
IGN SUPPLY
MIL (14W) CPC4
MALFUNCTION INDICATOR LAMP CHECK ENGINE LAMP 43
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
CPM3
CKT. IN THE CLUSTER 15 16 2 FUEL GAUGE
TANK UNIT
1
FUEL LEVEL SENSOR
80 A (MAXI FUSE) RADIATOR RELAY CPJ4
SULIN
CONDENSOR RELAY TO COOLING FAN
SERIES RELAY COOLING FAN (LOW SPEED)
CPK4 COOLING FAN 1 AND 2
44
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI PRELIMINARY INSPECTION OF ENGINE
OR Drive the car with weight equal to GVW in 3rd gear on level ground and let the speed drop down to approximately 15 kmph/10 mph. Now press accelerator pedal fully. With slipping clutch, the car speed will not pick up and also clutch burning smell will be noticed. If this does not occur and car picks up speed, it indicates that clutch does not slip.
Before proceeding to carry out actual overhauling of engine it is desirable to have a preliminary inspection of engine to ascertain whether an engine overhaul is necessary and to what extent. Most common reasons for which engine is overhauled are : 1.
Loss of power
2.
Excessive engine oil consumption
3.
Extremely low engine oil pressure
4.
Mechanical failures
e.
During driving apply brake number of times and then shift the gear to neutral position Check brake drums for over-heating and if necessary jack up the car and check the wheels for free rotation.
To know exact reason and general condition of engine, proceed as follows : 1.
f.
LOSS OF POWER
CHECKING ENGINE PRESSURE (Fig. 42)
COMPRESSION
If loss of power is not on account of defective fuel system, lack of air, choked exhaust silencer, clutch slipping and brake binding. check engine compression as follows :
Loss of engine power may be due to : a.
Defective Ignition system
b.
Defective Fuel system
c.
Clogged air cleaner/choked catalytic converter exhaust silencer
d.
Clutch slippage
e.
Brake binding
f.
Loss of engine compression
a.
IGNITION SYSTEM
1.
Warm up engine preferably by road drive to get a temperature of about 75 to 85 0C. 2. Remove all spark plugs. 3. Remove fuel connection to fuel rail (after relieving fuel pressure as indicated in fuel section) & suitably prevent fuel from spilling from open connection. 4. Remove air cleaner filter element. 5. Install Compression gauge (Range about 0 to 25 kg/cm2) into one of the spark plug hole. Note : Use adaptor which is available commercially to suit the size of the spark plug threads.
SULIN
Check all the sensors for proper function by using diagnostic monitor. Replace defective sensors. b.
BRAKE BINDING
FUEL SYSTEM Check condition of fuel filter. If found blocked replace fuel filter.
c.
CLOGGED AIR CLEANER/CHOKED EXHAUST SILENCER Check air filter element If found choked clean or replace.
d.
CLUTCH SLIPPAGE Clutch slipping can be confirmed by any of the following two methods : Drive the car in 1st or 2nd gear at maximum speed corresponding to that gear. With accelerator pedal fully pressed, apply brake gradually with left foot. If the engine stalls, it means that clutch does not slip.
Fig. 42 45
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI is higher, place the car on a level ground. 5.
Disengage clutch (to reduce starting load on engine) and depress accelerator pedal all the way to make throttle valve open fully.
6.
Crank engine with fully charged battery, and read the highest pressure on compression gauge.
7.
Carry out steps 5 to 7 on each cylinder to obtain compression pressures. The specified compression pressure is 9.5 bar minimum.
8.
Variation in compression pressure between cylinders should not be more than 0.5 bar.
9.
2.
Low compression pressure may be due to leakage past valves / piston rings/blown cylinder head gasket. To ascertain the point of leakage, spray small quantity of clean engine oil in to the cylinder showing low pressure and re-check compression pressure. If it improves, wear in piston rings/ cylinder bore is indicated. If it does not, leakage past the valves is indicated. If compression pressure of adjacent cylinder is also on lower side, it may be due to blown cylinder head gasket.
= 100 cc/ 625miles High engine oil consumption may also lead to overhauling of the engine but before proceeding to overhauling, check following points :
2.
Make sure that there is absolutely no external oil leak (i. e. from the camshaft oil seal, crankshaft oil seal, oil sump gasket, oil pump gasket, cylinder head cover gasket etc.) If no external leakage is found, determine the exact engine oil consumption, as per following procedure.
DETERMINING CONSUMPTION :
EXACT
ENGINE
OIL
CAUTION : Do not make a rough estimate of engine oil consumption by noting the kilometers covered by the car at any random stage and finding oil consumed from the topped up position taking into consideration dipstick level and oil sump capacity. PROCEDURE : 1.
Top up oil sump to its capacity of 4.5 litres.
3.
Warm up the engine so that oil temperature is 75 - 800 C.
4.
Take a clean vessel, place it below the drain plug of oil sump.
5.
Drain the hot oil into the clean vessel. Drain it fully.
6.
Screw in oil sump drain plug and tighten it.
7.
Weigh the vessel along with oil let this weight be ‘w1’, gms.
8.
Refill the weighed oil into the oil sump. Do not spill any oil. The vessel used for draining should not be used for any other purposes.
9.
Drive the vehicle approx. 200-300 km/125 - 185m. This drive should include at least 30-40 kms/ 20-25m of highway or similar road, vehicle running at about 60 kmph/ 40mph. Let this drive distance be ‘D’ miles.
10. Immediately after the test drive, place the vehicle at the same spot from where it started.
SULIN
EXCESSIVE ENGINE OIL CONSUMPTION
Maximum limit for Oil Consumption = 100 cc/ 1000km
1.
2.
Once it is doubted that engine oil consumption
11. Place the same previously used vessel below the oil sump, unscrew the drain plug and drain off oil into the vessel. Drain the sump fully. 12. Weigh the vessel along with oil, now for the second time. Let this weight be ‘w2’ gms. 13. Find out standard oil consumption as Std.oil consumption(w1-w2)(wt.ofoil consumed,gms)x1000 ‘C’ (litres/1000km)
=
sp. wt. of oil (gm/cm3) x ‘D’ (drive dist. in miles.)
w1 - w2 0.88 x D
‘C’
=
3.
EXCESSIVE EXTREMELY
litres/1000miles LOW
OIL
PRESSURE
Check the following : a.
External leakages.
b.
Oil level in sump upto maximum mark on dipstick.
c.
Oil pressure transducer for proper functioning.
d.
Functioning of pressure relief valve on oil pump.
e.
Oil pump performance using a suitable pressure gauge.
46
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Oil pressure found to be less than 2.8 bar at maximum speed and 1.2 bar at idling speed, may be due to improper functioning of oil pump or defective oil pump relief valve. If low oil pressure is not on account of above factors, wear of journals/bearings is indicated for which overhaul of engine may be considered. Checking oil pressure : Procedure for checking Before conducting the test ensure : 1. 2. 3.
Engine oil level is at high mark on dipstick, otherwise top up. No leakage. Correct grade of engine oil is used.
Remove electrical connection from oil pressure transducer. Remove oil pressure transducer from cylinder block. Install Oil pressure gauge in place of oil pressure transducer. Start engine and warm it up to normal operating temperature.
SULIN
Warm up the engine and measure oil pressure. It should be within specified limits. After checking oil pressure, stop engine and remove oil pressure gauge. Before reinstalling oil pressure transducer, be sure to apply sealant on screw threads and tighten transducer to specified torque. Tighten oil pressure switch to 3.0 - 4.0 Kgm torque. 4.
MECHANICAL FAILURES
Metallic knocking sound from an engine may be due to faulty ignition, excessive clearance in main and big end bearings, small end bush, tappets, piston slap, seizing of piston rings, scored cylinder bore or breakage of any moving parts. Defective alternator can also be a source of mechanical noise. Defect can be located by replacing alternator or power steering pump (if fitted) or AC compressor (if fitted) or belt tensioner pulley with a new one. Dismantling of engine may be considered if still noise occur even after attending all above mentioned problems.
47
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
ENGINE COVER MOUNTING
ASSY RUBBER GROMET 1.0
ENGINE COVER
1.0
ASSY BUFFER
SULIN ASSY ENGINE COVER MOUNTING BRACKET
ASSY LIFTING HOOK
2.5
-- SPECIFIED TORQUE IN Kgm
48
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI AIR - INTAKE SYSTEM
5 7 6 4 11
1
22
2
21
3 8
20 17 9
10 16 12
19
SULIN
18 14
13 15
Sr.No. 1 2 3 4 5 6 7 8 9 10 11
Sr.No.
PART DESCRIPTION Gasket (for Throttle Body) Throttle Body Rubber Bellow Hose Clamp (72 Dia) Assembly Air Filter Sealing Plug M12 Sealing Washer Isolator (for Air Filter) Assembly Bracket Front (for Air Filter Mtg.) Assembly Isolator (for Air Filter) Bracket Rear (for Air Filter Mtg.)
12 13 14 15 16 17 18 19 20 21 22
PART DESCRIPTION Assembly Bracket (for Resonator Mtg.) Resonator Box Assembly Isolator Rubber Grommet(for Resonator Box) Air Intake Snorkel Assembly Clamp(for Mtg. Snorkel) Hose (Resonator Box) Hose Clamp (42 Dia) Intake Duct Hose (Air Filter to Intake Duct) Hose Clamp (72 Dia)
49
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI ENGINE SUSPENSION
ENGINE MOUNTING ARM (FRONT) 1.5
LIFTING HOOK (FRONT)
4.0 2.5 ASSY ENGINE MOUNT A ASSY LIFTING HOOK
TOP PLATE (B MOUNT BRACKET STIFFNER)
ASSY BRACKET WITH STUD (FOR ENGINE MTG.)
2.5
ASSY ENGINE MOUNT B 2.5
SULIN 4.5
3.5
ASSY ENGINE MOUNT C
ASSY MOUNTING PLATE FOR B MOUNT
ASSY MOUNT INTERMEDIATE LINK 2.0
ASSY STOPPER (B MOUNT PLATE) ASSY BRACKET ENGINE STOPPER
ASSY BODY MOUNTING BRACKET
3.0
-- SPECIFIED TORQUE IN Kgm 8.0
50
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI INLET AND EXHAUST MANIFOLD NIPPLE (RESTRICTION)
CORE PLUG TUBE (FOR VACCUM BOOSTER)
STUD
INTAKE MANIFOLD
NIPPLE (TPV)
SULIN GASKET (FOR INLET MANIFOLD)
GASKET (FOR EXHAUST MANIFOLD)
-- SPECIFIED TORQUE IN Kgm
STUD
-- NON-REUSABLE PART
2.0
51
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI ENGINE TIMING - PETROL (EURO III) 2.0
SPRING (ROCKER ARM SHAFT)
ROCKER ARM
ROCKER SPRING SEAT
CAM THRUST PLATE 1.0 ASSY ROCKER SHAFT
CAMSHAFT
SULIN
OIL SEAL
TIMING BELT ASSY TIMING GEAR
8.0 ASSY TENSIONER
ASSY IDLER PULLEY 4.5 SPACER 4.0
-- SPECIFIED TORQUE IN Kgm
52
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI MOVING PARTS - BLOCK 16 17 18 15 19
11
7 5.0#
20
2
14 13 12
5.25# 6
5
SULIN
2.5
1 8
3 4+60º#
9
4
10
# = + 5% Tolerance on Torque value
-- SPECIFIED TORQUE IN Kgm
Sr.No. 1 2 3 4 5 6 7 8 9 10
Sr.No.
PART DESCRIPTION Crankshaft Cylinder Pin 8m 6 X 16 Assembly Gear(for crankshaft) Assembly Integral Vibration Damper Washer Key Assembly Flywheel Complete Main Bearing Half Shell Thrust Washer Upper Thrust Washer Lower
11 12 13 14 15 16 17 18 19 20
PART DESCRIPTION Connecting Rod Con Rod Cap Con Rod Bush Bearing Half Normal Piston Grade A (IP) Top Ring A (IP) Taper Faced Ring (IP) Assembly Oil Control Ring Piston Pin (IP) Internal Circlip 20
53
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI GASKET
ENGINE COOLING
ASSY WATER PUMP
CYLINDER HEAD
1.0 GASKET ELBOW
CYLINDER CRANK CASE ASSY COVER THERMOSTAT
ASSY ELBOW (FOR WATER HEATER) 2.0
1.0 TEMP.SENSOR RUBBER HOSE (THERMOSTAT COVER TO RAD)
HOSE CLAMP
SULIN 1.5
RUBBER HOSE HOSE CLAMP O-RING
THERMOSTAT HOUSING ASSY THERMOSTAT 1.5
COOLANT TEMP SENSOR
HOSE CLAMP 0.8
SEAL THERMOSTAT
GASKET
ASSY HOSE ASSY WATER BYPASS TUBE 1.0
-- SPECIFIED TORQUE IN Kgm -- NON-REUSABLE PART
54
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI FUEL INJECTION
INJECTOR RETAINER
1.0 INJECTOR HOSE (T-CONNECTOR TO INTAKE MANIFOLD)
T-CONNECTOR
2.0 HOSE (TPV BUNDY TO T-CONNECTOR)
SPRING CLIP
SULIN
ASSY FUEL RAIL
RUBBER HOSE (CPV TO T-CONNECTOR) 2.0 SUPPORT BRACKET FOR CPV
CANISTER PURGE VALVE
CLAMP (CPV) 1.0
RUBBER SLEEVE (CPV)
RUBBER HOSE (CARBON CANISTER TO CPV) SPRING CLIP SPRING CLIP
ASSY CARBON CANISTER
ASSY BRACKET (FOR CARBON CANISTER)
1.0
-- SPECIFIED TORQUE IN Kgm
55
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI CYLINDER HEAD AND COVER - PETROL EURO III 1.0
RUBBER SEAL
OIL FILLING CAP
SPACER TUBE
CYLINDER HEAD COVER
GASKET (BAFFLE) ASSY (BAFFLE) ASSY NIPPLE T-CONNECTOR
GASKET (CYLINDER HEAD COVER) VALVE SPRING RETAINER
1.0
SULIN
VALVE SPRING
CYLINDER HEAD
6.5
LOCK HALF
CORE PLUG
VALVE GUIDE SEAL
CORE PLUG (39 DIA)
SPRING SEAT
VALVE GUIDE (EXHUAST)
EXHAUST VALVE VALVE GUIDE (INLET) GASKET (FOR CYLINDER HEAD) INTAKE VALVE VALVE SEAT INSERT (EXHAUST) VALVE SEAT INSERT (INLET) -- SPECIFIED TORQUE IN Kgm -- NON-REUSABLE PART
56
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI GASKETS
Throttle Body Gasket Gasket
Oil Filter Gasket
Gasket (Cyl. Head Cover) Exhaust Manifold Gasket
SULIN Gasket Elbow
Intake manifold Gasket
Rear Gasket
Front Cover Gasket Water Pump Gasket Oil Sump Gasket Oil Pump Strainer Gasket
57
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI ENGINE ELECTRICAL EQUIPMENT ASSY A/C COMPRESSOR
2.5
BRACKET (FOR A/C COMP)
POLY V BELT
SLIDER (A/C IDLER)
SET ASSY IDLER
2.3
SULIN BRACKET (FOR ALTERNATOR TOP)
2.0
2.0
ALTERNATOR
2.0
SLIDER (FOR TENSIONER) 2.0 SHAFT (FOR TENSIONER)
2.0
2.3
SUPPORT BRACKET 2.3 PST
POLY V BELT
ASSY TENSION PULLEY (FOR A/C COMPONENTS)
BRACKET -- SPECIFIED TORQUE IN Kgm
58
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI REMOVAL OF 475 MPFI ENGINE FROM THE CAR : Remove bonnet (Fig. 43) Disconnect electrical cable connections for : • Battery • Starter motor • Alternator • Electrical connections of all sensors and actuators • Oil pressure switch • Water temperature transducer • Electric fan transducer • Reversing switch Disconnect cables for Accelerator, Speedometer drive, Clutch. Disconnect exhaust pipe from exhaust manifold
Fig.43
Drain coolant from cooling system Disconnect hoses from and to radiator and heater coil. Disconnect pipe from radiator to auxilliary tank and cylinder head to aux. tank. Remove AC pipe lines (if AC is fitted) Remove following sub assemblies : • Air filter • Gear shift linkages from transaxle Fig. 44 • Radiator (if required) Remove Battery.
SULIN Fig.44
Drain transaxle oil, Fig. 45.
Fig. 45 59
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Remove drive shafts (for procedure, see suspension group) Fix chain to front and rear engine lifting hooks and hold chain in position with crane. Fig. 46 Unscrew and remove nut on ‘B’ mount bracket. Fig. 47 Remove ‘A’ mount support arm. Fig. 47 Remove ‘C’ mount bracket. Fig. 47 Lift engine slightly on car with the help of crane. Place support stand under the engine & lower the engine along with transaxle assembly.Fig. 46 Remove the chain. Lift the front end of the car till the engine is clear ( It is recommended to use two pole hoist to lift the car) Remove the engine alongwith transaxle. Remove starter motor. Disconnect transaxle Assembly from engine. (Ref. transaxle group) Remove alternator and its mounting bracket. Mount the engine on work stand with mounting bracket Pt. No. 2702 5890 24 02 & 2702 5890 2403 Drain engine oil. Fig. 48
2702 5890 24 01
Fig.46
‘C’ MOUNT
SULIN
INSTALLATION OF ENGINE ON THE CAR : • Check engine mounting pads for wear. Replace them if necessary. • Install the engine in reverse sequence of removal • Tighten engine mounting bolts to specified torque • Connect all pipes, hoses and electrical connections • Fill specified quantity of oil in engine of recommended grade. • Fill coolant in the cooling system through aux. tank • Crank the engine momentarily. Let oil and coolant circulate through the system. • Confirm whether engine oil pressure indicator light is switching off when engine is started. • Check for leakage, rectify if any. • Top up coolant upto FULL mark in auxiliary tank, if necessary.
FRONT ‘A’ MOUNT
‘B’ MOUNT
Fig.47
Fig.48 60
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI REMOVAL OF RADIATOR FROM CAR :
1.
(Front bumper, Splash guard already removed - For procedure refer Body group of this manual) 1.
Drain the coolant.
2.
Remove all the hose connections i. e. i. From the thermostat ii. From the auxiliary tank. iii. To the outlet elbow.
3.
4.
2.
3.
Disconnect the electrical connections, i. To the condenser fan (For AC version) ii. To the temperature sensor of cooling fan.
1. ASSY. RADIATOR COMPLETE 2. CROSS MEMBER RADIATOR MOUNTING
Unscrew the 2 M8 bolts & remove the radiator bottom mounting member along with the radiator. Fig.49
SPECIFICATIONS Leakage testing pressure :
3. RUBBER GROMET
Fig. 49 1.5 bar AUXILLIARY TANK
Auxillary Tank Cap Fig.50 Pressure valve opening : 1 bar Vacuum valve opening : 0.05 bar (max) (suction)
AUXILLIARY TANK CAP
INSPECTION Check radiator for damages / leakages. Straighten bent fins if any.
SULIN
CLEANING Clean radiator frontal cores.
Installation : 1.
Fit the radiator along with the radiator bottom mounting member on to the car & tighten the mounting bolts. 2. Fit back the 3 hose connections. 3. Connect the electrical connections for temperature sensor & condenser fan (For AC version) Fill coolant (clean water blended with anti freeze agent as per recommendation). Top up coolant through auxiliary tank cap upto ‘Full” mark. Fit Auxillary tank cap. Run engine for short duration and top up coolant if necessary.
Fig. 50
61
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI ALTERNATOR / POWER STEERING PUMP BELT Removal : •
Loosen both the slider mounting screws on alternator belt tensioner.
•
Slide the slider to reduce the belt tension by rotating the slider screw at the bottom. Fig. 51
•
Remove the alternator belt.
Inspection : •
Inspect the alternator belt for wear, cracks and signs of failure. Replace, if necessary.
Fitment : •
Adjust the slider at the higher most position and keep the screws loose but engaged.
•
Install alternator belt over Crankshaft, Alternator, Power Steering pump and the tensioner pulley.
•
Slide the slider by rotating the bottom slider screw till correct belt tension is set.
•
Retighten the slider screws.
•
The belt tension to be adjusted such that on the spans shown in the Fig. 52. 180+10/5 Hz. (For only Alternator configuration) and 200 +10/-5 Hz. ( For Alternator and power steering configuration) is measured by CLAVIS gauge. Alternately belt can be depressed by 11 to 13 mm (for only Alternator configuration) & 9 to 11 mm (for alternator and power steering configuration) with thumb pressure applied.
SLIDER SCREWS
Fig. 51
SULIN
A.C. COMPRESSOR BELT
SPAN
ALTERNATOR BELT TENSIONER BOLT
Fig. 52
Removal : 1.
Loosen belt tensioner bolt (Fig. 53) on idler / tensioner.
2.
Release tension load on the belt and remove the belt from the pulleys.
SPAN
Inspection : 1.
Inspect the A. C. compressor belt for wear, cracks, and signs of failures. Replace if necessary.
2.
Inspect pulley grooves.
BELT TENSIONER ROLLER
BELT TENSION ADJUSTING SCREW
Fitment : 1.
Install the belt over crankshaft and A.C.
Fig. 53 62
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI compressor pulleys. 2.
Press the tensioner against the belt and tight the tension bolt to specified torque.
3.
Check belt tension.
4.
The belt tension to be adjusted such that on the span shown in Fig. 53, 200 +10/-5 Hz is measured by CLAVIS gauge. Alternately belt can be depressed by 11 to 13 mm with thumb pressure applied.
Fig. 54
TIMING BELT : Removal : Remove alternator and AC belt Unscrew the mounting screws & remove front timing gear train cover Fig.54 Keep crank shaft rotating with socket spanner simultaneously pressing camshaft timing pin till it locks camshaft Fig. 55.
SULIN Fig. 55
Check at this position whether timing pin 2702 5890 0605 in crankcase locks the flywheel or not Fig. 56. Remove timing pin locking the camshaft & now ensure that flywheel is in locked position.
Fig.56 63
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Fit lock plate for camshaft gear washer on cylinder head as shown in Fig.57 Slacken the camshaft gear fixing bolt. Slacken the mounting bolt of belt tensioner roller assembly and rotate the belt tensioner in anticlockwise direction to loosen the belt. Fig. 58 Remove timing belt. Inspection : Check belt in detail. If following flaws are evident, replace belt with new one. •
Back surface glossy, non elastic and so hard that even if finger nail is forced into it, no mark is produced.
•
Cracked back surface rubber
•
Cracked or exfoliated canvas
•
Cracked tooth bottom
•
Side of belt cracked
•
Side of belt excessively worn
•
Excessively worn teeth
•
Missing tooth
NOTE :
Fig. 57
SULIN
Normal belt should have clear cut sides, as if cut with a sharp knife. In the initial stage of wear, load side tooth flank will look like fluffy canvas fibre, rubber gone and colour changed to white. In the last stage of wear, canvas on load side tooth flank will be totally worn out exposding rubber.
Fig. 58
Fitment : Ensure that timing pin is in flywheel locked position. Check that the cam gear is “Just” freely rotating on the camshaft with mounting bolt in hand loose condition. Slacken all valve tappet clearance setting screws to such an extent that the screw bottom radius is just riding on the valve tips & tighten the locknuts.
64
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI NOTE :
Cam gear
This is to reduce the valve spring load on Camshaft, while rotating the camshaft.
White Mark
Using appropriate spanner on camshaft gear fixing bolt, rotate camshaft in clockwise direction with timing pin placed on the cylinder head reference hole, until the camshaft is locked in timing position. Cam plate
Slacken the fixing bolt so that the camshaft gear is “Just” freely rotating on camshaft. Fit the camshaft gear washer lock plate as shown in Fig. 57
White Mark
Check now that both the flywheel and camshaft are in locked in timing position. Fit timing belt on Crank shaft gear, water pump tensioner roller and camshaft gear.
Cam plate
Fig. 59 Ensure that the mark provided on target wheel mounted on Camshaft gear is in front of Cam sensor. Adjust the timing belt tension, by rotating tensioner roller clockwise and tighten the mounting screw, while tightening the mounting screw ensuring that the tensioner roller does not rotate further in clockwise direction. This will prevent overtensioning of timing belt.
SULIN
Tighten the cam gear fixing bolt to a lower tightening torque of 1 mkg. Remove cam shaft timing locking pin. NOTE : In this procedure timing pin locking the camshaft is removed from the cylinder head timing refrence hole, whenever camshaft is subjected to very high loosening and tightening torque through the gear fixing bolt. This is to prevent severe damage to cylinder head, camshaft timing slot and subsequent problem of very low oil pressure (due to increased bearing clearance on bearing No. 5 of cylinder head). Special ‘C’ tool should be used whenever cam gear fixing bolt is to be tightened or loosened. Never use the timing pin in locked timing position to hold the camshaft during tightening or loosening process. Re-tighten the cam gear fixing bolt to the specified torque.
Remove camshaft gear washer lock plate and flywheel locking pin.
Fig. 60 Set the flywheel and cam shaft in No.1 cylinder firing position. Adjust the valve clearances of cylinder No. 1 & 2 on inlet valves and cylinder No. 1 & 3 on exhaust valves Fig. 60. Remove the camshaft and crankshaft locking pins. Rotate the crankshaft by one rotation in the clockwise direction and insert the flywheel locking pin. Adjust the valve clearances of cylinder No. 3 & 4 on inlet valves and cylinder No. 2 & 4 on exhaust valves INLET Specified
0.20
EXHAUST 0.30
65
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI CYLINDER HEAD : (Engine on workstand) Disassembly: Remove electrical cable connections for: •
Spark plug leads. Fig 61
Fig. 61 •
Canister purge valve.Fig 62
SULIN Fig. 62 •
Coolant bypass line. Fig. 63
Fig. 63 66
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI •
Blowby hose connection to cylinder head cover. Fig.64
Fig. 64 •
Vacuum pipe from intake manifold to brake booster.
•
Vacuum pipe to canister purge valve Fig. 65.
SULIN Fig. 65 • • •
Dip stick clamping screw Accelerator cable connections Inlet manifold with throttle body Fig. 66
Fig. 66 67
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI • •
Exhaust manifold Fig. 67 Timing Cover
Fig. 67 •
Cylinder head cover Fig. 68
SULIN Fig. 68 Insert flywheel locking pin, fit camshaft gear washer lockplate and loosen camshaft gear mounting bolt. Fig. 69
Fig. 69 68
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Also remove • Timing belt Fig. 70
Fig. 70 Unscrew and remove cylinder head mounting screws in reverse order of tightening Fig. 71 Slightly lift cylinder head to clear locating hollow dowel in crank case and remove it. Remove • Cam shaft gear Fig. 72
SULIN Fig. 71
Fig. 72 69
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Remove •
Rocker arm shaft locking grub screws and rocker arm shafts. Fig. 73 & 74.
NOTE : 1) To ease the dismantling of rocker shaft relieve the valve spring load by slackening the tappet setting screws. In this condition do not attempt to rotate the cam shaft, if you do so valve tips will be damaged. 2) While pulling out Rocker arm shafts, take out the rocker arm with springs & spring seats carefully one by one.
Fig. 73
SULIN Fig. 74
70
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI INLET MANIFOLD WITH THROTTLE BODY (Removed from cylinder head) Disassembly : Remove fuel rail alongwith injectors Fig. 75
Fig. 75 •
Remove injector retainer clip from fuel rail.
Detach injectors from fuel rail Fig. 76
SULIN Fig. 76
71
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Remove integral throttle body from inlet manifold. Fig. 77 Assembly of inlet manifold For assembling the MPFI system component proceed in reverse order of disassembly of component.
Fig. 77
SPARK PLUG •
Remove Spark plugs Fig. 78
Spark Plug
-
Champion / BOSCH
Spark Plug no.
-
C9YC / FR 6 DC4
Spark Plug Gap
-
0.7 mm to 0.8 mm
SULIN
You should inspect the spark plugs periodically for carbon deposits. When carbon accumulates on the spark plug, a strong spark will not be produced. Remove carbon deposits using a spark plug cleaner. Spark Plug Replacement : 1.
Clean up any dirt or oil that is collected around the spark plug caps.
2.
Pull out the spark plug cables by gripping at the connector.
3.
Remove the spark plug with the help of box spanner 2702 5890 06 01
4.
Check and adjust the gap, it should be 0.7 mm to 0.8 mm. Fig. 79
5.
Replace the spark plug if the gap is more than 0.8 mm.
6.
Fix the spark plug and tighten it to the specified torque (dry.)
7.
Fit the spark plug cable.
Fig. 78
Repeat the procedure for the other spark plugs.
Fig. 79 72
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Tighten the spark plug carefully. Overtightening can damage the threads in the cylinder head. A loose spark plug can affect combustion and cause engine damage.
SPARK PLUG DEFECTS The condition of spark plug firing ends can act as a guide to the state of tune and general condition of the engine. The examples shown below are assumed to be the correct grade of engine. NORMAL Fig. 80 Core nose lightly coated with grey-brown deposits. Electrodes not burning unduly - gap increasing about 0.01 mm per 2000 km (with the use of unleaded fuel). Spark plugs ideally suited to engine.
Fig.80
Fig. 81
HEAVY DEPOSITS Fig. 81 Possible causes : Fuel or oil additives, Oil in combustion chamber, Worn valve guides, Unvarying speed (stationary engine). Replace spark plugs. CARBON FOULING
SULIN
Characterised by dull black sooty deposits although unleaded fuel carbon fouling can appear as glossy deposits similar in appearance to oil fouling. Deposits can short circuit the firing end; weakening or eliminating the spark. Check for clogged air filter. Replace spark plugs. OIL FOULING Deposits can short-circuit the firing end, weakening or eliminating the spark. May be caused by worn valve guides, bores or piston rings, or whilst a new or overhauled engine is running-in. Cure the oil problem, if possible. Temporary use of the next hotter grade of spark plug may stop the misfire. Replace spark plugs.
Fig. 82
OVERHEATING Likely causes are : Over-advanced ignition timing, Use of fuel with insufficient octance rating, Weak mixture. Discard spark plugs showing signs of overheating, and cure the cause. INITIAL PRE-IGNITION Caused by serious overheating. Causes are those listed for overheating but may be more severe. Corrective measures are urgently needed. Discard plugs in this condition.
Fig. 83 73
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI SPLIT CORE NOSE Fig. 82 May appear initially as a hair-line crack. Probably caused by detonation waves, indicating : use of fuel with insufficient octance rating, Manifold air-leaks, Cooling system problems, Incorrect gap setting technique, etc. Cylinder head disassembly continued •
Cyl. head cover mounting studs and spacer tubes. (replace if required) Fig. 83
•
Cam shaft locking plate from cam shaft bearing cap at the front
Push the cam shaft from rear and pull out from front, with oil seal Fig. 84 & 85 Fit support rail, (2702 5890 0616) to cylinder head Fig. 86
Fig. 84
With spring compressor (2702 5890 06 15) compress valve springs and remove valve lock halves Fig. 87 Remove valve lock retainers, valve springs, valve spring seats and valves. Place them in correct sequence.
SULIN Fig. 85
Fig. 87
Fig. 86
74
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Mating Surface : Using a straight edge and feeler gauge, check cylinder head mating surface with crank case, Fig. 88 & 89. If unevenness exceeds, replace cylinder head. CYLINDER HEAD TOP AND BOTTOM SURFACE REMACHINING, IN SERVICE IS NOT PERMITTED. Permissible unevenness of cyl. head overall mating surface (150 x 150) : cross wise 0.015 mm length wise 0.030 mm.
Fig. 88
SULIN Fig. 89
75
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI VALVES Fig. 90 Check valve leakages by pouring gasoline on valve head. Gasoline must not seep past valve seat. Valves with burnt heads, excessive scoring and wear on stem should be replaced. Check valve seat run out with respect to valve stem. Fig. 91. If it exceeds specified limit replace valve. No attempt should be made to straighten bent valves. If valve is free from any other defects except worn out seat, then only it can be rematched on valve grinding machine as follows:
ROCKER SHAFT 16º
SULIN
ROCKER SCREW ROCKER ARM
CAM SHAFT
VALVE RETAINER LOCK HALF VALVE GUIDE SEAL SPRING VALVE GUIDE
INTAKE PORT CYLINDER HEAD
16º VALVE
VALVE SEAT
Fig. 90 Valve Arrangement 76
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI • • • •
Clamp valve on grinding machine jaws as close as possible to valve head. Adjust grinding angle on graduated scale to achieve correct valve seat angle. Feed valve slowly towards grinding wheel until wheel just touches valve head. Grind at low feed until valve seat is just clean all around.
NOTE :
After grinding, valve head thickness should not be less than 0.85 mm.
Fig. 91
INLET VALVE
EXHAUST VALVE
B B
SULIN C
C
0
45
A
C
C
D
A
D
Fig. 92 VALVE GUIDES : In case of valve stem sticking in valve guide before or excessive clearance between them, remove valve guide from cylinder head using drift (2702 5890 0611) Fig. 93
Fig. 93 77
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Valve dimensions : Fig. 92 INLET Valve head dia. ‘A’ mm
EXHAUST
36.6/36.8
30.9/31.1
Valve seat angle
450 +25'
450+25'
Valve stem dia ‘B’ mm
6.97-0.015
6.96-0.015
Maximum run out of valve face with respect to valve stem mm
0.2
0.2
Valve seat dia ‘C’ mm
35
29.2
1.37/1.47
1.48/1.58
Maximum run out of valve seat with respect to valve steam
0.030
0.030
Valve seat dia in cylinder head mm
35±0.05
28.88±0.05
Valve seat end distance from valve face ‘D’ mm
SULIN
Distance between cylinder head mating surface with crank case to gauge diameter in cylinder head mm Maximum run out of valve seat in cylinder head with respect to valve guide axis mm
11.8±0.05
11.75±0.05
0.030
0.030
Remove valve guide seals. Check condition and replace if required with drift 2702 5890 0617 Fig. 94 Check valve guide bore diameter in cylinder head and if necessary, ream valve guide bore in cylinder head to next over size.
Fig. 94 78
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Install matching size valve guide in cylinder head using drift 2702 5890 0611 and spacer, 2702 5890 0612 Fig. 95. Ream valve guide inside diameter to specified size. Fit valve guide oil seals.
VALVE SEATS OF VALVES Check valve seat height with respect to cylinder head mating surface. Replace valve seat inserts if they are worn out beyond specified limit. Cut exhaust and inlet valve seats with a 450 cutter Fig. 96.
Fig. 95 Size
Valve guide bore in cyl. head
Valve guide OD,mm
Valve guide ID,mm
Normal
12.99+0.008/-0.01
13.0 + 0.046 + 0.028
7 - 0 (Inlet) + 0.020 7 + 0.005 (Exhaust)
Normal 1
13.09+0.008/-0.01
+ 0.015
13.1 + 0.046 + 0.028
SULIN
VALVE SEAT MUST BE ABSOLUTELY FAULTLESS AND WITHOUT ANY CHATTER MARKS If necessary lap valve seats to a smooth and even finish by using suitable hand pump grinder or a lapping paste and valve itself.
Valve guide length, mm
7 7
+ 0.015 - 0 + 0.020 + 0.005
(Inlet) (Exhaust)
39.5 (Inlet) 46 (Exhaust)
groove into valve seat insert and then pull it out with a suitable puller. In order to avoid damaging machined cylinder head mating surface with crank case, place any soft protective sheet metal under supports of puller. Measure valve seat insert bore in cylinder head.
Smear valve seat with carbon blue. Install valve in guide and turn it slowly under axial pressure. CONTACT LINE ON VALVE SEAT MUST BE AROUND ENTIRE CIRCUMFERENCE AT EQUAL WIDTH Distance between narrow diameter of valve face to contact line should be minimum 0.5 mm Check for leakages through valve seat by pouring gasoline on valve head. Gasoline must not seep past valve seat.
VALVE SEAT INSERTS : For removing valve seat inserts from cylinder head use a suitable boring machine. Bore old insert thin (about 0.5 mm thickness) and then pry it out. Alternatively use a suitable turning tool to cut an annular
Fig. 96 79
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI If boring and prying is done carefully without damaging valve seat insert bore in cylinder head, fitment of an over size valve seat insert will not be necessary. Remachined valve seat insert bore in cylinder head must be at 16º angle from vertical,Refer Fig.90. All specified dimensions should be strictly maintained to ensure proper interference of valve seat insert in its bore. Clean the valve seat insert and its bore in cylinder head thoroughly. Just before installation : •
Place valve seat insert in a mixture of Methanol and dry ice for about 20-30 minutes to bring its temperature down to -150 deg. C. Heat cylinder head to approximately 80 deg. C in water bath.
•
Install valve seat insert in cylinder head bore quickly by using mallet.
Carry out visual inspection of cam shaft for : •
• •
Deep scoring marks on journals and cam lobes Cracks, which should be checked on a magnetic crack detector.
Check hardness of cam shaft journals and cam lobes. It should be 40 HRC min.
Machine valve seat in cylinder head. CAM SHAFT INSPECTION
Fig. 97
SULIN
Overall heating of journals, which is indicated by bluish/brown colour
Check cam shaft runout at 2nd, 3rd & 4th journal by supporting it on V-block at 1st and 5th journal. Fig. 97 Check cam shaft journal dimensions.
Cam shaft journal & bearing bore dimensions (mm) : Journal No.
Cam shaft bearing journal bore diameter in cylinder head
1 2 3 4 5
42.000 - 42.025 41.500 - 41.525 41.000 - 41.025 40.500 - 40.525 40.000 - 40.025
41.925 - 41.950 41.425 - 41.450 40.925 - 40.950 40.425 - 40.450 39.925 - 39.950
Maximum permissible run out of cam shaft bearing journal Maximum permissible axial play of cam shaft in installed condition Runout of oil seal mating diameter. Valve seat insert : Valve seat insert thickness Inlet Exhaust
- 7.1 + 0.05 mm - 7.34 + 0.05 mm
Cam shaft bearing journal diameter.
0.025 mm 0.1/0.25 mm 0.02 mm
Valve seat inside dia in insert Inlet - 32.5 + 0.1mm Exhaust - 25.7 + 0.1mm
80
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Valve seat insert & bore dia. in cyl. head Stage
Valve seat insert bore diameter in cyl. head (mm)
Valve seat insert out side diameter (mm)
Normal Normal 1
38 / 38.03 38.23 / 38.28
38.13 / 38.155 38.43 / 38.455
EXHAUST - Normal - Normal 1
32.99 / 33.021 33.29 / 33.321
33.13 / 33.155 33.43 / 33.455
INLET -
Cylinder head cover: Remove the baffle plate in the cylinder head cover by removing the screws Fig. 98. Check the baffle plate gasket if it is torn/damage, replace if necessary otherwise it might result in high engine oil consumption.
SULIN Fig. 98
Assembly of cylinder head : Install valves in their respective positions Install spring seat, valve springs and valve retainers. Fit support rail (2702 5890 0616) on cylinder head Fig. 99.
Fig. 99 81
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI With spring compressor, (2702 5890 0615), compress valve springs and install valve lock halves Fig. 100. Smear cam shaft journals and cam lobes with moly paste grease Install cam shaft and lock it by lock plate at the front Fig. 101. Insert the rocker arm shaft with rocker arm spring and spring seat one by one CAREFULLY. Rocker arm and rocker shaft dimensions: +0.016
Rocker shaft dia. :15 - 0.027 mm Rocker bore dia. : 15
+ 0.018 - 0.000
mm
CAUTION : While inserting rocker arm shaft on inlet valves, ensure that tapped hole on the shaft is at the front end and for rocker arm shaft on exhaust valves the tapped hole on the shaft is at the rear end.
Fig. 100
Check cam shaft axial play. It should be within specified limits Fig. 102 Check camshaft for rotation.
SULIN
Fit camshaft oil seal with drift (Pt. No. 2654 5890 0508) Fit camshaft gear and hand tighten the mounting bolt.
Measure piston projection above crank case and select correct thickness of cylinder head gasket PISTON PROJECTION mm
GASKET THICKNESS, mm
-0.04 to 0.26
1.1
Fig. 101
MAXIMUM DIFFERENCE BETWEEN PISTON PROJECTIONS OF ANY TWO PISTONS IN CRANK CASE SHOULD NOT EXCEED 0.12 mm.
Fig. 102 82
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Ensure that cylinder head locating hollow dowel is in position on crank case. Ensure that timing pin 2702 5890 0605 is installed in position Fig. 103. Place cylinder head gasket of pre-determined thickness. Install cylinder head and tighten cylinder head 9
5
1 10
1
2 6
4
3 2
8
4 3
7
Fig. 103 mounting screws to 3 mkg torque in the correct sequence i.e. from centre to outwards. Then retighten screws to 5 mkg torque in the same sequence - Then loosen each screw by quarter turn and retighten to 6.5mkg. torque Fig. 104 Valve clearance adjustment. VALVE CLEARANCES SHOULD BE CHECKED ONLY WHEN ENGINE IS COLD.
SULIN
•
Fit camshaft gear
Fitment : Ensure that timing pin is in flywheel locked position. Check that the cam gear is “Just” freely rotating on the camshaft with mounting bolt in hand loose condition. Slacken all valve tappet clearance setting screws to such an extent that the screw bottom radius is just riding on the valve tips & tighten the locknuts.
Fig. 104
NOTE : This is to reduce the valve spring load on camshaft, while rotating the camshaft. Using an appropriate spanner on camshaft fixing bolt, rotate in camshaft in clock direction with timing pin placed on the cylinder head reference hole, until the camshaft is locked in timing position. Fig. 105 Slacken the fixing bolt so that the camgear is “Just” freely rotating on camshaft. Fit the camshaft gear washer locking plate. Check now that both the flywheel and camshaft are in locked timing position.
Fig. 105 83
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Fit timing belt on crank shaft gear, water pump tensioner roller and camshaft gear. Ensure that the mark provided on target wheel mounted on Camshaft gear is in front of Cam phase sensor.(Refer Fig. 59) Adjust the timing belt tension, (Fig. 106) by rotating tensioner roller clockwise and tighten the mounting screw, ensuring that the tensioner roller does not rotate further in clockwise direction. This will prevent overtensioning of timing belt.
Fig. 106 Tighten the cam gear fixing bolt to a lower tightening torque of 1 mkg Fig. 107. Remove cam shaft timing locking pin. Re-tighten the cam gear fixing bolt to the specified torque.
SULIN Fig. 107 •
Set the flywheel and cam shaft in No.1 cylinder firing position.
•
Adjust the valve clearances of cylinder No. 1 & 2 on inlet valves and cylinder No. 1 & 3 on exhaust valves Fig. 108
•
Remove the camshaft and crankshaft locking pins.
Fig. 108 84
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI •
Rotate the crankshaft by one rotation in the clockwise direction and insert the flywheel locking pin.
•
Adjust the valve clearances of cylinder No. 3 & 4 on inlet valves and cylinder No. 2 & 4 on exhaust valves Fig. 109
Specified
INLET
EXHAUST
0.20
0.30
Fig. 109 Assemble •
Spark plug. Fig. 110
SULIN Fig. 110 •
Exhaust manifold Fig. 111
Fig. 111 85
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI •
Inlet manifold with throttle body and gasket. Fig. 112
•
Spacer tube on cylinder head cover mtg. studs.
•
Cylinder head cover along with camshaft gear rear cover. Replace the gasket if required.
•
Timing belt gear cover Fig. 113.
•
Thermostat cartridge
•
Thermostat cover with gasket
•
Bypass line
•
Dip stick clamp screw
•
Vacuum pipe canister purge valve to intake manifold.
•
Hoses from intake manifold to cylinder head cover and brake booster.
•
Bracket supporting fuel lines.
•
Spark plug leads.
Fig. 112
Fill recommended quantity of oil.
SULIN Fig. 113
CYLINDER BLOCK (Cylinder head assembly removed) Disassembly Uniformly and evenly unscrew clutch pressure plate mounting screws and remove clutch pressure plate and clutch disc Fig. 114.
Fig. 114 86
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Remove : • Vibration damper Fig. 115.
Fig. 115 • • • •
Crankshaft gear Fig. 116. Water pump Timing belt tensioner Timing belt rear cover
SULIN Fig. 116 • •
Oil filter by using spanner (2702 5890 1802) Fig. 117 Engine mtg. bkt. (intermediate)
Fig. 117 87
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI •
Oil sump by extended socket (2702 5890 0603) Fig. 118
Fig. 118 • •
Oil pump strainer Fig. 119 Oil pump
Carefully remove combustion residues towards top end of cylinder bores, preferably by a broken piston ring or by a ridge cutter.
SULIN
Turn the crank shaft and bring a pair of piston to BDC
Fig. 119 Unscrew connecting rod bearing cap mounting nuts Fig. 120
Fig. 120 88
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Remove connecting rod bearing caps with bearing shells. Push these piston assemblies out of cylinders using the wooden handle of the mallet. Remove connecting rod bearing shells and duly mark them with paint on their backs in case these are to be reused. IT IS ESSENTIAL TO ASSEMBLE CONNECTING ROD BEARING CAPS TO THEIR RESPECTIVE CONNECTING RODS Verify serial numbers on connecting rod bearing caps and connecting rods. Remove remaining pistons in same manner Remove piston pin spring clips with suitable plier. Fig. 121
Fig. 121
Remove piston pins from piston by pushing them out using soft drift. Fig. 122 Remove connecting rod
KEEP PISTONS AND PISTONS PIN IN SETS.
SULIN Fig. 122
Insert flywheel locking pin. Fig. 123
Fig. 123 89
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Unscrew flywheel mounting screws Fig. 124 Remove flywheel locking pin. Remove flywheel. Unscrew and remove crankcase cover with oil seals.
Fig. 124 Unscrew main bearing cap mounting bolts and remove main bearing caps. Fig. 125 Remove crank shaft main bearing shells and thrust washers from crank case. Duly mark the main bearing shells with paint on their backs, in case these are to be reused.
SULIN Fig. 125
Remove crankshaft Fig. 126 IT IS ESSENTIAL TO ASSEMBLE MAIN BEARING CAPS TO THEIR RESPECTIVE POSITIONS IN CRANK CASE.
Fig. 126 90
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI PISTON AND PISTON RINGS : PISTON AND CYLINDER BORE SIZES : Type
Grade
Standard
Cylinder bore Piston Diameter mm Diameter mm
A
75.00/75.01
74.96
B
75.01/75.02
74.97
C
75.02/75.03
74.98
PISTON RINGS : Type of ring
Axial clearance Butt clearance in piston groove in cylinder bore
1st Compression 0.03 / 0.07 mm ring
0.15 / 0.3 mm
2nd Compression 0.02 / 0.06 mm ring
0.2 / 0.35 mm
3rd Oil control ring
0.2 / 0.6 mm
-
Fig. 127
Remove piston rings from piston using ring expander. Fig. 127
SULIN
Remove the carbon deposits from the piston Clean the piston and piston rings thoroughly
In case the cylinder bore taper and ovality is within specified limit, then same piston and piston rings may be reused. Examine the pistons for cracks, scoring, other damages, ring groove wear, piston pin bore wear, spring clip groove wear/damage etc.
Fig. 128
In case of any one piston with any one of this defect, complete piston set should be replaced. Examine piston rings for scoring, lateral clearance in piston ring groove and butt clearance in cylinder bore. Fig. 128 & 129 Piston pin dia. Piston Pin length Piston Pin bore in piston Height of Piston Piston to bore clearance Max. permissible difference in weights of pistons with pin & rings of an engine
20.00/19.996 mm 59.00/58.7 mm 19.998/20.003 mm 52.5 mm 0.040 - 0.050 mm
3 gms.
Fig. 129 91
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI BUTT CLEARANCE OF PISTON RING SHOULD BE MEASURED IN UNWORN PORTION OF CYLINDER BORE. In case of any piston ring with any one of this defect, complete ring set should be replaced. When cylinder bores are re-bored or honed, pistons and rings of appropriate size should be used. Piston size is stamped on piston crown. Install piston rings in their respective position on piston using ring expander, with “TOP” marking upward. Fig. 130 Ensure that piston & rings are clean. Assemble the expander of the oil ring in the 3rd groove & then the bottom & top rails. Do not wind in the rails on to the groove.
Fig. 130
Assemble Taper compression ring in the 2nd groove using ring plier. Ensure ‘TOP’ marking is towards the piston crown. Assemble the Gas nitrided steel ring in the top groove using a ring plier. Stagger the ring gap. Lightly oil the rings and use ring compressor, while inserting into the cylinder.
CONNECTING RODS
SULIN
Inspect connecting rod small end bush and if necessary, replace it. Check connecting rod small end parent bore dimension Fig. 131
If necessary machine connecting rod small end parent bore to next over size. NOTE : Ensure that the Connecting rod big end & small end axes are parallel to each other within specified limits. Ensure that centre distance between small end & big end is maintained within specified limit.
Fig. 131
Oil the parent bore in connecting rod. Install a new bush in such a way that slit is positioned approximately in vertical axis. Drill oil hole in the new bush Finish connecting rod small end bush bore on a connecting rod boring machine. Alternately connecting rod small end bush may be reamed. Install connecting rod bearing caps without bearing shells on connecting rod. Tighten connecting rod bearing cap mounting nuts to specified torque. Fig. 132
Fig. 132 92
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI CONNECTING ROD (DIMENSIONS) : Connecting rod small end Stage
parent bore diameter mm
bush outside diameter mm
Normal
23.021/23.000
23.086/23.111
Normal I
23.221/23.200
23.286/23.311
Maximum permissible taper and ovality of connecting rod small end parent bore and cylindricity
0.004 0.008
mm mm
20.0+0.020/0.007
mm
Maximum permissible out of parallelism (bend) between connecting rod small end and big end parent bores.
0.050
mm
Centre to centre distance between connecting rod small end and big end parent bores.
141.65±0.03
mm
0.050
mm
SULIN
48.655 /48.671
mm
0.005 0.01
mm mm
Bearing shells to be selected such that clearance is maintained as
0.024 to 0.075
mm
0.013-0.051
mm
5
gms
0.05 - 0.35
mm
Connecting rod small end bush inside diameter finished after installation) (Piston pin oiled has thumb push fit in small end bush).
Maximum permissible twist of connecting rod Connecting rod big end parent bore diameter
Maximum permissible taper and ovality of connecting rod big end parent bore and cylindricity
Pre-tension of connecting rod big end bearing shells Maximum permissible difference in weight of connecting rods in one engine Connecting rod big end axial play
93
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI NOTE : Ensure that the identification numbers for connecting rod & connecting rod bearing cap are matched & notches for bearing shells are on same side. Check twist and bend of connecting rod by using new piston pin in connecting rod small end bush. Measure twist and bend of connecting rod with feeler gauge with respect to vertical face of connecting rod alignment gauge in vertical and horizontal plane at a distance of 50 mm from the line joining centres of connecting rod small end and big end bosses. Fig. 133 & 134 If necessary, straighten the connecting rod in cold condition. Since a slight clearance exists between connecting rod bolts and corresponding connecting rod bearing cap holes, it is possible that connecting rod bearing cap once removed may be installed off centre, by which dimension of connecting rod big end parent bore will be different in different directions.
Fig. 133
If difference is noticed in connecting rod big end parent bore dimension, connecting rod bearing cap can be centralised by lightly tapping it with mallet in required direction after slightly loosening connecting rod bearing cap mounting nuts.
SULIN
Check connecting rod big end parent bore dimension. Fig. 135 If connecting rod big end parent bore is slightly more than maximum permissible limits, it is possible to reclaim connecting rod provided the wear is confined only to connecting rod bearing cap. Connecting rod bearing cap mating surface may be slightly faced. Parent bore should then be finished on a connecting rod boring machine.
Fig. 134
ENSURE THAT CONNECTING ROD BIG END AND SMALL END AXES ARE PARALLEL TO EACH OTHER WITHIN SPECIFIED LIMITS. CENTRE TO CENTRE DISTANCE BETWEEN CONNECTING ROD SMALL END AND BIG END IS MAINTAINED WITHIN SPECIFIED LIMITS. If one or more connecting rods are to be replaced, ensure that difference in weight of connecting rod in an engine is within permissible limits. Install new pair of connecting rod bearing shell according to size of crank pin journal diameter, making sure that securing lugs of bearing shells are properly seated in grooves of connecting rod and its bearing cap.
Fig. 135
94
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Install connecting rod bearing cap with bearing shell on connecting rod. Tighten connecting rod bearing cap mtg. nuts to specified torque Fig. 136
Fig. 136 Measure connecting rod bearing bore Fig. 137 IF CONNECTING ROD BIG END PARENT BORE DIMENSION IS MAINTAINED WITHIN SPECIFIED LIMITS. PROPER BEARING BORE DIMENSION IS AUTOMATICALLY ACHIEVED.
SULIN
However, it must be physically measured and confirmed . Measure pre-tension of connecting rod bearing shell with a feeler gauge after loosening connecting rod bearing cap mounting nut on opposite side of bearing shell lug. CONNECTING ROD BEARING SHELLS ARE PRECISION FINISHED AND SHOULD NOT BE BORED OR SCRAPED.
Fig. 137
95
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Crank shaft (dimensions) Stage
Crank case main bearing bore diameter with bearing shell mm
Crank shaft main bearing journal diameter mm
Normal
50.026 / 50.065
50.0/49.98
Normal 1
49.926/ 49.965
49.900/ 49.880
Repair 1
49.786 / 49.815
49.760/ 49.730
Repair 2
49.526 / 49.565
49.500/ 49.480
Stage
Connecting rod big end bore diameter with bearing shell (mm)
Crank pin journal diameter mm
Normal
45.007 / 45.043
44.995/44.980
Normal 1
44.907 / 44.943
44.895/ 44.880
Repair 1
44.757 / 44.793
44.745 / 44.730
Repair 2
44.507 / 44.543
44.495 / 44.480
Stage
Width of 4th main bearing journal (mm)
Thickness of 4th main bearing thrust washers, mm
Normal
24.052 / 24.000
2.62(2.60-2.65)
Standard 1
24.152 / 24.100
2.57(2.55-2.60)
Repair 1
24.252 / 24.200
2.52(2.50-2.55)
End play of crank shaft
SULIN
0.06 - 0.226 mm
Fillet radius of main bearing journals
2.5-0.5 mm
Fillet radius of crank pin journals
2.5-0.5 mm
Pre-tension of main bearing shells 0.018-0.040 mm Hardness of crank shaft main bearing and crank pin journals
50-60 HRC
Width of 1st, 2nd, 3rd and 5th main bearing journals
24.0+0.2 mm
Main bearing parent bore dia in crank case
Width of crank pin journals
24.0+0.2 mm
Maximum permissible taper of main bearing parent bore
0.005 mm
Maximum permissible ovality of main bearing parent bore.
0.005 mm
Maximum permissible cylindricity
0.0025 mm
Ovality of main brg. journal
0.005 mm
Max. permissible ovality of crank pin
0.005 mm
Maximum permissible run out of 2nd, 3rd and 4th main bearing journals when supported at 1st and 5th main bearing journals
0.02 mm
Maximum permissible out of parallelism between crank pin and main bearing journal axis
0.010 mm
Crank shaft journal to main bearing clearence
53.8 +0.019 mm + 0.00 mm
0.026 / 0.085 mm
96
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI CRANK SHAFT : Clean and carry out visual inspection of crankshaft for the following •
Overheating of journals, which is indicated by bluish brown colour.
•
Scoring marks on journals.
•
Cranks, which should be checked on magnetic crack detector.
Check crank shaft run out by supporting it on V-block at 1st and 5th main bearing journals. Fig. 138 If run out exceeds permissible limits, straighten crank shaft in cold condition on press carefully. Similarly check lateral and radial run outs of flywheel mounting flange. Check crank shaft main bearing and crank pin journal dimension.
Fig. 138
If necessary, grind crank shaft main bearing and crank pin journals to next under size. MAINTAIN CORRECT FILLET RADII FOR JOURNALS Care must be taken during grinding to ensure that width of journals is not increased.
SULIN
Should it be necessary to grind sides of 4th main bearing journal, grind it to next over size.
Re-chamfer oil holes on journals to avoid scoring of new bearing shells. Finish journals by lapping them with 320 grit lapping cloth of suitable width. After grinding recheck main bearing and crank pin journal dimensions. Also recheck run out of crank shaft.
Fig. 139
Thoroughly clean crank shaft with kerosene. Use wire brush for cleaning oil holes. IT IS ESSENTIAL TO RECHECK CRANK SHAFT FOR CRACKS AND BALANCE AFTER GRINDING Apply grease to all machined surfaces, if crank shaft is to be stored. Crank shaft must always be stored in vertical position.
CYLINDER BLOCK Check cylinder block for cracks by pressure testing method. Check crank case mating surface with cylinder head for unevenness with help of straight edge and feeler gauge. Fig. 139 & 140
Fig. 140 97
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI If necessary grind this surface just to clear unevenness. Ensure that the minimum height of crank case is not less than the specified minimum height. Thoroughly clean the main bearing caps and corresponding machined surfaces of crank case. Install main bearing caps without bearing shells in their respective positions of crank case. ENSURE THAT THE SERIAL NUMBERS ON CRANK CASE AND MAIN BEARING CAPS ARE MATCHING. ALSO CAPS ARE IN SERIAL ORDER AND NOTCHES FOR BEARING SHELLS ARE ON SAME SIDE. Tighten main bearing cap mounting bolts to specified torque. Fig. 141
Fig. 141 Check crank case main bearing parent bore dimensions. Fig. 142 Install new pairs of main bearing shells according to size of crank shaft main bearing journal diameter, making sure that securing lugs of bearing shells are properly seated in grooves of crank case and main bearing caps.
SULIN Fig. 142 Install main bearing caps with bearing shells in their respective position on crank case. Tighten main bearing cap mounting bolts in specified sequence to specified torque. Fig. 143
Fig. 143 98
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Measure the main bearing bore.
BOLT TIGHTENED
BOLT LOOSENED
IF MAIN BEARING PARENT BORE DIMENSION IS MAINTAINED WITHIN SPECIFIED LIMITS, PROPER MAIN BEARING BORE DIMENSION IS AUTOMATICALLY ACHIEVED. However, it must be physically measured and confirmed. Measure pre tension of main bearing shell with a feeler gauge after loosening main bearing cap mounting bolt on opposite side of bearing shell lug (This is to be done on a flat surface plate as it can not be measured on engine cylinder block because the main bearing caps are guided) Fig. 144 MAIN BEARING SHELLS ARE PRECISION FINISHED AND SHOULD NOT BE BORED OR SCRAPED.
PRETENSION GAP SURFACE PLATE
Schematic Sketch :
Main bearing shell pretension checking
Fig. 144
Select a new pair of thrust washer according to crank shaft 4th main journal width. Cylinder bores Clean cylinder bores thoroughly Check cylinder bore dimension, taper and ovality. Fig. 145
SULIN
If taper and ovality is found to exceed specified limit or bore is excessively worn out machine cylinder bore as given below to fit the liners. Record the readings in Engine inspection sheet no. 2 given in this manual. Rebore all the cylinders to 78+0.02 mm size and fit the liners as per the procedure given in 475 IDI Engine section.
Fig. 145 Cylinder Block (Dimensions) - in mm C
Height of crank case (Dimension A&B) Fig. 146
D
265.8/265.6
Maximum permissible unevenness of crank case mating surface with cylinder head 150x150 : cross wise ‘D’ Fig. 146
0.015
: length wise ‘C’ Fig. 146
0.030
Maximum permissible out of parallelism between crank case top and bottom machined surface
0.2
B A
Fig. 146 99
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
SULIN
OIL PATH RETURN OIL PATH
Fig. 147a 100
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI ENGINE LUBRICATION COMPONENTS
MAIN OIL GALLERY
OIL FILTER
OIL PUMP
GASKET
SULIN
OIL SUMP
STRAINER DRAIN PLUG
Fig. 147b Maximum permissible shift in perpendicularity of cylinder bore from crank shaft axis when checked from crank shaft centre line Maximum permissible taper and ovality of cylinder bore
0.25 mm
replace the oil pump assembly. Fit oil pump assembly with new gasket. Flow rate measured against back pressure of 3kg/ cm2 should be as follows using SAE-30 oil.
0.007
Pump rpm
Minimum flow rate in Ipm
4000
28
2000
14
800
5.6
LUBRICATION SYSTEM :Fig. 147a & 147b. OIL PUMP Unscrew screws holding oil pump to cyl. block and remove the oil pump assembly Check oil pump for flow rate at specified rpm. Check for any leakage at sealing plugs. Check functioning of Pressure relief valve. If the performance of the pump is not satisfactory, then
Engine oil pressure with coolant temperature of 700 C at idling speed 800+50 rpm - 1 bar at 5000 rpm - 3 bar Oil Pressure Switch NC contact opening pressure : 0.9 /0.6 bar 101
MAIN INDEX
GROUP INDEX
RADIATOR VENT HOSE AUXILARY WATER TANK
RADIATOR RADIATOR FAN
SULIN
MAIN INDEX
INTEGRAL WATER HOSE
GROUP INDEX
Flow of coolant
UPPER COOLING LINE THERMOSTAT HOUSING BYPASS LINE HEAD VENT LINE CAB HEATER FEEDING HOSE
ENGINE 475 SI MPFI
Fig. 148
102
COOLING CIRCUIT
ENGINE 475 SI MPFI COOLING SYSTEM : Fig.148
THERMOSTAT CLOSED
WATER PUMP
TO RADIATOR
Check water pump for free rotation. Check water pump for flow rate at specified rpm. Check for coolant leakage through leakage hole. It indicates that the seal is damaged and leaking. Replace the water pump if necessary. Water pump characteristics : ENGINE RPM PUMPRPM FLOW RATE AT BACK PRESSURE=0.3 BAR (LITRES PER MINUTE) 2000
2100
40
3000
3150
60
4000
4200
80
5000
5250
100
5500
5775
110
TO ENGINE
Fig. 149 THERMOSTAT OPEN
TO RADIATOR
Thermostat •
Start opening temperature : 82 0C ± 2
•
Full open temperature : 96 0C Max.
•
Leakage through main valve (including seepage hole) at room temperature and pressure of 1 kg/ cm2 : 150-250 ltrs/hr
•
Maximum leakage through by pass at full open temperature or main flow rate of 130 + 5 lpm : 1.5 lpm
SULIN
Thermostat is installed in cooling system between cyl. head & radiator inlet tank. The working principle of thermostat :
TO ENGINE
Fig. 150 3.
1.
For cold engine (immediately after starting) : Thermostat does not allow coolant to flow to radiator (Thermostat valve in closed position) instead coolant flows through thermostat by-pass outlet to engine. Thus short circuiting of radiator which helps for attaining engine working temperature in very short period. Fig. 149
2.
As soon as the coolant temperature reaches opening temperature of thermostat, the thermostat valve starts opening gradually and water flow starts to radiator. At the same time thermostat by pass starts closing gradually.
As the engine cooling temperature reaches thermostat full open temperature, thermostat valve opens fully and thermostat by-pass valve closes completely. Under such condition maximum quantity of engine coolant flows to radiator Fig. 150.
103
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Satisfactory operation of thermostat is very much essential for : •
Efficient engine operation
•
Longer engine life.
Defective thermostat may cause •
Over cooling due to thermostat valve sticking in full open position
•
Over heating due to thermostat valve sticking in partial/full closed condition
When above defects are observed, thermostat needs checking. Checking of thermostat element 1.
Remove thermostat element from thermostat housing Fig. 151
2.
Mount thermostat element in a suitable fixture and place the fixture in a vessel filled with water.
3.
Fix dial gauge with its spindle on valve surface with a pretension @ 0.5 mm
4.
Heat the vessel and measure the water temperature with proper thermometer
5.
Note down the temperature when dial gauge needle starts moving indicating valve opening.
6.
Note down the water temperature for needle movement of 8mm (valve fully open position)
7.
The opening temperature (Sl.No.5) and fully open temperature (Sl.No.6) as measured should be as mentioned.
Fig. 151
SULIN
If they do not meet the specifications, replace the thermostat element.
Fig. 152
Cylinder block Assembly : Install main bearing shells, in the block. Install thrust washers in crank case at their respective location on 4th main bearing sides. Apply light coat of engine oil to main bearing shells and main journals. Install crank shaft Fig. 152 Install 4th main bearing cap with thrust washers. Install 1st, 2nd, 3rd and 5th main bearing caps with shells in their respective position on crank case. Tighten main bearing cap mounting bolts evenly and uniformly to specified torque (first 3rd cap, next 4th and 2nd, lastly 5th and 1st) Fig. 153
Fig. 153 104
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Check that end float of crank shaft is within specified limits. Fig. 154
Fig. 154 Install rear oil seal using drift 2702 5890 0608 in crank case rear cover. Fig. 155 Clean the mating surfaces of crank case & rear cover.
SULIN Fig. 155 Fit crank case rear cover with new gasket Fig. 156 Locate flywheel on crank shaft rear flange. Screw-in flywheel mounting screws. Insert flywheel locking pin Tighten flywheel mounting screws to specified torque. Remove flywheel locking pin. Remove the connecting rod bearing cap with shell.
Fig. 156 105
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Assemble the connecting rod in piston such that when you hold the piston in your hand, the arrow mark on the piston crown is towards left and the cooling jet on connecting rod is towards you. Insert the piston pin. Fit piston pin spring clip. Fig. 157 Apply oil on piston, piston rings, cylinder bore and bearing shells. Turn the crank shaft and bring crank pin journal to top most position into which connecting rod with piston is to be fitted. Insert the connecting rod with piston upto piston rings into cylinder bore with arrow on piston crown pointing towards front. Stagger the piston ring gaps such that they are 1200 apart. Clamp piston ring compressor over piston rings such that piston with piston rings can slide inside it. Fig. 158
Fig. 157
Push the piston gradually inside cylinder bore using wooden handle of mallet till connecting rod locates on crank pin journal. Slowly rotate the crank shaft, simultaneously pushing piston till crank pin journal reaches BDC position.
SULIN Fig. 158
Install connecting rod bearing cap with bearing shell on connecting rod ensuring that bearing shell lugs are on same side Fig. 159.
JET LUGS
Fig. 159 106
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Tighten connecting rod bearing cap mounting nuts to specified torque. Fig. 160 Assemble other connecting rods with piston in same manner.
Fig. 160 Check end play of connecting rods Fig. 161 Fix oil pump gasket Install oil pump Assembly with gasket.
SULIN Fig. 161 Tighten the oil pump mtg. screws to specified torque. Fig. 162
Fig. 162 107
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Fit oil pump strainer with gasket. Fig. 163
Fig. 163 Fit water pump with new gasket. Fig. 164
SULIN Fig. 164 Install - Oil sump Fig. 165 - Timing gear rear covers - Timing belt tensioner - Crankshaft gear Install crank shaft pulley assembly (An additional multi groove pulley is provided for version with, for AC compressor drive).
Fig. 165 108
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Lock flywheel with timing pin Fig. 166
Fig. 166 Screw in crankshaft pulley mounting bolt with spacer and tighten it to specified torque. Fig. 167 Fit •
Alternator top mounting bracket
•
Alternator bottom mounting bracket
•
Alternator
SULIN Fig. 167
•
NEW oil filter Fig. 168
•
Fit coolant inlet elbow with gasket.
Fig. 168 109
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Fit clutch disc using mandrel (2702 5890 2501) Fig.169.
Fig. 169 Assemble Clutch pressure plate Fig. 170. FOR ASSEMBLY OF CYLINDER HEAD ON BLOCK TIMING BELT FITMENT ETC. PLEASE REFER RESPECTIVE SECTIONS OF THIS MANUAL.
SULIN Fig. 170
110
MAIN INDEX
GROUP INDEX
AIR FILTER
MAIN INDEX
SULIN
MAP SENSOR
SNORKEL
THROTTLE BODY CYLINDER HEAD
GROUP INDEX
INTAKE MANIFOLD
RESONATOR BOX
ENGINE 475 SI MPFI
Fig. 171
AIR INTAKE SYSTEM
111
ENGINE 475 SI MPFI AIR INTAKE SYSTEM : Fig. 171 For regular cleaning as per maintenance schedule : •
Unscrew and remove housing cover, and remove element. Fig. 172 - 174.
•
Clean it gently by tapping on clean table.
•
Use compressed air, at a very low pressure, for cleaning the element
•
Check the condition of rubber sealing
•
Check element for major rupture or puncture of paper pleats.
•
Replace element if any rupture or puncture is observed.
•
Check condition of air hose / resonator box
•
Check condition of rubber cuff on air filter and replace it if necessary.
•
Always use GENUINE air filter element to ensure long engine life.
•
Install paper filter element
•
Fit housing cover and clamp it firmly with the screws.
Fig. 172
SULIN Fig. 173
Fig. 174 112
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI ACCELERATOR CABLE : RHD :
2 1
1 2 3 4 5 6 7 8 9 10 11
CABLE PLASTIC END INNER CABLE END PLASTIC CLAMP PLASTIC CLAMP TOP SIDE NUT THROTTLE BODY BRACKET THROTTLE BODY SECTOR ACCELERATOR PEDAL RHD CABLE CLIP RUBBER STOPPER ASSEMBLY ACCELERATOR CABLE RHD 12 ASSEMBLY ACCELERATOR CABLE LHD 13 ACCELERATOR PEDAL LHD
8
6
7 5
10
9 4
3 11 1
LHD :
12
5
2
SULIN 13
Fig . 175 Removal : 1. Loosen the top side nut (5) from threaded end of accelerator cable at throttle body end. 2. Remove inner cable end from throttle body sector after disengaging the threaded end of the cable in throttle body bracket (6). 3. Remove accelerator cable from plastic clamp (3,4). 4. Remove inner cable end (plastic flower) (2) from accelerator pedal (8). 5. Remove accelerator cable plastic end (1) through firewall hole.
Installation : 1. Insert accelerator cable plastic end (1) inside the firewall hole. 2. Insert inner cable end (plastic flower) (2) in accelerator pedal. 3. Locate accelerator cable in plastic clamp (3) and (4). Ensure that rubber sleeve on accelerator cable are located inside the plastic clamps. 4. Loosen the top side nut (5) from threaded end of the cable. Engage the threaded end of the cable in throttle body bracket (6). Insert inner cable end in throttle body sector (7). 5. Ensure tightness in inner cable by adjusting the nuts on threaded end of cable. 6. Ensure that when accelerator cable (8) is fully depressed, full travel of throttle sector is achieved. 113
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI ASSY FOOT CONTROL MODULE
ASSY FOOT CONTROL MODULE ASSY FOOT CONTROL MODULE
CLUTCH PEDAL ASSISTANCE SPRING TORSION SPRING (FOR ACC PEDAL) 4.0
ASSY CONTROL MTG BRACKET
SLEEVE
CIRCLIP
SULIN RUBBER STOPPER STOP LIGHT SWITCH ASSY CLUTCH PEDAL LEVER
SLEEVE
ASSY ACC PEDAL WITH BUSH
ASSY BRAKE PEDAL LEVER RUBBER COVER
RUBBER COVER
RUBBER GRIP
PEDAL PLATE RUBBER GRIP
ACC PEDAL PLATE RUBBER COVER
TORSION SPRING (FOR BRAKE PEDAL RETURN)
-- SPECIFIED TORQUE IN Kgm
114
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI ENGINE TESTING
Allow engine to cool down for about 3 hours. Then remove cylinder head cover.
After assembly of the engine, mount engine on test bed, prepare engine for starting and testing in the following manner. Connect oil pressure gauge and temperature gauge. Connect coolant hose to and from radiator. Fill coolant in the cooling system. Fit radiator cap. Fill required quantity of recommended oil in the oil sump.
Loosen cylinder head mounting bolt by quarter turn and retighten immediately to 7 mkg torque in the correct sequence. Complete cylinder head tightening operation in the same sequence and with the same torque. Start the engine and check for any fuel leakages. Rectify, if necessary.
Mount air cleaner assembly on test bed suitably. Connect air cleaner outlet to engine intake using suitable hoses. Make suitable linkage for controlling accelerator lever. Connect exhaust pipe to exhaust manifold. Connect battery cables to starter motor. Ensure that -ve terminal is earthed. Crank engine with accelerator lever in idling position. Allow oil to be circulated through the system. Check and ensure that oil pressure indicated by gauge is satisfactory.
SULIN
Slightly raise the engine speed and check for any oil, fuel, coolant and air leakages. Rectify if any. Check colour of the exhaust gas. Check for any unusual noise from the engine. Connect engine to dynamometer and run for running in test as per schedule. Engine running in test schedule : Engine Speed (rpm)
Time (minutes)
Torque (mkg)
800 2000 2500 3000 3500 2500
5 5 5 5 5 5
0.0 2.3 4.6 5.8 4.9 8.2
After running in test of the engine, reduce dynamometer load to zero and allow engine to run at idling speed for about 5 minutes and then stop it.
115
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI TROUBLE SHOOTING NOTE : BEFORE CHANGING ANY SENSOR PLEASE CHECK THE FUSES,RELAYS & WIRING HARNESS CAREFULLY.
Sr. Problem Observed no. 1.
Engine not cranking
Probable Cause
Action to be taken
Low battery voltage
Clean and tighten the connectors Jump start using another battery Get battery charged or changed
2.
Engine cranks but doesnot start
Faulty starter
Rectify or replace
Worn out piston rings/seized pistons
Overhaul & replace affected parts
Faulty immobiliser
Check and rectify
Clogged air filter Incorrect valve timing Faulty spark plugs Faulty crank angle signal Faulty water temperature sensor Faulty MAP signal Faulty throttle position signal Faulty ISC valve Clogged injectors
Clean as per the instructions Set valve timing /check & reset Clean, check gap/replace if necessary Check & correct the gap Check & replace if necessary Check & replace if necessary Check & replace if necessary Check & replace if necessary Check & replace if necessary
Faulty fuel regulator
Check & replace if necessary
Clogged fuel filter
Replace
SULIN
3.
4.
Erratic idling
Does not idle
Faulty ignition coil
Check and replace
Faulty firing order/ injector (connection) order
Check and replace
Faulty E C U
Replace
Faulty inertia switch
Reset if tripped off or replace
Faulty Fuel Pump
Check and replace if necessary
Inlet manifold leakage/ vacuum connections Valve timing incorrect Vehicle speed signal faulty ISC valve faulty Vacuum line to presure regulator connections Faulty firing order/ injector(connection) order Faulty MAP signal Faulty ISC Valve Faulty fuel regulator
Check and rectify Set valve timing /check & reset Check & replace Check & replace Check & tighten/replace Check and rectify Check & replace Check & replace Check & replace
116
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Sr. Problem Observed no. 5. Maximum RPM low
Probable Cause
Action to be taken
Battery voltage low
Check and tighten connections Jump start using good battery Get battery charged/changed Clean as per instruction set valve timing /check & reset Clean and check gap/replace if necessary Flush the system and refill Check and rectify the gap 1.5 + 0.5 mm Check and Replace Check and Replace Replace
Clogged air filter Valve timing incorrect Spark plugs defective Adulterated fuel Faulty crank angle signal Clogged injectors Fuel pump faulty Clogged fuel filter Faulty firing order/ injector (connection) order 6.
Poor acceleration/Power
Low battery voltage
Clogged air filter Inlet manifold leakage/ vacuum connections Faulty ISC valve Clogged injectors Faulty fuel regulator Clogged fuel filter Faulty ignition coil Faulty firing order/ injector (connection) order Incorrect tappet clearances Valve timing incorrect Inlet manifold leakage/ vacuum connections Valve timing incorrect Worn out piston rings/seized pistons Spark plugs defective
SULIN
Adultrated fuel Clogged injectors Faulty fuel regulator Fuel pump faulty Clogged fuel filter Faulty firing order/ injector(connection) order
Check and rectify Check and tighten connections Jump start using good battery Get battery charged/changed Clean as per instructions Check and rectify Check & replace Check & replace Check and replace Replace Check and replace Check and replace Check and reset Set valve timing /check & reset Check and rectify Set valve timing /check & reset Overhaul /replace affected parts Clean and check gap/replace if necessary Flush the system and refill Check and Replace Check and Replace Check and Replace Replace Check and rectify
117
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI Sr. Problem Observed no.
Probable Cause
Action to be taken
7.
Spark plugs defective Adultrated fuel Vacuum line to presure regulator connections Incorrect valve timing
Clean and check gap/replace if necessary Flush the system and refill
Inlet manifold leakage/ vacuum connections Incorrect tappet clearances Valve timing incorrect Spark plugs defective
Check and Replace Check and rectify Check and reset Set valve timing /check & reset Clean and check gap/replace if necessary Flush the system and refill Check and rectify the gap Check and Replace
8.
Knocking
Misfiring
Adultrated fuel Faulty crank angle signal Clogged injectors Faulty firing order/ injector(connection) order 9.
Whitish/Bluish smoke
Clean as per instructions Overhaul /replace affected parts Check and Replace Flush the system and refill
Low battery voltage
Check and tighten connections Jump start using good battery Get battery charged/changed Set valve timing /check & reset Check and rectify Check and reset Set valve timing /check & reset Overhaul /replace affected parts Clean and check gap/replace if necessary Flush the system and refill Check and Replace Check and Replace Check and Replace
Inlet manifold leakage/ vacuum connections Incorrect tappet clearances Valve timing incorrect Worn out piston rings/seized pistons Spark plugs defective Adultrated fuel Faulty lambada signal Clogged injectors Faulty fuel regulator Vacuum line to presure regulator connections Faulty firing order/ injector (connection) order 11. High oil consumption
Check and Rectify
Clogged air filter Worn out pistonirings/seized pistons Valve guide seals leaking Adultetated fuel
SULIN
10. High fuel consumption
Check and tighten/replace Check and adjust.
Clogged Air Filter Worn out piston rings/siezed pistons Valve guide seals leaking
Check and tighten/replacet Check and rectify
Clean/replace Overhaul /replace affected parts Check and Replace
118
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI ENGINE INSPECTION SHEET CYLINDER BLOCK AND PISTONS Engine No.
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Chassis No. Kilometres
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Kilometres since last overhaul
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50--6
Reason for dismantling
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COMPRESSION READING Cyl.
1
2
3
4
Pressure
Kg/cm2 CYLINDER BORE Dial gauge set at .....mm.
A = Non thrust side B = Thrust side
Cyl. No.
1
Pistons
A
Piston size (Stamped)..... mm
2
B
Ovality
aa
A
B
3 Ovality
A
4
B
Ovality
A
B
Ovality
SULIN
bb cc dd dd ee ff Taper Max. taper .....mm
Max. ovality .....mm
Rebore to size .....mm
Piston Rings Piston Ring No.
1
PISTON RING BUTT CLEARANCE (mm)
PISTON RING LATERAL CLEARANCE (mm)
PISTON NO.
PISTON NO.
2
3
4
1
2
3
4
1 2 3
*Check butt clearance at unworn portion of cyl. bore (bottom)
Piston rings and grooves should be properly cleaned of carbon and other deposits.
PISTON RING GROOVES
Conclusions/Recommendations :
N.B. - Check lateral clearance of new piston rings in grooves Piston Ring No.
New piston ring lateral clearance 1
2
3
4
1 2 3
Checked by
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Date
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119
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI ENGINE INSPECTION SHEET CYLINDER BLOCK & PISTONS Engine No.
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Chassis No. Kilometres
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Kilometres since last overhaul
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SHEET II
Reason for dismantling
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C
C
B A
B A
WITHOUT BEARING SHELL
WITH BEARING SHELL
SULIN
Measuring with bearing shells : Measuring Direction
Dial gauge set at ...mm
CRANK SHAFT BEARING NO. 1
A
mm
B
mm
C
mm
OVALITY
mm
2
3
4
Measuring without bearing shells : Measuring Direction
5
Dial gauge set at ...mm PARENT BORE NO.
1 A
mm
B
mm
C
mm
OVALITY
mm
2
3
4
5
Conclusions/Recommendations :
Checked by
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Date
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120
MAIN INDEX
GROUP INDEX
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ENGINE 475 SI MPFI ENGINE INSPECTION SHEET CRANKSHAFT MAIN AND BIG END BEARING JOURNALS
Engine No.
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Chassis No. Kilometres
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Kilometres since last overhaul
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Reason for dismantling
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SHEET III
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Run-out of crankshaft 4th main journal when supported on journal Nos. 1 and 7
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width of 4th main journal Max DIRECTION aa AND cc AT THE SECTION WHERE FILLET RADIUS ENDS DIRECTION bb NEAR THE CENTRE
DIRECTION A,B & C 120o APART
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MAIN JOURNAL
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mm mm
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BIG END JOURNAL
Taper Ovality
MEASUREMENTS IN DIRECTION JOURNAL No. aa 1
MAIN JOURNAL GAUGE SET AT .....mm A
B
SULIN C
Ovality
BIG END JOURNAL GAUGE SET AT .....mm
A
B
C
Ovality
bb cc
Taper aa 2 bb cc Taper aa 3
bb cc
Taper aa 4
bb cc
Taper aa 5
bb cc
Taper Conclusions / Recommendations
Checked by
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Date
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121
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
ENGINE INSPECTION SHEET CONNECTING ROD BEARING AND PARENT BORES Engine No.
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Chassis No. Kilometres
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Kilometres since last overhaul MEASURING
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Reason for dismantling
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BIG END BEARING BORE DIA. (WITH SHELLS INSTALLED) GAUGE SET AT.....mm
DIRECTION
1
A
mm
B
mm
C
mm
OVALITY
mm
WEIGHT GROUP
}
COLOUR MARKS
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SHEET IV
2
3
4
SMALL END : BIG END : B C
SULIN CONNECTING ROD BIG END PARENT BORE
MEASURING DIRECTION
1
A
mm
B
mm
C
mm
OVALITY
mm
GAUGE SET AT.....mm
2
3
CONNECTING ROD SMALL END PARENT BORE 1 A
mm
B
mm
OVALITY
mm
A
4
GAUGE SET AT.....mm
2
3
4
3
4
ALIGNMENT 1
2
TWIST BEND Conclusions/Recommendations :
Checked by
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Date
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122
MAIN INDEX
GROUP INDEX
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ENGINE 475 SI MPFI ENGINE INSPECTION SHEET CAMSHAFT JOURNAL AND BEARING BORE
Engine No.
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Chassis No. Kilometres
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Kilometres since last overhaul
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Reason for dismantling
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SHEET V
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CAMSHAFT JOURNAL Journal
NO. 1 CAMSHAFT JOURNAL
Measuring Direction
No.
Dia A(mm)
Dia B(mm)
Ovality (mm)
Remarks
aa 1 bb aa 2 bb
MEASURING DIRECTION
aa 3 bb
SULIN aa
4 bb Run-out of intermediate journals when supported on journal Nos. 1 & 4 2
3
Camshaft re-ground to repair size
4
1
2
3
4
5
Conclusions/ Recommendations : CAMSHAFT BEARING BORE (Bearing Shells installed) Measuring Direction Bearing No.
Remarks A-Dia (mm)
B-Dia (mm)
Ovality (mm)
1 2 Checked by Date
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3 4
123
MAIN INDEX
GROUP INDEX
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