Tata Indica Manual De Taller 501662

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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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 ed by Hitachi EMS

Ignition system

:

Grouped Ignition ed 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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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.

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 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 t 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, 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 #

SULIN

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

SULIN

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

By 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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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

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’ V

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)

9

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ENGINE 475 SI MPFI

ENGINE

FEATURE

HOW ACHIEVED

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 convenience

‘LIMP HOME’ ISC Valve

When ISC Valve fails in closed condition, open throttle marginally to start the engine.

convenience

Engine Stall protection

When engine rpm is as low as 650 rpm, ECU cuts A/C relay.

Better Idle stability and 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

SULIN

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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ENGINE 475 SI MPFI FEATURE

HOW ACHIEVED

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 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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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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ENGINE 475 SI MPFI LAMBDA SENSOR (O2 Sensor) Fig. 13 & 14 Type : ENGINE

LSH 24

Heated Ceram ic Oxygen Sensor 3 Pin Connector

Working prinle (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. 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 s 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 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 age 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-ing 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 age 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

’

Measure the resistance across pin P & 11

System Diagnosis :

Electrical Circuit :

Use Hitachi Diagnostic tester Check for C 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 ()

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 U 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

U : H8

Air temp.Sensor Throttle Position Sensor Water temp. sensor

Ignition Coil * 1 ISC solenoid

U 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 – 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.

C 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.

C 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 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 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

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 V (380)

12

RUBBER HOSE-V 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

BKT.(FOR ALT.BKT.& TOP )

05

HEX FL SCREW M8X18

06

BRACKET (FOR ALT.TOP )

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 BY GASKET (FOR WATER BY TUBE) HEX FL NUT BM6 ASSY.HOSE (WATER BY) (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 arm. Fig. 55 Remove ‘C’ mount bracket. Fig. 55 Lift engine slightly on car with the help of crane. Place 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 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 ing fuel lines. Fig. 70

SULIN Fig. 70 l

Coolant by 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

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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

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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

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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

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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

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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

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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 s 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. 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 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 ing 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

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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

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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

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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

By 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 ing 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

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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 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 ing 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 ed 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 ing 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 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

BYLINE

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 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 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- 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 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- 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

121

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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:

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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.

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 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 ts 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, 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 ing 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 by 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 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 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 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 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.

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» 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 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.

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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 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

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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 <S>

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 prinle (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. 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. 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 G2 : Signal

Manually rotate the speedometer cable and check for 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

G2

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 discs and ed 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 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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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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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 age 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

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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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ENGINE 475 SI MPFI ENGINE CONTROL UNIT (ECU) : Fig. 39,40 & 41. Type : S2000PL4 12 MIPS U 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 U Make : SIEMENS U Type : SAK 167 Processor Speed : Over 12 MIPS

Fig. 41 34

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ENGINE 475 SI MPFI U Data Processing size :

36.2 mm

32 bits U Clock Speed : 20 Mhz U Data Communication Size : 16 bits Memory : RAM - 4KB ROM - 256KB FEATURES : •

Grouped Ignition

•

Sequential Injection

204 mm

SULIN

35

MAIN INDEX

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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

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ENGINE 475 SI MPFI CONNECTOR (BROWN) :

AC PRESS SW

FUEL LEVEL

FAN2 LO SPEED

(VIEW SEEN FROM CABLE ENTRY SIDE)

PIN NO A1 A2 A3 A4 B1 B2 B3 B4 C1 C2 C3 C4 D1 D2 D3 D4 E1 E2 E3 E4 F1 F2 F3 F4 G1 G2 G3 G4 H1 H2 H3 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 J1 J2 J3 J4 K1 K2 K3 K4 L1 L2 L3 L4 M1 M2 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

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 D3 C3 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

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 S)

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

E3

42

MAIN INDEX

GROUP INDEX

ENGINE 475 SI MPFI

3 CAN_H 11 CAN_L

0.5 mm

B4

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) C4

MALFUNCTION INDICATOR LAMP CHECK ENGINE LAMP 43

MAIN INDEX

GROUP INDEX

ENGINE 475 SI MPFI

M3

CKT. IN THE CLUSTER 15 16 2 FUEL GAUGE

TANK UNIT

1

FUEL LEVEL SENSOR

80 A (MAXI FUSE) RADIATOR RELAY J4

SULIN

CONDENSOR RELAY TO COOLING FAN

SERIES RELAY COOLING FAN (LOW SPEED)

K4 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 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 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 BY 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 (V TO T-CONNECTOR) 2.0 BRACKET FOR V

CANISTER PURGE VALVE

CLAMP (V) 1.0

RUBBER SLEEVE (V)

RUBBER HOSE (CARBON CANISTER TO V) 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

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

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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 arm. Fig. 47 Remove ‘C’ mount bracket. Fig. 47 Lift engine slightly on car with the help of crane. Place 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 by 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

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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

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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 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

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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 s 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. LINE ON VALVE SEAT MUST BE AROUND ENTIRE CIRCUMFERENCE AT EQUAL WIDTH Distance between narrow diameter of valve face to 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 ing 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 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

•

By 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 ing 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 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 ing 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 ed 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 ing 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 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 BY 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 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- 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 starts closing gradually.

As the engine cooling temperature reaches thermostat full open temperature, thermostat valve opens fully and thermostat by- 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 ed 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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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 ed 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