CityRover WORKSHOP MANUAL Publication Part No. RCLOSB7ENG - Issue 1 Published by MG Rover Group After Sales ‘MG Rover Group Limited 2003, All rights reserved. No part of this publication may be produced, stored in a retrieval system or transmitted in any form, electronic ‘mechanical, pholocopying, recording of olher means without prior writen parmission of MG Rover Group LidMAIN INTRODUCTION All specifications are given in C.GS. System (Metric System) unless otherwise specified, Reproduction or translation of the whole or part of the workshop manual without our written approval is, prohibited, Subject to modification in Design, Specification and Equipment.INTRODUCTION INTRODUCTION: How to use this manual : This manual is divided into 16 groups. Each group includes : +” Technical specifications + Tightening torques : List of special tools : Disassembly / Assembly procedures : Use of special tools : Inspection of parts + Trouble shooting. ‘The corresponding pages of each group are marked with black tabs and line up with one of the thumb index tabs on the group index page. You can quickly find the first page of each group without looking through a full manual ‘The symbol printed at the top comer of each page can also be used as a quick reference system. ‘This manual covers the repair and overhaul of CityRover cars and assumes that the technician is fully conversant with general automobile practices. The repair procedures outlined in this manual emphasize the special aspects of the product. This will enable youto build and maintain a reputation of quality service, The manual includes instructions on components manufactured by MG Rover. For repairs of proprietary components such as Brakes, Power Steering, Air-conditioning etc, the instructions of the respective component manufacturers are included in this manual. The purpose behind incorporating these instructions in this manual is to enable technicians to understand their functions properly and thus judge the performance of the car as a whole. All data contained in this manual is based on the latest product information available at the time of publication. The right is reserved to make changes in design, specification and equipment at any time without notice. This manuals also applicable to LHD versions as the basic components are the same. In the case of LHD versions only the driving controls and electrical circuits are different. For any further technical advice or clarification please contact or write to : MG Rover Group Ltd. PO Box 41, Longbridge, Birmingham, 831 2TB, England.INTRODUCTION GROUP INDEX GENERAL ENGINE (475 SI MPFl) FUEL SYSTEM EXHAUST CLUTCH TRANSAXLE SUSPENSION BRAKES ABS MECHANICAL STEERING POWER STEERING WHEELS AND TYRES BODY AIR CONDITIONING ELECTRICAL DIAGNOSTICSGENERAL INTRODUCTION : This manual provides information on workshop practices and safety precautions, chassis & component ‘numbering systems, location of chassis & component numbers, and a technical specification including capacities. It also provides information on fuel, lubricants and coolants required for CityRover cars. All lubrication & maintenance work should be carried out as given in the service schedule chartGENERALGENERAL CONTENTS Sr.No. Description Page No. | 1 Workshop Practices and Safety Precautions 1 2 Lifting and Jacking Points 5 3. Chassis Numbering System 7 4 Component Numbering System 8 5. Location of Chassis & Component Numbers 9 6. Technical Specifications 10 7. Tightening Torques of Standard Bolts & Nuts 6 8. Filling Capacities, Fuel, Lubricants & Coolants 16 9. Branded Lubricants and Coolants / Recommended Oils, Lubricants and Filling Capacities 17 10. Service Schedule 8GENERAL Good Workshop Practice & Safety Precautions Following are some safety precautions to be observed in the workshop. + Always ensure that all the repair / maintenance work carried out should be as per the instructions provided in the workshop manual. + Use protective clothing, apron, hand gloves, and safety shoes while working in the workshop. Do not wear watch, rings and belt while serving the vehicle. + Keep your work area, equipment and tools clean’ at all times. + Make sure you use the proper tool for the job and use it the right way. Improper tool or its incorrect use can damage the part you are working on or cause injury or both + Never keep the tools on the floor/vehicle. The tools should be kept in the tool box after use. + Coverbody panels, seats, steering wheel and any other parts that are likely to get scratchedisoiled before starting any service work Fig. 1 *+ Before starting the engine ensure that the gear shift leveris in neutral position and parking brake is fully applied. Never run the engine without proper ventilation and adequate means of getting rid of exhaust gases. + Do not work near the radiator fan when engine is, running to avoid getting injured by electrically operated radiator fan. + Allthe reusable dismantled components must be kept in a suitable container sequentially in an orderly manner to facilitate their accurate and proper reinstallation Fig. 2 + Never reuse the parts like oil seals, gaskets, packing, O-rings, locking washers, split pins, self locking nuts and certain other parts. + Plug the ports / openings of components such as Fuellines Injectors, TMC, etc., whenever removed from the car. Fig. 7 Fig. 2GENERAL + For correct reinstallation of vacuum fuel hoses attach a label describing the correct positions Fig. 3. and sealants are used Fig. 3 + Check al the lines for leaks related to the systems like fuel, ol, coolant, vacuum, exhaust and brakes after servicing Fig. 4 + For vehicles equipped with fuel injection systems do not disconnect the fuel line between the injector and the fuel pump without releasing the fuel pressure or fuel can be sprayed out under pressure. Precaution for Catalytic Converter (MPFI Petrol Engine) : Fig. 5. Caution : If large amount of unburnt fuel enters the converter, it may overheat and creat a fire hazard. To prevent this, observe the following precautions. * Use only unleaded gasoline (98RON). + Engine compression checks should be carried out within the shortest possible time only. + Ifnecessary then only conduct a spark jump test within the shortest possible time, + Donotrun the engine when the fuel tank is nearly ‘empty to avoid engine misfire and damage to catalytic converter.GENERAL Precaution for Electrical circuit service : * Disconnect the negative cable of the battery while servicing the electrical parts that do not require batlery power Fig. 6 + While removing the battery first disconnect the negative cable and then the positive cable. When reinstalling the battery, first connect the positive cable and then negative cable. + Be sure to turn the ignition switch off before disconnecting and connecting coupler to avoid electronic parts damage Fig. 7. + Donot touch the electrical terminals of parts which use microcomputers (e.g. electronic control units like ECM etc. to avoid damage to these parts from static electricity from your body Fig. 7. + Always use the correct voltmeter, ohmmeter for taking measurement to avoid damage to the electronic control unit and sensors. + Make sure to insert the probe from wire harness side of the connector for taking measurement. + Make sure the connector halves are mating properly and terminals seating precisely in the connector body Fig. 8 Fig. 6 Fig. 7 Fig. 8GENERAL + Dirt/ corroded terminals resultin improper contact. The terminals should be cleaned carefully + Improper contact pressure between mating terminals disturbs the connectivity between them, + Replace the damaged connector body to avoid exposure of the terminals in case of inadequate contact pressure. + Ensure proper connection between the terminal to the wire. Rectify the loose connection by repairing {replacing the wire harness Fig. 9. + Worn out insulation of the wire may result in short circuit. + Avoid water entering the connectors, Towing the Vehicl + Boltable tow hook is provided in the too! kit. + When towing a car use a recovery vehicle. Alternatively use a rigid tow bar. + Avoid using a flexible cable or rope as your car may crash into the towing vehicle if it stops suddenly. + Switch ‘ON’ the hazard warning signals of both the cars to warn other road users. + Where possible, keep the engine idling so that power steering assistance and brake vacuum are available, + Limit the speed to 20-30 kmph/10-20mph. + Incase of brake failure, use the parking brake to control the car. Rear Tow Hook : Fig.10 + Boltable tow hook is provided inthe toolkit + Remove cover on rear bumper. + Bolt the tow hook (ensure proper fitment). + Whenever tow hook is not required unscrew the tow hook and keep it in toolkit. + Press the cover to close the hole for tow hook in rear bumper. Fig. 10 DO NOT use the towing hook to tow a trailer or a caravan. DO NOT use the towing hook for lashing purposes.GENERAL LIFTING AND JACKING POINTS WI Front lifting points Rear lifting points Fig. 11 USING THE TWO POLE HOIST : Make sure you follow the hoist manufacturers instructions while lifting the car on the hoist. Fig. 11 ‘Always ensure vehicle balance in service while applying holst to under body. Care should be taken that the hoist arm is not in contact with any bracket, brake or fuel pipes etc. Before servicing, make sure to lock the hoist after the vehicle is lifted up. USING THE FLOOR JACK: Use the jacks at the locations indicated Fig 12 Do not apply the jack against any part which may get deformed, I front end or rear end of the vehicle is to be jacked ensure the wheels on ground are blocked with wheel hocks for safety. Note : Always use safety stands when working on or under any vehicle that is supported by only a jack. eB Fig. 12GENERAL CHASSIS TYPE NO. AND SALES DESIGNATIONS CHASSIS TYPES Chassis | Sales Designation | Description 604201 | CityRover'SOLO” CityRover ‘SOLO’ car with 475 SI MPFI Euro Ill Petrol Engine, with heating and demisting and airbag, 604221 | CityRover'SPRITE’ | CityRover'SPRITE’ car with 475 SI MPFI Euro Ill Petrol Engine, with heating and demisting and airbag, 604241 | CityRover'SELECT | CityRover'SELECT car with 475 SI MPFI Euro Ill Petrol Engine, with HVAC and airbag, 604261 | CityRover'STYLE’ CityRover ‘STYLE’ car with 475 SI MPF! Euro Ill Petrol Engine, with HVAC and airbag,GENERAL VEHICLE IDENTIFICATION NUMBERS (VIN) CHASSIS NUMBER Chassis number consists of 17 digits as given below MAT 200000 x xX 900% Indicates produced in TATA Motors, India Chassis type No. Serial No. to start every (Model, execution year with 00001 on First, wheel base etc.) January Year of Producto Drive Type-R -For RHD L-ForLHD Year Code Plant location 4.1,2003 to 31.12.2003 3 P Fork Block, Pune 4.1.2004 to 31.12.2004 4 4.1,2008 to 31.12.2005 5 Example MAT 604201 3 PR 00065 indicates CityRover car with 475 Si MPF Euro-lIl petrol engine, with heating and demisting and Airbag, produced between 1.1.2003 to 31.12.2003 in K-block Pune, Right hand drive for export and Sr. No. of the car is 00065,GENERAL ENGINE NUMBER : ENGINE : Numbering HHKKK XK XK AXKKK 1 23 4 5 6 Barrel 1: Indicates engine mode! 475 SI : For MPFl engine Barrel 2: Variation in basic model - 475 SI Injected type petrol engine, 85 PS, @ 5500 1pm, MPFI, meeting EURC-IIl emission norms Barrel 3: Month of production jonth [Code [Month [Code [Month [Code| january| A |May Sept. [J February] B \June F Octobe] Kk farch | C [July G Nov. L prt | D JAugust | H — | Dec. M Barrel 4: Year of production Wz- For2003, Vz- For2004 UZ- For2005 Barrel_5 : Indicates plant location. P-for’K’ block, Pune Barrel_ 6 :Serial No. Indicates Serial No. Of engine. The barrel consists of 5 digits and commences from serial number 00001 and will start every year on first January. Example 475 S145 FWZP 00451 ‘TRANSAXLE : NUMBERING xx xx x x OOKK 1 2 3 4 5 Barrel 1: Indicates basic model 21 For TA6S Transaxle Barrel 2 3. First digit indicates control of vehicle as below For normal control vehicle Full forward control vehicle ‘Second digit indicates first and second gear speed ratio with version of gear box as below - F - for first gear ratio 3.42 / second gear ratio 1.95 with 5 gear version, Gear final 65/14 with speedo ratio 19/17, Barrel 3 Barrel 4 Barrel 5 Indicates year of production 3for - 2003 4for - 2004 Sfor - 2005 Indicates plant location P fork’ Block Pune Indicates Serial No. of Transaxle, consists of 5 digits and commences from serial no. 00001 and will start every year on first January. Example -211F 3P 00005 BODY SHELL : Numbering xX xX 1 Barrel 1 Barrel 2 Barrel 3 Barrel 4 Example X XXX 2 3 4 - Indicates, Basic model M1 for CityRover - Indicates year of production 3 for 2003 4 for 2004 5 for 2005 - Indicates plant location P for K Block Pune - Indicates cumulative serial number to start every year with 00001 on first January, M1 3P 00001GENERAL LOCATION OF CHASSIS AND MAIN COMPONENT NUMBERS (CHASSISNUMBER VINPLATE, LENGINENUVEER ‘TRANSAXLE NUMBER.GENERAL TECHNICAL SPECIFICATIONS 1. ENGINE Model Type No. of Cylinders Bore/Stroke Capacity Max. Engine Output as per DIN:70020 Maximum Torque ‘at 2500 rpm Compression Ratio Firing Order Air Filter Oil Filter Fuel Filter Engine Oil Capacity 2.CLUTCH Outside diameter of Cluteh Lining Friction Area Petrol MPFI ‘TATA475 SI MPFI EURO Il EOBD Water cooled MPFI Petrol Engine 4inline 75/79.5 mm 1405 cc 62.3PS@ 5500 rpm 4120 Nm (12Kgm) @ 3500 rpm to:1 1342 Dry Type Spin on type Clip on type 45 Litres Cable operated single plate dry friction diaphragm type, 190mm, 285 sq.cm. 0GENERAL 3. TRANSAXLE, Front wheel drive through constant velocity joints Model TAGS -5/3.42 with overdrive Type ‘Synchromesh on all forward gears. Sliding mesh for reverse gears No. of gears Sforward ‘reverse Gear ratios 4st-3.42 2nd-1.95 3rd -1.36 4th -0.95 sth -0.74 REV. - 3.58 Final drive ratios 4.64 Gear shift Floor mounted with international “H" pattern with fith and reverse gear inline. 4, SUSPENSION Front Independent, Lower wishbone, McPherson Strut type Rear Independent, Semi-trailing arm with coil spring mounted on hydraulic shock absorbers. 5. STEERING Type City Rover-SOLO-RHD CityRover- SPRITE CityRover- SELECT CityRover - STYLE (RHD & all version) Steering Wheel Manual Rack & Hydraulic power assisted Pinion Steering Gear Rack and Pinion Steering with collapsible Gear with collapsible steering column steering column 380 mm dia. 380 mm dia. 6. BRAKES. Service Brakes Dual circuit, diagonal split hydraulic brakes through tandem master cylinder. Anti Lock Brake : ABS 5.3 with electronic brake force distribution (EBD). System (ifequipped) Front Brakes : 231 mm dia. ventilated disc brake Rear Brakes : 200 mm dia. drum brake Parking Brakes Lever type, Console mounted, twin Cable operated mechanical linkages action on rear wheels. "GENERAL 7.WHEELS AND TYRES Tyres Whee! Rims No. of Wheels 8. FUEL TANK Capacity 9.B0DY 10. ELECTRICAL SYSTEMS System Voltage Battery Alternator Capacity ‘11. EXCLUSIVE CHASSIS FITMENTS Power Steering Radial ply tyres Steering Whee! 12. PERFORMANCE Max. speed at rated GVW 13, MAIN CHASSIS DIMENSIONS Whee! Base Track Front Track Rear Front Overhang Rear Overhang OverallLength Max. Width : Overbody (Over outer rear view mirror in folded condition Overall Height (Unladen) 175/60 R14 Tubeless 5x 14 Stylised steel rims / Al. Alloy rims Front-2, Rear 2, Spare -1( steel imif2+2A\. alloy rims equipped.) 37 litres ‘Semi-mono volume, Mini size door hatchback, steel monocoque body. 12Volts-ve earth 12V, DIN 44 (High Density) 12V 90 Amps ‘Standard (Except CityRover- SOLO version) ‘Standard Four spoke (PU) (Except CityRover- SOLO version) 160 Kmph/100 mph 2400 1380 1374 800 500 3700 1625 1690 1496 2GENERAL Minimum Turning Circle Dia Minimum Turing Clearance Circle Dia Ground Clearance (Unladen) 14, WEIGHTS (kg) Complete vehicle kerb weightas per ISO : 1176 (with spare wheel & tools) Gross Vehicle Weight Payload 15, PASSENGER CAPACITY 16. LUGGAGE SPACE Net inside loading space 9.8m 10.45m 148 1040 1440 400 2 front + 3 rear 0.22 cubic metre upto the rear seat backrest, 0.61 cubic metre upto front seat backrest when the rear seat folded. 13GENERALGENERAL TIGHTENING TORQUES OF STANDARD BOLTS & NUTS Wherever the tightening torques are not specified use the following values for these fastners. Grade Bolt orNutSize | Pitch (mm) Tightening Nem we 10 5-10 MB 1.25 21-25 15 41-81 mio 1.0 46 -56 Bolt 8.8 Nute.o 175 72-88 M2 15 75-91 20 113-138 Mia 15 126-154 20 176-215 m6 15 189-231 M6 19 12-14 1.25 29-35 MB 1.0 32-39 15 58-70 M10 10 64-78 Bok 108 1.75 99-121 ‘Nut 10.0 7 Me 15 104-127 20 162-198 Mia 15 176-215 20 248-303, m6 15 266-325 1. This standard is applicable to bolts having the following marks embossed on the bolt head and punch mark on the nut head. Grade 88 For TheBolt 109 ForTheBolt 8 For The Nut 10 For The Nut Note : Always use the calibrated torque wrenches. 15GENERAL FILLING CAPACITIES Engine coolant+ Softwater 50:50 =6 Litres ‘Windshield Washer reservoir =3.5 Litres for front & rearwipers/ washer. 1.5 Lts for only front wipertwasher Brake fluid = 0.27 Litres TRANSAXLE OIL 2.9Litres: IMPORTANT : Always use only unleaded petrol with an octane rating of at least 95 For recommended oil grades and change intervals, refer lubricants chart and service schedule TYRE PRESSURE Wie FRONT REAR. 175160 R14 | 34psi(2.3bar)| 28 si.(1.9bar) Tubeless Fig. 14 FUEL, LUBRICANTS & COOLANTS Fuel : For Petrol car Vehicles with catalytic converter : Unleaded regular grade petrol conforming RON 95 is recommended to be used as fuel Do not use leaded petrol in car fitted with catalytic converter. Even single fll of leaded petrol will seriously damage the catalytic converter. Lubricants: Engine oll : ‘Ambient Temp. indeg. C Engine oil grade OW/40 or ACEA-A2 = 20 deg. to 40 deg Transaxle : Texaco Geartex S475W90 Grease for axle bearings : Lithium base complex grease Brake fluid : Dots Power Steering : Dexron Ill Coolants : Presence of dirtin the coolant chokes up passages in the radiator, cylinder head and cylinder block, thereby causing insufficient cooling of engine. To prevent rust formation and freezing of coolant inside the passages of radiator, cylinder block and cylinder head, mix antifreezing agent with distilled water (soft water ) in the ratio of 50:50. Coolant should be drained and replenished every two years or at every 40,000km/ 25000m whichever is earlier. Engine Coolant Antifreeze : ‘Texaco/Arteco Havoline XLC 6GENERAL Kal BRANDED LUBRICANTS & COOLANTS : USE ONLY GENUINE ENGINE OILS, COOLANTS AND OTHER LUBRICANTS BRANDED BY ROVER FOR OPTIMUM PERFORMANCE || RECOMMENDED OILS, LUBRICANTS AND FILLING CAPACITIES ficorecare SPECIFICATION FILLING CAPACITY Engine Use engine ol conforming to SAE 10W 40 4s Lites Transaxle Texaco Geartex S475W90 2.9 Lives Power Steering | Desronill 42 Lites Brake Fuld bora 0270 Lives Wheel Bearing | Lithium base complex grease “110 gm Coolant TexacolArteco Havoine XL Stites Clutch release | __ Multipurpose grease LIT MP As required 7ENGINE 475 SI MPFI INTRODUCTION : CityRover 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. Allinlet valves on one side & all exhaust valves on other side. 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, and complies to the EURO Ill emission regulations.ENGINE 475 SI MPFI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 Ill engine 5 5. 475 SIMPFI engine advantages 6 6. 475 MPFI Euro Ill system : Schematic representation 7 7. Exploded view of : EMS Kit Components 8 8. Engine Management System (EMS) Overview 9 9. MPFI sensors / actuators, " 10. Integrated Intank fuel pumpwith pressure regulator at 11 Ignition Coil Assembly 22 12. ECU 34 13. ECUHandling and care 40 14. Schematic wiring diagram of power relay a 15. Schematic wiring diagram of some other EMS components 42 16. Preliminary inspection of engine 45, 17. Exploded Views: a. Engine cover mounting 48 b. Air-Intake system 49 cc. Engine suspension 50 d. __Inletand exhaust manifold 51 . Engine Timing - Petrol (Euro I) 52 f. Moving parts - block 53 g. Engine cooling 54 h. — Fuelinjection 55 i. Cylinder Head and Cover - Petrol EURO Ill 56 i. Gaskets 7 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 6 20. _Alternator/Power steering pump belt and A.C. compressor belts removal, inspection, 62 and fitmentENGINE 475 SI MPFI Seo. Description Page No. 21. Timing belt Removal/ Fitment 6 22. Cylinder Head (Engine on Workstand) 6 23. Cylinder block sub assembly 86 24. Lubrication system 100 25. Cooling system 102 26. Airintake system mm 27. Accelerator Cable 113 28. Engine Testing 15 29. Trouble Shooting 116ENGINE 475 SI MPFI TECHNICAL SPECIFICATION ENGINE Model TATAATS SI MPFI Type Water cooled Mult Point Fuel Injection Petrol Engine No. of cylinders 4inline Bore x Stroke 75 mm x79.5 mm Capacity 1405 ce Max. engine output 85 PS at 5500 rpm as per ISO : 1585 Max. torque 120Nm (12Kgm) @ 3500 rpm Compression ratio 10:1 Fring order 13-42 Fuel system ‘Sequential Injection with close loop Air/Fuel control Ignition system Grouped Ignition Emission compliance EURO Il with EOBD Engine oil capacity 45 ites Cooling system capacity 6 Lites Ai fiter Dry (paper) type oilfiter Spin on fulflow paper ype Valve train SOHC, 2Vioylinder EMSs JCAE EMS, S 2000 PL4ENGINE 475 SI MPFI LIST OF SPECIAL TOOLS Sr.No. Description Part No. 1 Box spanner (16 A/F) for spark plug 2702 5890 0601 2 Extended socket (10mmAVF) 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 oll seal in rear cover 2702 5890 06 08 7 Drift for removal /ftment of valve guide 2702 5890 06 11 8 ‘Spacer for valve guide fitment 2702 5890 06 12 8 Drift for tment of ol seal on valve guide 2702 5890 06 14 10. _Valvespring compressor 27025890 06 15 11. Support rail 27025890 06 16 12. _Diiftfor valve guide seal tment 2702 5890 06 17 13. Drift for oll pump oll seal 27025890 1801 14, Spanner foroilfiter 27025890 18 02 15. Bracket (LH) for mounting engine on stand 2702 6890 24.02 16. Bracket (RH) for mounting engine on stand 2702 5890 24.03 17, Engine repair stand 2573 5890 24.01 18. —_Diiftfor fitment of camshaft oll seal 2654 58900508 19. Engine support stand 2702 5890 2401 20. Tata Diagnostic Too!ENGINE 475 SI MPFI TIGHTENING TORQUES ‘The fasteners should be tightened to specified torque at recommended intervals (kmim). If various fasteners are ‘ot tightened to specified torques, that is either over tightened or left loose, it will result in leakage at joints and damage to the parts/threads. It will also adversely affect the performance of the partsisystems as clearances! bearing plays in the components are governed by the tightening torques of the fasteners. ‘When choosing the torque wrench, remember that it should not be subjected to torque exceeding three fourths of its capacity. Before tightening, clean the threads and apply a litle oil Note: For tightening torque of EMS components, refer to respective sections. Es Serial Description Torque in Nm No. 1 Main Bearing Cap bolt M10 x 1 54 2 Cylinder head bolts M10 x 1.1 29, 49, 64 (Ref. Note) # 3 ‘Spark plug in cylinder head M14 x 1.5 8 4 Cylinder head cover bolts M6 10# 5. Oil sump Screw M6 x 1 6to7# 6 ‘Sealing plug for oll gallery block rear M14 x 1.5 4 7 ll sump drain plug M12 x 1.5 4 8 Rear timing cover to block M6 x 1 10 8 Rear timing cover to head cover M6 x 1 10 10. Timing belt cover M6 x 1 10 " Rear cover crank case on cylinder block screw M6 x 1 10# 12. Connecting rod cap Nut M9 x 1 St 13. Flywheel mounting screw M10 x 1 40 14, Crankshaft gear to crankshaft bolt M14 x 1 39+60°H 15. Vibration damper /5 groove A/C pulley to crankshaft gear 8 16. __Belttensioner adjuster bolt M10 x 1.5, 2 17. Camthrust plate 10 18. Timing beltidler to cylinder block bolt M10 x 1.5 4a 19. Camshaft gear to camshaft screw M12.x 1.25 78 20. Lock Nut (Rocker adjusting screw) M9 x 1 2 21. Assembly Fuel feed pump on cylinder head screw MB x 1.25 208 22. Exhaust manifold mounting bolts on cylinder head MB x 1.25 208 23, Starter motor on Transaxle bolt M8 x 1.25 28 24. Alternator bracket to cylinder crankcase M8 X 1.25 2 25, Alternator to bracket M10 2ENGINE 475 SI MPFI Serial Description Torque in Nm. No. 26. Adapter to cylinder head Stud M6 x 1 208 27. Alternator tensioner bracket to block MB x 1.25 2 28. Alternator to tensioner bracket screw MB x 1.25 18 29. Oilpump on cylinder block 10# 30. Assembly Strainer to oll pump M6 x 1 10 31. Assembly oilfiter to cylinder crankcase M12 x 1.5 Ref. Note @# 32. Oil pressure switch on cylinder crankcase M20 x 1.5 2 33. Waller pump to cylinder crankcase screw M6 x 1 10# 34, Waler outlet elbow to intake manifold Nut M6 x 1 10% 35. Waler inlet elbow to cylinder crankcase screw M8 x 1.25 2» 36. Temperature Transducer on cylinder head M14 x 1.5, 18 37. Waler inlet elbow to intake manifold nut M6 x 1 10 38. Thermostat cover to intake manifold nut M6 x 1 10 39, Lifting hooks to cylinder head screw MB x 1.25 8 40. Engine mounting bracket to block M10 x 1.5 “4 41, Engine mounting bracket to arm 39 42, Powersteering pump mounting on bracket screw M8 x 1.25 8 43, AIC Compressor bracket to cylinder block screw MB x 1 8 44. AIC Compressor to AIC compressor bracket bolt M8 x 1.25 8 45, Powersteering pulley to power steering pump Nut M12x 1.25 78 46, Assembly Idler to Slider (A/C compressor belt tensioner) Nut M8 x 1.25 8 47. Lambda Sensor on Front exhaust pipe & Catalytic Convertor 34-44 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 aver tighten.ENGINE 475 SI MPFI 475 MPFI EURO Ill ENGINE OIL FILLER CAP IGNITION COIL INTAKE EXHAUST MANIFOLD MANIFOLD THROTTLE BODY PHASE SENSOR ENGINE RPM SENSOR MAP SENSOR OIL FILTER DIPSTICK TUBE POWER STEERING PUMPENGINE 475 SI MPFI MAP SENSOR CYLINDER HEAD COVER BLOWBY HOSE CYLINDER HEAD FUEL RAIL INTAKE MANIFOLD INTAKE MANIFOLD WITH THROTTLE BODY IAC VALVE THROTTLE BODY CANISTER PURGE VALVE 475 S| 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 toa 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, 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,ENGINE 475 SI MPFI EA 475 MPFI EURO Ill SYSTEM: SCHEMATIC REPRESENTATION NAN SUPPLY RELAY FUEL PUMP RELAY FANRELAY IDLE AR CONTROL VALVE “THROTTLE POSITION SENSOR. CATALYST eg (OXYGEN SENSOR (SOs SERA BOS DAGROSTC TESTER TOPURGE VALVE "AR COROMTIONNG| POWER STEERING ‘ANTVTHEFTENGINE 475 SI MPFI EMS KIT COMPONENTS. [-srecrteo Torque nn BrNo. PART DESCRIPTION Sr.No. PART DESCRIPTION 1 Crank Angle and Shaft RPM 6 ‘Sensor Plate (Cam Shaft Gear) ‘Sensor 7 Knock Sensor 2 Bracket (Crank Angle Sensor) 8 MAP Sensor 3 Cam Sensor 9 Coolant Temperature Sensor 4 Bracket (for Cam Sensor) 10 Throttle Body 5 Rubber Grommet (Dust seal) 1 Ignition CoitENGINE 475 SI MPFI ENGINE MANAGEMENT SYSTEM (EMS) OVERVIEW : CityRoveris powered with 475-SI Multi Point Fuel _In- jected (MPF) engine, which generates 85Hp. The JCAE (Johnson Controls Automotive Electronics) ‘$2000 Engine Management System combined with the suitable hardware meets the EURO — III regulations. ‘The Engine Management System is modular with a basic core group of essential sensors, actuators and strategies(refer block diagram below). The strategies are derived from physical modeling of the engine and vehicle, The S 2000 PL 4 is dedicated for EURO III / Engine On Board Diagnostics(EOBD) Engine management systems. It benefits from new technologies includes a 256Kbit flash memory, allowing a downloading of the engine parameters and has a 12MIPS (Million Inputs Per Second) processing capability. The following matrix identifies the features used on CityRover application ; + Distributorless Grouped Ignition ( Wasted Spark Ignition) + Sequential Multi point (MPI) Injection engine control + Engine Phase detection Dual (Up stream & Downstream) O, 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 (Antitheft) management + Air Conditioning and Fan Control + Keyword 2000 (ISO 914 )interface + Electrical diagnostic and protection (Short and open circuits, signals) | ‘Additional Features + Warm Up Corrections + Mode! Based transient injection control + Model based transient ignition control + Model based air/water temperature compensation + Limphome 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) > Starting: The Idle Air Control Valve is opened to allow the correct amountof 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ENGINE 475 SI MPFI » Idle Air Control: Proper Idling of the engine is ensured irrespective of different operating conditions with help of closed loop control. The Idle Air control valve (IACV) that allows air to bypass the throttle controls idle air. The activation of the IAC occurs in three strategies: 4. During Starting to provide correct amount of airto the engine 2. During engine Idle. Depending upon the engine coolant temperature, the amountof the airinducted through the valve is varied by the varying the position of the valve, ensuring a closed loop control to a target Idle Speed, 3. During engine running to enhance driveability by controlling engine torque changes on closing throttle (depression limiting). » Engine Load Determinatiot 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 ifeither the Throttle Position or Manifold Absolute Pressure Sensors fails. ‘The MBF model or Thermo model is a heat transfer ‘model, which use the heat exchange between the air and the manifold walls. The manifold also takes into account of all temperature variations (E.g.: purging) that will occur during the running > 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 ofthe 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 e., each injector is opened relative to its own cylinder timing, ‘Amount ofthe fuel required (Le. the Injector pulse time) depends largely on the engine load and speed. Further adjustments are to account for the variations in the operating conditions (e.g. Engine temperature). ‘To maximise the engine performance the fuelling is enriched to give maximum power at wide-open throttle (WOT) conditions. Not all the fuel injected by the Injectors enters the engine directly, some amountis deposited onthe Inlet port walls as a puddle whose size varies with the throte position, engine speed and engine temperature. The puddle evaporates over the time and its effect is particularly significant during transients. To account for these transient effects, the puddle dynamics are modelled and the fuelling is adjusted accordingly. Overrun fuel cut-offs 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. » Ignition: ‘The optimum ignition timing depends largely upon the engine speed and load. Further small corrections are applied to improve driveability and to account for the variations in the operating conditions (e.g. engine temperature, Inlet air temperature). The ignition timing is also adjusted in conjunction with the Idle Air Control Valve to control the idle speed of the Engine. » Throttle Position and Adaptation: ‘The throttle position potentiometer output may differ between vehicle and can also change over time due to component aging. A corrective term is applied to compensate for this effect; this is an adaptive (learning) value thats updated throughout the vehicle's ite, » 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’. 10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 Driveabilly. Gear ratio, and hence the gear engaged, is calculated trom the vehicle's measured engine speed and road speed. This inputis 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 rewing. The cut off is introduced progressively to make the operation smooth to the driver. » Vehicle Speed Limitin The vehicle speed is limited from over speeding to provide safely and protection. Asmooth vehicle speed cut off is applied in order to have a better driveability feel » 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 lke 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 Auel level sensor provides the necessary information for the low-level inputs for the EOBD strategies activation. "ENGINE 475 SI MPFI MPFI SENSORS / ACTUATORS CRANK ANGLE SENSOR: (Fig.1 and 2). Type: o3vR Inductive pick up (Variable reluctance) 3Pin connector Working Principle : ‘The sensor is positioned near the flywheel mounted toothed wheel. An A.C. voltage is induced in sensor coil, when the flywheel tooth projection pass through the sensor. This A.C. voltage is directly proportional to the speed of rotation. This sensor signal is first processed by an ASIC and then by the ECU, ‘System Integration : ‘The sensor provides the speed and crank angle input to the ECU. The system uses a 60 - 2 = 58 tooth spaced at 6° intervals. The tooth wheel (target wheel) is integral part of the flywheel. This wheel has 2 teeth missing (at 114° ATDC of cylindert) to allow the engine position to be determined, ‘The sensor signal is used to calculate engine speed & crank angle position (Fig. 3 and 4), Fitment Data: This sensor is mounted on the cylinder block over the flywheel (Fig. 1). Sensor Gap = 1.5 +0.5 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. ‘Stand Alone Diagnosis : (At NTP conditions) Use Multimeter Coil resistance = 3000hm - 420 ohm (between pin 1 and pin 2) Check gap between flywheel and sensor tip ‘Sensorend Pinassignment 4: ECU pin M2B1: +ve 2: ECU pin M2B2: -ve 3: Shield Fig. 1 Crank angle sensor 4 _—~~ Fig. 2 Crank angle sensor ‘System Diagnosis : Use Tata Diagnostic Tool. Check for engine RPM during cranking. 12ENGINE 475 SI MPFI EA Fig. 3 Fig. 4 ‘SCHEMATIC WIRING DIAGRAM: CRANK ANGLE SENSORENGINE 475 SI MPFI WATER TEMPERATURE SENSOR (Fig.5) Type: tert Negative Temperature Coefficient (NTC) 2Pin 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. Fitment Data : WTSis fitted on thermostat housing (before thermostat) which is in contact with the engine coolant. (Fig. 5) Installation Torque : 8Nm ‘Stand Alone Diagnosis (See Illustration) : Use Multimeter Nominal Thermister resistance values 2500 ohm @ 20° C 833.9 ohm @ 50° C ‘Sensor end Pin assignment = 41: ECUM1D4: -ve 2: ECU M1E4: +ve Measure the resistance across pins 1 and 2. ‘System Diagnosis Use Tata Diagnostic Tool. Check for Water Temp’ values. ‘SCHEMATIC WIRING DIAGRAM: Fig. 5 Water temperature sensor Resistance / Temperature Characteristic MES ecu iuip4a 14ENGINE 475 SI MPFI MAP &TSENSOR (Manifold Air Pressure and Temperature Sensor) (Fig. 6 and 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. Air temp : ‘Semiconductor material changes resistance when exposed to variable temperature source. ‘System Integration : This provides manifold vacuum (ABS) signal and air temperature input to ECU. The sensors activated by excitation voltage supplied by ECU. Fitment Data This sensor i fitted on Inlet manifold pleanum.(Fig. 6) Installation Torque : 10Nm ‘Stand Alone Diagnosis : Use Multimeter With ignition “ON. ‘Supply volt = 5.00 vde Signal volt = 0.4 V @ 10 kpa (abs) = 4.85 V @ 115 kpa (abs) Pin assignment (Fig.7) 41: M2A2 : Ground 2: M1A2 : Temp. Signal 3: M2E1 : Supply 5V 4: M2C1 : Pressure Signal Measure signal volt at pint and pin with sensor Fig. 6 Manifold air pressure sensor Fig. 7 Manifold air pressure sensor Characteristic of MAP Sensor aa aa ogENGINE 475 SI MPFI connected to wiring harness. ‘System Diagnosis : Use Tata Diagnostic Tool Check for ‘Intake manifold pressure’ and air temperature value. ‘SCHEMATIC WIRING DIAGRAM : MAP &T Characteristic of Temperature Sensor “powwe Dado Don oo www ml a2 M2E1, ECU ect 2a2 16ENGINE 475 SI MPFI ‘THROTTLE POSITION SENSOR (TPS) Fig. 8 and 9. Type: osTP 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 : 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 Installation Guidelines : Diameter of screws used to fix potentiometer = 12mm 5+0.5Nm Tightening Torqu Stand Alone Diagnosis Use Multimeter With ignition "ON". ‘Supply volt 5.00 vde Signal volt 0.5 vde at Idle position 4.5 + 0.15 vde at WOT position Sensor end Pin Assignment 1: ECU pin M1A3 : Gnd, 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 Fig. 8 Throttle Position Sensor (TPS) Fig. 9 Throttle Position Sensor ‘Sensor Characteristics Note [The broken tines represent acceptable divergence limits 7ENGINE 475 SI MPFI ES! ‘SCHEMATIC WIRING DIAGRAM: rs] w2ca | 2] mips Lt mare ‘THROTLE POSITION SENSOR FROM POWER RELAY (BASE PIN NO 8) ECU MiE2 M2B3 UPSTREAMLAMBDA (0,) SENSOR FROM POWER RELAY (BASE PIN NO 8) mip2eCU IM1E3 IM1p3 DOWNSTREAM LAMBDA (0, ) SEN- SORENGINE 475 SI MPFI LAMBDA SENSOR (0, Sensor) Fig. 10 and 11 Type: Heated Ceramic Oxygen Sensor 4Pin Connector 08LS Down Stream Oxygen Sensor O9LS Up Stream Oxygen Sensor Working princple (See Illustration) : special ceramic body with gas permeable platinum electrodes on its surface, operates, depending upon ceramic materia’s porosity which allows oxygen in the air to diffuse when the ceramic body is exposed to temperatures above 350°C. Voltage is generated across the electrodes which are exposed to gas with different levels of oxygen contents. System Integration : This sensor provides Air/Fuel ratio signal in the form of mV to ECU as a function of varying Air/Fuel ratio 0.95" 840 + 70my (rich) 1.05’ 20+ 50mv (lean) ‘Typical values at 350°C: Fitment Data : Fitted on the exhaust pipe as shown in Fig. 10 (Down stream O, Sensor). Installation And Handling : + Donotstore 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 Fig. 10 Lambda sensor iilfed ON Exhaust pipe Fig. 11 Lambda sensor (O,sensor) 19ENGINE 475 SI MPFI Stand Alone Diagnosis : Use Multimeter Heaterfunction Heater Resistance OBLS : 6.0 # tohm (23 + 5° C) O9LS : 3.3 (+0.7ohmV-0.30hm) (23+ 5° C) Pin assignment (Fig. 12) Up Stream Oxygen Sensor (Green colour) 11: 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 M12 : Heater 3: ECU pin M1D3 : Signal -ve 4: ECU pin M1E3 : Signal +ve Measure the signal volt - mV, across pin 1 and 2 and engine ground with sensor connected to wiring harness. ‘System Diagnosis : Use Tata Diagnostic Tool For Pin Nos. please refer fo marking on casing Fig. 12 20ENGINE 475 SI MPFI LAMBDA SENSOR: Lambda oxygen sensor located in exhaust pipe Fig. 13. 1. Special ceramic coat Electordes Contact Housing Exhaust pipe Shield (porous) Exhaust gas. Air ePNEgaeND Lambda (oxygen) sensor voltage curve at 600°C operating temperature Fig. 14 a) Rich mixture (air deficiency) ) Lean mixture (excess air) Heated Lambda (oxygen) sensor Fig. 15 1. Probe housing 2. Ceramic Shield tube 3, Electrical connections 4, Shield tube with slits 5. Active ceramic sensor layer 6. Contact 7. Shield 8, Heating lement 9 Clamp connections for heater element 7. Fig. 13 Lambda Sensor Oxygen-sensor voltage mv —>——— 1000 00 00 400 200 osos 4 11 12 Excess-air factor Fig. 14 Lambda Sensor Voltage Curve 6 789 Fig. 15 Heated Lambda Sensor 2ENGINE 475 SI MPFI VEHICLE SPEED SENSOR (VSS) Fig. 16 and 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 sensoris mounted on the gearbox __Fig. 16 Location of VSS on Transaxle on speedo output location. Fig. 16. Stand Alone Diagnosi Use Multimeter Pinassignment 1: Supply 2: Ground 3: ECU pin CPG2 : Signal Manually rotate the speedometer cable and check for contact make and break pulses 8 timesirev. 12 Volt DC | pains. Measure pulse volt across ECU pin No. 6 and car body as ground with wiring hamess connected to Fig. 17 Vehicle Speed Sensor (VSS) ECU, ‘System Diagnosis : Use Tata Diagnostic Tool Check for Vehicle speed sensor Value’ during driving SCHEMATIC WIRING DIAGRAM : FROM POWER RELAY (BASE PINNO 8) VEHICLE SPEED SENSOR 22ENGINE 475 SI MPFI KNOCK SENSOR Fig. 18 and 19 Type: Piezo electric ‘Sagem Working Principle : Knock sensor is directly mounted on the cylinder block. When knock occurs due to the uncontrolled combustion, vibrations are generated on the block ‘These vibration forces cause a charge transfer and a voltage is generated by the sensor element. This is, tapped off by contact discs and passed to the ECU where itis processed. ‘System Integration : Fig. 18 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, Fitment Data: —y Mounted on the cylinder block. Installation Guidelines : ‘The sensor is fixed with screws and without washer. Screw sizes:Cast Block: M8 x 25 and M10 x 1.5 -30 Tightening Torque: 20 + 5 Nm ‘Stand Alone Diagnosis : ‘Sensor end Pin assignment Fig.19 =] 4: ECU pin M13: +ve 2: ECU pin M1B3:-ve ‘SCHEMATIC WIRING DIAGRAM: 1 kKNocK SENSOR KNOCK SENSOR 23ENGINE 475 SI MPFI CAM PHASE SENSOR Fig. 20 and 21 Type: AAC KO Hall Effect Sensor Asignal voltage is generated by the sensor when the ‘target’ wheel pass through the sensor supplied with 12V supply. The position of the ‘target’ indicates the phase of the engine. ‘System Integration : ‘Sensor provides the information toECUtodetermine Fig. 20. the phasing. The software reads the state of the Camshaft sensor on each engine revolution, by the signal provided by the sensor. Fitment Data: This sensor is mounted near the Camgear on the cylinder head, fn ns Sensor Gap : 1.5 + 0.5mm Installation Guidelines : 6 - 10 Nm Stand Alone Diagnosis : Pin Assignment 4: Ground ae 2: ECU pin M1F3 : Signal 3: Supply 12V (From relay - pin 8 of base) ‘SCHEMATIC WIRING DIAGRAM : FROM POWER RELAY (BASE PIN NO 8) FUSE 10A, MiF3 Ecu CAMSHAFT POSITION SENSOR Fig.21 24ENGINE 475 SI MPFI IDLE AIR CONTROL VALVE (IAC) Fig. 22 and 23 Type: o1sMo03 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 openiclose directions operated by a stepper motor. System Integration : ECU provides drive signal to the stepper motor of AC valve to allow moreiles ar depending upen engine demand to maintain target speed of 750 rpm CN = 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, e.g. 30°C = 1100 rpm, Fitment Data : This actuator is part of Integral Throttle Body which is fitted on inlet manifold upstream side. Fig. 22 and 23. Installation Guidelines : ‘Screws to be used for fastening MS x 0.8 x 14. Torque : 4+ 0.4 Nm - Thread locking adhesives can be used to prevent loosening. Stand Alone Diagnosis : Use Multimeter Single Phase coil resistance = 63 + 5.3 ohm Actuator end Pin assignment (REP ) TE Measure the coil resistance across pins M2E3 and M2D1, M2D2 and M2D3. ‘System Diagnosis : Use Tata Diagnostic Tool. Check for IAC valve steps For normal idling at hat condition IAC valve steps = 12 +3 steps. ‘SCHEMATIC WIRING DIAGRAM: ECU pin M2E3 : CollA ECU pin M2D2 : CoilB ECU pin M2D3 = CoilB ECU pin M2D1 = CoilA com> Fig. 22 Throlile Body showing Idle Air control valve fitted Fig. 23 dle Air control valve (IAC) Throttle Body Intake Manifold Airinlet Throttle Plate Fig. 24 1AC valve illustration 25ENGINE 475 SI MPFI INTEGRAL THROTTLE BODY Type: osTB 2.44 mm throttle valve, integrated with throttle position sensor, |ACV (Idle Air Control Valve). Working Principle : Airflow 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 @ 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. Fitment Data : Fitted on the upstream of the inlet manifold. Fig. 25, Installation Guidelines : Manifold mounting lange screw torque : 6Nm Tightening Torques tem Dimension forque(Nm) Throttle Screw Ma x 0.7 22+05 Idle actuator fastening |MSSPIRALOCK| 4.5 + 0.5 screws, TPS fastening screws |M4SPIRALOCK) 2.5 + 0.5| Cable bracket screw |MSSPIRALOCK 5.5 +1.0 Idle adjusting screw MSx 0.5 _ Stand Alone Diagnosis : Refer to IAC, TPS section. System Diagnosis: Use Tata Diagnostic Tool Serviceability : ‘The following parts can be replaced in service 2) Idle Air Control Valve (Stepper Motor) b) Throttle Position Sensor Fig. 25 Fig. 26 Integral throttle body Fig. 27 26ENGINE 475 SI MPFI CANISTER PURGE VALVE Fig. 28 and 29 Type: Purge value : Sagem 2Pin connector Working Principle : Fig. 30 ‘A solenoid valve opens and closes the gas passage depending upon ECU signal to the solenoid valve. Gas (petrol vapour) flows into manifold from canister and the flow rate varies depending upon valve duty cycle ratio (open time to close time ratio) and pressure differential between canister and inlet manifold, System Integration : ECU provides drive signal|to this solenoid valve to purge the petrol vapour from canister 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, Fitment Data : 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. 28 Stand Alone Diagnosis : Use Multimeter Solenoid coil resistance = 26 ohm +4 ohm @ 20°C Actuator end Pin assignment —— 1: ECU pin M2F2 cars 2: Supply Measure the resistance across pin 1 and 2 ‘System Diagnosis : Use Tata Diagnostic Tool Fig. 28 Location of purge valve Fig. 29 Purge valve aENGINE 475 SI MPFI ES! ICANISTER PURGE VALVE - ILLUSTRATION : t HOSE CONNECTION NON RETURN VALVE LEAF SPRING ‘SEALING ELEMENT ‘SOLENOIDARMATURE ‘SEALING SEAT SOLENOID COIL. SSE SES Fig. 30 ‘SCHEMATIC WIRING DIAGRAM: FUSE 10A FROM POWER RELAY (BASE PIN NO 5) PURGE VALVE 28ENGINE 475 SI MPFI FUEL INJECTOR Fig. 31, 32 and 33 Type: F type short 2Pin 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 low rate fora 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 (speediioad). 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: 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 : Use multimeter Injector coil resistance 12.25 ohm + 0.50 ohm Actuator end Pin assignment — Injector [eae] 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 ‘System Diagnosis : Use Tata Diagnostic Tool. Fig. 31 Fuel Injectors location in the engine Injectors Fig.32 Fuel Injectors Fig. 33 Fuel Injector 29ENGINE 475 SI MPFI ES! ‘SCHEMATIC WIRING DIAGRAM: FROM POWER RELAY (BASE PIN NO 5) a FUSEI5A INJECTORS 30ENGINE 475 SI MPFI INTEGRATED INTANK FUEL PUMP WITH PRESSURE REGULATOR FIG. 34 and 35. Type: PENTADEWA Intank - Electric Fuel Pump with inbuilt pressure regulator 2Pin connector Working Principle : Appositive displacement pump assembly 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 Fig, a4 return ine. ‘The pressure regulator is a diaphragm operated valve which regulates pressure in the system (at fuel ail) to 3.5 bar and retums the excess fuel back to the tank ‘The diaphragm is operated by differential pressure between the system (fuel rail and lines) and the atmosphere. 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 Motor armature resistancs Fig. 35 Intank Fue! Pump 200hm @ 20°C ‘Actuatorend (Pump) Pinassignment | Measure the coil resistance across pin 1 and 2 4: from relay 2 : car body 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 second if engine is not cranked a4ENGINE 475 SI MPFI ES! ‘SCHEMATIC WIRING DIAGRAM: FUSE 15A FROM POWER RELAY (BASE PIN NO 5) FUEL PUMP FROM POWER RELAY (BASE PIN NO 5) IGNITION COIL, IGNITION COIL ASSEMBLY Type: BAEO4 Four output Ignition Coil 4Pin 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ENGINE 475 SI MPFI System Integration : ECU provides the trigger pulse to switch ON/OFF the power switch builtin the coll which provides 2 sparks simultaneously in cylinders 1 and 4 or 2 and 3s 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 (Le. one spark in the end of compression and one spark at the end of exhaust). This enables maintenance of optimum dwelltime at very high engine speeds, Fitment Data : ‘The ignition collis 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 with regard to the functioning of ECU. Fig. 36 and 37 Stand Alone Diagnosis (See Illustration) : Use Multimeter Check for 12 V power supply P/G on wiring harness Firing order (1,3,4,2) and HT cable connections (ee llustration) ‘Actualorend __ _Pinassignment 3: Supply 4: Ground (through suppressor) 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 and cyl. 4 (or cyl. 2 and 3). ‘System Diagnosis : Use Tata Diagnostic Tool Check for Ignition timing value’ during idling. Cylinder nos’ marked for HT cable fitment. Fig. 38 33ENGINE 475 SI MPFI ENGINE CONTROL UNIT (ECU Fig. 39,40 and 41. Type: ‘S2000PL4 12 MIPS CPU Processor with 256KB ROM and 4KB RAM 84 PIN connector Working principle : Microprocessor based engine control system. ‘System Integration : Allsensors (e.g. water temperature, air temperature, etc.) input signals are processed by the micro- processor 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. Fitment Data : (Fig. 39) ECUis 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. SPECIFICATIONS : Type: ‘S2000PL4 CPU Make : SIEMENS CPU Type: SAK 167 Processor Speed : Over 12MIPS Fig. 39 ECU Mounting location Fig. 40 Fig. 47 34ENGINE 475 SI MPFI CPU Data Processing size : 32 bits CPU Clock Speed : 20 Mhz CPU Data Communication Size : 16 bits Memory : RAM - 4KB ROM - 256KB, FEATURES: Grouped Ignition ‘Sequential Injection 35ENGINE 475 SI MPFI CONNECTOR CLM1(BLACK): c =] elo coo a” a et” et” a” a ey eo ol a@ et PINNO, PIN ASSIGNMENT CABLE CODE(Please Refer Page 39) M1 Al NOTUSED ~ M1 A2__ AIR TEMPERATURE SENSOR BR M1 A3_ SENSOR GROUND 2 Low M1 A4 — Vbatt SWITCH BR M1B1 NOTUSED - M1B2 NOTUSED - M1B3 KNOCK SENSOR - B M1B4 THROTTLE POSITION BrG M11 NOTUSED - M1C2 NOTUSED - M13 KNOCK SENSOR + w M1C4 ALTERNATOR CURRENT BY M1D1 NOT USED) - M1D2 DOWNSTREAM LAMBDA SENSOR HEATER BrG M1D3_ DOWNSTREAM LAMBDA SENSOR - B M1D4 WATER TEMPERATURE INPUT - Rg M1E1 NOTUSED - M1E2 UPSTREAM LAMBDA HEATING DRIVER PB M1E3 DOWNSTREAM LAMBDA SIGNAL INPUT + w M1E4 WATER TEMPERATURE INPUT + Bw M1F1 NOTUSED - M1F2 MAIN RELAY DRIVER P M1F3 CAM SENSOR INPUT w M1F4 NOTUSED - M1G1 NOTUSED - M1G2 NOTUSED - M1G3_ COILS 1 AND 4 WL M1G4 NOTUSED. - M1H1 NOTUSED - M1H2 NOT USED - M1H3 COILS 2AND3 G M1H4 POWER GROUND n3 BR 36ENGINE 475 SI MPFI CONNECTOR CLM2 (GREY): a" are ol a a” el” @ J" oe of e ana a a Qa e! of a" of eo a oe 4: id. we. PINNO, PIN ASSIGNMENT CABLE CODE(Please Refer Page 39) M2 Al NOTUSED - M2 A2_ MAP SENSOR GROUND 1 BR M2 A3_ UPSTREAM LAMBDA SENSOR + B M2 A4 NOTUSED : M2 B1 ENGINE SPEED SENSOR + w M2 B2 ENGINE SPEED SENSOR - B M2 B3 UPSTREAM LAMBDA SIGNAL INPUT - w M2 B4 NOTUSED - M2 C1 INLET AIR PRESSURE wo M2 C2 NOTUSED - M2 C3. SENSOR +5V_2 VR M2 C4 NOTUSED - M2 D1 ICS STEPPER DRIVER OUTPUT D Leo M2 D2 ICS STEPPER DRIVER OUTPUT B wy M2 D3 ICS STEPPER DRIVER OUTPUT C. RL M2 D4 NOTUSED - M2 E1 SENSOR +5V_1 wy M2 £2 NOTUSED - M2 £3 ICS STEPPER DRIVER OUTPUTA, GR M2 £4 NOTUSED - M2 F1 NOTUSED - M2 F2 PURGE CANISTER YL M2 F3 POWER RELAY we M2 F4 NOTUSED - M2 G1 CHECK ENGINE LAMP LR M2 G2 INJECTOR CYLINDER 3 YL M2 G3__ INJECTOR CYLINDER 2 YL M2 G4 NOT USED - M2 Hi POWER GROUND n4 Br M2 H2_— INJECTOR CYLINDER 1 Ls M2 H3_— INJECTOR CYLINDER 4 LgP M2 H4 NOTUSED - a7ENGINE 475 SI MPFI CONNECTOR CP (BROWN) : ©|_©|__© ao © a oa | et a PINNO. oP cP cP cP cP cP cP cP cP cP cP cP cP cP cP cP cP cP cP cP cP cP cP cP cP cP cP cP cP cP cP cP Al A2 AB A Bt B2 B3 Ba ct c2 c3 ca D1 D2 D3 D4 Et £2 3 4 Ft F2 F3 Fa Gt G2 G3 Ga Hi H2 H3, Ha PIN ASSIGNMENT NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED LLINE IGNITION SWITCH INPUT NOT USED NOT USED AIR CON OP (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 KLINE NOT USED NOT USED CABLE CODE(Please Refer Page 39) 38ENGINE 475 SI MPFI PINNO — PINASSIGNMENT CABLE CODE CP Jt NOTUSED cP J2 NOTUSED - cP J3. NOTUSED CP J4 COOLING FAN 4 (RELAY DRIVER) cP Kt NOTUSED - cP K2 NOTUSED - cP K3 NOTUSED - CP K4 FAN 2 RELAY DRIVER YB CP.L1 NOTUSED - CP.L2 NOTUSED - CP.L3 NOTUSED - CP L4 POWER GROUND1 Br cP M1 NOTUSED - cP M2 NOTUSED - CP M3 LOW FUEL LEVEL INPUT vR CP M4 POWER GROUND2 Br 2. FOR VERSION : NON AC WITH POWER STEERING. ALLPINOUTAREAS PER REFERENCE VERSION EXCEPT CP D3 AC REQUEST INPUT BY NOT CONNECTED CP C3 AC COMPRESSOR DRIVER GP 12 SUPPLY CP E2 COOLING FAN HIGH SPEED GY —NOTCONNECTED 3. FOR VERSION : NONAC WITHOUT POWER STEERING ALLPINOUTAREAS PER REFERENCE VERSION EXCEPT CP D3 AC REQUEST INPUT BY NOT CONNECTED CP C3 ACCOMPRESSOR DRIVER GP 12 SUPPLY CP E2 COOLING FAN HIGH SPEED GY —NOTCONNECTED CP E3 POWERSTEERING STOP INPUT GrW NOTCONNECTED CABLECODE CABLE COLOUR B BLACK Br BROWN GREEN GREY BLUE ORANGE PINK RED WHITE YELLOW VIOLET LIGHT GREEN SKY BLUE @5< 2 t — 1 Ch [-srecirteoronauewnn ra os eS z fino PARTDESCRIPTION Aan pAETDESCRETION 1 ASSEMBLY NYLON PIPE Hose (rev T0T-CONNECTOR) 2 ASSEMBLY VAPOURLINE PRPE(7800.x0 THICK) 3 SPRINGCLAMP 4) RUBBER HOSE 4 TANKPRESGURE CONTROL VALVE LANE (IPE BxBXA.75x475) 5 ASSEMBLYPPE CLAMPINGPLATE (FOR PLASTICCLAMPS) & ASSEMBLY CARBON CANISTER LAME (PIPE Tone TSK) 7 RUBBERHOSE CLAMP (exaxd.75X4 78) 2 SPaNGCL (19 eracket 8 CANISTERPURGE VALVE ClAt PIPE exaxs.75x4.75) fo RUBBERHOSE ClaNPnceuste it SPRING CLAN (10) CLAMP (IPERS 75) 12 TICONNEGTOR VAC. CONNECTION TOEGRS. VALVE) oonFUEL SYSTEM The fuel system consists of : 1. Fuel tank assembly 2. Electric intank fuel pump with in built pressure regulator Fuel level gauge (tank unit) Fuel level gauge (dashboard) Fuel filter Fuel filler cap Fuel hoses, fuel lines and fuel rail (ie. delivery, return and vapour lines) ‘The evaporative emission system consists of : a) Tank pressure valve b) Canister purge valve ) Carbon canister 4) Restrictor ) Vapour separator Nogae GENERAL OPERATION OF EVAPORATIVE EMISSION SYSTEM: ‘The system operates when outdoor temperature is higher, after the vehicle has been parked / standstill for a long time, the fuel temperature increases and brings about a pressure rise inside the tank. This in- crease may occur with medium - low fuel levels or with the tank full condition During tank refiling, the pressure inside is more or less same as atmosphere pressure. The breather port on fuel tank is connected to the breather port on filler neck which allows tank breathing during fuel filling When the tank is completely filled, there is small pocket of air provided for efficient operation of the evaporative control system when the vehicle is running, When the fuel filler cap is closed, it seals the system, the vapours generated inside the tank (with vehicle moving or while parked) build up due to fuel volatlty, and tank internal pressure also builds up until the tank pressure valve opening level is exceeded, ‘When the engine is inoperative, (Le.while parked), fuel vapour generated inside the fuel tank due to fuel volality are absorbed and stored in the canister. When the ‘engine is running, the fuel vapours absorbed in the canister are purged into intake manifold through ‘canister purge valve operated by the ECU. Warning : Before performing the following operation, release the fuel pressure from the fuel system to reduce the possibility of injury or fire. ‘While removing the fuel tank from the vehicle, keep sparks, cigarettes and open flames away from it. Before repairing fuel tank assembly, clean it thoroughly. Disconnect negative cable terminal at battery. Always wear safety glasses.FUEL SYSTEM FUEL TANK The fuel tank is located under the rear seat of the vehicle. The fuel pump and fuel level gauge are assembled on the upper part of fuel tank. For servicing the fuel level gauge the fuel tank must be removed from the vehicle. (Fig 2) Removal : 1. Removetuel filer cap. 2. Drain the fuel from the fuel tank before removing the tank from the vehicle via drain plug (Fig 3).Do not drain or store fuel in an open container to avoid possibilty of fire or explosion. Putlid on container. 3. Releasing fuel system pressure - Since the fuel system remains under pressure when the engine is not running release the fuel system pres- sure before disconnecting any fuel ines as per follow- ing procedure. a) Start engine. ») Disconnect fuel pump electric connector located Under middle floor carpet. (Fig 4) ©) Let engine stall, then turn “OFF” ignition switch. 4) Disconnect negative cable at battery. Fig 2.FUEL SYSTEM 4. Disconnect the fuel lines (delivery and return) from the fuel pump. Disconnect quick fix couplings by pressing the two tabs as indicated. (Fig 5) 5. Disconnect fuel filer hose from fuel hose. (Fig 6) Loosen the fuel tank mounting screws and take ut the fuel tank down. 6. Disconnect breather hose and restricter hose from fuel neck. (Fig 7) Fig 6. Fig 6.FUEL SYSTEM 7. Disconnect underbody delivery line from T-connector. (Fig 8) Warning : small amount of fuel may be released after fuel lines are disconnected. To avoid the chance of injury, cover the pipe to be disconnected with cotton cloth. Do not use cotton waste. Note : To avoid damage to vapour hoses while disconnecting, slide back the clamps then twist the lines as you pull 8. Remove fueliiter from bracket. 9. Loosen fuel pump mounting screws. 10. Loosen fuel level gauge mounting screws. Inspection : 1. While removing fuel tank, check all hoses and pipes connected to fuel tank forleaks, loose _con- nections, deterioration or damage. Replace ifnec- essary. 2. Check fuel pump and fuel level gauge gaskets for leaks, cracks etc. Replace if necessary. 3. Visually inspect fuel tank for leaks and damage. Replace ifnecessary.FUEL SYSTEM FUEL TANK PURGING PROCEDURE Caution : The purging may not remove all fuel vapours. Therefore any repair on fuel tank using external heat or flame may result in explosion causing personal injury or damage. 1. Remove fuel tank from the vehicle. Refer proce- dure as mentioned for fuel tank removal. 2. Remove all hoses from fuel tank. 3. Remove fuel pump and fuel level gauge from fuel tank. 4. Shift the tank to flushing area. 6. Filltank with warm water or normal tap water and agitate rigorously and drain the water through drain plug. Repeat this procedure until inside of tankis clean. Replace the fuel tank if itis rusty inside. 6 Completely flush out remaining water after washing. Warning : Do not allow water to remain inside fuel tank after washing. This will cause corrosion inside fuel tank. Use clean cotton cloth for tank clean- ing. Do not use cotton waste. ‘Assembly: 1. Assemble fuel pump to fuel tank. Tighten the fuel pump screw to tightening torque 8 - 10 Nm. Replace gaskets for pump and fuel level gauge, if necessary. 2. Assemble fuel level guage to fuel tank. Tighten the screws to tightening torque 5 Nm. 3. Connect quick fix couplings on to the pump stems by hearing a click sound (Fig 9). Connectors must be pushed onto a mating stem and then pulled back to assure complete connections. The stem should be lubricated with SAE 30 weight oil before re-connections. 4. Connect fuel breather hose and fuel filer hose to fuel tank. Fig 10. 5. Assemble filter mounting bracket. 6. Assemble fuel tank on the vehicle. Tighten the fuel tank mounting screw to tightening torque 22.Nm. 7. Assemble filter. The arrow stamped on the outer case of the filter indicates the fuel flow direction. Fig 11 Fig 17FUEL SYSTEM 8. Connect fuel delivery pipe to filter and return pipe to T connector (Fig 12). Connect quick fix cou- plings on to the pump stems by hearing a click sound. Connectors must be pushed onto a mat- ing stem and then pulled back to ensure com- plete connection. The stem should be lubricated with SAE 30 oll before re-connecting, 9. Assemble underbody delivery line quick fix coupling to T connector. 10. Connect fuel pump and fuel level gauge connectors. 11. Fill the tank with fuel 12. Connectnegative cable at battery. 13. With engine “OFF” condition and ignition switch “ON”, check for fuel leakage. 14. Start engine and check each joint of exhaust system for leakage. Rectify if necessary. Fig 12.FUEL SYSTEM ELECTRIC INTANK FUEL PUMP WITH IN BUILT PRESSURE REGULATOR : ‘The electric fuel pump is located inside the fuel tank. Itis a positive displacement pump assembly driven by motor to provide continuous flow of fuel to the high pressure fuel system from fuel tank. This pump is inbuiltwith pressure regulator. The pressure regulator maintains the pressure in fuel line. A return line is provided after fuel fiter so that incase if pressure tends to rise, excess fuel returns back to fuel tank.This ensures the constant operating pressure of 3.5 bar in the fuel rail. The fuel pump consists of check valve to maintain pressure in the fuel feed line even when the fuel pump is switched OFF. Removal / Inspection : 1 Before removal, check fuel pump for operation as follows a) Remove fuel filer cap. b) Release the fuel system pressure as mentioned above for ‘removal of tank’ ©) Turmignition switch ‘ON’ 8) Check whether fuel pump is running by listening for sound at fue! fter inet @)Ifnosoundis heard, measure voltage between fuel pump eletrical connector wire to chassis ‘ground, The voltage should be approx. 12V. 1) voltage is not correct, check for fuel pump relay and related wiring hamess 9) If you do not measure 12V, check for continuity between fuel pump connector terminal wires (battery) and (ground). h) Ifthere is continuity, replace fuel pump. )Ifthere is no continuity, repair ground circu }) For fuel pump removal fold the rearseat and ‘open the plastic lid located under the floor carpet. Disconnect electrical connectors. Release the fuel system pressure as already ‘explained in fuel tank removal. Disconnect the quick fix couplings by pressing the two tabs. Loosen fuel pump mounting screws. Push the ring aside while taking pump out. k)_ Check fuel pump filter for evidence of dirt and contamination. If so, clean and check for presence of dirt in fuel tank, Fig 13, 10FUEL SYSTEM 2. 3, 4 6. Check fuel pump for pressure: a) Release the fuel system pressure as mentioned above for removal of tank’ b) Disconnect negative battery terminal ©) Remove fuel delivery hose from T connector 4) Connect uel pressure gauge(having a range of 0- 10bar) tothe delivery port of T connector. ©) Check that battery voltage is 12V 1) Turn ignition switch ON to operate fuel pump and after 2 seconds tur it OFF. Repeat this 3-4 times and measure fuel pump pressure. Itshould be 3.5 ber. 9) If itis not within specification, replace fuel pump. + Ifthe pressure is high, check for a) restricted fuel return ine b) Ifthe retum line is clean, replace fuel pump. + Ifthe pressure is too low :- a) Block return line and check if pressure rises, b) If pressure does rise, reassemble fuel pump. ©) If pressure does not rise, replace fuel pump or check for leakages. After checking fuel pressure, remove fuel pressure gauge. Connect fuel delivery hose to T connector and ensure that quick fix couplings are properly fitted With engine OFF and ignition ON check for fuel leakage Warning : Unless replacements necessary, fuel pump, fuel level gauge should not be removed from the tank since the rubber parts ie. gasket, seals etc. may get exposed tol, light and may become hard. Never apply an excessive force to the fuel pump nipple or lead wire. This may result in bent or poor contact, ‘Assemble the pump in reverse order of removal as explained in 1 j 1FUEL SYSTEM 7 2. FUEL LEVEL GAUGE (TANK UNIT) : 2PNCONNECTOR 1 @p- Sie ey ee | Removal : 4 —= wise. RelerproceduressmentonedinFuettankremovat. — | [our Inspection : Leben 1. Use an chrmetr to confi hat ho reitance of he us ovelsansr changes a witha oat poston. ig 14a ants eae The spected resistance vaio the ul gauge are gvenbatow fig 14 Tancuel — Capay Wes] —pastiovat —-Resitanee ——]—Tawanss leven toatintrk | vaiuoinOnm | vakeinOhm 95 1a Eimay (ow) = 445 75 Empty (high) 70 45 64.5 9 414 50 +4 109.5 18 112 32.5 +3 164.5 29.5 314 a7 +3, 207s a tian 5 # Assembly: gauge unit is assembled with ‘0’ ring in place. ‘When installing fuel tank gauge, ensure that fuel tank ae eaus_| rama Uf (erovny Lr Fig 14a, Fig 15: 2FUEL SYSTEM FUEL LEVEL GAUGE (DASHBOARD) : (FIG. 16). Removal : 1 Check fuel level gauge on dashboard for operation as follows a) Pullout the wiring harness connector on tank. unit under rear seat carpet. b) Disconnect the connector and check fuel gauge of cluster. Fuel gauge shows zero (empty) with ignition ON. ©) By-shorting the two wires. Brown and violet of, wiring harness connector the fuel gauge will show full, CAUTION: If gauge needle shows full, reconnect wires and check for fuel tank gauge. Ifneedle does not show full check fuse wiring connector. If OK, replace gauge and retest. Fig 16. 13FUEL SYSTEM FUEL FILTER : ‘The fuel fer is located under the body near the fuel tank along the pipe carrying the fuel to fuel rail as shown Fig 17, Itis made up of an outer case and an integral mount that holds a filter element with high filtering capacity. It fiers the fuel being deliver under pressure by the fuel pump. This is essential for ensuring fuel injection operation since the injector is extremely sensitive to foreign particles in the supply circuit. Since it cannot be disassembled, it must be replaced as an assembly at the recommended intervals. Fig 17 Inspection : 1 Check fue! fteras per following procedure. a) Release the fuel system pressure as mentioned above for ‘Removal of tank’ b) Disconnect negative battery terminal ©) Jack up the vehicle / hoist the vehicle. @) Install pressure gauge having a range of 0-10 bar at the delivery port of T connector. ©) Connect negative battery terminal ) Connect fuel pump connectors. @)_ Turn ignition switch ‘ON’ - run engine idle. h) Measure fuel pressure on gauge. Reading should be 3.5 bar. . Ifitis not, replace filter and retest. . ITitis OK assemble fuel filter. Removal : Refer to Procedure above from (a) to (c). Place fuel container under fuel filter. Disconnect inlet and outlet hoses from fuel filter. Collect fuel emerging during the operation in suitable container. 4Cautior FUEL SYSTEM ‘Asmall amount of fuel may be released after fuel hose is disconnected. To avoid the chance of accident, cover hose and pipe disconnected with a clean cloth. Assembly: 1 2. oe Assemble filter. The arrow stamped on the outer case of the filter indicates the fuel flow direction. Tighten the filter clamping screws to tightening torque 8 - 10 Nm. Connect inlet hose, outlet hose to fiter. Ensure that quick fix couplings are fitted properly. Connect negative battery terminal. ‘With engine ‘OFF’ condition and ignition switch ON’ check for fuel leakage. Start engine and check each joint of exhaust system for leakage. Reetify if necessary. 15FUEL SYSTEM FUEL FILLER CAP ‘The fuel tank filler neck has a non vented (sealed) cap. A ratchet device on the threaded fuel filler cap reduces the chances of overtightening and incorrect installation, which would prevent sealing fuel vapours. After the ‘O’ ring on fuel filler cap and the fuel filler neck flange contacts, the ratchet produces a loud clicking sound, indicating the seal has been set, Removal / Inspectio! 1. Remove fuel filer cap. 2. Check O ring for even filler neck imprint. 3. Check O ring for any deterioration or any damage. If found damaged replace fuel filer cap. Note : In case of fuel filer cap, replacement to be done with correct cap. Otherwise it may result in critical malfunction of the system. Tas FUEL TANK CAP (NON-VENTED) THIS ISTOBE ASSEMBLED WITHFILLERNECK Fig 18. 6FUEL SYSTEM FUEL HOSES & LINES : ‘The delivery and return lines are made up of nylon pipes with quick fix couplings at the joints. ‘The vapour lines are made up of rubber hoses and pipes with clamps at the joints. Removal : 1. Referto Procedure ‘removal of fuel tank’. 2. To avoid damage to the vapour hoses while disconnecting slide back the clamps then twist the lines as you pull 3. Disconnect quick fix couplings by pressing the two tabs. Fig 19, Inspection : 1. Visually check all hoses and pipes connected via clamp/quick fix couplings for leaks, loose connections, deterioration or damage, hose crack etc. Replace if necessary. 2. Make sure that all clamps are secure. 3. If the pipe clamps / quick fix couplings found deformed, bent or broken, replace with new one. Assembly: 1. Donottighten the clamps used on breather hose filler hose excessively to avoid damage to hoses, Use suitable too! for fitment of clamp. 2. Fuelhoses to uel pipe connections varies for each type of pipe. Necessary care tobe taken to con- ect and clamp each hose correctly. 3. Ensure that quick fix couplings are fitted properly (on to pipe, filter, pump fitings. 4. Do not kink or twist hose / pipe when they are routed, 5. Install fuel filler hose after fuel tank has been mounted in place on vehicle otherwise this may lead to leakage of fuel around hose connections. Connect negative terminal at battery. 7. Turignition switch ON andrun engine idle. Check for fuel leakages. FUEL LEVEL WARNING LIGHT (Fig. 20) : 7FUEL SYSTEM a 1. Drain fuel tank into an approved container refer to procedure ‘fuel tank removal 2. Ensure that the car is parked on level surface 3. Add less than 7.5 ltres of fuel and turn the ignition switch ON, Fig 20. 4, The low fuel warning light should come on within 2 sec. a) If ight comes on go to step 5. b) Iflight does not come ON or only comes ON dimly check wiring. If OK, remove combination meter and check bulb. If bulb is OK,replace fuel tank gauge. 5. Add fuel so that the total fuel will be more than 8 lit and check that the light goes OFF. a) If light does not go OFF, check for short circuit in the wiring hamess. If no short circuit, replace fuel tank gauge. b) If light goes OFF, turn the key OFF.Test is complete. 8FUEL SYSTEM EVAPORATIVE EMISSION CONTROL SYSTEM : ‘The car is fitted with an evaporative system to meet alll requirements of evaporative emission. ‘The system is designed to prevent fuel vapours formed within the tank and fuel system from escaping into the atmosphere. The evaporative emission system con- sists of a) Restrictor b) Vapour Separator ©) Tank pressure valve d) Carbon canister ©) Canister Purge valve a) Restrictor: Fig. 21 The restrictor is welded on top portion of the fuel tank assembly. The restrictor allows the flow of gasoline vapours only and not liquid fuel in both directions, b) Vapour Separator : Fig. 22 The separator is made of high grade of polypropylene and is mounted near to the filler eck area on the rear wheel arch. A vapour liquid separator allows only liquid free vapour to pass from fuel tank restrictor to the carbon canister through tank pressure valve. The vapours getting condensed / liquid fuel goes to the filler neck. Removal : 1. To avoid damage to the vapour hoses while disconnecting slideback the clamps and pull the hoses. 2. Loosen vapour seperator mounting screws, Inspection : Check for crack or deformation of vapour separator. Replace ifnecessary. Assembly: 1. Vapour hoses connections varies for each type of hose. Necessary care to be taken to connect and clamp each hose correctly. Use suitable tool for fitment of clamp. Do not kink or twist hose when they are routed. 3. Forhose connection to vapour separator follow schematic circuit figure. Refer to markings on vapour separator. Refer Fig. 22. 4. The port bearing the word ‘TANK ’to be connected to the restrictor on fuel tank. \L Fue Tank ASSEMBLY Fig 21 Fig 22. 3t05mm Fig 23. Hose Clamp fitment 19FUEL SYSTEM 5. The port bearing the word ‘CAN’ to be connected to underbody vapour lines going to tank pressure valve, 6. The port bearing the word F' to be connected to fuel filer neck tube. Warning Unless replacement vapour separtaris necessary. itshould not be removed fom the body Never apy BB 22s cto veser seen. Ths may result in bend/damage. c) Tank Pressure Valve : Fig. 24 & 25, The tank pressure valve is provided to keep the pressure in the fuel ank constant. The valve operates according to the pressure inside tank and engine Fig 24 ON / OFF condition, 1. The tank pressure valve opens when the engine is| ON (since the vacuum from the inlet manifold lifts the valve) and allows vapours from the tank to the engine via carbon canister depending upon the opening, closing of canister purge valve operated by ECU. 2. The tank pressure valve also opens when the en- gine is OFF and the pressure inside the tank be- comes positive and exceeds on established level of 3.7 ~5 kpa. 3. The valve is otherwise closed Le, when the engine is OFF and the vapour pressure inside tank is TANKTUBE CANISTER TUBE less than 3.7 kpa. 4. When the pressure in the fuel tank becomes negative (vacuum) and reaches it specified value it opens the valve to let the air flow into the fuel Fig 25. tank via the canister bottom breathing port. Inspection : vaccUM TUBE 1. Cheok tank pressure valve for crack or damage, Replace if necessary. 2. Air should pass through valve smoothly from fuel tank side at moderate pressure. 3. Air also should pass when blown softly from canister side. 4. Ifair does not pass through valve in step 2 or a hard blow is required in step 3, replace tank pres- sure valve, Warning: Do not suck air through tank pressure valve. Fuel vapours inside the valve are harmful 20FUEL SYSTEM Removal : To avoid damage to the vapour hoses while disconnecting slide back the clamps and pull the hoses. Assembl 1. Vapour hose connections vary for each type of joint. Necessary care must be taken to connect. and clamp each hose correctly. Use a suitable tool for fitment of the clamp. 2. Do not kinkipinch or twist hoses when they are routed. This will reduce the effectiveness of the emission control system and may cause damage to fuel tank etc. 3. Tank pressure valve must be fitted the right way around. The port bearing the word "Tank” (tank end) must be positioned towards the tank. The port bearing the word "CAN" (canister end) must be positioned towards the canister. The vacuum port to be connected to T connector which is connected to intake manifold. (Refer schematic circuit diagram Fig. 25) NOTE: Unless replacementis necessary, the Tank Pressure Valve should not be removed from the circuit. Do not apply an excessive force to the tank pressure valve nipple. This may result in bend / damage. d) Carbon canister : Fig. 26 & 27 A canister made of high grade Nylon 66/PA66, containing special dust free activated carbon is used to adsorb fuel vapours. The lower end of the canister contains a foam fier to protect the canister from dust and dirt during operation. When the engine is inopera- tive ((.e. while parked) fuel vapours generated inside the fuel tank due to fuel volatility are absorbed and stored in the canister through tank pressure valve. ‘When the engine is running, the fuel vapours absorbed inthe canister are purged into intake manifold through canister purge valve operated by ECU. The purging takes place as air is drawn through the canister due to pressure differential between manifold vacuum and atmosphere. Removal: Fig 26. 21FUEL SYSTEM 1. Disconnect hose ( from canister to purge valve). 2. When the airis blown into Tank por, there should be no restriction of flow through Purge port and Air port(.e. canister bottom por). 3. Ifthe operation differs from the above description, canister must be replaced. 4. Connect hoses to canister. 5. Ensure that hoses are clamped securely. Warning : Do not suck air through canister port. Fuel vapours inside canister are harmful Inspection : 4. Remove fue filer cap. 2. Ifcheck results not satisfactory, check for vacuum hose, purge valve, wire hamess etc. Check carbon canister for signs of damage and defects. + Ifdetective, replace canister. + IFOK, go to step 3 3. Warm up engine tonormal operating temperature. 4. Disconnect purge” end hose (Irom the canister to purgevalve) 5. a) Place finger against the end of disconnected hoses. Check that vacuum is felt there when engine is running at idle speed ») Also check that vacuum is felt when engine speed is increased to higher than 2000/3000rpm. 6. Start engine and run it at idle speed. Disconnect vacuum hose(from canister purge valve to T Connector). Block the T connector port from where the hose has been removed, with finger placed against the hose disconnected. Check that vaccum is applied. Iftis not applied clean vacuum passage by blowing compressed air ‘Assembly: For hose connection refer schematic circuit diagram-Fig. 1. The canister ports are markied "purge” and “tank” (Fig. 27), Fig 27.