TATA Indica Manual de Taller

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.
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

CONTENTS
Sr. No.
Description
Page No.
1.
Technical specifications
2.
List of special tools
3.
Tightening torques
4.
Carburetted engine vs MPFI engine
5.
MPFI engine advantages
6.
MPFI schematic circuit diagram
7.
Features of MPFI engine
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
For 75 PS : 42, 50, 57 & 63. Please also check page no. 65 for selection of camshaft.
iii
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

TECHNICAL SPECIFICATION
ENGINE
ENGINE
Model
TATA 475 SI MPFI
Type
Water cooled Multi Point Fuel Injection Petrol Engine
No. of cylinders
4 inline
Bore / Stroke
75 mm x 79.5 mm
Capacity
1405 cc
(For LX & LXi)
85 PS (62.5 kw) at 5500 rpm as per ISO : 1585
(For LEi & LSi)
75 PS (55.2 kw) at 5500 rpm as per ISO : 1585
(For LX & LXi)
115 Nm at 3000 rpm as per ISO : 1585
(For LEi & LSi)
110 Nm at 3000 rpm as per ISO : 1585
Compression ratio
9.5 : 1
Firing order
1-3-4-2
Fuel system
Grouped Injection with close loop Air / Fuel control supported by Hitachi EMS
Ignition system
Grouped Ignition supported by Hitachi EMS
Emission compliance
EURO II
Engine oil capacity
4 Litres
Cooling system capacity
6 Litres
Air filter
Dry (paper) type
Oil filter
Spin on full flow paper type
Max. engine output
Max. torque
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MAIN INDEX
GROUP INDEX
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
SULIN
10.
Valve spring com pressor
2702 5890 06 15
11.
Support rail
2702 5890 06 16
12.
Drift for valve guide seal fitment
2702 5890 06 17
13.
Drift for oil pump oil seal
2702 5890 18 01
14.
Spanner for oil filter
2702 5890 18 02
15.
Bracket (LH) for mounting engine on stand
2702 5890 24 02
16.
Bracket (RH) for mounting engine on stand
2702 5890 24 03
17.
Engine repair stand
2573 5890 24 01
18.
Drift for fitment of camshaft oil seal
2654 5890 05 08
19.
Engine support stand
2702 5890 24 01
20.
Hitachi HDM 2000 diagnostic monitor w ith accessories

and Telco cartridge 1.20
2932 9900 60 54
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ENGINE 475 SI MPFI

TIGHTENING TORQUES :
The fasteners should be tightened to specified torque at recommended intervals (km). If various fasteners are not
t ight ened t o specified t orques, t hat is eit her over t ight ened or let loose, it w ill result in leakage at joint s and
dam age t o t he part s/ t hreads. It w ill also adversely affect t he perform ance of t he part s/ syst em s as clearances/
bearing plays in the aggregates are governed by the tightening torques of the fasteners.
When choosing the torque wrench, remember that it should not be subjected to torque exceeding three fourths
of its capacit y. Before tightening, clean the threads and apply a little oil.
Serial
No.
Description
Torque in mkg.
1.
Main Bearing Cap bolt M10 x 1
5.5 #
2.
Cylinder head bolts M10 x 1.1
3, 5, 7.5 (Ref. Note) #
3.
Spark plug in cylinder head M14 x 1.5
4.
Cylinder head cover bolts M6
5.
Oil sump Screw M6 x 1
6.
Sealing plug for oil gallery block rear M14 x 1.5
3.5
7.
Oil sump drain plug M12 x 1.5
3.5
8.
Rear timing cover to block M6 x 1
1.0
9.
Rear timing cover to head cover M6 x 1
1.0
10.
Timing belt cover M6 x 1
1.0
11.
Rear cover crank case on cylinder block screw M6 x 1
1.0 #
12.
Connecting rod cap Nut M9 x 1
5.25 #
13.
Flywheel mounting screw M10 x 1
5.0 #
14.
Crankshaft gear to crankshaft bolt M14 x 1
15.
Vibration damper / 4 groove A/C pulley to crankshaft gear
2.5
16.
Belt tensioner adjuster bolt M10 x 1.5
3.0
17.
Cam thrust plate
1.0
18.
Timing belt idler to cylinder block bolt M10 x 1.5
19.
Camshaft gear to camshaft screw M12 x 1.25
8.0
20.
Lock Nut (Rocker adjusting screw) M9 x 1
3.5
21.
Assembly Fuel feed pump on cylinder head screw M8 x 1.25
2.0 #
22.
Exhaust manifold mounting bolts on cylinder head M8 x 1.25
2.0 #
23.
Starter motor on Transaxle bolt M8 x 1.25
2.4
24.
Alternator bracket to cylinder crankcase M8 X 1.25
2.0
25.
Alternator to bracket M10
2.0
2.5
1.0 #
0.6 to 0.7 #
SULIN
4+60 0 #
4.5 #
MAIN INDEX
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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.
MAIN INDEX
GROUP INDEX
Cylinder
Head Cover
Inlet
Manifold
Exhaust
Manifold
Oil Filling
Cap
Cylinder
Head Cover
Oil Filling
Cap
Inlet
Manifold
Exhaust
Manifold
Throttle
Body
Throttle
Body
MAIN INDEX
SULIN
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
Fuel Metering
Ignition System
Cold Start
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
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
Bypass
p ort
Prim ary m ain jet
Id le p ort
Fig. 1 Carburettor system - illustration

2
1. Fuel
2. Air
3.Throttle valve
4. Intake manifold
5. Injector
6. Engine
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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.
SINGLE POINT FUEL INJECTION (THROTTLE BODY

INJECTION)
2
1. Fuel
2. Air
3.Throttle valve
4. Intake manifold
5. Injectors
6. Engine
M U LTI POINT FUEL INJECTION

Fig. 2
6
MAIN INDEX
GROUP INDEX
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.
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
MPFI SCHEMATIC CIRCUIT DIAGRAM
ENGINE
SULIN
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

FEATURES OF MPFI
FEATURE
HOW ACHIEVED
USER BENEFIT
CRANKING MODE :
ENGINE
Variable Injected Quantity
Injector pulse width starts

with very high value and
drops as cranking rpm, Air & Water
t em perat ure increases.
Good Cold starting
Divided fine injection

pulse w idth method
Further total pulse width is

divided into fine pulse w idths
for efficient mixture formation
Low Emissions
Fuel is cut if Throttle

valve is opened
When throttle valve is

opened more than 700 ECU
cuts the fuel by reducing pulse
width to very low value
Good startability in all

conditions
(both hot & cold)
Ignition timing for

starting is calculated
ECU identifies cranking

m ode and calculates spark
timing depending upon water
t em perat ure and engine speed.
Good startability in all

conditions (both hot &
cold)
A/ C Compressor is kept
OFF
SULIN
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

m ode and sw itches OFF CPV
Good startability
Based on inputs to ECU
Bet t er Idle st abilit y
ISC Valve position (steps)

is continuously memorised
and renewed in memory.
Bet t er Idle st abilit y

w henever Idle st at e
changes.
IDLING MODE :
Idle speed is dependent on
l Water t em perat ure
l Engine Load (A/ C)
l Battery Voltage
l Manifold Vacuum.
and speed is maintained
by Closed Loop control
ISC Valve memorises
the previous position
(Learned Function)
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
ENGINE
FEATURE
HOW ACHIEVED
USER BENEFIT
LIMP HOME Idle Speed
When the following sensors

are No Good, then idle
speed assum es default value
for Throttle position sensor,
MAP Sensor,Vehicle speed
sensor, air temperature sensor,
water temperature sensor.
Flexibility and user

convenience
LIMP HOME ISC Valve
When ISC Valve fails in

closed condition, open throttle
marginally to start the engine.
User convenience
Engine Stall protection
When engine rpm is as low

as 650 rpm, ECU cuts A/C
relay.
Better Idle stability and

user convenience
High Engine Speed

Control
Fuel is cut beyond 6500 rpm
Engine safety
High Vehicle Speed

Control
Fuel is cut beyond

165 Kmph
Vehicle Safety
Fuel is cut if no load

acceleration is sustained
beyond certain time say,
180 sec.
Better fuel economy
Variable Acceleration
Enrichm ent
Four levels of acceleration

is det ect ed depending upon
throttle position and vehicle
speed and injected quantity
is varied.
Better Fuel economy

Bet t er Em issions
Better Overt aking abilit y
Anti Surge Function
Ignition timing is varied to

dampen sudden torque
variations.
Driving comfort
High w at er t em perat ure

A/ C cut OFF
beyond 1100c.
ECU cuts A/ C relay when the

w at er t em pet ure increases
Engine Safety
A/ C compressor is kept
OFF during rapid
accelerat ion
A/ C relay is cut-off depending

upon vehicle speed
and throttle position .
Better over taking ability
ACCELERATION MODE :
Zero Vehicle Speed Fuel

cut
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
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

FEATURE
HOW ACHIEVED
USER BENEFIT
Anti-Surge Function
Ignition timing is varied to

dam pen sudden torque
variat ions.
Driving comfort
Accurate Basic Map

Data for efficient
Injection and Ignition
cont rol
High resolution data on a

16 x 16 matrix
Best compromise for

Driveabilit y and Fuel
econom y
Closed Loop Air/ Fuel

ratio control
Lambda sensor input to

ECU maintains
Stoichiometric Air/ Fuel
ratio
LIMP HOME mode

When one or many
sensors fails to function
(Except crank angle sensor)
the vehicle will run in default
and the engine check lamp
on the instrument cluster
will glow continuously. The
car can be driven to the
nearest w orkshop for
rect ificat ion.
ECU assumes default

values
ENGINE
STEADY STATE MODE :
Emission Compliance
Safety and Comfort
SULIN
Inertia Switch (Fig. 4).
When the Vehicle collision

occurs, inertia sw itch cuts
OFF fuel pump
Safety (Fire Protection)
Immobiliser (If fitted)
Rem ot e operat ed
Immobiliser cuts supply to
Main Relay and Fuel Pump.
Safety (Anti-theft device)
Fig. 4 Inertia switch under drivers seat

11
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

MPFI SENSORS / ACTUATORS
CRANK ANGLE SENSOR : (Fig.5 & 6).
ENGINE
Type :
RS 313 B
Inductive pick up (Variable reluctance)
2 Pin connector
Working Principle
An A.C. voltage is induced in sensor coil when flywheel
holes pass t hrough t he sensor by rot at ion. This A.C.
vo lt ag e is d irect ly p ro p o rt io n al t o t h e sp eed o f
rot at ion.
System Integration :
This sensor p rovid es sp eed and crank angle inp ut
signals t o ECU w hen p laced over rot at ing flyw heel
with 7 holes, located at different angular dispositions.
Fig. 5 Crank angle sensor
Fitment Data :
This sensor is mounted on the cylinder block over the
flyw heel (Fig. 5).
Sensor Gap = 1.5 + 0.5 mm
SULIN
Stand Alone Diagnosis :

Use Mult im et er
Coil resistance = 1200 W + 15% @ 200 C
Check gap between flywheel and sensor tip
Sensor end
Pin assignment
ECU 20 = (CR+)
20
21
ECU 21 = (CR-)
Measure resistance across pin
20 & 21
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.
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
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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GROUP INDEX
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
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

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.
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
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

THROTTLE POSITION SENSOR (TPS)
Fig. 11 & 12
Type :
ENGINE
SERA 483-06
Linear Pot ent iom et er t ype
3-Pin Connector
Working Principle :
A fixed input DC volt to a potentiom eter provides a
variable output DC volt when the circuit resistance is
varied externally.
Ou t p u t vo lt ag e in creases w h en circu it resist an ce
red uces.
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 :
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

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 :

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
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

LAMBDA SENSOR (O2 Sensor) Fig. 13 & 14
Type :
ENGINE
LSH 24
Heated Ceram ic Oxygen Sensor

3 Pin Connector
Working princple (See Illustration) :

A special ceramic body with gas permeable platinum
electrodes on it s surface, operates, depending upon
ceramic materials 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.
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
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.
System Diagnosis :
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.
Special ceramic coat

Electordes
Cont act
Housing
Exhaust pipe
Ceramic Shield (porous)
Exhaust gas.
Air
ENGINE
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
800
SULIN
600
400
200
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
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 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.
This provides vehicle speed input signal to ECU in the
form of ON/ OFF pulses. When a reed switch is driven
t hrough speedom et er cable.
Specification : 4 pulses per revolution & 2550 contacts
per km .
Fig. 18 Instrument cluster (rear view)
Fitment Data :
This reed switch is integral part of instrument cluster
and is driven by Speedometer cable Fig. 18.
SULIN
Use Mult im et er
Manually rotate the speedometer cable and check for

contact make & break pulses 4 times/ rev.
VSS
With Ignition ON,

Pulse volt in ON condition = 4.5 Volt DC
Measure pulse volt across ECU pin no. 6 and car body
as ground with wiring harness connected to ECU.
System Diagnosis :
Fig. 19 Vehicle Speed Sensor (VSS)

Check for Vehicle speed sensor Value during driving.
NG condition : 2 km/ hr irrespective of vehicle speed.
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.
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
SULIN
Use Multimeter
Single Phase coil resistance = 49 W
Actuator end
2
9
P1
P2
3
10
R/L
3 ISC S/M A (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
2 ISC S/M A (ISCA)
0.75
FWH
9 ISC S/M B (ISCB)
10 ISC S/M B (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 :
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
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.
This Integral Throttle Body is with a throttle valve
(See Illustration) in the air flow path (of 38 mm). The
throttle is actuated by the lever and the shaft assembly
w hich in t urn op erat es Throt t le p osit ion sensor t o
provide engine load signal.
Fig. 23
Manifold air p ressure sensor fit t ed on t he air flow

passage dow nst ream of t he t hrot t le valve provides
m anifold pressure signal.
An ISC valve fitted on the throttle body allows the air
flow into the engine by-passing the main air flow path.
SULIN
Ho t w at er p assag e is p ro vid ed f o r co ld clim at ic

operat ions (de-iceing).
Fitment Data :
Fitted on the upstream of the inlet manifold. Fig. 24

Use Mult im et er
Fig. 24 Integral throttle body
Refer to MAP sensor, TPS sensor and ISC valve.
System Diagnosis :
Use Hitachi Diagnostic tester 2000
Refer to MAP sensor, TPS sensor and ISC Valve.
20
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

CANISTOR PURGE VALVE Fig. 25 & 26
Type :
ENGINE
TEV 2 BOSCH
Solenoid valve
2 Pin connector
Working Principle : Fig. 27 & 28

A solenoid valve opens and closes t he gas passage
depending upon ECU signal to the solenoid valve. Gas
(petrol vapour) flows into manifold from canistor and the
flow rate varies depending upon valve duty cycle ratio
(open time to close time ratio) and pressure differential
between canistor and inlet manifold.
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

Use Multimeter
Solenoid coil resistance = 26 W @200 C
Actuator end
P
11
Pin assignment
Fig. 26 Purge valve
P supply (+) main relay

ECU 11
CP
Measure the resistance across pin P & 11
System Diagnosis :

Check for CPC solenoid ON/ OFF condition by freely
accelerating the engine from idle to 4000 rpm.
CANISTER PURGE VALVE

0.75
EWH
EWH
[ MAKE HITACHI ]
Y/L
FWH
11 CANISTER PURGE
(CP)
ECU
21
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
CANISTER PURGE VALVE - ILLUSTRATION :

ENGINE
1.
HOSE CONNECTION
2.
NON RETURN VALVE
3.
LEAF SPRING
4.
SEALING ELEMENT
5.
SOLENOID ARMATURE
6.
SEALING SEAT
7.
SOLENOID COIL.
1
2
3
4
5
6
7
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
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

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
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

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.
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

Check for leaking diaphragm. Leakage is confirmed if
fuel traces are noticed on vacuum side.
System Diagnosis :
Fig. 33 Fuel pressure regulator

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 pumps suction end in the fuel. Fig. 35

Use Multimeter
Motor armature resistance = 20W @200C
Actuator end (Pump)
2
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 :
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.
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

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
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 :
Check for Ignition timing value during idling.
27
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

FROM IGNITION
ENGINE
H.T. CABLE
0.75
H.T. CABLE
H.T. CABLE
AV 0.75
[ MAKE ANU/DELTRONIX ]
SPARK
PLUGS
BODY EARTH
[MAKE MICO]
15 IGNITION1(IG1)
1CYL, 4CYL
EWH
H.T. CABLE
H.T. CABLE
0.75
AV 0.75
16 IGNITION2(IG2)
EWH
2CYL, 3CYL
ECU
IGNITION COIL
[ MAKE HITACHI ]
ENIGNE GND
GND (ENGINE)
SULIN
28
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

IGNITION COIL ILLUSTRATION :
ENGINE
PRINCIPLE OF OPERATION OF IGNITION COIL
VCC
IGN RELAY
91 W
IGNITION COIL
91 W
1g. Key S. W.
CURRENT LIMIT CIRCUIT
POWER TRANSISTOR UNIT

ENG. CONTROL UNIT
SULIN
Fig. 39
FIRING ORDER (1,3,4,2)

HEAT SINK & CONNECTOR FACING UP
4 - RS
CYL. 4
CYL. 1
ENGINE FRONT
SIDE
CYL. 2
CYL. 3
Fig. 40
29
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

ENGINE CONTROL UNIT (ECU) Fig. 41 & 42
ENGINE
Type :
H8 536
16 Bit, 16 MHz CPU with 62k ROM & 2k RAM
48 pin connector
Working Principle :
Microprocessor based Engine Control System .
System Integration (See Illustration) :

All sen sors (e.g. Wat er t em p erat ure sen sor), in p ut
sig n als are p rocessed b y t h e m icrop rocessor an d
control signals are provided for various actuators (e.g.
ISC Valve) for satisfactory engine performance. Various
control Algorithms (software) are used in conjunction
w it h M ap / t ab le d at a t o p ro vid e vario u s co n t ro l
functions for optimum functioning of the engine, which
in turn provides best fuel consumption/ Emissions.
Fig. 41
Fitment Data :
ECU is fitted below the steering column in the driver
cabin. Fig. 41

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 :
Check for all dat a w hen engine st art ing and idling
normally (typical data for normal idling are given on
page no. 34)
Fig. 42 Electronic control unit
30
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

ENGINE CONTROL UNIT - ILLUSTRATION :
Block Diagram :
ENGINE
Input
Control Unit
Output
Injector * 4
Crank angle sensor

Speed sensor
CPU : H8
Air temp.Sensor
Throttle Position
Sensor
Water temp. sensor
Ignition Coil * 1
ISC solenoid
CPU
Signal
Condi-
ROM
tioner
A/D
RAM
Fuel pump relay

Buffer
Diagnosis Lamp
I/O
Others
Battery
Oxygen Sensor
D/N Switch
A/C switch
Others
Voltage
Regulator
Watch dog
timer
SULIN
* D/N Switch - applicable for AUTOTRANSMISSION only.
Fig. 43
SPECIFICATIONS :
Type :
H8 536
Data Line :
16 Bit
Clock Speed :
Intelligent Driver ICs :

1. Idle Speed control
2. Diagnostic line
Diagnosis level :
16 MHz
3 levels
Memory :
a) Test switch (Actuators)
62k ROM
b) Read Memory switch (Blink code)
2K RAM
c) Diagnostic Monitor (HDM 2000)
A/D Convertor :
10 Bit (high accuracy)
FEATURES :
Grouped Ignition
Grouped Injection
Note : For MPFI ECU Schematic circuit refer electrical group.
31
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

TROUBLE SHOOTING OF SENSORS USED IN
MPFI :
ENGINE
Pow er
Monitor
Lamp
Method No. 1
HITACHI DIAGNOSTIC MONITOR ( HDM 2000 ) should

be loaded with the cartridge TATA Indica Version 1.2.
Fig. 44
Display
Screen
Rub b er
Jacket
Key
Pad
Pow er
Switch
This is an user friendly diagnostic kit, makes the Trouble

Shooting simpler.
This HDM 2000 can also be used as :
Wrist
Strap
Cart rid ge
LED
Display
1. A multimeter
St rap
Hook
2. An Oscilloscope
The monitor provides the diagnostic data for efficient
trouble shooting.
Fig. 44
Connecting the Diagnostic Equipment :

Not e : Connect t he HDM only wit h t he Ignit ion
switch in OFF position.
HDM 2000 is given w it h an int erm ediat e cable,one
end of it is connected to HDM 2000 and the other end
to the female socket below the co-driver's seat Fig. 45.
The power supply for it is taken from the battery of the
vehicle through the same cable. No need of separate
power supply.
SULIN
During diagnosis this instrument provides data in graphical

form. Also allows measurement and recording of data for
analysis and efficient trouble shooting.
StoresNo Good conditions of Sensors/Actuators as listed
in Read Memory Switchs diagnostic mode.That is in E C
Us 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 CODESisto 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-drivers seat as shown
in Fig. 48. Blink Code checks t he funct ioning of t he
Sensors/ Actuators as indicated in the Blink code table.
WHITE
CONNECTOR
BLACK
CONNECTOR
Fig. 49
34
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

TROUBLE SHOOTING PROCEDURE :
HITACHI DIAGNOSTIC MONITOR DATA :
1. Short the terminals of the connector using suitable

connector and OBSERVE the following :
TYPICAL DATA DURING NORMAL IDLING :

Value changes in accordance with the change in engine
temperature.
2. Turn the ignition ON

a. If the CHECK ENGINE lamp on the dash board
blinks cyclically at every 0.5 secs, Then there is
NO TROUBLE with the engine sensors.
SR. NO.
PARAMETER
VALUE
1.
Battery Voltage
14.0 V
b. Ot h erw ise t h e lam p b lin kin g f req u en cy is

correlated to a trouble code and corresponding
sensor/ actuator is indicated to be fault y.
2.
Vehicle Speed
0.0 kmph
3.
Engine Speed
750 rpm
4.
Coolant Temperature
85 0C
BLINK CODE TABLE :
5.
Ignition Timing
9-100 BTDC
Read m em ory sw it ch m ode connect or in follow ing

shorted condition.
6.
Throttle Position Sensor Volt
0.50 V
7.
Fuel Injection # 1 Pulse
2.30ms
Code
8.
ISC Valve Step
23.5 Step
Water temperature Sensor
31
9.
Engine Load
34.4%
Pressure Sensor
33
10.
Front O2 Sensor
0.24 to 0.68V
ISC Valve
34
11.
Max. Value of O2 Sensor
0.76v
Air Temperature Sensor
36
12.
Min. value of O2 Sensor
0.10v
Throttle Sensor
41
13.
A/F Correction # 1
-2.3 to -3.9%
O2 Sensor
42
14.
CPC Valve Duty Ratio
0%
Vehicle Speed Sensor
43
15.
Manifold Absolute Pressure
280/300 mm Hg
16.
Intake Air Temperature
28o C
17.
Ignition Switch
ON
18.
Test Mode Signal
OFF
19.
Read Memory Signal
OFF
20.
Idle Switch
ON
21.
A/C Switch
OFF
22.
A/C Relay
OFF
23.
Fuel Pump Relay
ON
24.
CPC Solenoid Valve
OFF
25.
Front O2 Rich Signal
OFF/ON
26.
Crank Shaft Position Signal
ON
Item
SULIN
For Example :
If the Check Engine lamp gives 3 slow blinks (of 1.2 Secs
each) representing the first digit of the failcode viz.,3"
followed by 1 fast blink (of 0.16 Secs each) representing
the second digit of the failcode viz.,1" in a cyclic fashion,
thus flashing the code 3 1 indicating that the water Temp
Sensor is faulty (from the table below).
If there are t wo or more sensors fault y, then the blink
codes are repeated cyclically. For example, if the water
temperature sensor and lambda sensor are faulty then
t h e b lin kin g co d es w ill b e rep eat ed like
..31 .42 .31 .42 .
N OTE:
At the end of each diagnosis and rectification of the fault,
HISTORY CODE is to be erased by opting CLEARMEMORY
option in HDM 2000 or by removing the battery supply for
atleast 3 minutes.
35
MAIN INDEX
GROUP INDEX
ENGINE
ENGINE 475 SI MPFI
ENGINE
ECU HANDLING CARE :
Do not try to repair the ECU.
Earth (Ground) Connection
Use standard harness for circuit connections.
Connect GND - P, GND - I, GND - C each to the engine

block.
Ensure that Do not try to insert any thing into the ECU
case.
The above mentioned GND should be connected

firmly using screws.
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).
Take care to avoid any bending of the connector pins

while inserting the connector.
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.
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.
Ensure that key SW is in OFF position while plugging

- in the connector to the ECU.
Do not plug - in the connector again to the ECU for at

least 100 sec after disconnecting it.
Input
SULIN
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 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.
Ensure that there is no water seepage into the ECU.
Do not use an ECU which has been dropped once.
36
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

PRELIMINARY INSPECTION OF ENGINE :
gradually with left foot. If the engine stalls, it means

that clutch does not slip.
Before proceeding to carry out actual overhauling of

engine it is desirable to have a preliminary inspection
of engine to ascertain whether an engine overhaul is
necessary and to w hat extent.
OR
Drive the car with weight equal to GVW in 3rd gear
on level ground and let the speed drop down to
approximately 15 kmph. Now press accelerator pedal
fully.With slipping clutch,the car speed will not pick
up and also clutch burning smell will be noticed. If
t his does not occur and car picks up speed, it
indicates that clutch does not slip.
Most common reasons for which engine is overhauled

are :
1.
Loss of power
2.
Excessive engine oil consumption
3.
Extrem ely low engine oil pressure
4.
Mechanical failures
e.
LOSS OF POWER
BRAKE BINDING
During driving apply brake number of times and then
shift the gear to neutral position Check brake drums
for over-heating and if necessary jack up the car and
check the wheels for free rotation.
To know exact reason and general condition of engine,

proceed as follow s :
1.
ENGINE
f.
Loss of engine power may be due to :
CHECKING ENGINE COMPRESSION PRESSURE

If loss of power is not on account of defective fuel
system, lack of air, choked exhaust silencer, clutch
slip p in g an d b rake b in d in g . ch eck en g in e
compression as follows :
a.
Defective Ignition system
b.
Defective Fuel system
c.
Clogged air cleaner/ choked cat alyt ic convert er

exhaust silencer
1.
Warm up engine preferably by road drive to get

a temperature of about 75 to 85 0C.
d.
Clut ch slippage
2.
Remove all spark plugs.
e.
Brake binding
3.
Rem ove air cleaner filter elem ent.
f.
Loss of engine compression
4.
a.
IGNITION SYSTEM
Install Compression gauge (Range about 0 to 25

kg/ cm 2) into one of the spark plug hole.
SULIN
Note :
Use adaptor w hich is available com m ercially to
suit the size of the spark plug threads.
Check all the sensors for proper function by

using diagnostic m onitor. Replace defective
sensors.
b.
FUEL SYSTEM
Check condit ion of fuel filt er. If found blocked
replace fuel filt er.
c.
CLOGGED AIR CLEANER/ CHOKED EXHAUST

SILENCER
Check air filter element If found choked clean or
rep lace.
d.
CLUTCH SLIPPAGE
Clutch slipping can be confirmed by any of the
following two methods :
Drive t he car in 1st or 2nd gear at m axim um
sp eed co rresp o n d in g t o t h at g ear. Wit h
accelerat o r p ed al fu lly p ressed , ap p ly b rake
Fig. 50
37
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

5.
Disengage clutch (to reduce starting load on engine)

and depress accelerator pedal all the way to make
throttle valve open fully.
6.
Crank engine with fully charged battery, and read

the highest pressure on compression gauge.
7.
Carry out steps 5 to 7 on each cylinder to obtain

co m p ressio n
p ressu res. Th e
sp ecif ied
compression pressure is 9.5 bar minimum.
ENGINE
8.
Variation in compression pressure between cylinders

should not be more than 0.5 bar.
9.
Low compression pressure may be due to leakage

past valves / piston rings/blown cylinder head gasket.
To ascertain the point of leakage,spray small quantity
of clean engine oil in to the cylinder showing low
pressure and re-check compression pressure. If it
im proves, w ear in pist on rings/ cylinder bore is
indicated. If it does not, leakage past the valves is
indicat ed. If com pression pressure of adjacent
cylinder is also on lower side, it may be due to blown
cylinder head gasket.
2.
EXCESSIVE ENGINE OIL CONSUMPTION
High engine oil consumption may also lead to overhauling

of the engine but before proceeding to overhauling, check
following points :
4.
Take a clean vessel, place it below the drain plug of

oil sump.
5.
Drain the hot oil into the clean vessel. Drain it fully.
6.
Screw in oil sump drain plug and tighten it.
7.
Weigh the vessel along with oil let this weight be

w1, gms.
8.
Refill the weighed oil into the oil sump. Do not spill
any oil. The vessel used for draining should not be
used for any other purposes.
9.
Drive the vehicle approx. 200 - 300 km. This drive

should include at least 30 - 40 kms. of highway
or similar road, vehicle running at about 60 kmph.
Let this drive distance be D kms.
10.
Immediately after the test drive, place the vehicle

at the same spot from where it started.
11.
Place the same previously used vessel below the

oil sum p, unscrew t he drain plug and drain off
oil into the vessel. Drain the sump fully.
12.
Weig h t h e vessel alon g w it h oil, n ow for t h e

second t im e. Let t his w eight be w 2 gm s.
SULIN
1.
2.
Make sure that there is absolutely no external oil

leak (i. e. from the camshaft oil seal, crankshaft oil
seal, oil sump gasket, oil pump gasket, cylinder head
cover gasket etc.)
13.
Find out standard oil consumption as -
Std. oil consumption

C (litres/ 1000km)
If no external leakage is found, determine the exact

engine oil consumption, as per following procedure.
(w1 - w2)(wt. of oil consumed, gms) x 1000

sp. wt. of oil (gm/ cm 3) x D (drive dist. in km.)
w1 - w2
0.88 x D
litres/ 1000km
3.
EXCESSIVE LOW OIL PRESSURE EXTREMELY
Check the following :
DETERMINING EXACT ENGINE OIL CONSUMPTION :
a.
Ext ernal leakages.
CAUTION :
b.
Oil level in su m p u p t o m axim u m m ark o n

dip st ick.
c.
Oil pressure transducer for proper functioning.
d.
Functioning of pressure relief valve on oil pump.
e.
Oil pump performance using a suitable pressure

gauge.
Do not make a rough estimate of engine oil consumption by

noting the kilometerscovered by the car at any random stage
and finding oil consumed from the topped up position
taking into consideration dipstick level and oil sump
capacity.
PROCEDURE :
1.
Once it is doubted that engine oil consumption is

higher, place the car on a level ground.
2.
Top up oil sump to its capacity of 4 litres.
3.
Warm up the engine so that oil temperature is 75 800 C.
Oil pressure found to be less than 2.8 bar at maximum

sp eed and 1.2 b ar at id ling sp eed , m ay b e d ue t o
im p rop er funct ioning of oil p um p or d efect ive oil
pum p relief valve.
If low oil pressure is not on account of above factors,
w ear o f j o u rn als/ b earin g s is in d icat ed f o r w h ich
overhaul of engine may be considered.
38
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

Checking oil pressure :
Procedure for checking
ENGINE
Before conducting the test ensure :

1.
Engine oil level is at high mark on dipstick, otherwise

top up.
2.
No leakage.
3.
Correct grade of engine oil is used.
Remove electrical connection from oil pressure transducer.

Remove oil pressure transducer from cylinder block.
In st all Oil p ressure g aug e in p lace of oil p ressure
t ransducer.
St art eng ine and w arm it up t o norm al op erat ing
t em p erat ure.
Warm up t h e en g in e an d m easure oil p ressure. It
should be w ithin specified limits.
After checking oil pressure, stop engine and remove
oil pressure gauge.
Before reinstalling oil pressure transducer, be sure to
apply sealant on screw threads and tighten transducer
t o specified t orque.
SULIN
Tighten oil pressure switch to 1.2 - 1.5 mkg torque.
4.
MECHANICAL FAILURES
Metallic knocking sound from an engine may be due

to faulty ignition, excessive clearance in main and big
end bearings, sm all end bush, t appet s, pist on slap,
seizin g o f p ist o n rin g s, sco red cylin d er b o re o r
breakage of any moving parts.
Defective alternator can also be a source of mechanical
noise. Defect can be located by replacing alternator
or pow er steering pum p (if fitted) or AC com pressor
(if fitted) or belt tensioner pulley with a new one.
Dismantling of engine may be considered if still noise
o ccu r even af t er at t en d in g all ab o ve m en t io n ed
p rob lem s.
39
MAIN INDEX
GROUP INDEX
ENGINE
PART DESCRIPTION
01
ASSY.ENGINE COVER
02
ASSY.RUBBER GROMMET (ENGINE COVER MTG)
03
CR CSK SCREW M6X16
04
ASSY.ENGINE COVER MTG.BKT. (FRONT)
05
PAN HD SCR M6X8
06
ASSY.BUFFER (FOR ENG.COVER MTG.)
07
HEX FL NUT
08
ASSY.LIFTING HOOK REAR
09
HEX.FL.SCREW M8X18
ENGINE 475 SI MPFI
40
SR. NO.
SULIN
MAIN INDEX
GROUP INDEX
2.5
ENGINE COVER MOUNTING

(same for 85 PS & 75 PS engines)
ENGINE 475 SI MPFI
- Specified Torque in Kgm
MOVING PARTS (For 85 PS engine)
# Allowed Tolerance of 5%
-Non Reusable Part
MAIN INDEX
SULIN
5.5 #
GROUP INDEX
SR. NO.
PART DESCRIPTION
01
ASSY.CRANKSHAFT WITH PIN - NORMAL
01-a
CRANKSHAFT-NORMAL
08
KEY
01-b
CYL PIN 8m6X16
09
ASSY.FLYWHEEL COMPLETE.
13
ASSY.CONNECTING ROD
02
ASSY.GEAR (FOR CRANKSHAFT) (SINTERED)
09-a
DOWEL
(FOR CLUTCH ON FLYWHEEL)
13-a
BOLT (FOR CONNECTING ROD)
10
HEX.BOLT (FOR FLYWHEEL)
11
SET MAIN BEARING SHELLS NORMAL

(BIMETAL)
41
03
PULLEY CRANKSHAFT-ALT.DRIVE (4-GROOVES)
04
PULLEY (4 GROOVE)(ON CRANKSHAFT FOR AC)
05
HEX FL BOLT M8X38
06
HEX.BOLT (FOR CRANKSHAFT GEAR)
07
WASHER (FOR CRANKSHAFT GEAR)
12
SET THRUST WASHERS (BIMETAL)
13-b
NUT (FOR CONNECTING ROD)
13-c
SET BRG.HALF NORMAL (CON.ROD) (BIMETAL)
14
PISTON SET WITH RINGS GRADE A (IP)
14-a
PISTON SET WITHOUT RINGS GRADE A (IP)
14-b
SET PISTON RINGS ABC STD (IP)
ENGINE
ENGINE
ENGINE 475 SI MPFI
42
MOVING PARTS (For 75 PS engine)
-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
TIMING BELT
OIL SEAL (CAMSHAFT-FRONT)
TIMING GEAR (CAMSHAFT)
WASHER (FOR CAMSHAFT GEAR)
HEX BOLT (CAMSHAFT GEAR MTG.)
ASSY.TENSIONER (TIMING BELT)
SPACER(TIMING BELT TENSIONER)
HEX FL BOLT M10X65
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

43
ENGINE
ENGINE
PART DESCRIPTION
01
ASSY.FUEL RAIL (CASTING)
02
HEX FL SCREW M8X18
03
HOSE (PR.REGULATOR TO I.MANIFOLD)205
04
SPRING CLIP (10)
05
SUPPORT BRACKET - CANISTER PURGE VALVE
06
HEX FL SCREW M8X16
GROUP INDEX
07
08
RUBBER SLEEVE (CANISTER PURGE VALVE)
09
CLAMP - CANISTER PURGE VALVE
10
HEX FL SCREW M6X10
11
RUBBER HOSE-CARBON CANISTER TO CPV (380)
12
RUBBER HOSE-CPV TO INTAKE MANIFOLD (240)
13
SPRING CLAMP (14)
14
SPRING CLIP (10)
15
ASSY.ACT.CARBON CANISTER (KOEL)
16
ASSY.BRACKET (FOR CARBON CANISTER MTG.)
17
HEX FL SCREW M6X16
SULIN
MAIN INDEX
SR. NO.
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)

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) )
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

ENGINE 475 SI MPFI
GASKET KIT (same for 85 PS & 75 PS engines)
Cylinder Head Cover Gasket
Oil Filler Cap Gasket
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
Exhaust Manifold Gasket
Inlet Manifold Gasket
GROUP INDEX
Cylinder Head Gasket
Oil Sump Gasket
Rear Gasket
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)
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.)
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

ENGINE
ENGINE
-Non Reusable Part
ENGINE ELECTRICAL EQUIPMENT (75 PS)

2.0
2.0
3.0
2.5
SULIN
MAIN INDEX
4.0
1.5
2.0
8.0
GROUP INDEX
SR. PART DESCRIPTION

NO.
01
02
03
04
05
06
07
08
BRACKET (FOR 75 AMP ALT.& PSTG.)

STUD (FOR A.C. & ALT. BRACKET)
HEX FL SCREW M8X18
HEX FL NUT AM8
HEX FL BOLT M8X125
BRIGHT WASHER 8.4
NYLOC NUT M8
ASSY.CLAMP ROD COMP.WITH BRACKET (172mm)
08-a
ASSY.CLAMP ROD (COMPLETE) 172 mm
08-a-a
ASSY.CLAMP ROD WITH SILENT BLOCK
08-a-b
ASSY.CLAMPING PIECE
08-a-b-a CLAMPING PIECE
08-a-b-c CYL PIN 8m6X25 IS2393
08-b
ASSY.BRACKET (ALTERNATOR - UPPER)
08-c
HEX FL BOLT M10X40
9
HEX FL SCREW M8X18
1 0 HEX FL BOLT M8X45
11
12
13
14
22
23
24
25
HEX THIN NUT M12

LOW OIL PRESSURE SWITCH
POLY-V BELT (4 GROOVES-875)
ALTERNATOR 12V 75A W/ IEM W/ O VP-OFFER
POWER STEERING PUMP
HEX FL SCREW M8X18
PULLEY (POWER STG.PUMP) 4 GROOVES
HEX FL.NUT AM12X1.25
ENGINE 475 SI MPFI
50
ENGINE 475 SI MPFI
ENGINE ELECTRICAL EQUIPMENT (85 PS)

SR.
NO.
PART DESCRIPTION
01
BRACKET (ALTERNATOR,IDLER & PSTG.MTG.)
02
HEX FL SCREW M8X18
03
HEX FL BOLT M8X25
04
SUPPORT BKT.(FOR ALT.BKT.& TOP SUPPORT)
05
HEX FL SCREW M8X18
06
BRACKET (FOR ALT.TOP SUPPORT)
07
HEX FL BOLT M8X25
2.0
SLIDER (FOR TENSIONER MTG.) (ALUMINIUM)
09
WASHER (FOR AC COMPRESSOR IDLER)
10
SLIDER SCREW (FOR TENSIONER)
11
ASSY.SHAFT W/ H DUST SHIELDFOR TENSIONER
12
ASSY.TENSION PULLEY.
(FOR A/ C COMP.)(INA)
13
HEX.NUT(FOR MTG.70 DIA.INA-TENSIONER)
14
POLY VEE BELT (5 PK-1095)
15
ALTERNATOR 12V 90A W/ VP W/ IEM
16
PULLEY-PSTG.PUMP (5-GROOVES)
SULIN
MAIN INDEX
08
2.0
2.0
2.0
2.3
GROUP INDEX
4.0
2.3
51
ENGINE
ENGINE
ENGINE 475 SI MPFI
52
ENGINE ELECTRICAL/A.C. EQUIPMENT

MAIN INDEX
SULIN
2.4
5.0
2.5
2.5
GROUP INDEX
-Non Reusable Part

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

ENGINE 475 SI MPFI
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

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

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)
39
40
41
42
43
44
45
46
47
48
THERMOSTAT HOUSING
O-RING 42.52X2.62 A NITRILE
HEX FL NUT AM8
STUD CM6X25
ASSY.COVER (THERMOSTAT)
ASSY.THERMOSTAT (82 DEG.SOT )
SEAL THERMOSTAT
HEX FL NUT AM6
SEALING WASHER 12X15.5
TEMPERATURE TRANSDUCER-M/ S PRICOL
49
50
51
52
53
54
55
56
57
58
SEALING WASHER 14X18

STUD CM6X16
ASSY.TUBE WATER BYPASS
GASKET (FOR WATER BYPASS TUBE)
HEX FL NUT BM6
ASSY.HOSE (WATER BYPASS) (SPR.BAND)
HOSE CLAMP 35
ASSY.ELBOW (FOR WATER INLET
GASKET (FOR WATER INLET ELBOW)
HEX FL SCREW M8X18
ENGINE 475 SI MPFI
54
ENGINE COOLING SYSTEM (same for 85 PS & 75 PS engines)
TO WATER ELBOW
08
FROM HEATER
06
07
1.0
17
Fitted on Body
18
08
Fitted on Body
1.0
19
1.5
09
To Heater
TH
ER
M
OS
TA
T
1.5
1.5
TO
MAIN INDEX
SULIN
OCK
TO BL
GROUP INDEX

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)
SPRING BAND CLAMP FORM-A 12X28D
SPRING CLIP (25)
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)
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
RUBBER HOSE-COVER THERMOSTAT TO RADIATOR
ASSY.AUX.WATER TANK W/ H PR.CAP
ASSY.BRACKET-REAR (FOR AUXILLIARY TANK)
HEX FL SCREW M6X12
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
1.5
-Non Reusable Part
4.0
2.5
2.5
c
b
4.5
2.5
2.5
3.5
SULIN
2.0
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
1.5
-Non Reusable Part
4.0
2.5
2.5
c
b
4.5
2.5
2.5
3.5
SULIN
2.0
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

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
Air filter
Gear shift linkages from transaxle Fig. 52
Radiator (if required)
Drain transaxle oil, Fig. 53.
Fig. 52
Fig. 53
58
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

Remove drive shafts (for procedure, see suspension group)
Fix chain to front and rear engine lifting hooks and hold
chain in position with crane. Fig. 54
ENGINE
Unscrew and remove nut on B mount bracket. Fig. 55

Remove A mount support arm. Fig. 55
Remove C mount bracket. Fig. 55
Lift engine slightly on car with the help of crane.
Place support stand under the engine & lower the engine
along with transaxle assembly.
Remove the chain.
Lift the front end of the car till the engine is clear ( It is
recommended to use two pole hoist to lift the car) Remove
the engine alongwith transaxle.
Remove starter motor.
Disconnect transaxle Assembly from engine. (Ref. transaxle
group)
2702 5890 24 01
Fig. 54
Remove alternator and its mounting bracket.
C MOUNT
Mount the engine on work stand with mounting bracket

Pt. No. 2702 5890 24 02 & 2702 5890 2403
Drain engine oil. Fig. 56
INSTALLATION OF ENGINE ON THE CAR :
SULIN
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 sp ecif ied q u an t it y o f o il in en g in e o f

recommended brand.
Fill coolant in the cooling system through aux. tank
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.
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. 55
Fig. 56
59
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

REMOVAL OF RADIATOR FROM CAR
(Front bum p er, Splash guard already rem oved - For
procedure refer Body group of this manual)
ENGINE
1.
Drain the coolant.
2.
Remove all the hose connections i. e.

i.
From the thermostat
ii.
From the auxiliary tank.
iii. To the outlet elbow.
3.
4.
1.
2.
3.
Disconnect the electrical connections,

i.
To the condenser fan (For AC version)
ii. To the temperature sensor of cooling fan.
1. ASSY. RADIATOR COMPLETE

2. CROSS MEMBER RADIATOR MOUNTING
i.
Unscrew the 2 M8 bolts & remove the radiator

bottom m ounting m em ber along w ith the
radiator.Fig 57
ii.
Remove upper support bracket.
3. RUBBER GROMET
Fig. 57
SPECIFICATIONS
Leakage testing pressure
AUXILLIARY TANK
1.5 bar
:
:
1 bar
0.05 bar (max)
AUXILLIARY TANK CAP
Auxillary Tank Cap Fig. 58

Pressure valve opening
Vacuum valve opening
(suct ion)
INSPECTION
SULIN
Check radiat or for dam ages / leakages. St raight en

bent fins if any.
CLEANING
Clean radiator frontal cores.
Installation :
1.
i.
ii.
Fit the radiator along with the radiator bottom

mounting member on to the car & tighten the
mounting bolts.
Fit upper mounting bracket.
2.
Fit back the 3 hose connections.
3.
Connect the electrical connections for temperature

sensor & condenser fan (For AC version)
Fig. 58
a.
Fill branded premixed ready to use coolant in the

auxiliary tank after ensuring all the hoses are secured
and leak proof.
b.
Du rin g fillin g , keep t h e h ose clam p loose at

thermostat housing.
c.
During coolant filling, ensure that the air in the

system is removed from this then tighten the hose,
using a screwdriver.
d.
Start the engine & slowly raise the engine speed &
wait for the temperature to reach 850 C to 900 C to
allow the thermostat to open up. Engine running at
idling speed, open the bleeding screw by using a
screwdriver to allow any trapped air in the system to
escape. Tighten the bleeding screw & top up with
coolant to max. level.
Fill branded coolant as per specification.

Top up coolant through auxiliary tank cap upto Full mark.
Fit Auxillary tank cap.
Run engine for short durat ion and t op up coolant if
necessary. Rem ove t he t rap p ed air t hough vent ing
screw .
Bleeding procedure for cooling system :

(For refilling or during reconditioning after complete
draining)
60
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

ALTERNATOR / POWER STEERING PUMP BELT (specific to 85 PS engine)
Removal :
ENGINE
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.
Slide the slider to reduce the belt tension by rotating

the slider screw at the bottom. Fig. 59.
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.
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. 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.

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
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.
Crankshaft
Pulley
ENGINE
10 -1 1mm
Alternator
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.
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. 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 isJust 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
Canister purge valve
Bracket supporting fuel lines. Fig. 70
SULIN
Fig. 70
l
Coolant bypass line. Fig. 71
Fig. 71
67
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

l
Blowby hose connection to cylinder head cover.

Fig. 72
ENGINE
Fig. 72
l
Vacuum pipe from intake manifold to brake booster.
Vacuum pipe to canister purge valve Fig. 73.
SULIN
Fig. 73
l
Inlet manifold with throttle body Fig. 74.
Fig. 74
68
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GROUP INDEX
ENGINE 475 SI MPFI

l
Exhaust manifold Fig. 75
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
Timing belt Fig. 78

Dip stick clamping screw
Fig. 78
Unscrew and remove cylinder head mounting screws in
reverse order of tightening Fig. 79
Slightly lift cylinder head to clear locating hollow dowel in
crank case and remove it.
l
Cam shaft gear Fig. 80
SULIN
Fig. 79
l
Rocker arm shaft locking grub screws and rocker

arm shafts. Fig. 81
Fig. 80
70
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

NOTE :
1) To ease the dismantling of rocker shaft relieve
the valve spring load by slackening the tappet
setting screws. In this condition do not attempt
to rotate the cam shaft, if you do so valve tips
will be damaged. (Fig. 81)
ENGINE
2) While pulling out Rocker arm shafts, take out

t he rocker arm w it h springs & spring seat s
carefully one by one. (Fig. 82)
Fig. 81
SULIN
Fig. 82
INLET MANIFOLD WITH THROTTLE BODY (Removed

from cylinder head)
Disassembly :
Rem ove ignit ion coil assem b ly from inlet m anifold
Fig. 83 (Four bolt)
Fig. 83
71
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

Disconnect the tube from inlet manifold to fuel pressure
regulator
ENGINE
Remove the fuel rail mtg. bolt on inlet manifold Fig. 84
Fig. 84
Remove fuel rail alongwith injectors Fig. 85
SULIN
Fig. 85
Detach injectors from fuel rail Fig. 86
Fig. 86
72
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

Remove fuel pressure regulator from fuel rail Fig. 87
ENGINE
Fig. 87
Rem ove int egral t hrot t le body from inlet m anifold.
Fig. 88
Assembly of inlet manifold

For assembling the MPFI system component proceed
in reverse order of disassembly of component.
SULIN
Fig. 88
SPARK PLUG
l
Remove Spark plugs Fig. 89
Spark Plug
Champion
Spark Plug no.
C9YC
Spark Plug Gap
0.7 mm to 0.8 mm
You should inspect the spark plugs periodically for carbon

deposits. When carbon accumulates on the spark plug, a
strong spark will not be produced. Remove carbon deposits
using a spark plug cleaner.
Spark Plug Replacement :

1.
Clean up any dirt or oil that is collected around the

spark plug caps.
Fig. 89
73
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
ENGINE
2.
Pull out the spark plug cables by gripping at the

connector.
3.
Remove the spark plug with the help of box spanner

2702 5890 06 01 (Fig. 89)
4.
Check and adjust the gap, it should be 0.7 mm to 0.8

mm. Fig. 90
5.
Replace the spark plug if the gap is more than 0.8

mm.
6.
Fix the spark plug and tighten it to the specified

torque (dry.)
7.
Fit the spark plug cable.
Repeat the procedure for the other spark plugs.

Tighten the spark plug carefully. Overtightening can
damage the threads in the cylinder head. A loose spark
plug can affect combustion and cause engine damage.
Fig. 90
SPARK PLUG DEFECTS

The condit ion of spark plug firing ends can act as a
guide t o t he st at e of t une and general condit ion of
t he engine.
NORMAL Fig. 91
SULIN
Core nose light ly coat ed w it h grey-brow n deposit s.

Electrodes not burning unduly - gap increasing about
0.01 mm per 2000 km (with the use of unleaded fuel).
Spark plugs ideally suited to engine.
HEAVY DEPOSITS Fig. 92

Possible causes : Fuel or oil additives. Oil in combustion
ch am b er. Wo rn valve g u id es. Unvar yin g sp eed
(stationary engine). Replace spark plugs.
Fig. 91
Fig. 92
CARBON FOULING
Charact erised by dull black soot y deposit s alt hough
unleaded fuel carb on fouling can ap p ear as glossy
deposits similar in appearance to oil fouling. Deposits
can sh o rt circu it t h e f irin g en d ; w eaken in g o r
elim inat ing t he spark. Check for : Over-rich m ixt ure
setting, fault y choke mechanism or clogged air filt er.
Replace spark plugs.
OIL FOULING
Deposits can short-circuit the firing end, weakening or
eliminating the spark. May be caused by worn valve guides,
Fig. 93
74
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ENGINE 475 SI MPFI

bores or piston rings, or whilst a new or overhauled engine
is running-in.Cure the oil problem, if possible.Temporary
use of the next hotter grade of spark plug may stop the
misfire. Replace spark plugs.
ENGINE
OVERHEATING
Likely causes are : Over-advanced ignition timing. incorrect
distributor advanced curve. Use of fuel with insufficient
octance rating. Weak mixture. Discard spark plugs showing
signs of overheating, and cure the cause.
INITIAL PRE-IGNITION
Caused by serious overheating. Causes are those listed
for overheat ing but m ay be m ore severe. Correct ive
measures are urgently needed before engine occurs.
Discard plugs in this condition.
Fig. 94
SPLIT CORE NOSE Fig. 93

M ay ap p ear in it ially as a h air-lin e crack. Prob ab ly
cau sed b y d et o n at io n w aves, in d icat in g : Overad van ced ig n it io n t im in g . In co rrect d ist rib u t o r
advance curve, use of fuel w it h insufficient oct ance
rat in g, Weak m ixt u re, M an if o ld air-leaks, Co o lin g
system problems, Incorrect gap setting technique, etc.
Cylinder head disassembly continued
SULIN
Remove :
l
Cyl. head cover mounting studs and spacer tubes.

(replace if required) Fig. 94
Fig. 95
l
Cam shaft locking plate from cam shaft bearing cap

at the front
Push the cam shaft from rear and pull out from front, with
oil seal Fig. 95 & 96
For Camshaft inspection go to Page No. 81
Fig. 96
75
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

Fit sup p ort rail, (2702 5890 0616) t o cylinder head
Fig. 97
ENGINE
Fig. 97
With spring compressor (2702 5890 06 15) compress valve
springs and remove valve lock halves Fig. 98
Remove valve lock retainers, valve springs, valve spring
seats and valves. Place them in correct sequence.
SULIN
Fig. 98
Mating Surface :
Using a straight edge and feeler gauge, check cylinder
head mating surface with crank case, Fig. 99 & 100.
If unevenness exceeds, replace cylinder head.
Fig. 99
76
MAIN INDEX
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ENGINE 475 SI MPFI

CYLINDER HEAD TOP AND BOTTOM SURFACE
REMACHINING, IN SERVICE IS NOT PERMITTED.
Permissible unevenness of cyl. head overall mating surface
(150 x 150) :
cross wise 0.015
mm
lengt h w ise 0.030
mm.
ENGINE
VALVES Fig. 101

Check valve leakages by pouring gasoline on valve
head. Gasoline must not seep past valve seat.
Valves with burnt heads, excessive scoring and wear on
stem should be replaced.
Fig. 100
ROCKER SHAFT
SULIN
ROCKER SCREW
ROCKER ARM
CAM SHAFT
VALVE RETAINER
LOCK HALF
VALVE GUIDE SEAL
SPRING
VALVE GUIDE
INTAKE PORT
CYLINDER HEAD
VALVE
VALVE SEAT VALVE SEAT INSERT (external fitment)
Fig. 101 Valve Arrangement

77
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
ENGINE
Check valve seat run out with respect to valve stem. Fig.
102. If it exceeds specified limit (0.030 mm both inlet &
exhaust) replace valve. No attempt should be made to
straighten bent valves. If valve is free from any other
d efect s excep t w orn out seat , t hen only it can b e
rematched on valve grinding machine as follows.
l
Clamp valve on grinding machine jaws as close as

possible to valve head.
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. 102
EXHAUST VALVE
INLET VALVE
VALVE STEM
SULIN
B
VALVE SEAT
C
45
VALVE SEAT ANGLE
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
ENGINE 475 SI MPFI

Valve dimensions : Fig. 101
INLET
EXHAUST
ENGINE
Valve head dia. A mm
36.6/36.8
30.9/31.1
Valve seat angle
450 +15'
450+15'
Valve stem dia B mm
6.97-0.015
6.96-0.015
Maximum run out of valve face with respect

to valve steam mm
0.2
0.2
Valve seat dia C mm
35
29.2
2.65+0.1
2.82+0.1
Maximum run out of valve seat with

respect to valve steam
0.030
0.030
Valve seat dia in cylinder head mm
34
28.0
Valve seat end distance from valve face D mm
SULIN
Distance between cylinder head mating

surface with crank case to valve seat in
cylinder head mm
Maximum run out of valve seat in cylinder

head with respect to valve guide axis mm
14.4+0.05
14+0.05
0.030
0.030
Remove valve guide seals. Check condition and replace if

required with drift 2702 5890 0617 Fig. 105
Check valve guide bore diameter in cylinder head and if
necessary,ream valve guide bore in cylinder head to next
over size. (Refer table on next page)
Fig. 105
79
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

Install matching size valve guide in cylinder head using
d rift 2702 5890 0611 an d sp acer, 2702 5890 0612
Fig. 106.
ENGINE
Ream valve guide inside diameter to specified size.

Fit valve guide oil seals.
VALVE SEATS OF VALVES

Check valve seat (this is the position on valve seat insert,
where valve face rest) height with respect to cylinder
head mating surface. Replace valve seat inserts if they are
worn out byond specified limit.
Cut exhaust and inlet valve seat s w it h a 45 0 cut t er
Fig. 107.
Fig. 106
Size
Valve guide
bore in cyl. head
Valve guide
OD,mm
Valve guide
ID,mm
Normal
12.99+0.008/-0.01
13.0 + 0.046
+ 0.028
7
7
+ 0.015
- 0
+ 0.016
+ 0.004
(Inlet)
(Exhaust)
13.1 + 0.046
+ 0.028
7
7
+ 0.015
- 0
+ 0.016
+ 0.004
(Inlet)
(Exhaust)
Normal 1
13.09+0.008/-0.01
SULIN
VALVE SEAT MUST BE ABSOLUTELY FAULTLESS AND

WITHOUT ANY CHATTERMARKS
Valve guide
length, mm
39.5 (Inlet)
46 (Exhaust)
suitable puller. In order to avoid damaging machined

cylinder head mating surface with crank case, place any
soft protective sheet metal under supports of puller.
If necessary lap valve seats to a smooth and even finish by

using suitable hand pump grinder or a lapping paste and
valve itself.
Measure valve seat insert bore in cylinder head & then

select suitable insert after referring table on next page.
Smear valve seat with carbon blue. Install valve in guide

and turn it slowly under axial pressure.
CONTACT LINE ON VALVE SEAT MUST BE AROUND ENTIRE
CIRCUMFERENCE AT EQUAL WIDTH
Dist ance bet w een narrow diam et er of valve face t o
contact line should be minimum 0.5 mm
Check for leakages t hrough valve seat b y p ouring
gasoline on valve head. Gasoline must not seep past
valve seat.
VALVE SEAT INSERTS :

For removing valve seat inserts from cylinder head use
a suitable boring machine. Bore old insert thin (about
0.5 mm thickness) and then pry it out.
Alternatively use a suitable turning tool to cut an annular
groove into valve seat insert and then pull it out with a
Fig. 107
80
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

If boring and prying is done carefully without damaging
valve seat insert bore in cylinder head, fitment of an over
size valve seat insert will not be necessary.
ENGINE
Re-machined valve seat insert bore in cylinder head must

be exactly at right angle to cylinder head mating surface
with crank case. All specified dimensions should be strictly
maintained to ensure proper interference of valve seat
insert in its bore.
Clean the valve seat insert and its bore in cylinder head
thoroughly.
Just before installation :
l
Place valve seat insert in a mixture of Methanol and
d ry ice fo r ab o u t 20-30 m in u t es t o b rin g it s
temperature down to -150 deg. C.
Fig. 108
Heat cylinder head to approximately 80 deg. C in

water bath.
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
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.
Check cam shaft runout at 2nd, 3rd & 4th journal by
supporting it on V-block at 1st and 5th journal. Fig. 108
Check cam shaft journal dimensions.
81
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

Cam shaft journal & bearing bore dimensions (mm) :
Journal No.
Cam shaft bearing journal

bore diameter in cylinder head
42.000 - 42.025
41.925 - 41.950
41.500 - 41.525
41.425 - 41.450
41.000 - 41.025
40.925 - 40.950
40.500 - 40.525
40.425 - 40.450
40.000 - 40.025
39.925 - 39.950
ENGINE
Cam shaft bearing

journal diameter.
Maximum permissible run out of cam shaft bearing journal
0.025 mm
Maximum permissible axial play of cam shaft in installed condition

Runout of oil seal mating diameter.
0.1/ 0.25 mm
0.02 mm
Cylinder head cover:

Remove the baffle plate in the cylinder head cover by
removing the screws Fig. 109.
Check the baffle plate gasket if it is torn/damage, replace
if necessary otherwise it might result in high engine oil
consumption.
SULIN
Fig. 109
Assembly of cylinder head :

Install valves in their respective positions
Install spring seat, valve springs and valve retainers.
Fit sup p ort rail (2702 5890 0616) on cylind er head
Fig. 110.
Fig. 110
82
MAIN INDEX
GROUP INDEX
ENGINE 475 SI M PFI

With spring compressor,(2702 5890 0615),compress valve
springs and install valve lock halves Fig. 111.
(Note : Camshaft for 85 PS engine & 75 PS engine are
different).
ENGINE
Smear cam shaft journals and cam lobes with moly paste
grease
Install cam shaft and lock it by lock plate at the front
Fig. 81 & Fig. 112.
Insert the rocker arm shaft with rocker arm spring and
spring seat one by one CAREFULLY.
Rocker arm and rocker shaft dimensions:
Rocker shaft dia. :15
Rocker bore dia. : 15
- 0.016
+ 0.011
mm
mm
Fig. 111
CAUTION :
While inserting rocker arm shaft on inlet valves, ensure

that tapped hole on the shaft is at the front end and
for rocker arm shaft on
exhaust valves the tapped hole
- 0.027
on the shaft is at the rear end.
- 0.000
Ch eck cam sh af t axial p lay. It sh o u ld b e w it h in

specified limits (0.1/ 0.25 mm) Fig. 113
SULIN
Check camshaft for rotation.
Fit camshaft oil seal with drift (Pt. No. 2654 5890 0508)
Fit camshaft gear and hand tighten the mounting bolt.
Measure piston projection above crank case and select
correct thickness of cylinder head gasket
PISTON
PROJECTION
mm
GASKET
THICKNESS,
mm
0.04 - 0.26
1.1
Fig. 112
MAXIMUM DIFFERENCE BETWEEN PISTON PROJECTIONS

OF ANY TWO PISTONS IN CRANK CASE SHOULD NOT
EXCEED SPECIFIED VALUE.
Fig. 113
83
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

Ensure that cylinder head locating hollow dowel is in
position on crank case (Block).
ENGINE
Ensure t hat flyw heel locking pin 2702 5890 0605 is

installed in position Fig. 114.
Place cylinder head gasket of pre-determined thickness.
Install cylinder head and tighten cylinder head mounting
screws to 3 mkg torque in the correct sequence i.e. from
1
10
2
6
3
2
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 :
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 isJust freely
rotating on camshaft. Fit the camshaft gear washer locking
plate. (Fig. 65)
locked timing position.
Fig. 116
84
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

Fit timing belt on crank shaft gear, water pump tensioner
roller and camshaft gear.
Adjust the timing belt tension, (Fig. 117) by rotating tensioner
roller clockwise and tighten the mounting screw, ensuring
that the tensioner roller does not rotate further in clockwise
direction.This will prevent overtensioning of timing belt.
ENGINE
Fig. 117
Tighten the cam gear fixing bolt to a lower tightening
torque of 1 mkg Fig. 118.
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.
Adjust the valve clearances of cylinder No. 1 & 2 on

inlet valves and cylinder No. 1 & 3 on exhaust valves
Fig. 119
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.

Fig. 120
ENGINE
Specified
INLET
EXHAUST
0.20
0.30
Assemblies
Fig. 120
Spark plug. Fig. 121
SULIN
Fig. 121
l
Fig. 122
86
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ENGINE 475 SI MPFI

l
Inlet m anifold w it h t hrot t le b od y and gasket .

Fig. 123
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. 124.
Thermostat cartridge
Thermostat cover with gasket
Bypass line
Dip stick clamp screw
Vacuum pipe canister purge valve to intake manifold.
Hoses from intake manifold to cylinder head cover

and brake booster.
Bracket supporting fuel lines.
Spark plug leads.
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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ENGINE 475 SI MPFI

Remove :
l
Vibration damper Fig. 126.
ENGINE
Fig. 126
l
Crankshaft gear Fig. 127.
Water pump
Timing belt tensioner
Timing belt rear cover
SULIN
Fig. 127
l
Oil filter by using spanner (2702 5890 1802)

Fig. 128
Engine mtg. bkt. (intermediate)
Fig. 128
88
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ENGINE 475 SI MPFI

l
Oil sump by extended socket (2702 5890 0603)

Fig. 129
ENGINE
Fig. 129
l
Oil pump strainer Fig. 130a
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
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ENGINE 475 SI MPFI

Remove connecting rod bearing caps with bearing shells.
ENGINE
Push these piston assemblies out of cylinders using the

wooden handle of the mallet.
Remove connecting rod bearing shells and duly mark them
with paint on their backs in case these are to be reused.
IT ISESSENTIAL TO ASSEMBLECONNECTING ROD BEARING
CAPSTO THEIR RESPECTIVE CONNECTING RODS
Verify serial numbers on connecting rod bearing caps and
connecting rods.
Remove remaining pistons in same manner
Rem ove p ist on p in sp ring clip s w it h suit ab le p lier.
Fig. 132
Fig. 132
Remove piston pins from piston by pushing them out
using soft drift. Fig. 133
Remove connecting rod
SULIN
Fig. 133
KEEP PISTONS AND PISTONS PIN IN SETS :

Insert flywheel locking pin. Fig. 134
Fig. 134
90
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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
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ENGINE 475 SI MPFI

PISTON AND PISTON RINGS :
PISTON AND CYLINDER BORE SIZES :
ENGINE
Type
Grade
Cylinder bore
Diameter mm
Piston
Diameter mm
75.00/ 75.01
74.96
75.01/ 75.02
74.97
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
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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.EnsureTOPmarking 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
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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
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

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
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ENGINE 475 SI MPFI

NOTE :
Ensure that the identification numbers for connecting rod
& connecting rod bearing cap are matched & notches for
bearing shells are on same side.
ENGINE
Check twist and bend of connecting rod by using new

piston pin in connecting rod small end bush.
Measure twist and bend of connecting rod with feeler
gauge with respect to vertical face of connecting rod
alignment gauge in vertical and horizontal plane at a
dist ance of 50 m m from t he line joining cent res of
connecting rod small end and big end bosses.
Fig. 144 & 145
If necessary, st raight en t he connect ing rod in cold
cond it ion. Since a slight clearance exist s b et w een
connecting rod bolts and corresponding connecting
rod bearing cap holes, it is possible that connecting
rod bearing cap once rem oved m ay be inst alled off
centre, by which dimension of connecting rod big end
parent bore w ill be different in different directions.
Fig. 144
If d ifference is not iced in connect ing rod b ig end

parent bore dim ension, connect ing rod bearing cap
can be centralised by lightly tapping it with mallet in
required direction after slightly loosening connecting
rod bearing cap mounting nuts.
SULIN
Check connecting rod big end parent bore dimension.

Fig. 146
If connecting rod big end parent bore is slightly more
t han m axim um p erm issib le lim it s, it is p ossib le t o
reclaim connecting rod provided the wear is confined
only to connecting rod bearing cap.
Fig. 145
Connect ing rod bearing cap m at ing surface m ay be

slightly faced. Parent bore should then be finished on
a connecting rod boring machine.
ENSURE THAT CONNECTING ROD BIG END AND SMALL
END AXES ARE PARALLEL TO EACH OTHER WITHIN
SPECIFIED LIM ITS. CENTRE TO CENTRE DISTANCE
BETWEEN CONNECTING ROD SMALL END AND BIG END
IS MAINTAINED WITHIN SPECIFIED LIMITS.
If one or more connecting rods are to be replaced, ensure
that difference in weight of connecting rod in an engine
is within permissible limits.
Install new pair of connecting rod bearing shell according
to size of crank pin journal diameter, making sure that
securing lugs of bearing shells are properly seated in
grooves of connecting rod and its bearing cap.
Fig. 146
95
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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
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ENGINE 475 SI MPFI

Crank shaft (dimensions)
Stage
Crank case main bearing bore

diameter with bearing shell mm
Crank shaft main bearing journal

diameter mm
Normal
50.026 / 50.065
50.0/ 49.98
Normal 1
49.926/ 49.965
49.900/ 49.880
Repair 1
49.786 / 49.815
49.760/ 49.730
Repair 2
49.526 / 49.565
49.500/ 49.480
Stage
Connecting rod big end bore

diameter with bearing shell (mm)
Crank pin journal diameter mm
Normal
45.007 / 45.043
44.995/ 44.980
Normal 1
44.907 / 44.943
44.895/ 44.880
Repair 1
44.757 / 44.793
44.745 / 44.730
Repair 2
44.507 / 44.543
44.495 / 44.480
Stage
Width of 4th main bearing

journal (mm)
Thickness of 4th main

bearing thrust washers, mm
Normal
24.052 / 24.000
2.62(2.60-2.65)
Standard 1
24.152 / 24.100
2.57(2.55-2.60)
Repair 1
24.252 / 24.200
2.52(2.50-2.55)
End play of crank shaft
SULIN
0.06 - 0.226 mm
Fillet radius of main bearing journals
2.5-0.5 mm
Fillet radius of crank pin journals
2.5-0.5 mm
Pre-tension of main bearing shells

Hardness of crank shaft main
bearing and crank pin journals
ENGINE
0.018-0.040 mm
50-60 HRC
Width of 1st, 2nd, 3rd and 5th

main bearing journals
24.0+0.2 mm
Main bearing parent bore dia in

crank case
Width of crank pin journals
24.0+0.2 mm
Maximum permissible taper of

main bearing parent bore
0.005 mm
Maximum permissible ovality of

main bearing parent bore.
0.005 mm
Maximum permissible cylindricity
0.0025 mm
Ovality of main brg. journal
0.005 mm
Max. permissible ovality of crank pin
0.005 mm
Maximum permissible run out of

2nd, 3rd and 4th main bearing journals
when supported at 1st and 5th main
bearing journals
Maximum permissible out of parallelism
between crank pin and main
bearing journal axis
0.02 mm
Crank shaft journal to main

bearing clearence
53.8 +0.019 mm
+ 0.00 mm
0.026 / 0.085 mm
0.010 m m
97
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

4th main bearing journal
CRANK SHAFT :
ENGINE
Clean and carry out visual inspection of crankshaft for the

following
l
Overheating of journals, which is indicated by bluish

brown colour.
Scoring marks on journals.
Cranks, which should be checked on magnetic crack

detector.
Check crank shaft run out by supporting it on V-block at

1st and 5th main bearing journals. Fig. 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
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
265.8/ 265.6
Maximum permissible unevenness

of crank case mating surface with cylinder
head 150x150 : cross wise D Fig. 157
0.015
: length wise C Fig. 157
0.030
Maximum permissible out of

parallelism between crank case top and
bottom machined surface
Maximum permissible shift in
perpendicularity of cylinder bore
from crank shaft axis when
checked from crank shaft centre line
Maximum permissible taper and
ovality of cylinder bore
B
A
0.2
0.25 mm
Fig. 157
0.007
SULIN
102
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

LUBRICATION SYSTEM :
Pump rpm
Minimum flow rate in Ipm
OIL PUMP
4000
28
Unscrew screws holding oil pump to cyl. block and remove

the oil pump assembly Check oil pump for flow rate at
specified rpm. Check for any leakage at sealing plugs.
2000
14
800
5.6
Ch eck fu n ct io n in g o f Pressu re relief valve. If t h e

performance of the pump is not satisfactory, then replace
the oil pump assembly.
Fit oil pump assembly with new gasket.
Flow rate measured against back pressure of 3kg/ cm 2
should be as follows using SAE-30 oil.
ENGINE
Engine oil pressure with coolant temperature of 700 C at

idling speed
800+50 rpm - 1 bar
at 5000 rpm - 3 bar
Oil Pressure Switch

NC contact opening pressure : 0.9 / 0.6 bar
ENGINE LUBRICATION COMPONENTS
SULIN
MAINOIL
GALLERY
OILFILTER
OILPUMP
GASKET
OILSUMP
STRAINER
DRAINPLUG
Fig. 158
103
MAIN INDEX
GROUP INDEX
ENGINE
RADIATORVENT HOSE
AUXILIARYWATERTANK
SULIN
MAIN INDEX
RADIATOR
INTEGRAL HOSE
WATERINLET ELBOW
HEATER RETURN HOSE
GROUP INDEX
CYLINDER HEAD VENT LINE
BYPASSLINE
UPPERCOOLINGLINE
THERMOSTATCOVER
WATERTEMP.SENSOR
THERMOSTATHOUSING
CAB HEATER FEEDER HOSE
ENGINE 475 SI MPFI
Fig. 159
104
COOLING CIRCUIT
ENGINE 475 SI MPFI

COOLING SYSTEM : Fig.159
THEMOSTATE CLOSED
WATER PUMP
ENGINE
Check water pump for free rotation. Check water pump for
flow rate at specified rpm. Check for coolant leakage through
leakage hole. It indicatesthat the seal isdamaged and leaking.
Replace the water pump if necessary.
Water pump characteristics :
ENGINE RPM
PUMP RPM
FLOW RATE AT BACK

PRESSURE=0.3 BAR
(LITRES PER MINUTE)
2000
2100
40
3000
3150
60
4000
4200
80
5000
5250
100
5500
5775
110
Fig. 160
THEMOSTATE OPEN
Thermostat
l
Start opening temperature - 87 0C 2
Full open temperature - 93 0C 2
By pass port closed at or before
Leakage through main valve (including seepage

hole) at room temperature and pressure of 1 kg/
cm 2 : 150-250 ltrs/ hr
Maximum leakage through by pass at full open

t em p erat u re
or
m ain
f lo w
rat e
of
130 + 5 lpm : 1.5 lpm
SULIN
Thermostat is installed in cooling system between cyl.

head & radiator inlet tank.
The working principle of thermostat :
1.
For cold engine (im m ed iat ely aft er st art ing) :

Thermostat does not allow coolant to flow to radiator
(Thermostat valve in closed position) instead coolant
flows through thermostat by-pass outlet to engine.
Thus short circuiting of radiator which helps for
attaining engine working temperature in very short
period. Fig. 160
2.
As soon as the coolant temperature reaches opening

temperature of thermostat, the thermostat valve
starts opening gradually and water flow starts to
radiator.At the same time thermostat by pass starts
closing gradually.
Fig. 161
3.
As t h e en g in e co o lin g t em p erat u re reach es

thermostat full open temperature, thermostat valve
opens fully and thermostat by-pass valve closes
completely.Under such condition maximum quantity
of engine coolant flows to radiator Fig. 161.
105
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

Satisfactory operation of thermostat is very much essential
for :
ENGINE
Efficient engine operation
Longer engine life.
Defective thermostat may cause

l
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.
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 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

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
Alternator bottom mounting bracket
Alternator
SULIN
Fig. 178
NEW oil filter Fig. 179
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
Unscrew and remove housing cover, and remove

element. Fig. 183
Clean it gently by tapping on clean table.
Use com pressed 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 elem ent if any rupt ure or punct ure 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. 183
SULIN
114
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
ACCELERATOR CABLE
ENGINE
11
10
SULIN
ASSY.ACC.CABLE-RHD
CLIP
HOSE
GROMMET
HEX FL SCREW M6X10
CABLE TIE 4.7X110
BRACKET ACC. CABLE
TOP SIDE NUT
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.
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
0.0
2000
2.3
2500
4.6
3000
5.8
3500
4.9
2500
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
Fault y throttle position signal
Fault y ISC valve
Clogged inject ors
Fault y fuel regulator
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
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
Check & replace

119
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

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

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
Rep lace
6.
Poor
acceleration/Power
injector (connection) order
Check and rectify
Low battery voltage

Get bat t ery charged/ changed
Clogged air filt er
Clean as per instructions

vacuum connections
Check and rectify
SULIN
Fault y ISC valve
Check & replace
Clogged inject ors
Check & replace
Check and replace
Rep lace
Fault y ignition coil
Check and replace

(connect ion) order
Check and replace
Incorrect t appet clearances
Check and reset

vacuum connections
Check and rectify
Worn out piston rings/ seized pistons
Overhaul / replace affect ed part s
Clean an d
necessary
Adult rat ed fuel
Clogged inject ors
Check and Replace

Fuel pump fault y
Check and Replace

Check and Replace
Rep lace

Check and rectify
120
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

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

Check and t ight en/ replace
Check and adjust.

vacuum connections
Check and Replace

Check and rectify
Check and reset
Clean an d
necessary
Adult rat ed fuel
Faulty crank angle signal
Check and rectify the gap
Clogged inject ors
Check and Replace

Check and Rectify
Clogged air filt er
Worn out piston irings/ seized pistons
SULIN
10. High fuel

consumption
Overhaul / replace affected parts
Valve guide seals leaking
Check and Replace
Adult et at ed fuel
Low battery voltage

Get bat t ery charged/ changed
11. High oil consumption

vacuum connections

Check and rectify
Check and reset
Worn out piston rings/ seized pistons
Clean and check gap/ replace if

necessary
Adult rat ed fuel
Faulty lambada signal

Clogged inject ors
Check and Replace

Check and Replace
Check and Replace

Check and t ight en/ replacet

(connect ion) order
Check and rectify
Clogged Air Filter
Clean/ replace
Worn out piston rings/ siezed pistons
Check and Replace
121
MAIN INDEX
GROUP INDEX
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.
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

CONTENTS
Sr. No.
Description
Page No.
1.
Technical specifications
2.
List of special tools
3.
Tightening torques
4.
475 MPFI Euro III engine
5.
475 SI MPFI engine advantages
6.
475 MPFI Euro III system : Schematic representation
7.
Exploded view of : EMS Kit Components
8.
Engine Management System (EMS) Overview
9.
MPFI sensors / actuators
11
10.
Integrated Intank fuel pumpwith pressure regulator
31
11.
Ignition Coil Assembly
32
12.
ECU
34
13.
ECU Handling & care
40
14.
Schematic wiring diagram of power relay
41
15.
Schematic wiring diagram of some other EMS components
42
16.
Preliminary inspection of engine
45
17.
Exploded Views:
SULIN
a.
Engine cover mounting
48
b.
Air - Intake system
49
c.
Engine suspension
50
d.
Inlet & exhaust manifold
51
e.
Engine Timing - Petrol (Euro III)
52
f.
Moving parts - block
53
g.
Engine cooling
54
h.
Fuel injection
55
i.
Cylinder Head & Cover - Petrol EURO III
56
j.
Gaskets
57
k.
Engine electrical equipment
58
18.
Removal & Installation of 475 MPFI engine from the car
59
19.
Removal and Installation of Radiator from the car
61
20.
Alternator/Power steering pump belt & A.C. compressor belts removal, inspection,
62
& fitment
iii
MAIN INDEX
GROUP INDEX
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
SULIN
MAIN INDEX
GROUP INDEX
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
SULIN
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
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

LIST OF SPECIAL TOOLS
Sr. No.
Description
Part No.
1.
Box spanner (16 A/F) for spark plug
2702 5890 06 01
2.
Extended socket (10mmA/F) for oil sump mounting screw
2702 5890 06 03
3.
Camshaft Locking Pin
2702 5890 06 04
4.
Flywheel locking pin
2702 5890 06 05
5.
Lock plate for camshaft gear washer
2702 5890 06 07
6.
Drift for crankshaft oil seal in rear cover
2702 5890 06 08
7.
Drift for removal / fitment of valve guide
2702 5890 06 11
8.
Spacer for valve guide fitment
2702 5890 06 12
9.
Drift for fitment of oil seal on valve guide
2702 5890 06 14
10.
Valve spring compressor
11.
Support rail
2702 5890 06 16
12.
Drift for valve guide seal fitment
2702 5890 06 17
13.
Drift for oil pump oil seal
2702 5890 18 01
14.
Spanner for oil filter
2702 5890 18 02
15.
Bracket (LH) for mounting engine on stand
2702 5890 24 02
16.
Bracket (RH) for mounting engine on stand
2702 5890 24 03
17.
Engine repair stand
2573 5890 24 01
18.
Drift for fitment of camshaft oil seal
2654 5890 05 08
19.
Engine support stand
2702 5890 24 01
20.
Tata Diagnostic Tool
SULIN
2702 5890 06 15
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

TIGHTENING TORQUES :
The fasteners should be tightened to specified torque at recommended intervals (km/m). If various fasteners are
not tightened to specified torques, that is either over tightened or let loose, it will result in leakage at joints and
damage to the parts/threads. It will also adversely affect the performance of the parts/systems as clearances/
bearing plays in the aggregates are governed by the tightening torques of the fasteners.
When choosing the torque wrench, remember that it should not be subjected to torque exceeding three fourths of
its capacity. Before tightening, clean the threads and apply a little oil.
Note: For tightening torque of EMS components, refer to respective sections.
Serial
No.
Description
Torque in mkg.
1.
Main Bearing Cap bolt M10 x 1
5.5 #
2.
Cylinder head bolts M10 x 1.1
3, 5, 6.5 (Ref. Note) #
3.
Spark plug in cylinder head M14 x 1.5
4.
Cylinder head cover bolts M6
5.
Oil sump Screw M6 x 1
6.
Sealing plug for oil gallery block rear M14 x 1.5
3.5
7.
Oil sump drain plug M12 x 1.5
3.5
8.
Rear timing cover to block M6 x 1
1.0
9.
Rear timing cover to head cover M6 x 1
1.0
10.
Timing belt cover M6 x 1
1.0
11.
Rear cover crank case on cylinder block screw M6 x 1
1.0 #
12.
Connecting rod cap Nut M9 x 1
5.25 #
13.
Flywheel mounting screw M10 x 1
5.0 #
14.
Crankshaft gear to crankshaft bolt M14 x 1
15.
Vibration damper / 5 groove A/C pulley to crankshaft gear
2.5
16.
Belt tensioner adjuster bolt M10 x 1.5
3.0
17.
Cam thrust plate
1.0
18.
Timing belt idler to cylinder block bolt M10 x 1.5
19.
Camshaft gear to camshaft screw M12 x 1.25
20.
Lock Nut (Rocker adjusting screw) M9 x 1
21.
Assembly Fuel feed pump on cylinder head screw M8 x 1.25
2.0 #
22.
Exhaust manifold mounting bolts on cylinder head M8 x 1.25
2.0 #
23.
Starter motor on Transaxle bolt M8 x 1.25
2.4
24.
Alternator bracket to cylinder crankcase M8 X 1.25
2.0
25.
Alternator to bracket M10
2.0
2.5
1.0 #
0.6 to 0.7 #
SULIN
4+60 0 #
4.5 #
8.0
2 Kgm
MAIN INDEX
GROUP INDEX
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.
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
475 MPFI EURO III ENGINE
OIL FILLER CAP

IGNITION COIL
INTAKE
MANIFOLD
EXHAUST MANIFOLD
THROTTLE BODY
PHASE SENSOR
AC
COMPRESSOR
SULIN
ENGINE RPM
SENSOR
MAP
SENSOR
OIL FILTER
DIPSTICK TUBE
ALTERNATOR
POWER STEERING PUMP
MAIN INDEX
GROUP INDEX
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.
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
475 MPFI EURO III SYSTEM: SCHEMATIC REPRESENTATION
SULIN
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

EMS KIT COMPONENTS
1
1
2
1.4
0.8
SULIN
4
11
3
10
5
1
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 475SI Multi
Point Fuel Injected (MPFI) engine, which
generates 85Hp. The JCAE (Johnson Controls
Automotive Electronics) S2000 Engine Management
System combined with the suitable hardware meets
the EURO III regulations.
The Engine Management System is modular with a
basic core group of essential sensors, actuators and
strategies(refer block diagram below). The strategies
are derived from physical modeling of the engine and
vehicle. The S 2000 PL 4 is dedicated for EURO III /
Engine On Board Diagnostics(EOBD) Engine
management systems. It benefits from new
technologies includes a 256Kbit flash memory,
allowing a downloading of the engine parameters and
has a 12MIPS (Million Inputs Per Second)
processing capability. The following matrix identifies
the features used on Indica MPFI - Euro III application
Distributorless Grouped Ignition ( Wasted Spark

Ignition)
Sequential Multi point (MPI) Injection engine
control
Engine Phase detection
Dual (Up stream & Downstream) O2 Sensor
Interfaces with independent monitoring and heater
drivers
Idle Speed Control by Stepper motor
EOBD Functions (Catalyst Monitoring, Mis-fire
detection ,Oxygen sensors, Fuel system etc)
Canister Purge Control Valve

Integrated Fault tolerant System
Immobilizer (Anti theft) management
Air Conditioning and Fan Control
Keyword 2000 (ISO 9141)interface
Electrical diagnostic and protection (Short and
open circuits, signals)
Additional Features
Warm Up Corrections
Model Based transient injection control
Model based transient ignition control
Model based air/water temperature compensation
Limp home and recovery
Adaptive fuel injection control
Catalyst light-off control during engine warm up
Altitude compensation
Deceleration fuel cut-off
Engine Knock Control
Fuel Pump relay Control
Post Ventilation Fan control
Accessory Load based Idle Speed regulation
GENERAL SYSTEM OVERVIEW
Refer page No. 7 + Block Diagram of JCAE EMS
(below)
SULIN
Starting:
The Idle Air Control Valve is opened to allow the
correct amount of extra air into the engine for starting.
The Ignition timing and the amount of the fuel are
adjusted according to the engine temperature, giving
quick starts regardless of the different ambient
conditions.
INPUTS
OUTPUTS
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ENGINE 475 SI MPFI

Idle Air Control:
Proper Idling of the engine is ensured irrespective of
different operating conditions with help of closed loop
control. The Idle Air control valve (IACV) that allows air
to bypass the throttle controls idle air. The activation
of the IACV occurs in three strategies:
1.
2.
3.
During Starting to provide correct amount of

air to the engine
During engine Idle. Depending upon the
engine coolant temperature, the amount of the
air inducted through the valve is varied by the
varying the position of the valve, ensuring a
closed loop control to a target Idle Speed.
During engine running to enhance driveability
by controlling engine torque changes on
closing throttle (depression limiting).
Engine Load Determination:

Fuelling and Ignition timing requirements of the
engine are dependent on the Engine load. The Load
determination is done using the Model Based
Fuelling (MBF) strategy.
The strategy uses the estimated temperature and
pressure at the intake port together with the engine
speed to estimate the amount of air entering the
cylinder at the next induction stroke.
To calculate the airflow as precisely as possible, a
thermal model of the Intake manifold is used, which is
a correction factor applied to the load equation to
determine the correct amount of the fuel to deliver to
the engine.
This model also serves as a backup strategy if either
the Throttle Position or Manifold Absolute Pressure
Sensors fails.
The MBF model or Thermo model is a heat transfer
model, which use the heat exchange between the air
and the manifold walls. The manifold also takes into
account of all temperature variations (E.g.: purging)
that will occur during the running.
depends largely on the engine load and speed.

Further adjustments are to account for the variations
in the operating conditions (e.g. Engine temperature).
To maximise the engine performance the fuelling is
enriched to give maximum power at wide-open throttle
(WOT) conditions.
Not all the fuel injected by the Injectors enters the
engine directly, some amount is deposited on the Inlet
port walls as a puddle whose size varies with the throttle
position, engine speed and engine temperature. The
puddle evaporates over the time and its effect is
particularly significant during transients. To account
for these transient effects, the puddle dynamics are
modelled and the fuelling is adjusted accordingly.
Overrun fuel cut-off is provided for fuel economy and
improved emissions performance.
A closed loop fuelling system is used a further
correction is applied to the open loop pulse time to
maintain a stoichiometric air fuel ratio under certain
operating conditions. The closed loop system also
provides adaptive (Learning) fuelling to compensate
for the wear of the intake system, component
tolerances and vehicle to vehicle variations.
SULIN
Fuelling:
The Fuel is injected into the Inlet ports (Port Fuel
Injection) by the solenoid operated Fuel Injectors which
are driven by ECU. The amount of the fuel delivered
during each engine cycle is proportional to duration of
the Injector open time. Injector timing (phasing) is
controlled to optimise performance. The injection is
sequential i.e., each injector is opened relative to its
own cylinder timing.
Amount of the fuel required (i.e. the Injector pulse time)
Ignition:
The optimum ignition timing depends largely upon the
engine speed and load. Further small corrections are
applied to improve driveability and to account for the
variations in the operating conditions (e.g. engine
temperature, Inlet air temperature).
The ignition timing is also adjusted in conjunction with
the Idle Air Control Valve to control the idle speed of
the Engine.
Throttle Position and Adaptation:
The throttle position potentiometer output may differ
between vehicle and can also change over time due to
component aging. A corrective term is applied to
compensate for this effect; this is an adaptive
(learning) value that is updated throughout the vehicles
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.
10
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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
vehicles measured engine speed and road speed. This
input is further synchronised with the Anti- surge
functions for a smoother driveability during the
transients (accelerations and decelerations).
Purge Control:
Fuel vapours generated in the fuel tank is stopped in a
canister, in order to limit the hydrocarbon emissions
into the atmosphere. The vapours stored in the
canister are purged into the engine under controlled
conditions via a Purge valve to minimise any
detrimental effects on driveability or on the emissions.
Engine Speed Limiting:
A rev-limiter protects the engine from over revving. The
cut off is introduced progressively to make the
operation smooth to the driver.
Vehicle Speed Limiting:
The vehicle speed is limited from over speeding to
provide safety and protection. A smooth vehicle speed
cut off is applied in order to have a better driveability
feel.
SULIN
Cooling Fan Control:

Cooling Fans are switched ON if the engine
temperature is too high, and remains on until the
temperature falls to an acceptable level.This
operation controls fan speed in two stages.The fans
also runs even after the ignition is switched off. if the
engine is hot.
Auxiliary load Input Information:
Auxiliary drive like power steering, Air-conditioning and
Alternator load information are taken into
consideration in order to have a better Idle speed
control and the driveability
Fuel Level Sensor
A fuel level sensor provides the necessary information
for the low-level inputs for the EOBD strategies
activation.
11
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ENGINE 475 SI MPFI

MPFI SENSORS / ACTUATORS
CRANK ANGLE SENSOR : (Fig.1 & 2).
Type :
03VR
Inductive pick up (Variable reluctance)
3 Pin connector
Working Principle :
The sensor is positioned near the flywheel mounted
toothed wheel. An A.C. voltage is induced in sensor
coil, when the flywheel tooth projection pass through
the sensor. This A.C. voltage is directly proportional
to the speed of rotation. This sensor signal is first
processed by an ASIC and then by the ECU.
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 tooth
missing (at 114 ATDC of cylinder1) to allow the engine
position to be determined.
SULIN
The sensor signal is used to calculate engine speed

& crank angle position.(Fig. 3 & 4).
Fitment Data :
This sensor is mounted on the cylinder block over the
flywheel (Fig. 1).
Sensor Gap = 1.5 0.75 mm
Installation Guideline :
Sensor to be fitted in a suitable bracket and secured

by use of a bolt tightened to a torque of 6 to 10 Nm.

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
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.
This sensor provides water temperature input to ECU
when placed in water stream.
Fig. 5 Water temperature sensor
Fitment Data :
WTS is fitted on thermostat housing (before thermostat)
which is in contact with the engine coolant.(Fig. 5)
Installation Torque : 8Nm
Use Multimeter
Nominal Thermister resistance values
2500 ohm @ 20 C
833.9 ohm @ 50 C
Sensor end
Pin assignment
1 : ECU M1D4: -ve
SULIN
2 : ECU M1E4: +ve

Measure the resistance
across pins 1 & 2.
System Diagnosis :
Check for Water Temp values.
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.
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
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
10
4 : M2C1 : Pressure Signal
115
Absolute Pressure Pabs in kPa
Measure signal volt at pin1 and pin3 with sensor
15
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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 C
2
+
SIG
-
3
4
M1A2
SULIN
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.
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 :
is fitted on inlet manifold upstream side. Throttle lever
shaft is extended to a crank lever which operates the
sensor (varies the circuit resistance). Fig. 8
SULIN
Installation Guidelines :
Diameter of screws used to fix potentiometer = 12mm
Tightening Torque = 2.5 + 0.5 Nm
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 :
Check for Throttle sensor voltage by pressing the
accelerator pedal in and out.
Volts
1 : ECU pin M1A3 : Gnd.
0.68 + 0.1
91
98
Degrees
Note :
The broken lines represent acceptable divergence limits <S>
17
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ENGINE 475 SI MPFI

+ VE
SIG
M2C3
M1B4
M1A3
- VE
THROTLE POSITION SENSOR

FROM POWER RELAY (BASE PIN NO 8)
FUSE 15A
+ VE
- VE
SIG
- VE
SULIN
1
2
M1E2
M2A3
M2B3
UPSTREAM LAMBDA (O2 )SENSOR

FUSE 15A
+ VE
- VE
SIG
- VE
1
2
M1D2
M1E3
M1D3
DOWNSTREAM LAMBDA (O2 )SENSOR

18
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ENGINE 475 SI MPFI

LAMBDA SENSOR (O2 Sensor) Fig. 10 & 11
Type :
Heated Ceramic Oxygen Sensor
4 Pin Connector
08LS Down Stream Oxygen Sensor
09LS Up Stream Oxygen Sensor
Working princple (See Illustration) :
A special ceramic body with gas permeable platinum
electrodes on its surface, operates, depending upon
ceramic materials 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.
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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ENGINE 475 SI MPFI

Use Multimeter
Heater function
Heater Resistance
For Pin nos. please refer

to marking on casing.
08LS : 6.0 1ohm ( 23 5 C)

09LS : 3.3 (+0.7ohm/-0.3ohm) ( 23 5 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 :
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
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ENGINE 475 SI MPFI

LAMBDA SENSOR :
Lambda oxygen sensor located in exhaust pipe

Fig. 13.
1. Special ceramic coat

2. Electordes
3. Contact
4. Housing
5. Exhaust pipe
6. Shield (porous)
7. Exhaust gas.
8. Air
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
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
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 8 9
Fig. 15 Heated Lambda Sensor

21
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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.
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

Use Multimeter
Pin assignment
1 : Supply
SULIN
2 : Ground
3 : ECU pin CPG2 : Signal
Manually rotate the speedometer cable and check for

contact make & break pulses 8 times/rev.
With Ignition ON,
Pulse volt in ON condition = 12 Volt DC
Measure pulse volt across ECU pin no. 6 and car body
as ground with wiring harness connected to ECU.
PIN NOS.
Fig. 17 Vehicle Speed Sensor (VSS)
System Diagnosis :
Check for Vehicle speed sensor Value during driving.

FUSE 15A
+ VE 1
CPG2
SIG 3
2
- VE
VEHICLE SPEED SENSOR

22
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ENGINE 475 SI MPFI

KNOCK SENSOR Fig. 18 & 19
Type :
Piezo electric
Sagem
Working Principle :
Knock sensor is directly mounted on the cylinder
block. When knock occurs due to the uncontrolled
combustion, vibrations are generated on the block.
These vibration forces cause a charge transfer and a
voltage is generated by the sensor element. This is
tapped off by contact discs and passed to the ECU
where it is processed.
Fig.18
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.
The sensor is fixed with screws and without washer.

Screw sizes:Cast Block: M8X25 & M10X1.5 -30
Tightening Torque: 20 + 5 Nm
Sensor end
Pin assignment
Fig.19
1 : ECU pin M1C3 : +ve

2 : ECU pin M1B3 : -ve
M1C3
M1B3
KNOCK
SENSOR
KNOCK SENSOR
23
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ENGINE 475 SI MPFI

CAM PHASE SENSOR Fig. 20 & 21
Type :
AAC K9
Hall Effect Sensor
Working Principle :
A signal voltage is generated by the sensor when the
target wheel pass through the sensor supplied with
12V supply. The position of the target indicates the
phase of the engine.
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
Installation Guidelines : 6 - 10 Nm
Pin Assignment
1 : Ground
2 : ECU pin M1F3 : Signal
Fig.21
3 : Supply 12V (From relay - pin 8 of base)


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
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.
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.
Screws to be used for fastening M5X0.8X14.
Torque : 4+ 0.4 Nm - Thread locking adhesives can be
used to prevent loosening.
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

Check for IAC valve steps
For normal idling at hot condition
IAC valve steps = 12 3 steps. (typical value)
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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ENGINE 475 SI MPFI

INTEGRAL THROTTLE BODY
Type :
09TB
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.
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.
Fig. 25
Fitment Data :
Fitted on the upstream of the inlet manifold. Fig. 25
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

Refer to IAC, TPS section.
System Diagnosis :
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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CANISTOR PURGE VALVE Fig. 28 & 29
Type :
Sagem make purge value
2 Pin connector
A solenoid valve opens and closes the gas passage
depending upon ECU signal to the solenoid valve. Gas
(petrol vapour) flows into manifold from canistor and
the flow rate varies depending upon valve duty cycle
ratio (open time to close time ratio) and pressure
differential between canistor and inlet manifold.
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

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 :
27
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ENGINE 475 SI MPFI

CANISTER PURGE VALVE - ILLUSTRATION :
1. HOSE CONNECTION
2. NON RETURN VALVE

3. LEAF SPRING
4. SEALING ELEMENT
5. SOLENOID ARMATURE
6. SEALING SEAT
7. SOLENOID COIL.
6
7
SULIN
Fig. 30
M2B1
FUSE 10A

PURGE VALVE
28
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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.
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.
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 :
Fig. 33 Fuel Injector

29
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

FUSE 15A
2
1
INJECTOR
CYLINDER 1
2
1
INJECTOR
CYLINDER 2
SULIN
1
INJECTOR
CYLINDER 3
2
1
INJECTOR
CYLINDER 4
INJECTORS
30
MAIN INDEX
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 pumps suction end in the fuel.
Pressure regulator is fitted on the return line of the
pump.
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 :
Check for Fuel pump relay ON/OFF condition.
NOTE :
With ignition ON, Fuel pump is switched off after 1
sec. if engine is not cranked.
31
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

M
FUSE 15A

FUEL PUMP
FROM POWER RELAY

(BASE PIN NO 5)
FUSE 15A
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
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

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

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 :
Check for Ignition timing value during idling.
Cylinder nos. marked for HT cable fitment.
Fig. 38
33
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

ENGINE CONTROL UNIT (ECU) :
Fig. 39,40 & 41.
Type :
S2000PL4
12 MIPS CPU Processor with 256KB ROM & 4KB
RAM
84 PIN connector
Working principle :
Microprocessor based engine control system.
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.
Note : Please also refer to ECU Handling Care
section,page no. 42
Use multimeter.
Perform continuity check on the ECU connection at
wiring harness end to any sensor/actuator depending
upon engine symptom.
Fig. 40
SPECIFICATIONS :
Type :
S2000PL4
CPU Make :
SIEMENS
CPU Type :
SAK 167
Processor Speed :
Over 12 MIPS
Fig. 41
34
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

CPU Data Processing size :
36.2 mm
32 bits
CPU Clock Speed :
20 Mhz
CPU Data Communication Size :
16 bits
Memory :
RAM - 4KB
ROM - 256KB
FEATURES :
Grouped Ignition
Sequential Injection
204 mm
SULIN
35
MAIN INDEX
GROUP INDEX
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
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

CONNECTOR CLM2 (GREY) :
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

BrR
B
W
B
W
WO
VR
LGO
WV
RL
WY
GR
YL
WG
LR
YL
YL
Br
LG
LgP
-
SULIN
37
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

CONNECTOR CP (BROWN) :
AC PRESS SW
FUEL LEVEL
FAN2
LO SPEED
PIN NO
CP A1
CP A2
CP A3
CP A4
CP B1
CP B2
CP B3
CP B4
CP C1
CP C2
CP C3
CP C4
CP D1
CP D2
CP D3
CP D4
CP E1
CP E2
CP E3
CP E4
CP F1
CP F2
CP F3
CP F4
CP G1
CP G2
CP G3
CP G4
CP H1
CP H2
CP H3
CP H4
PIN ASSIGNMENT
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
L-LINE
IGNITION SWITCH INPUT
NOT USED
NOT USED
AIR CON O/P (Relay Driver)
ONBOARD DIAGNOSTIC FAULT INDICATOR(MIL)
NOT USED
NOT USED
AC REQUEST INPUT
NOT USED
NOT USED
COOLING FAN - HIGH SPEED
POWER STEERING STOP INPUT
NOT USED
NOT USED
NOT USED
ANTI THEFT LINK
NOT USED
NOT USED
VEHICLE SPEED SENSOR INPUT
NOT USED
NOT USED
NOT USED
K LINE
NOT USED
NOT USED

RG
GR
GP
WP
BY
GY
GrW
WG
V
YR
-
SULIN
38
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

PIN NO
CP J1
CP J2
CP J3
CP J4
CP K1
CP K2
CP K3
CP K4
CP L1
CP L2
CP L3
CP L4
CP M1
CP M2
CP M3
PIN ASSIGNMENT
NOT USED
NOT USED
NOT USED
COOLING FAN 1 (RELAY DRIVER)
NOT USED
NOT USED
NOT USED
FAN 2 RELAY DRIVER
NOT USED
NOT USED
NOT USED
POWER GROUND1
NOT USED
NOT USED
LOW FUEL LEVEL INPUT
CP M4
POWER GROUND2
CABLE CODE
Y
YB
Br
VR
Br
2. FOR VERSION : NON AC WITH POWER STEERING

ALL PINOUT ARE AS PER REFERENCE VERSION EXCEPT
CP D3
CP C3
CP E2
AC REQUEST INPUT
AC COMPRESSOR DRIVER
COOLING FAN HIGH SPEED
BY
GP
GY
NOT CONNECTED
12 V SUPPLY
NOT CONNECTED
SULIN
3. FOR VERSION : NON AC WITHOUT POWER STEERING

ALL PINOUT ARE AS PER REFERENCE VERSION EXCEPT
CP
CP
CP
CP
D3
C3
E2
E3
AC REQUEST INPUT
AC COMPRESSOR DRIVER
COOLING FAN HIGH SPEED
POWER STEERING STOP INPUT
CABLE CODE
B
Br
G
Gr
L
O
P
R
W
Y
V
Lg
Sb
BY
GP
GY
GrW
NOT CONNECTED
12 V SUPPLY
NOT CONNECTED
NOT CONNECTED
CABLE COLOUR
BLACK
BROWN
GREEN
GREY
BLUE
ORANGE
PINK
RED
WHITE
YELLOW
VIOLET
LIGHT GREEN
SKY BLUE
39
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

ECU HANDLING CARE :
Ensure that the connector is inserted in the end

after all the installation is complete.
To carry out welding job on the car the ECU

should be disconnected.
Earth (Ground) Connection
Ensure all the ground connections are fixed

correctly.
DO NOT leave any grounded wire loose or open.
Power Supply
The power for the ECU should be taken through

the Main Relay. Do not take out the connector
from the ECU for at least 1 minute after IGNITION
OFF. Never take out the connector from the ECU
during IGNITION ON.
Ensure that key SW is in OFF position while

plugging - in the connector to the ECU.
Input
Ensure that the Input signal line is as far as possible

from noise sources such as High Tension Cable,
Horn relay, Motor etc.
Ensure that sealed wire are used for input line of

O2 Sensor, Crank Angle Sensor and Knock Sensor
and the wiring is as far as possible from the noise
sources similar to the ones above (Unsealed wire
may be used for O2 sensor if the noise level is
small enough so as not to affect the Air/Fuel
control).
SULIN
Output
Take care to avoid dead - short (solenoid short circuit etc.) and similar circuit misconnection while
checking (to avoid any damage). Use a solenoid
which does not use a fly - back diode (reverse
polarity may damage the Output Power Transistor).
Installation
Ensure that the ECU is secured firmly to the body

using screws.
Ensure that there is no water seepage into the

ECU.
Do not use an ECU which has been dropped once.
Do not try to repair the ECU.
Use standard harness for circuit connections.
Do not try to insert any thing into the ECU case.
Take care to avoid any bending of the connector

pins while inserting the connector.
40
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

SCHEMATIC WIRING DIAGRAM OF POWER RELAY :
BAT
30A (EMS ECU

MAXI FUSE)
MAIN
RELAY
NO
M1F2
NC
2
4
P
INERTIA
SWITCH
M1A4
M2F3
POWER
RELAY
(2 NO CONTACTS)
SULIN
IMMOBILISER
6
5
26
IMMOBILISER PIN
15A
FUSE
FUEL
15A
FUSE PUMP
IGNITION COIL
INJECTORS
UPSTREAM O2 SENSOR
DOWNSTREAM 02 SENSOR STEPPER MOTOR
CAMSHAFT POS SENSOR PURGE VALVE
VEH SPEED SENSOR
NOTE :
If a group of sensors like upstream O2 sensor, downstream O2 sensor, camshaft sensor, vehicle speed
sensor, are not functioning, first check for conditions of fuses and power relay.
41
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

SCHEMATIC WIRING DIAGRAM OF SOME OTHER EMS COMPONENTS :
MIC4
SULIN
CPE3
42
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
3 CAN_H
11 CAN_L
0.5 mm
CPB4
7 ISO 9141k
15 ISO 9141L
16 12V+ve
1 GND
SULIN
10A FUSE
IGN SUPPLY
IGNITION KEY
CEL (1.4W)
M2G1
10A FUSE
IGN
SUPPLY
MIL (14W)
CPC4
MALFUNCTION INDICATOR LAMP CHECK ENGINE LAMP

43
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
CPM3
CKT. IN THE CLUSTER

15
16
2
FUEL
GAUGE
TANK UNIT
FUEL LEVEL SENSOR
80 A (MAXI FUSE)
RADIATOR
RELAY
CPJ4
SULIN
CONDENSOR
RELAY
TO COOLING FAN
SERIES
RELAY
COOLING FAN
(LOW SPEED)
CPK4
COOLING FAN 1 AND 2
44
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

PRELIMINARY INSPECTION OF ENGINE
OR
Drive the car with weight equal to GVW in 3rd
gear on level ground and let the speed drop down
to approximately 15 kmph/10 mph. Now press
accelerator pedal fully. With slipping clutch, the
car speed will not pick up and also clutch burning
smell will be noticed. If this does not occur and
car picks up speed, it indicates that clutch does
not slip.
Before proceeding to carry out actual overhauling of

engine it is desirable to have a preliminary inspection
of engine to ascertain whether an engine overhaul is
necessary and to what extent.
Most common reasons for which engine is overhauled
are :
1.
Loss of power
2.
Excessive engine oil consumption
3.
Extremely low engine oil pressure
4.
Mechanical failures
e.
During driving apply brake number of times and

then shift the gear to neutral position Check brake
drums for over-heating and if necessary jack up
the car and check the wheels for free rotation.
To know exact reason and general condition of engine,

proceed as follows :
1.
f.
LOSS OF POWER
CHECKING ENGINE
PRESSURE (Fig. 42)
COMPRESSION
If loss of power is not on account of defective fuel

system, lack of air, choked exhaust silencer,
clutch slipping and brake binding. check engine
compression as follows :
Loss of engine power may be due to :

a.
Defective Ignition system
b.
Defective Fuel system
c.
Clogged air cleaner/choked catalytic converter

exhaust silencer
d.
Clutch slippage
e.
Brake binding
f.
Loss of engine compression
a.
IGNITION SYSTEM
1.
Warm up engine preferably by road drive to get a

temperature of about 75 to 85 0C.
2. Remove all spark plugs.
3. Remove fuel connection to fuel rail (after relieving
fuel pressure as indicated in fuel section) &
suitably prevent fuel from spilling from open
connection.
4. Remove air cleaner filter element.
5. Install Compression gauge (Range about 0 to 25
kg/cm2) into one of the spark plug hole.
Note :
Use adaptor which is available commercially to
suit the size of the spark plug threads.
SULIN
Check all the sensors for proper function by using

diagnostic monitor. Replace defective sensors.
b.
BRAKE BINDING
FUEL SYSTEM
Check condition of fuel filter. If found blocked
replace fuel filter.
c.
CLOGGED AIR CLEANER/CHOKED EXHAUST

SILENCER
Check air filter element If found choked clean or
replace.
d.
CLUTCH SLIPPAGE
Clutch slipping can be confirmed by any of the
following two methods :
Drive the car in 1st or 2nd gear at maximum speed
corresponding to that gear. With accelerator
pedal fully pressed, apply brake gradually with
left foot. If the engine stalls, it means that clutch
does not slip.
Fig. 42
45
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

is higher, place the car on a level ground.
5.
Disengage clutch (to reduce starting load on

engine) and depress accelerator pedal all the way
to make throttle valve open fully.
6.
Crank engine with fully charged battery, and read

the highest pressure on compression gauge.
7.
Carry out steps 5 to 7 on each cylinder to obtain

compression pressures. The specified
compression pressure is 9.5 bar minimum.
8.
Variation in compression pressure between

cylinders should not be more than 0.5 bar.
9.
2.
Low compression pressure may be due to leakage

past valves / piston rings/blown cylinder head
gasket. To ascertain the point of leakage, spray
small quantity of clean engine oil in to the cylinder
showing low pressure and re-check compression
pressure. If it improves, wear in piston rings/
cylinder bore is indicated. If it does not, leakage
past the valves is indicated. If compression
pressure of adjacent cylinder is also on lower
side, it may be due to blown cylinder head
gasket.
= 100 cc/ 625miles

High engine oil consumption may also lead to
overhauling of the engine but before proceeding to
overhauling, check following points :
2.
Make sure that there is absolutely no external

oil leak (i. e. from the camshaft oil seal, crankshaft
oil seal, oil sump gasket, oil pump gasket, cylinder
head cover gasket etc.)
If no external leakage is found, determine the
exact engine oil consumption, as per following
procedure.
DETERMINING
CONSUMPTION :
EXACT
ENGINE
OIL
CAUTION :
Do not make a rough estimate of engine oil consumption
by noting the kilometers covered by the car at any random
stage and finding oil consumed from the topped up
position taking into consideration dipstick level and
oil sump capacity.
PROCEDURE :
1.
Top up oil sump to its capacity of 4.5 litres.
3.
Warm up the engine so that oil temperature is

75 - 800 C.
4.
Take a clean vessel, place it below the drain plug

of oil sump.
5.
Drain the hot oil into the clean vessel. Drain it

fully.
6.
Screw in oil sump drain plug and tighten it.
7.
Weigh the vessel along with oil let this weight be

w1, gms.
8.
Refill the weighed oil into the oil sump. Do not

spill any oil. The vessel used for draining should
not be used for any other purposes.
9.
Drive the vehicle approx. 200-300 km/125 - 185m.

This drive should include at least 30-40 kms/
20-25m of highway or similar road, vehicle running
at about 60 kmph/ 40mph. Let this drive distance
be D miles.
10. Immediately after the test drive, place the vehicle

at the same spot from where it started.
SULIN
EXCESSIVE ENGINE OIL CONSUMPTION
Maximum limit for Oil Consumption = 100 cc/ 1000km
1.
2.
Once it is doubted that engine oil consumption
11. Place the same previously used vessel below

the oil sump, unscrew the drain plug and drain
off oil into the vessel. Drain the sump fully.
12. Weigh the vessel along with oil, now for the
second time. Let this weight be w2 gms.
13. Find out standard oil consumption as Std.oil consumption(w1-w2)(wt.ofoil consumed,gms)x1000
C (litres/1000km)
sp. wt. of oil (gm/cm3) x D (drive dist. in

miles.)
w1 - w2
0.88 x D
3.
EXCESSIVE
EXTREMELY
litres/1000miles
LOW
OIL
PRESSURE
Check the following :

a.
External leakages.
b.
Oil level in sump upto maximum mark on dipstick.
c.
Oil pressure transducer for proper functioning.
d.
Functioning of pressure relief valve on oil pump.
e.
Oil pump performance using a suitable pressure

gauge.
46
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

Oil pressure found to be less than 2.8 bar at maximum
speed and 1.2 bar at idling speed, may be due to
improper functioning of oil pump or defective oil pump
relief valve.
If low oil pressure is not on account of above factors,
wear of journals/bearings is indicated for which overhaul
of engine may be considered.
Checking oil pressure :
Procedure for checking
Before conducting the test ensure :
1.
2.
3.
Engine oil level is at high mark on dipstick,

otherwise top up.
No leakage.
Correct grade of engine oil is used.
Remove electrical connection from oil pressure

transducer.
Remove oil pressure transducer from cylinder block.
Install Oil pressure gauge in place of oil pressure
transducer.
Start engine and warm it up to normal operating
temperature.
SULIN
Warm up the engine and measure oil pressure. It

should be within specified limits.
After checking oil pressure, stop engine and remove
oil pressure gauge.
Before reinstalling oil pressure transducer, be sure to
apply sealant on screw threads and tighten transducer
to specified torque.
Tighten oil pressure switch to 3.0 - 4.0 Kgm torque.
4.
MECHANICAL FAILURES
Metallic knocking sound from an engine may be due

to faulty ignition, excessive clearance in main and big
end bearings, small end bush, tappets, piston slap,
seizing of piston rings, scored cylinder bore or
breakage of any moving parts.
Defective alternator can also be a source of mechanical
noise. Defect can be located by replacing alternator
or power steering pump (if fitted) or AC compressor (if
fitted) or belt tensioner pulley with a new one.
Dismantling of engine may be considered if still noise
occur even after attending all above mentioned
problems.
47
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
ENGINE COVER MOUNTING
ASSY RUBBER GROMET

1.0
ENGINE COVER
1.0
ASSY BUFFER
SULIN
ASSY ENGINE COVER
MOUNTING BRACKET
ASSY LIFTING HOOK
2.5
-- SPECIFIED TORQUE IN Kgm
48
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

AIR - INTAKE SYSTEM
5
7
6
4
11
22
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
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

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)
STUD
-- NON-REUSABLE PART
2.0
51
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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
52
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

MOVING PARTS - BLOCK
16
17
18
15
19
11
7
5.0#
20
14
13
12
5.25#
6
SULIN
2.5
1
8
3
4+60#
10
# = + 5% Tolerance on Torque value
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
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ENGINE 475 SI MPFI

GASKET
ENGINE COOLING
ASSY WATER PUMP
CYLINDER HEAD
1.0
GASKET
ELBOW
CYLINDER CRANK CASE

ASSY COVER THERMOSTAT
ASSY ELBOW (FOR WATER HEATER)

2.0
1.0
TEMP.SENSOR
RUBBER HOSE (THERMOSTAT COVER TO RAD)
HOSE CLAMP
SULIN
1.5
RUBBER HOSE
HOSE CLAMP
O-RING
THERMOSTAT
HOUSING
ASSY THERMOSTAT
1.5
COOLANT TEMP
SENSOR
HOSE CLAMP
0.8
SEAL THERMOSTAT
GASKET
ASSY HOSE
ASSY WATER BYPASS TUBE
1.0

54
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

FUEL INJECTION
INJECTOR RETAINER
1.0
INJECTOR
HOSE (T-CONNECTOR TO
INTAKE MANIFOLD)
T-CONNECTOR
2.0
HOSE (TPV BUNDY
TO T-CONNECTOR)
SPRING CLIP
SULIN
ASSY FUEL RAIL
RUBBER HOSE (CPV

TO T-CONNECTOR)
2.0
SUPPORT BRACKET FOR CPV
CLAMP (CPV)
1.0
RUBBER SLEEVE (CPV)
RUBBER HOSE (CARBON CANISTER TO CPV)

SPRING CLIP
SPRING CLIP
ASSY CARBON CANISTER
ASSY BRACKET (FOR

CARBON CANISTER)
1.0
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)
56
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

GASKETS
Throttle Body Gasket

Gasket
Oil Filter Gasket
Gasket (Cyl. Head Cover)

Exhaust Manifold
Gasket
SULIN
Gasket Elbow
Intake manifold Gasket
Rear Gasket
Front Cover Gasket

Water Pump Gasket
Oil Sump Gasket
Oil Pump Strainer Gasket
57
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

ENGINE ELECTRICAL EQUIPMENT
ASSY A/C COMPRESSOR
2.5
BRACKET (FOR A/C COMP)
POLY V BELT
SLIDER (A/C IDLER)
SET ASSY IDLER
2.3
SULIN
BRACKET (FOR ALTERNATOR TOP)
2.0
2.0
ALTERNATOR
2.0
SLIDER (FOR TENSIONER)

2.0
SHAFT (FOR TENSIONER)
2.0
2.3
SUPPORT BRACKET
2.3
PST
POLY V BELT
ASSY TENSION PULLEY

(FOR A/C COMPONENTS)
BRACKET
58
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ENGINE 475 SI MPFI

REMOVAL OF 475 MPFI ENGINE FROM
THE CAR :
Remove bonnet (Fig. 43)
Disconnect electrical cable connections for :
Battery
Starter motor
Alternator
Electrical connections of all sensors and

actuators
Oil pressure switch
Water temperature transducer
Electric fan transducer
Reversing switch
Disconnect cables for Accelerator, Speedometer drive,
Clutch.
Disconnect exhaust pipe from exhaust manifold
Fig.43
Drain coolant from cooling system

Disconnect hoses from and to radiator and heater coil.
Disconnect pipe from radiator to auxilliary tank and
cylinder head to aux. tank.
Remove AC pipe lines (if AC is fitted)
Remove following sub assemblies :
Air filter
Gear shift linkages from transaxle Fig. 44
Radiator (if required)

Remove Battery.
SULIN
Fig.44
Drain transaxle oil, Fig. 45.
Fig. 45
59
MAIN INDEX
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ENGINE 475 SI MPFI

Remove drive shafts (for procedure, see suspension
group)
Fix chain to front and rear engine lifting hooks and
hold chain in position with crane. Fig. 46
Unscrew and remove nut on B mount bracket.
Fig. 47
Remove A mount support arm. Fig. 47
Remove C mount bracket. Fig. 47
Lift engine slightly on car with the help of crane.
Place support stand under the engine & lower the
engine along with transaxle assembly.Fig. 46
Remove the chain.
Lift the front end of the car till the engine is clear ( It is
recommended to use two pole hoist to lift the car)
Remove the engine alongwith transaxle.
Remove starter motor.
Disconnect transaxle Assembly from engine. (Ref.
transaxle group)
Remove alternator and its mounting bracket.
Mount the engine on work stand with mounting bracket
Pt. No. 2702 5890 24 02 & 2702 5890 2403
Drain engine oil. Fig. 48
2702 5890 24 01
Fig.46
C MOUNT
SULIN
INSTALLATION OF ENGINE ON THE CAR :
Check engine mounting pads for wear. Replace

them if necessary.
Install the engine in reverse sequence of removal
Tighten engine mounting bolts to specified torque
Connect all pipes, hoses and electrical

connections
Fill specified quantity of oil in engine of

recommended grade.
Fill coolant in the cooling system through aux.

tank
Crank the engine momentarily. Let oil and coolant

circulate through the system.
Confirm whether engine oil pressure indicator

light is switching off when engine is started.
Check for leakage, rectify if any.
Top up coolant upto FULL mark in auxiliary tank,

if necessary.
FRONT
A MOUNT
B MOUNT
Fig.47
Fig.48
60
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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.

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
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
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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.

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 :
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
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

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

torque of 1 mkg.
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.
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.
INLET
Specified
0.20
EXHAUST
0.30
65
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

CYLINDER HEAD : (Engine on workstand)
Disassembly:
Remove electrical cable connections for:
Spark plug leads. Fig 61
Fig. 61
Canister purge valve.Fig 62
SULIN
Fig. 62
Coolant bypass line. Fig. 63
Fig. 63
66
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
Blowby hose connection to cylinder head cover.

Fig.64
Fig. 64
Vacuum pipe from intake manifold to brake

booster.
Vacuum pipe to canister purge valve Fig. 65.
SULIN
Fig. 65
Dip stick clamping screw

Accelerator cable connections
Inlet manifold with throttle body Fig. 66
Fig. 66
67
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

Timing Cover
Fig. 67
Cylinder head cover Fig. 68
SULIN
Fig. 68
Insert flywheel locking pin, fit camshaft gear washer
lockplate and loosen camshaft gear mounting bolt.
Fig. 69
Fig. 69
68
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

Also remove
Timing belt Fig. 70
Fig. 70
Unscrew and remove cylinder head mounting screws
in reverse order of tightening Fig. 71
Slightly lift cylinder head to clear locating hollow dowel
in crank case and remove it.
Remove
Cam shaft gear Fig. 72
SULIN
Fig. 71
Fig. 72
69
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

Remove
Rocker arm shaft locking grub screws and rocker

arm shafts. Fig. 73 & 74.
NOTE :
1) To ease the dismantling of rocker shaft relieve
the valve spring load by slackening the tappet
setting screws. In this condition do not
attempt to rotate the cam shaft, if you do so
valve tips will be damaged.
2) While pulling out Rocker arm shafts, take
out the rocker arm with springs & spring seats
carefully one by one.
Fig. 73
SULIN
Fig. 74
70
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

INLET MANIFOLD WITH THROTTLE BODY
(Removed from cylinder head)
Disassembly :
Remove fuel rail alongwith injectors Fig. 75
Fig. 75
Remove injector retainer clip from fuel rail.
Detach injectors from fuel rail Fig. 76
SULIN
Fig. 76
71
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

Remove integral throttle body from inlet manifold.
Fig. 77
Assembly of inlet manifold
For assembling the MPFI system component proceed
in reverse order of disassembly of component.
Fig. 77
SPARK PLUG
Remove Spark plugs Fig. 78
Spark Plug
Champion / BOSCH
Spark Plug no.
C9YC / FR 6 DC4
Spark Plug Gap
0.7 mm to 0.8 mm
SULIN
You should inspect the spark plugs periodically for

carbon deposits. When carbon accumulates on the
spark plug, a strong spark will not be produced. Remove
carbon deposits using a spark plug cleaner.
Spark Plug Replacement :
1.
Clean up any dirt or oil that is collected around

the spark plug caps.
2.
Pull out the spark plug cables by gripping at the

connector.
3.
Remove the spark plug with the help of box

spanner 2702 5890 06 01
4.
Check and adjust the gap, it should be 0.7 mm

to 0.8 mm. Fig. 79
5.
Replace the spark plug if the gap is more than

0.8 mm.
6.
Fix the spark plug and tighten it to the specified

torque (dry.)
7.
Fit the spark plug cable.
Fig. 78
Repeat the procedure for the other spark plugs.
Fig. 79
72
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

Tighten the spark plug carefully. Overtightening can
damage the threads in the cylinder head. A loose spark
plug can affect combustion and cause engine damage.
SPARK PLUG DEFECTS

The condition of spark plug firing ends can act as a
guide to the state of tune and general condition of the
engine.
The examples shown below are assumed to be the
correct grade of engine.
NORMAL Fig. 80
Core nose lightly coated with grey-brown deposits.
Electrodes not burning unduly - gap increasing about
0.01 mm per 2000 km (with the use of unleaded fuel).
Spark plugs ideally suited to engine.
Fig.80
Fig. 81
HEAVY DEPOSITS Fig. 81

Possible causes : Fuel or oil additives, Oil in
combustion chamber, Worn valve guides, Unvarying
speed (stationary engine). Replace spark plugs.
CARBON FOULING
SULIN
Characterised by dull black sooty deposits although

unleaded fuel carbon fouling can appear as glossy
deposits similar in appearance to oil fouling. Deposits
can short circuit the firing end; weakening or eliminating
the spark. Check for clogged air filter. Replace spark
plugs.
OIL FOULING
Deposits can short-circuit the firing end, weakening
or eliminating the spark. May be caused by worn valve
guides, bores or piston rings, or whilst a new or
overhauled engine is running-in. Cure the oil problem,
if possible. Temporary use of the next hotter grade of
spark plug may stop the misfire. Replace spark plugs.
Fig. 82
OVERHEATING
Likely causes are : Over-advanced ignition timing, Use
of fuel with insufficient octance rating, Weak mixture.
Discard spark plugs showing signs of overheating, and
cure the cause.
INITIAL PRE-IGNITION
Caused by serious overheating. Causes are those
listed for overheating but may be more severe.
Corrective measures are urgently needed. Discard
plugs in this condition.
Fig. 83
73
MAIN INDEX
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ENGINE 475 SI MPFI

SPLIT CORE NOSE Fig. 82
May appear initially as a hair-line crack. Probably
caused by detonation waves, indicating : use of fuel
with insufficient octance rating, Manifold air-leaks,
Cooling system problems, Incorrect gap setting
technique, etc.
Cylinder head disassembly continued
Cyl. head cover mounting studs and spacer

tubes. (replace if required) Fig. 83
Cam shaft locking plate from cam shaft bearing

cap at the front
Push the cam shaft from rear and pull out from front,
with oil seal Fig. 84 & 85
Fit support rail, (2702 5890 0616) to cylinder head
Fig. 86
Fig. 84
With spring compressor (2702 5890 06 15) compress

valve springs and remove valve lock halves Fig. 87
Remove valve lock retainers, valve springs, valve spring
seats and valves. Place them in correct sequence.
SULIN
Fig. 85
Fig. 87
Fig. 86
74
MAIN INDEX
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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
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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
16
SULIN
ROCKER SCREW
ROCKER ARM
CAM
SHAFT
VALVE RETAINER
LOCK HALF
VALVE GUIDE
SEAL
SPRING
VALVE GUIDE
INTAKE PORT
CYLINDER HEAD
16
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
45
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
350.05
28.880.05
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
11.80.05
11.750.05
0.030
0.030
Remove valve guide seals. Check condition and replace

if required with drift 2702 5890 0617 Fig. 94
Check valve guide bore diameter in cylinder head and
if necessary, ream valve guide bore in cylinder head to
next over size.
Fig. 94
78
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

Install matching size valve guide in cylinder head using
drift 2702 5890 0611 and spacer, 2702 5890 0612
Fig. 95.
Ream valve guide inside diameter to specified size.
Fit valve guide oil seals.
VALVE SEATS OF VALVES

Check valve seat height with respect to cylinder head
mating surface. Replace valve seat inserts if they are
worn out beyond specified limit.
Cut exhaust and inlet valve seats with a 450 cutter
Fig. 96.
Fig. 95
Size
Valve guide
bore in cyl. head
Valve guide
OD,mm
Valve guide
ID,mm
Normal
12.99+0.008/-0.01
13.0 + 0.046
+ 0.028
7 - 0 (Inlet)
+ 0.020
7 + 0.005 (Exhaust)
Normal 1
13.09+0.008/-0.01
+ 0.015
13.1 + 0.046
+ 0.028
SULIN
VALVE SEAT MUST BE ABSOLUTELY FAULTLESS

AND WITHOUT ANY CHATTER MARKS
If necessary lap valve seats to a smooth and even
finish by using suitable hand pump grinder or a lapping
paste and valve itself.
Valve guide
length, mm
7
7
+ 0.015
- 0
+ 0.020
+ 0.005
(Inlet)
(Exhaust)
39.5 (Inlet)
46 (Exhaust)
groove into valve seat insert and then pull it out with a
suitable puller. In order to avoid damaging machined
cylinder head mating surface with crank case, place
any soft protective sheet metal under supports of puller.
Measure valve seat insert bore in cylinder head.
Smear valve seat with carbon blue. Install valve in guide

and turn it slowly under axial pressure.
CONTACT LINE ON VALVE SEAT MUST BE
AROUND ENTIRE CIRCUMFERENCE AT EQUAL
WIDTH
Distance between narrow diameter of valve face to
contact line should be minimum 0.5 mm
Check for leakages through valve seat by pouring
gasoline on valve head. Gasoline must not seep past
valve seat.
VALVE SEAT INSERTS :

For removing valve seat inserts from cylinder head use
a suitable boring machine. Bore old insert thin (about
0.5 mm thickness) and then pry it out.
Alternatively use a suitable turning tool to cut an annular
Fig. 96
79
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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 16 angle from vertical,Refer Fig.90. All
specified dimensions should be strictly maintained to
ensure proper interference of valve seat insert in its
bore.
Clean the valve seat insert and its bore in cylinder
head thoroughly.
Just before installation :
Place valve seat insert in a mixture of Methanol

and dry ice for about 20-30 minutes to bring
its temperature down to -150 deg. C.
Heat cylinder head to approximately 80 deg. C
in water bath.
Install valve seat insert in cylinder head bore quickly

by using mallet.
Carry out visual inspection of cam shaft for :
Deep scoring marks on journals and cam lobes

Cracks, which should be checked on a magnetic
crack detector.
Check hardness of cam shaft journals and cam lobes.

It should be 40 HRC min.
Machine valve seat in cylinder head.

CAM SHAFT INSPECTION
Fig. 97
SULIN
Overall heating of journals, which is indicated

by bluish/brown colour
Check cam shaft runout at 2nd, 3rd & 4th journal by

supporting it on V-block at 1st and 5th journal.
Fig. 97
Check cam shaft journal dimensions.
Cam shaft journal & bearing bore dimensions (mm) :

Journal No.
Cam shaft bearing journal

bore diameter in cylinder head
1
2
3
4
5
42.000 - 42.025
41.500 - 41.525
41.000 - 41.025
40.500 - 40.525
40.000 - 40.025
41.925 - 41.950
41.425 - 41.450
40.925 - 40.950
40.425 - 40.450
39.925 - 39.950
Maximum permissible run out of cam shaft bearing journal

Maximum permissible axial play of cam shaft in installed condition
Runout of oil seal mating diameter.
Valve seat insert :
Valve seat insert thickness
Inlet
Exhaust
- 7.1 + 0.05 mm
- 7.34 + 0.05 mm
Cam shaft bearing

journal diameter.
0.025 mm
0.1/0.25 mm
0.02 mm
Valve seat inside dia in insert

Inlet
- 32.5 + 0.1mm
Exhaust
- 25.7 + 0.1mm
80
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

Valve seat insert & bore dia. in cyl. head
Stage
Valve seat insert bore

diameter in cyl. head (mm)
Valve seat insert

out side diameter (mm)
Normal
Normal 1
38 / 38.03
38.23 / 38.28
38.13 / 38.155
38.43 / 38.455
EXHAUST
- Normal
- Normal 1
32.99 / 33.021
33.29 / 33.321
33.13 / 33.155
33.43 / 33.455
INLET
-
Cylinder head cover:

Remove the baffle plate in the cylinder head cover by
removing the screws Fig. 98.
Check the baffle plate gasket if it is torn/damage,
replace if necessary otherwise it might result in high
engine oil consumption.
SULIN
Fig. 98
Assembly of cylinder head :

Install valves in their respective positions
Install spring seat, valve springs and valve retainers.
Fit support rail (2702 5890 0616) on cylinder head
Fig. 99.
Fig. 99
81
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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
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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
1
10
2
6
3
2
4
3
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 :
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
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.
locked timing position.
Fig. 105
83
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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
torque of 1 mkg Fig. 107.
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
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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
Fig. 111
85
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
Inlet manifold with throttle body and gasket.

Fig. 112
Spacer tube on cylinder head cover mtg. studs.
Cylinder head cover along with camshaft gear

rear cover. Replace the gasket if required.
Timing belt gear cover Fig. 113.
Thermostat cartridge
Thermostat cover with gasket
Bypass line
Dip stick clamp screw
Vacuum pipe canister purge valve to intake

manifold.
Hoses from intake manifold to cylinder head cover

and brake booster.
Bracket supporting fuel lines.
Spark plug leads.
Fig. 112
Fill recommended quantity of oil.
SULIN
Fig. 113
CYLINDER BLOCK
(Cylinder head assembly removed)
Disassembly
Uniformly and evenly unscrew clutch pressure plate
mounting screws and remove clutch pressure plate
and clutch disc Fig. 114.
Fig. 114
86
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

Remove :
Vibration damper Fig. 115.
Fig. 115
Crankshaft gear Fig. 116.

Water pump
Timing belt tensioner
Timing belt rear cover
SULIN
Fig. 116
Oil filter by using spanner (2702 5890 1802)

Fig. 117
Engine mtg. bkt. (intermediate)
Fig. 117
87
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
Oil sump by extended socket (2702 5890 0603)

Fig. 118
Fig. 118
Oil pump strainer Fig. 119

Oil pump
Carefully remove combustion residues towards top end

of cylinder bores, preferably by a broken piston ring or
by a ridge cutter.
SULIN
Turn the crank shaft and bring a pair of piston to BDC
Fig. 119
Unscrew connecting rod bearing cap mounting nuts
Fig. 120
Fig. 120
88
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

Remove connecting rod bearing caps with bearing
shells.
Push these piston assemblies out of cylinders using
the wooden handle of the mallet.
Remove connecting rod bearing shells and duly mark
them with paint on their backs in case these are to be
reused.
IT IS ESSENTIAL TO ASSEMBLE CONNECTING
ROD BEARING CAPS TO THEIR RESPECTIVE
CONNECTING RODS
Verify serial numbers on connecting rod bearing caps
and connecting rods.
Remove remaining pistons in same manner
Remove piston pin spring clips with suitable plier.
Fig. 121
Fig. 121
Remove piston pins from piston by pushing them out

using soft drift. Fig. 122
Remove connecting rod
KEEP PISTONS AND PISTONS PIN IN

SETS.
SULIN
Fig. 122
Insert flywheel locking pin. Fig. 123
Fig. 123
89
MAIN INDEX
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ENGINE 475 SI MPFI

Unscrew flywheel mounting screws Fig. 124
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
75.00/75.01
74.96
75.01/75.02
74.97
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
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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.
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

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.
141.650.03
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
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

big end parent bore and cylindricity
Pre-tension of connecting rod big end bearing shells

Maximum permissible difference in weight of
connecting rods in one engine
Connecting rod big end axial play
93
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

NOTE :
Ensure that the identification numbers for connecting
rod & connecting rod bearing cap are matched &
notches for bearing shells are on same side.
Check twist and bend of connecting rod by using new
piston pin in connecting rod small end bush.
Measure twist and bend of connecting rod with feeler
gauge with respect to vertical face of connecting rod
alignment gauge in vertical and horizontal plane at a
distance of 50 mm from the line joining centres of
connecting rod small end and big end bosses.
Fig. 133 & 134
If necessary, straighten the connecting rod in cold
condition. Since a slight clearance exists between
connecting rod bolts and corresponding connecting
rod bearing cap holes, it is possible that connecting
rod bearing cap once removed may be installed off
centre, by which dimension of connecting rod big end
parent bore will be different in different directions.
Fig. 133
If difference is noticed in connecting rod big end parent

bore dimension, connecting rod bearing cap can be
centralised by lightly tapping it with mallet in required
direction after slightly loosening connecting rod bearing
cap mounting nuts.
SULIN
Check connecting rod big end parent bore dimension.

Fig. 135
If connecting rod big end parent bore is slightly more
than maximum permissible limits, it is possible to
reclaim connecting rod provided the wear is confined
only to connecting rod bearing cap.
Connecting rod bearing cap mating surface may be
slightly faced. Parent bore should then be finished on
a connecting rod boring machine.
Fig. 134
ENSURE THAT CONNECTING ROD BIG END AND

SMALL END AXES ARE PARALLEL TO EACH
OTHER WITHIN SPECIFIED LIMITS. CENTRE TO
CENTRE DISTANCE BETWEEN CONNECTING ROD
SMALL END AND BIG END IS MAINTAINED WITHIN
SPECIFIED LIMITS.
If one or more connecting rods are to be replaced,
ensure that difference in weight of connecting rod in
an engine is within permissible limits.
Install new pair of connecting rod bearing shell
according to size of crank pin journal diameter, making
sure that securing lugs of bearing shells are properly
seated in grooves of connecting rod and its bearing
cap.
Fig. 135
94
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

Install connecting rod bearing cap with bearing shell
on connecting rod.
Tighten connecting rod bearing cap mtg. nuts to
specified torque Fig. 136
Fig. 136
Measure connecting rod bearing bore Fig. 137
IF CONNECTING ROD BIG END PARENT BORE
DIMENSION IS MAINTAINED WITHIN SPECIFIED
LIMITS. PROPER BEARING BORE DIMENSION IS
AUTOMATICALLY ACHIEVED.
SULIN
However, it must be physically measured and confirmed

. Measure pre-tension of connecting rod bearing shell
with a feeler gauge after loosening connecting rod
bearing cap mounting nut on opposite side of bearing
shell lug.
CONNECTING ROD BEARING SHELLS ARE
PRECISION FINISHED AND SHOULD NOT BE
BORED OR SCRAPED.
Fig. 137
95
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

Crank shaft (dimensions)
Stage
Crank case main bearing bore

diameter with bearing shell mm
Crank shaft main bearing journal

diameter mm
Normal
50.026 / 50.065
50.0/49.98
Normal 1
49.926/ 49.965
49.900/ 49.880
Repair 1
49.786 / 49.815
49.760/ 49.730
Repair 2
49.526 / 49.565
49.500/ 49.480
Stage
Connecting rod big end bore

diameter with bearing shell (mm)
Crank pin journal diameter mm
Normal
45.007 / 45.043
44.995/44.980
Normal 1
44.907 / 44.943
44.895/ 44.880
Repair 1
44.757 / 44.793
44.745 / 44.730
Repair 2
44.507 / 44.543
44.495 / 44.480
Stage
Width of 4th main bearing

journal (mm)
Thickness of 4th main

bearing thrust washers, mm
Normal
24.052 / 24.000
2.62(2.60-2.65)
Standard 1
24.152 / 24.100
2.57(2.55-2.60)
Repair 1
24.252 / 24.200
2.52(2.50-2.55)
End play of crank shaft
SULIN
0.06 - 0.226 mm
Fillet radius of main bearing journals
2.5-0.5 mm
Fillet radius of crank pin journals
2.5-0.5 mm
Pre-tension of main bearing shells 0.018-0.040 mm

Hardness of crank shaft main
bearing and crank pin journals
50-60 HRC
Width of 1st, 2nd, 3rd and 5th

main bearing journals
24.0+0.2 mm
Main bearing parent bore dia in

crank case
Width of crank pin journals
24.0+0.2 mm
Maximum permissible taper of

main bearing parent bore
0.005 mm
Maximum permissible ovality of

main bearing parent bore.
0.005 mm
Maximum permissible cylindricity
0.0025 mm
Ovality of main brg. journal
0.005 mm
Max. permissible ovality of crank pin
0.005 mm
Maximum permissible run out of

2nd, 3rd and 4th main bearing journals
when supported at 1st and 5th main
bearing journals
0.02 mm
Maximum permissible out of parallelism

between crank pin and main
bearing journal axis
0.010 mm
Crank shaft journal to main

bearing clearence
53.8 +0.019 mm
+ 0.00 mm
0.026 / 0.085 mm
96
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

CRANK SHAFT :
Clean and carry out visual inspection of crankshaft for
the following
Overheating of journals, which is indicated by

bluish brown colour.
Scoring marks on journals.
Cranks, which should be checked on magnetic

crack detector.
Check crank shaft run out by supporting it on V-block

at 1st and 5th main bearing journals. Fig. 138
If run out exceeds permissible limits, straighten crank
shaft in cold condition on press carefully.
Similarly check lateral and radial run outs of flywheel
mounting flange.
Check crank shaft main bearing and crank pin journal
dimension.
Fig. 138
If necessary, grind crank shaft main bearing and crank

pin journals to next under size.
MAINTAIN CORRECT FILLET RADII FOR JOURNALS
Care must be taken during grinding to ensure that width
of journals is not increased.
SULIN
Should it be necessary to grind sides of 4th main

bearing journal, grind it to next over size.
Re-chamfer oil holes on journals to avoid scoring of

new bearing shells.
Finish journals by lapping them with 320 grit lapping
cloth of suitable width.
After grinding recheck main bearing and crank pin
journal dimensions.
Also recheck run out of crank shaft.
Fig. 139
Thoroughly clean crank shaft with kerosene. Use wire

brush for cleaning oil holes.
IT IS ESSENTIAL TO RECHECK CRANK SHAFT FOR
CRACKS AND BALANCE AFTER GRINDING
Apply grease to all machined surfaces, if crank shaft
is to be stored. Crank shaft must always be stored in
vertical position.
CYLINDER BLOCK
Check cylinder block for cracks by pressure testing
method.
Check crank case mating surface with cylinder head
for unevenness with help of straight edge and feeler
gauge. Fig. 139 & 140
Fig. 140
97
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

If necessary grind this surface just to clear unevenness.
Ensure that the minimum height of crank case is not
less than the specified minimum height.
Thoroughly clean the main bearing caps and
corresponding machined surfaces of crank case.
Install main bearing caps without bearing shells in their
respective positions of crank case.
ENSURE THAT THE SERIAL NUMBERS ON CRANK
CASE AND MAIN BEARING CAPS ARE MATCHING.
ALSO CAPS ARE IN SERIAL ORDER AND NOTCHES
FOR BEARING SHELLS ARE ON SAME SIDE.
Tighten main bearing cap mounting bolts to specified
torque. Fig. 141
Fig. 141
Check crank case main bearing parent bore
dimensions. Fig. 142 Install new pairs of main bearing
shells according to size of crank shaft main bearing
journal diameter, making sure that securing lugs of
bearing shells are properly seated in grooves of crank
case and main bearing caps.
SULIN
Fig. 142
Install main bearing caps with bearing shells in their
respective position on crank case.
Tighten main bearing cap mounting bolts in specified
sequence to specified torque. Fig. 143
Fig. 143
98
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

Measure the main bearing bore.
BOLT TIGHTENED
BOLT LOOSENED
IF MAIN BEARING PARENT BORE DIMENSION IS

MAINTAINED WITHIN SPECIFIED LIMITS, PROPER
MAIN BEARING BORE DIMENSION IS
AUTOMATICALLY ACHIEVED.
However, it must be physically measured and
confirmed.
Measure pre tension of main bearing shell with a feeler
gauge after loosening main bearing cap mounting bolt
on opposite side of bearing shell lug (This is to be
done on a flat surface plate as it can not be measured
on engine cylinder block because the main bearing
caps are guided) Fig. 144
MAIN BEARING SHELLS ARE PRECISION FINISHED
AND SHOULD NOT BE BORED OR SCRAPED.
PRETENSION
GAP
SURFACE PLATE
Schematic Sketch :
Main bearing shell pretension

checking
Fig. 144
Select a new pair of thrust washer according to crank

shaft 4th main journal width.
Cylinder bores
Clean cylinder bores thoroughly
Check cylinder bore dimension, taper and ovality.
Fig. 145
SULIN
If taper and ovality is found to exceed specified limit or

bore is excessively worn out machine cylinder bore
as given below to fit the liners.
Record the readings in Engine inspection sheet no. 2
given in this manual.
Rebore all the cylinders to 78+0.02 mm size and fit
the liners as per the procedure given in 475 IDI Engine
section.
Fig. 145
Cylinder Block (Dimensions) - in mm
C
Height of crank case

(Dimension A&B) Fig. 146
265.8/265.6
Maximum permissible unevenness

of crank case mating surface with cylinder
head 150x150 : cross wise D Fig. 146
0.015
: length wise C Fig. 146
0.030
Maximum permissible out of

parallelism between crank case top and
bottom machined surface
0.2
B
A
Fig. 146
99
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI
SULIN
OIL PATH
RETURN OIL PATH
Fig. 147a
100
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

ENGINE LUBRICATION COMPONENTS
MAIN OIL
GALLERY
OIL FILTER
OIL PUMP
GASKET
SULIN
OIL SUMP
STRAINER
DRAIN PLUG
Fig. 147b
Maximum permissible shift in
perpendicularity of cylinder bore
from crank shaft axis when
checked from crank shaft centre line
Maximum permissible taper and
ovality of cylinder bore
0.25 mm
replace the oil pump assembly.

Fit oil pump assembly with new gasket.
Flow rate measured against back pressure of 3kg/
cm2 should be as follows using SAE-30 oil.
0.007
Pump rpm
Minimum flow rate in Ipm
4000
28
2000
14
800
5.6
LUBRICATION SYSTEM :Fig. 147a &

147b.
OIL PUMP
Unscrew screws holding oil pump to cyl. block and
remove the oil pump assembly Check oil pump for
flow rate at specified rpm. Check for any leakage at
sealing plugs.
Check functioning of Pressure relief valve. If the
performance of the pump is not satisfactory, then
Engine oil pressure with coolant temperature of 700 C

at idling speed
800+50 rpm - 1 bar
at 5000 rpm - 3 bar
Oil Pressure Switch
NC contact opening pressure : 0.9 /0.6 bar
101
MAIN INDEX
GROUP INDEX
RADIATOR VENT HOSE

AUXILARY WATER TANK
RADIATOR
RADIATOR FAN
SULIN
MAIN INDEX
INTEGRAL WATER HOSE
GROUP INDEX
Flow of coolant
UPPER COOLING LINE

THERMOSTAT HOUSING
BYPASS LINE
HEAD VENT LINE
CAB HEATER FEEDING HOSE
ENGINE 475 SI MPFI
Fig. 148
102
COOLING CIRCUIT
ENGINE 475 SI MPFI

COOLING SYSTEM : Fig.148
THERMOSTAT CLOSED
WATER PUMP
TO
RADIATOR
Check water pump for free rotation. Check water pump for
flow rate at specified rpm. Check for coolant leakage
through leakage hole. It indicates that the seal is damaged
and leaking. Replace the water pump if necessary.
Water pump characteristics :
ENGINE RPM PUMPRPM FLOW RATE AT BACK
PRESSURE=0.3 BAR
(LITRES PER MINUTE)
2000
2100
40
3000
3150
60
4000
4200
80
5000
5250
100
5500
5775
110
TO
ENGINE
Fig. 149
THERMOSTAT OPEN
TO
RADIATOR
Thermostat
Start opening temperature : 82 0C 2
Full open temperature : 96 0C Max.
Leakage through main valve (including seepage

hole) at room temperature and pressure of 1 kg/
cm2 : 150-250 ltrs/hr
Maximum leakage through by pass at full open

temperature or main flow rate of 130 + 5 lpm :
1.5 lpm
SULIN
Thermostat is installed in cooling system between cyl.

head & radiator inlet tank.
The working principle of thermostat :
TO
ENGINE
Fig. 150
3.
1.
For cold engine (immediately after starting) :

Thermostat does not allow coolant to flow to
radiator (Thermostat valve in closed position)
instead coolant flows through thermostat by-pass
outlet to engine. Thus short circuiting of radiator
which helps for attaining engine working
temperature in very short period. Fig. 149
2.
As soon as the coolant temperature reaches

opening temperature of thermostat, the
thermostat valve starts opening gradually and
water flow starts to radiator. At the same time
thermostat by pass starts closing gradually.
As the engine cooling temperature reaches

thermostat full open temperature, thermostat valve
opens fully and thermostat by-pass valve closes
completely. Under such condition maximum
quantity of engine coolant flows to radiator
Fig. 150.
103
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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
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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 the connecting rod bearing cap with shell.
Fig. 156
105
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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
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GROUP INDEX
ENGINE 475 SI MPFI

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
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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
7
5
10
9
4
3
11
1
LHD :
12
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)
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
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ENGINE 475 SI MPFI

TROUBLE SHOOTING
NOTE : BEFORE CHANGING ANY SENSOR PLEASE CHECK THE FUSES,RELAYS & WIRING HARNESS CAREFULLY.

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
Overhaul & replace affected parts
Faulty immobiliser
Check and rectify
Clogged air filter

Faulty spark plugs
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
Faulty fuel regulator
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

vacuum connections
Vehicle speed signal faulty
ISC valve faulty
regulator connections
Faulty firing order/
injector(connection) order
Faulty MAP signal
Faulty ISC Valve
Check and rectify

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

no.
5. Maximum RPM low
Probable Cause
Action to be taken
Battery voltage low

Clean as per instruction
set valve timing /check & reset
Clean and check gap/replace if
necessary
Check and rectify the gap 1.5 + 0.5 mm
Check and Replace
Check and Replace
Replace
Clogged air filter

Adulterated fuel
Clogged injectors
Fuel pump faulty
Clogged fuel filter
injector (connection) order
6.
Poor
acceleration/Power
Low battery voltage
Clogged air filter

vacuum connections
Faulty ISC valve
Clogged injectors
Clogged fuel filter
Faulty ignition coil
(connection) order
Incorrect tappet clearances
vacuum connections
SULIN
Adultrated fuel
Clogged injectors
Fuel pump faulty
Clogged fuel filter
Check and rectify

Check and rectify
Check & replace
Check & replace
Check and replace
Replace
Check and replace
Check and replace
Check and reset
Check and rectify
Overhaul /replace affected parts
necessary
Check and Replace
Check and Replace
Check and Replace
Replace
Check and rectify
117
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

no.
Probable Cause
Action to be taken
7.

Adultrated fuel
Clean and check gap/replace if necessary


vacuum connections
Check and Replace

Check and rectify
Check and reset
necessary
Check and rectify the gap
Check and Replace
8.
Knocking
Misfiring
Adultrated fuel
Clogged injectors
9.
Whitish/Bluish smoke

Check and Replace
Low battery voltage

Check and rectify
Check and reset
necessary
Check and Replace
Check and Replace
Check and Replace

vacuum connections
Adultrated fuel
Faulty lambada signal
Clogged injectors
(connection) order
11. High oil consumption
Check and Rectify
Clogged air filter

Worn out pistonirings/seized pistons
Adultetated fuel
SULIN
10. High fuel

consumption
Check and tighten/replace

Check and adjust.
Clogged Air Filter

Worn out piston rings/siezed pistons
Check and tighten/replacet

Check and rectify
Clean/replace
Check and Replace
118
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

ENGINE INSPECTION SHEET
CYLINDER BLOCK AND PISTONS
Engine No.
Chassis No.
Kilometres
Kilometres since last overhaul
50--6
Reason for dismantling
COMPRESSION READING
Cyl.
Pressure
Kg/cm2
CYLINDER BORE
Dial gauge set at .....mm.
A = Non thrust side B = Thrust side
Cyl. No.
Pistons
Piston size (Stamped)..... mm
Ovality
aa
3
Ovality
Ovality
Ovality
SULIN
bb
cc
dd
dd
ee
ff
Taper
Max. taper .....mm
Max. ovality .....mm
Rebore to size .....mm
Piston Rings
Piston
Ring
No.
PISTON RING BUTT CLEARANCE (mm)
PISTON RING LATERAL CLEARANCE (mm)
PISTON NO.
PISTON NO.
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
1
2
3
Checked by
Date
119
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

CYLINDER BLOCK & PISTONS
Engine No.
Chassis No.
Kilometres
SHEET II
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
mm
mm
mm
OVALITY
mm
Measuring without bearing shells :

Measuring
Direction
Dial gauge set at ...mm

PARENT BORE NO.
1
A
mm
mm
mm
OVALITY
mm
Checked by
Date
120
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

CRANKSHAFT MAIN AND BIG END BEARING JOURNALS
Engine No.
Chassis No.
Kilometres
SHEET III
Run-out of crankshaft 4th main journal when

supported on journal Nos. 1 and 7
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
MAIN JOURNAL
mm
mm
BIG END JOURNAL
Taper
Ovality
MEASUREMENTS IN DIRECTION
JOURNAL
No.
aa
1
MAIN JOURNAL GAUGE SET AT .....mm

A
SULIN
C
Ovality
BIG END JOURNAL GAUGE SET AT .....mm
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
Date
121
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

CONNECTING ROD BEARING AND PARENT BORES
Engine No.
Chassis No.
Kilometres

MEASURING
BIG END BEARING BORE DIA. (WITH SHELLS INSTALLED) GAUGE SET AT.....mm
DIRECTION
mm
mm
mm
OVALITY
mm
WEIGHT GROUP
COLOUR MARKS
SHEET IV
SMALL END :
BIG END :
B
C
SULIN
CONNECTING ROD BIG END PARENT BORE
MEASURING
DIRECTION
mm
mm
mm
OVALITY
mm
GAUGE SET AT.....mm
CONNECTING ROD SMALL END PARENT BORE

1
A
mm
mm
OVALITY
mm
GAUGE SET AT.....mm
ALIGNMENT
1
TWIST
BEND
Checked by
Date
122
MAIN INDEX
GROUP INDEX
ENGINE 475 SI MPFI

CAMSHAFT JOURNAL AND BEARING BORE
Engine No.
Chassis No.
Kilometres
SHEET V
CAMSHAFT JOURNAL
Journal
NO. 1
CAMSHAFT JOURNAL
Measuring Direction
No.
Dia
A(mm)
Dia
B(mm)
Ovality
(mm)
Remarks
aa
1
bb
aa
2
bb
MEASURING
DIRECTION
aa
3
bb
SULIN
aa
4
bb
Run-out of intermediate
journals when supported
on journal Nos. 1 & 4
2
Camshaft re-ground
to repair size
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
3
4
123
MAIN INDEX
GROUP INDEX

TATA Indica Manual de Taller

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TATA Indica Manual de Taller

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Available Formats

ENGINE 475 SI MPFI

Tata Indica (Petrol) is available in 4 versions namely LEi,

475 MPFI engine is fitted with 16 Bit inbuilt microprocessor

ENGINE 475 SI MPFI

List of special tools

Carburetted engine vs MPFI engine

MPFI engine advantages

MPFI schematic circuit diagram

Features of MPFI engine

MPFI sensors / actuators

Intank fuel pump

Ignition Coil Assembly

Trouble shooting of MPFI sensors

ECU Handling & care

Preliminary inspection of engine

Removal & installation of engine from the car

Radiator, removal and installation

Timing belt Removal / Fitment

Cylinder Head Sub-assembly

Cylinder block sub assembly

Air intake system

Assembly Foot Control

Evaporative Emission Circuit

For 85 PS : 41, 51, 56 & 61

ENGINE 475 SI MPFI

TATA 475 SI MPFI

Water cooled Multi Point Fuel Injection Petrol Engine

(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

Grouped Ignition supported by Hitachi EMS

Engine oil capacity

Cooling system capacity

Dry (paper) type

Spin on full flow paper type

Max. engine output

ENGINE 475 SI MPFI

Box spanner (16 A/ F) for spark plug

Extended socket (10mmA/ F) for oil sump mounting screw

Camshaft Locking Pin

Flyw heel locking pin

Lock plate for camshaft gear washer

Drift for crankshaft oil seal in rear cover

Drift for removal / fitment of valve guide

Spacer for valve guide fitment

Drift for fitment of oil seal on valve guide

Valve spring com pressor

Drift for valve guide seal fitment

Drift for oil pump oil seal

Spanner for oil filter

Bracket (LH) for mounting engine on stand

Bracket (RH) for mounting engine on stand

Engine repair stand

Drift for fitment of camshaft oil seal

Engine support stand

Hitachi HDM 2000 diagnostic monitor w ith accessories

ENGINE 475 SI MPFI

Main Bearing Cap bolt M10 x 1

Cylinder head bolts M10 x 1.1