PDFsamTMPbufferHYICN1 SULIN

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
SULIN
SULIN 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.
475 MPFI engine is fitted with 16 Bit inbuilt microprocessor
intelligence into the engine control system.
475 MPFI engine provides better engine performance,
better cold starting and warm up, better fuel economy,
quick response and confirms the EURO II emission norms.
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MAIN INDEX GROUP INDEX
ENGINE 475 SI MPFI
CONTENTS
Sr. No. Description Page No. ENGINE
1. Technical specifications 1
2. List of special tools 2
3. Tightening torques 3
4. Carburetted engine vs MPFI engine 6
5. MPFI engine advantages 7
6. MPFI schematic circuit diagram 8
7. Features of MPFI engine 9
8. MPFI sensors / actuators 12
9. Intank fuel pump 26
10. Ignition Coil Assembly 27
11. ECU 30
12. Trouble shooting of MPFI sensors 32
13. ECU Handling & care 36
14. Preliminary inspection of engine 37
15. Exploded Views 40
16. Removal & installation of engine from the car 58
17.
18.
Radiator, removal and installation
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Alternator/Power steering pump & A. C. compressor belts removal, inspection, & fitment
a. For 85 PS Engine
60
61
b. For 75 PS Engine 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 67
b. Assembly of cylinder head 82
c. Valve clearance adjustment 84
21. Cylinder block sub assembly
a. Disassembly, inspection & assembly of : Pistons & piston rings, Connecting rods, 87
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
28. Engine Testing 117
29. Evaporative Emission Circuit 118
30. Trouble Shooting 119
Note : This section is common for both 85 PS & 75 PS engines, but following pages are exclusive for respective engines:
l For 85 PS : 41, 51, 56 & 61 l For 75 PS : 42, 50, 57 & 63. Please also check page no. 65 for selection of camshaft.
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ENGINE 475 SI MPFI
TECHNICAL SPECIFICATION
ENGINE ENGINE
Model : TATA 475 SI MPFI
Type : Water cooled Multi Point Fuel Injection Petrol Engine
No. of cylinders : 4 inline
Bore / Stroke : 75 mm x 79.5 mm
Capacity : 1405 cc
Max. engine output

(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
Max. torque
(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 SULIN

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
1
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
10.
11.
Valve spring com pressor
Support rail
SULIN 2702 5890 06 15
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 2932 9900 60 54
and Telco cartridge 1.20
2
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 ENGINE
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 Description Torque in mkg.

No.
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 2.5
4. Cylinder head cover bolts M6 1.0 #
5. Oil sump Screw M6 x 1 0.6 to 0.7 #
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.
10. Timing belt cover M6 x 1

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Rear timing cover to head cover M6 x 1 1.0
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 4+60 0 #
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 4.5 #
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
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ENGINE 475 SI MPFI

No.
ENGINE
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 1.0 #
30. Assembly Strainer to oil pump M6 x 1 1.0
31. Assembly oil filter to cylinder crankcase M12 x 1.5 Ref. Note @#
32. Oil pressure switch on cylinder crankcase M20 x 1.5 3.0
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.
41. Engine mounting bracket to arm
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Engine mounting bracket to block M10 x 1.5 4.5
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
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.
4
ENGINE 475 SI MPFI
ENGINE 475 MPFI - EURO II
Cylinder Oil Filling

Cylinder Oil Filling
Head Cover Cap
Head Cover Cap
Inlet Inlet
Manifold Throttle
Manifold
Exhaust Body
Exhaust
Throttle Manifold
Manifold
Body
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Timing
Timing Cover
Cover
MAIN INDEX
AC
Compressor Cylinder Block
AC
Compressor Cylinder Block
Vibration Damper Vibration Damper Alternator

Alternator
GROUP INDEX
Power Steering Power Steering

Pump Pump
85 PS ENGINE 75 PS ENGINE
5
ENGINE
ENGINE 475 SI MPFI
CARBURETTED ENGINE V/s MPFI ENGINE Prim ary m ain jet

Typically a carburetted engine differs from petrol injected Slow
ENGINE engine in following aspects. air hole no. 1
l Fuel Metering
Prim ary
l Ignition System slow jet
l Cold Start
l Ch an g e in At m osp h eric Con d it ion Resp on se
(Alt it ude, Tem perat ure et c.) Bypass
p ort
Carburetted Engine : (Fig 1).
Prim ary m ain jet
l In this case fuel metering is done by carburettor i.e.
fuel quantity is controlled by fuel jet and air flow
Id le p ort
into the engine due to the vacuum available at the
venturi. Fuel quantity is a continuously variable Fig. 1 Carburettor system - illustration
function with respect to air flow.
2
l Ignition system consists of a Distributor driven by a 1. Fuel
camshaft. The Distributor timing is a continuously 2. Air 1
3.Throttle valve 5
variable function as engine speed and load changes.
4. Intake manifold
Due to Mechanical make/break system, the Ignition 5. Injector
energy is low (low dwell time) at high speeds. 6. Engine 3
Petrol Injected Engine :

l SULIN
In this case fuel delivery to the engine is through
one or more than one Injectors. (See illustration
4
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 6
cont inuously variab le funct ion b ut a d iscret e
SINGLE POINT FUEL INJECTION (THROTTLE BODY
function as ECU calculates optimum fuel quantity
INJECTION)
required for any speed and load condition of the
2
engine. The correction in fuel quantit y is almost
1. Fuel
instantaneous (less than one cycle time).
2. Air
3.Throttle valve 3
l Ignition system of Petrol Injection engine consists
4. Intake manifold 4
of Ignit ion Coil w it h built in Pow er Sw it ch and 5. Injectors
t he spark t im ing is cont rolled by ECU. Ignit ion 6. Engine
timing is varied discretely, depending upon the
1
engine sp eed and load. This syst em m aint ains
optimum Ignition energy levels for a good spark
5
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.
6
M U LTI POINT FUEL INJECTION
Fig. 2
6
ENGINE 475 SI MPFI
Manifold pressure
ENGINE
sensor
Throt t le
body
Cylinder head
cover
LTRS
arrangem ent
Blow
ISC Valve
by hose
Fuel Canist er
rail purge
valve
Cylind er
head Int ake
manifold
SULIN Ignit ion
coil
Fig. 3 Intake Manifold with throttle body
475 SI MPFI ENGINE ADVANTAGES speed is increased as a function of Water and Air
temperature inputs to the ECU.
475 MPFI engine uses HITACHI multipoint fuel injection
system. Seven sensors located at various points in the l Emission :
engine, sense important parameters of the engine The petrol injection engine has low emissions because
operation & send signals to a ECU located under the air fuel ratio is controlled to stoichiometric using
dashboard. Based on predetermined engine mapping, lambda sensor.Faster warm up from cold start ensures
the ECU precisely controls the fuel delivery injection early operation of catalytic converter in turn reducing
t im ing t o ensure op t im um fuel ut ilisat ion w it h the emission.
minimum emission.
l Fuel Economy :
MPFI engine provides the following advantages :
The petrol injection engine has a better fuel economy
l Better Engine Performance : because the engine is optimised at each operating
Optimum fuel quantity and Spark timing is calculated point,discretly.
by ECU for any operating condition. l Quick Response :
l Better Cold Starting and Warm up : Th e p et ro l in ject io n en g in e w ill h ave a b et t er
ECU identifies cranking condition and quick starting is driveability and better acceleration since the fuel
ensured by providing sufficient fuel quantity and delivery and spark t im ing are cont rolled by ECU,
optimum spark timing. For quicker warm up, idling which quickly responds to engine/ Driver demands.
7
ENGINE 475 SI MPFI
ENGINE
MPFI SCHEMATIC CIRCUIT DIAGRAM
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8
ENGINE 475 SI MPFI
FEATURES OF MPFI
FEATURE HOW ACHIEVED USER BENEFIT
CRANKING MODE : ENGINE
Variable Injected Quantity Injector pulse width starts Good Cold starting
with very high value and
drops as cranking rpm, Air & Water
t em perat ure increases.
Divided fine injection Further total pulse width is Low Emissions

pulse w idth method divided into fine pulse w idths
for efficient mixture formation
Fuel is cut if Throttle When throttle valve is Good startability in all

valve is opened opened more than 700 ECU conditions
cuts the fuel by reducing pulse (both hot & cold)
width to very low value
Ignition timing for ECU identifies cranking Good startability in all

starting is calculated m ode and calculates spark conditions (both hot &
timing depending upon water cold)
t em perat ure and engine speed.
A/ C Compressor is kept
‘OFF’
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ECU identifies cranking
mode and sw itches ‘OFF’
Good startability due to
reduced engine load
the A/ C relay.
Fuel pump is kept ‘ON’ If the engine is not started Safet y

during Cranking only or stalls due to absence of
NOT OTHERWISE rpm signal, Fuel pump is cut ‘OFF’.
Canister Purge Valve is ECU identifies cranking Good startability

kept ‘OFF’ m ode and sw itches ‘OFF’ CPV
IDLING MODE :
Idle speed is dependent on Based on inputs to ECU Bet t er Idle st abilit y
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 ISC Valve position (steps) Bet t er Idle st abilit y
the previous position is continuously memorised w henever Idle st at e
(Learned Function) and renewed in memory. changes.
9
ENGINE 475 SI MPFI
‘LIMP HOME’ Idle Speed When the following sensors Flexibility and user
ENGINE
are ‘No Good’, then idle convenience
speed assum es default value
for Throttle position sensor,
MAP Sensor,Vehicle speed
sensor, air temperature sensor,
water temperature sensor.
‘LIMP HOME’ ISC Valve When ISC Valve fails in User convenience
closed condition, open throttle
marginally to start the engine.
Engine Stall protection When engine rpm is as low Better Idle stability and
as 650 rpm, ECU cuts A/C user convenience
relay.
ACCELERATION MODE :
High Engine Speed Fuel is cut beyond 6500 rpm Engine safety
Control
High Vehicle Speed Fuel is cut beyond Vehicle Safety

Control 165 Kmph
Zero Vehicle Speed Fuel

cut
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Fuel is cut if ‘no load
acceleration’ is sustained
Better fuel economy
beyond certain time say,

180 sec.
Variable Acceleration Four levels of acceleration Better Fuel economy

Enrichm ent is det ect ed depending upon Bet t er Em issions
throttle position and vehicle Better Overt aking abilit y
speed and injected quantity
is varied.
Anti Surge Function Ignition timing is varied to Driving comfort

dampen sudden torque
variations.
High w at er t em perat ure ECU cuts A/ C relay when the Engine Safety
A/ C cut ‘OFF’ w at er t em pet ure increases
beyond 1100c.
A/ C compressor is kept A/ C relay is cut-off depending Better over taking ability

‘OFF’ during ‘rapid’ upon vehicle speed
accelerat ion and throttle position .
DECELERATION MODE :
Fuel Cut during ECU cuts the fuel depending upon Better fuel economy
deceleration throttle position and rate of
change of rpm.
10
ENGINE 475 SI MPFI
Anti-Surge Function Ignition timing is varied to Driving comfort ENGINE

dam pen sudden torque
variat ions.
STEADY STATE MODE :
Accurate Basic Map High resolution data on a Best compromise for

Data for efficient 16 x 16 matrix Driveabilit y and Fuel
Injection and Ignition econom y
cont rol
Closed Loop Air/ Fuel Lambda sensor input to Emission Compliance

ratio control ECU maintains
Stoichiometric Air/ Fuel
ratio
‘LIMP HOME’ mode ECU assumes default Safety and Comfort

When one or many values
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
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rect ificat ion.
Inertia Switch (Fig. 4). When the Vehicle collision Safety (Fire Protection)
occurs, inertia sw itch cuts
‘OFF’ fuel pump
Immobiliser (If fitted) Rem ot e operat ed Safety (Anti-theft device)
Immobiliser cuts supply to
Main Relay and Fuel Pump.
Fig. 4 Inertia switch under driver’s seat
11
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 Fig. 5 Crank angle sensor
signals t o ECU w hen p laced over rot at ing flyw heel
with 7 holes, located at different angular dispositions.
Fitment Data :
This sensor is mounted on the cylinder block over the
flyw heel (Fig. 5).
Sensor Gap = 1.5 + 0.5 mm
Stand Alone Diagnosis :
Use Mult im et er
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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-) Fig. 6 Crank angle sensor
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
W 0.75 EWH
CRANK ANGLE SENSOR 21 CRANK
FWH
(CR+) ANGLE
SENSOR
B 0.75 EWH [ MAKE HITACHI ]
CRANK ANGLE SENSOR 20
FWH
(CR-)
CRANK ANGLE SENSOR SHIELD 19 FWH
EWH
(CRS) W/Y AV 0.75
ECU
12
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 Fig. 7 Air temperature sensor
st ream .
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)
Stand Alone Diagnosis (See Illustration) :
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for both ATS & WTS
Use Mult im et er
Therm ist er resist ance
2.5 kW+ 0.25 k W @ 200 + 10C
0.84 k W+ 0.10 k W @ 500 + 10C W
Fig. 8 Water temperature sensor
Air temperature sensor :
ECU 18 TA
18 26
ECU 26 TAG
Measure the resistance across pins 18 & 26
EWH
Water temperature sensor : R/G 0.75 WATER

WATER TEMP. SENSOR 24 TEMP.
Sensor end Pin assignment SIGNAL (TW) FWH
SENSOR
[ MAKE HITACHI ]
ECU 24 TW BR/W 0.75
24 32 WATER TEMP. SENSOR 32
GND. (TWG) FWH EWH
ECU 32 TWG
Measure the resistance across pins 24 & 32 AIR TEMP SENSOR 18
W/P 0.75
AIR
FWH
SIGNAL (TA) TEMP.
System Diagnosis : SENSOR
BR/B 0.75 [ MAKE HITACHI ]
Use Hitachi Diagnostic Monitor AIR TEMP.SENSOR 26
FWH
GND. (TAG)
Check for ‘Air Tem p’ or ‘Wat er Tem p’ values d uring ECU

Idling.
13
ENGINE 475 SI MPFI
MANIFOLD AIR PRESSURE SENSOR (MAP)

(Fig. 9 & 10)
ENGINE Type :
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
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is fitted on Inlet manifold upstream side (Fig. 9)
Use Mult im et er
With ignition “ON”.
Supply volt » 5.12 vdc

~
~ Signal volt » 4.2 vdc @710 mmHg of Atm pr. (abs)
~
~ = 4.6 vdc @760 mmHg of Atm pr.(abs) Fig.10 Manifold air pressure sensor (Top view)
ECU 31 supply, VCC

ECU 22 signal, PM
31 22 112
ECU 112 ground, GNDS
M easu re sig n al vo lt at p in 22 & 112 w it h sen so r Electrical Circuit :

connected to w iring harness.
EWH
System Diagnosis : SENSOR POWER SUPPLY 31
W/Y AV 0.75
FWH EWH
(+5V)(VCC)
PRESSURE/MAP
Use Hitachi Diagnostic tester W/O 0.75 SENSOR
PRESSURE SENSOR 22
FWH EWH [ MAKE HITACHI ]
SIGNAL (PM)
Ch eck for ‘In t ake m an ifold p ressure’ value d urin g
BR/R 0.75
cranking. SENSOR GND. 112
(GNDS)
FWH EWH
0.75
ECU
To Throttle Position
Sensor
14
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
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Use Mult im et er
With ignition “ON”.
Supply volt » 5.12 vdc
Signal volt » 0.5 vdc at Idle position
= 4.5 + 0.15 vdc at WOT position
Sensor end Pin Assignment Fig. 12 Throttle Position Sensor (Side view)
ECU 31 Supply VCC
ECU 23 Signal THS
31 23 30
ECU 30 Ground THSG
Measure signal voltage across pin 23 & 30 with
sensor connected to w iring hamess.
System Diagnosis : Electrical Circuit :
Use Hitachi Diagnostic tester
From Pressure/Map
Check for ‘Throttle sensor’ voltage by pressing the Sensor
accelerator pedal in and out. THROTTLE

V/R 0.75 EWH POSITION
THROTTLE SENSOR 23
FWH SENSOR
SIGNAL (THS)
[ MAKE HITACHI ]
BR/G 0.75 EWH
THROTTLE SENSOR GND 30
FWH
ECU
15
ENGINE 475 SI MPFI
LAMBDA SENSOR (O2 Sensor) Fig. 13 & 14

Type :
ENGINE
LSH 24
Heated Ceram ic Oxygen Sensor
3 Pin Connector
Working princple (See Illustration) :
A special ceramic body with gas permeable platinum
electrodes on it s surface, operates, depending upon
ceramic material’s porosity which allows oxygen in the
air t o diffuse w hen t he ceram ic body is exposed t o
t em p erat u res ab o ve 350 0 C. Vo lt ag e is g en erat ed
across the electrodes w hich are exposed to gas w ith
different levels of oxygen contents.
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: = 0.95 840 + 70mv (rich)

= 1.05 20 + 50mv (lean)
Fitment Data :
Fitted on the exhaust pipe as shown in Fig. 13
Use Mult im et er
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Heater function
(Coil resistance : 4.2 Wat 300C)
A Heater (+)
A B 17
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.
Check for ‘Front O2 Sensor’ value at idling. LAMBDA SENSOR
(A +ve)
(200mv to 600mv continuously varying due to lambda (B -ve) GY/O
control function). 17 LAMBDA SENSOR(O2)
0.75
GND(ENGINE) 25 LAMBDA SENSOR SHIELD
ECU
16
ENGINE 475 SI MPFI
LAMBDA SENSOR :
l Lambda oxygen sensor located in exhaust pipe Fig.
5 7 6
15. 4 8 ENGINE
1. Special ceramic coat

2. Electordes
3. Cont act
4. Housing
5. Exhaust pipe 3
6. Ceramic Shield (porous)
7. Exhaust gas.
8. Air 1 2
Fig. 15 Lambda Sensor
l Lambda (oxygen) sensor voltage curve at 6000C

operating temperature Fig. 16
mV
a) Rich mixture (air deficiency) a b
b) Lean mixture (excess air) 1000
Oxygen-sensor voltage
800
SULIN 600
400
200
0
0.8 0.9 1 1.1 1.2
Excess-air factor
Fig.16 Lambda Sensor Voltage Curve
l Heated Lambda (oxygen) sensor Fig. 17

1. Probe housing
2. Ceramic Shield tube 1 2 3
3. Electrical connections
4. Shield tube with slits
5. Active ceramic sensor layer
6. Contact
7. Shield
8. Heating lement
9. Clamp connections for heater element
5 6 7 8 9
Fig. 17 Heated Lambda Sensor
17
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 Fig. 18 Instrument cluster (rear view)
per km .
Fitment Data :
This reed switch is integral part of instrument cluster
and is driven by Speedometer cable Fig. 18.
Use Mult im et er
Manually rotate the speedometer cable and check for
contact make & break pulses 4 times/ rev.
SULIN 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 PIN NO:1

VEHICLE SPEED PULSE 6
INST CLUST
(SPD) FWH
[ MAKE PRICOL/VDO ]
ECU
TO VEHICLE SPEED SENSOR
18
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 Fig. 20 Throttle Body showing Idle Speed control valve fitted
Idle Speed for various engine loads ISC Valve in inset
e.g. : A/ C idle speed = 800 rpm
Engine water temp dependent Speed, say at 300C =
1100 rpm.
0.75
0.75
Fitment Data : P1 P2
LG/B 0.75
This actuator is part of Integral Throttle Body which is fitted FWH
2 ISC S/M ØA (ISCA)
on inlet manifold upstream side. Fig. 20
G/R 0.75

Use Multimeter
Single Phase coil resistance = 49 W
SULIN M
R/L
FWH
0.75
FWH
3 ISC S/M ØA (ISCA)
9 ISC S/M ØB (ISCB)
W/V 0.75
Actuator end Pin assignment FWH
10 ISC S/M ØB (ISCB)
ECU 2 Coil A STEPPING MOTOR

ECU
2 P1 3 P1 Supply (+) TYPE ISC VALVE

ECU 3 Coil A’ [ MAKE HITACHI ]
9 P2 10
P2 Supply (+)
ECU 10 Coil B’
Measure coil resistance across pins = P1 & 2, P1 & 3, P2 & Fig. 21 Electric Circuit of ISC Valve
9, P2 & 10
System Diagnosis :
Use Hitachi Diagnostic tester Throttle Body
Check for ISC valve steps
For normal idling at hot condition
ISC valve steps = 20 + 3 steps.
AIR FLOW (L/min) Illustration of graph showing air
flow and step number on ISC valve.
600
500
400 Air Cleaner Air Outlet
Stepper
300 Motor
200
100 Air Inlet Throttle Plate Intake Manifold
0
0 20 40 60 80 100 120
Step Num ber Fig. 22 ISC valve illustration
19
ENGINE 475 SI MPFI
INTEGRAL THROTTLE BODY

Type :
ENGINE RTT 38
Æ 38 mm throttle valve, integrated with MAP sensor
Throttle position sensor & ISC valve
Air flow control valve.
Working Principle :
Air flow into the engine is varied by varying the cross
sect ion area. In addit ion, flow rat e is dependent on
engine speed.
This Integral Throttle Body is with a throttle valve
(See Illustration) in the air flow path (of ø 38 mm). The Fig. 23
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.
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
SULIN
flow into the engine by-passing the main air flow path.
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
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 Fig. 25 Location of purge valve
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.
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 Pin assignment
Fig. 26 Purge valve
P supply (+) main relay
P 11
ECU 11 CP
Measure the resistance across pin P & 11
CANISTER PURGE VALVE
Check for CPC solenoid ‘ON/ OFF’ condition by freely 0.75 Y/L
11 CANISTER PURGE
accelerating the engine from idle to 4000 rpm. EWH EWH FWH (CP)
[ MAKE HITACHI ]
ECU
21
ENGINE 475 SI MPFI
CANISTER PURGE VALVE - ILLUSTRATION :

ENGINE 1. HOSE CONNECTION
1
2. NON RETURN VALVE
3. LEAF SPRING 2
4. SEALING ELEMENT
3
5. SOLENOID ARMATURE
4
6. SEALING SEAT
5
7. SOLENOID COIL.
Fig. 27 SULIN
3.5
3.0
2.5
0.2
FLOW IN M 3 / H
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
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
Inject ors
ball type seating valve acts as a good anti-deposit.
ECU provides drive signal to Injector (normally closed Fig. 29 Fuel Injectors location in the engine
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 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
SULIN
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.
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 Fig. 30 Fuel Injector
Stand Alone Diagnosis : System Diagnosis :

Use Hitachi Diagnostic tester.
Use multimeter
Check for ‘Fuel injection 01 pulse
Injector coil resistance 8.6 W Values during idling : 2.0 to 2.5 ms
Actuator end Pin assignment NOTE :
1 Pow er supply, m ain Pu lse w id t h w ill co n t in u o u sly vary t o m ain t ain
1 101 relay stoichiometric Air/Fuel ratio.
ECU 101 Injector 1 & 4 Electrical Circuit :
or ECU 102 Injector 2 & 3 L/G
1.0 R/B 1 CYL 0.75
101 INJECTOR (IJ1)
Measure the resistance across the pin P and ECU101 EWH
4 CYL
EWH
FWH
1CYL, 4CYL.
0.75
(or ECU 102). With ignition ON, measure the supply voltage 2 CYL 0.75
Y/G
102 INJECTOR (IJ2)
FWH
2CYL, 3CYL
w.r.t.engine ground at the wiring harness end by removing 3 CYL
EWH
0.75
ECU
all injector connectors. INJECTOR 8.6_ X 4
[ MAKE HITACHI ]
(+ ve)
23
ENGINE 475 SI MPFI
FUEL INJECTOR - ILLUSTRATION :

ENGINE
FUEL IN
FILTER
(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
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 Fig. 32 Fuel pressure regulator
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 :
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 VC PIPE AIR
lam b d a co n t ro l is in p ro g ress t o m ain t ain CHAMBER
stoichiometric Air / Fuel ratio.
DIAPHRAGM FUEL IN
VALVE
TO FUEL OUTLET PIPE

TANK
Fig. 34 Fuel pressure regulator illustration
25
ENGINE 475 SI MPFI
INTANK FUEL PUMP Fig. 35 & 36

Type :
ENGINE
F002 KIA 004, BOSCH / PENTADEWA
Intank - Electric Fuel Pump
2 Pin connector
Working Principle :
A p osit ive d isp lacem ent p um p assy. is d riven b y a
m ot or t o p rovid e con t in uous flow of fuel t o h ig h
pressure fuel system from fuel tank.
This Intank pump provides continuous flow of fuel to
fuel rail w here a variable fuel pressure is m aintained
by a fuel regulator as a function of varying manifold
vacuum .
Fig. 35
Fitment Data :
This Intank pump is fitted inside the fuel tank by immersing
the pump’s suction end in the fuel. Fig. 35
Use Multimeter
Motor armature resistance = 20W @200C
Actuator end (Pump)
1 2
Pin assignment
1 from relay
SULIN
2 car body
Measure the coil resistance across Pin 1&2

Actuator end (Relay) Pin assignment
P Supply (+)
P 108 Fig. 36 Intank Fuel Pump
ECU 108 FP
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
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.
Fig. 37 Ignition coil with built in power switch
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.
Fitment Data :
SULIN
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 Measure supply volt across pin P and G on wiring harness
with Ignition ON. Measure secondary coil resistance across
Firing ord er (1,3,4,2) & HT cab le connect ions (See High tension terminals of cyl. 1 & cyl. 4 (or cyl. 2 & cyl. 3).
Illustration)
System Diagnosis :
Secondary coil resistance = 13 k W
Check for ‘Ignition timing value’ during idling.
ECU 16 supply (use for cyl. 2&3)
G ground (engine)
15 G 16 P
ECU 15 signal (use for cyl. 1&4)
P Power supply
27
ENGINE 475 SI MPFI
ENGINE FROM IGNITION
H.T. CABLE
0.75
H.T. CABLE
H.T. CABLE
AV 0.75
[ MAKE ANU/DELTRONIX ] 15 IGNITION1(IG1)
EWH
H.T. CABLE 1CYL, 4CYL
SPARK
PLUGS H.T. CABLE 0.75
BODY EARTH AV 0.75
1 2 [MAKE MICO] 3 4 EWH

16 IGNITION2(IG2)
2CYL, 3CYL
ECU
IGNITION COIL
[ MAKE HITACHI ]
GND (ENGINE)
ENIGNE GND
SULIN
28
ENGINE 475 SI MPFI
IGNITION COIL ILLUSTRATION :
ENGINE
PRINCIPLE OF OPERATION OF IGNITION COIL
IGN RELAY VCC IGNITION COIL
91 W 91 W
1g. Key S. W.
CURRENT LIMIT CIRCUIT
POWER TRANSISTOR UNIT
ENG. CONTROL UNIT
Fig. 39 SULIN
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
ENGINE 475 SI MPFI
ENGINE CONTROL UNIT (ECU) Fig. 41 & 42

Type :
ENGINE 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 Fig. 41
functions for optimum functioning of the engine, which
in turn provides best fuel consumption/ Emissions.
Fitment Data :
ECU is fitted below the steering column in the driver
cabin. Fig. 41
Use Mult im et er.
Perform continuit y check only on ECU connection at
SULIN
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 Fig. 42 Electronic control unit
page no. 34)
30
ENGINE 475 SI MPFI
ENGINE CONTROL UNIT - ILLUSTRATION :

Block Diagram :
ENGINE
Input Control Unit Output
Crank angle sensor Injector * 4
Speed sensor CPU : H8 Ignition Coil * 1
Air temp.Sensor ISC solenoid

CPU
Throttle Position Signal
Fuel pump relay
Sensor ROM RAM
Condi- Buffer
Diagnosis Lamp
Water temp. sensor tioner A/D I/O
Battery Others
Oxygen Sensor
D/N Switch
A/C switch Voltage Watch dog

Regulator timer
Others
SULIN
* D/N Switch - applicable for AUTOTRANSMISSION only.
Fig. 43
SPECIFICATIONS :
Type : Intelligent Driver ICs :
H8 536
1. Idle Speed control
Data Line :
2. Diagnostic line
16 Bit
Diagnosis level :
Clock Speed :
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
ENGINE 475 SI MPFI
TROUBLE SHOOTING OF SENSORS USED IN

Display
Pow er
MPFI : Monitor
Screen Rub b er
Jacket
Lamp
ENGINE Method No. 1
Key
HITACHI DIAGNOSTIC MONITOR ( HDM 2000 ) should Pad Pow er
be loaded with the cartridge TATA Indica Version 1.2. Switch
Fig. 44
This is an user – friendly diagnostic kit, makes the Trouble
Shooting simpler.
This HDM 2000 can also be used as : Cart rid ge Wrist
Strap
1. A multimeter LED
Display
2. An Oscilloscope St rap
Hook
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.
SULIN
The power supply for it is taken from the battery of the
vehicle through the same cable. No need of separate
power supply.
During diagnosis this instrument provides data in graphical
form. Also allows measurement and recording of data for
analysis and efficient trouble shooting.
Stores‘No Good’ conditions of Sensors/Actuators as listed
in Read Memory Switch’s diagnostic mode.That is in E C
U’s memory. Fig. 45 Female socket below co-driver seat
The error codes are stored in two areas :
1. Current Error Codes – to diagnose exiting faults.
2. History of Error Codes – to diagnose previous stored
faults.
NOTE :
At the end of each diagnosis and rectification of the
fault,‘HISTO RY CODES’isto be erased by opting
‘CLEAR MEMORY’ option in the menu and check for
normal functioning of Engine/Vehicle
32
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 ENGINE
shows the main functions of the keys.These key functions

vary depending on the selected mode.
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
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) :
Fig. 48 Read memory switch mode white connector in
Read m em o ry sw it ch m o d e m et h o d (Blin k co d e
shorted condition.
method) is a manual diagnostic method used to check
the malfunctioning of the following parts.
DIAGNOSTIC TESTER
1. Water t em p erat ure sensor
2. Air t em perat ure sensor
3. Manifold air pressure sensor
READ TEST
4. Idle speed control valve MEMORY SWITCH
5. Throttle position sensor
6. Lam bada sensor
7. Vehicle speed sensor
WHITE BLACK
To check t hrough t his m ode, w e have t o short t he CONNECTOR CONNECTOR
terminals of the Read Memory Switch mode connector
which is situated below the co-driver’s seat as shown
in Fig. 48. Blink Code checks t he funct ioning of t he
Sensors/ Actuators as indicated in the Blink code table.
Fig. 49
34
ENGINE 475 SI MPFI
TROUBLE SHOOTING PROCEDURE : HITACHI DIAGNOSTIC MONITOR DATA :

1. Short the terminals of the connector using suitable TYPICAL DATA DURING NORMAL IDLING :
connector and OBSERVE the following : ENGINE
Value changes in accordance with the change in engine
2. Turn the ignition ‘ON’ temperature.
a. If the ‘CHECK ENGINE’ lamp on the dash board SR. NO. PARAMETER VALUE
blinks cyclically at every 0.5 secs, Then there is
‘NO TROUBLE’ with the engine sensors. 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 2. Vehicle Speed 0.0 kmph
correlated to a trouble code and corresponding 3. Engine Speed 750 rpm
sensor/ actuator is indicated to be fault y.
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 6. Throttle Position Sensor Volt 0.50 V
shorted condition. 7. Fuel Injection # 1 Pulse 2.30ms
Item 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
O2 Sensor
SULIN
41
42
13.
14.
A/F Correction # 1
CPC Valve Duty Ratio
-2.3 to -3.9%
0%
Vehicle Speed Sensor 43 15. Manifold Absolute Pressure 280/300 mm Hg
16. Intake Air Temperature 28o C
For Example :
17. Ignition Switch ON
If the “Check Engine” lamp gives 3 slow blinks (of 1.2 Secs
each) representing the first digit of the failcode viz.,”3" 18. Test Mode Signal OFF
followed by 1 fast blink (of 0.16 Secs each) representing
19. Read Memory Signal OFF
the second digit of the failcode viz.,”1" in a cyclic fashion,
thus flashing the code “3 1” indicating that the water Temp 20. Idle Switch ON
Sensor is faulty (from the table below).
21. A/C Switch OFF
If there are t wo or more sensors fault y, then the blink
22. A/C Relay OFF
codes are repeated cyclically. For example, if the water
temperature sensor and lambda sensor are faulty then 23. Fuel Pump Relay ON
t h e b lin kin g co d es w ill b e rep eat ed like
24. CPC Solenoid Valve OFF
..31… .42… .31… .42… .
25. Front O2 Rich Signal OFF/ON
N OTE:
26. Crank Shaft Position Signal ON
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
ENGINE 475 SI MPFI
ECU HANDLING CARE : l Do not try to repair the ECU.
Earth (Ground) Connection l Use standard harness for circuit connections.

ENGINE
l Connect GND - P, GND - I, GND - C each to the engine l Ensure that Do not try to insert any thing into the ECU
block. case.
l The above mentioned GND should be connected l The installation should be done in such a way as to
firmly using screws. keep the connector side down and the wiring done
accordingly (to avoid water penetration into the ECU
l Ensure that the ignition coil GND and ECU GND - C through the wiring).
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 l Take care to avoid any bending of the connector pins
d et ached from t he eng ine b lock, t hey are not while inserting the connector.
detached from each other. l Ensure that the connector is inserted in the end after
Power Supply all the installation is complete.
l The power for the ECU should be taken through the l To carry out welding job on the car the ECU should
Main Relay. Do not take out the connector from the be disconnected.
ECU for at least 5 sec after IGNITION OFF. Never take
out the connector from the ECU during IGNITION ON.
l Ensure that key SW is in OFF position while plugging
- in the connector to the ECU.
l Do not plug - in the connector again to the ECU for at
least 100 sec after disconnecting it.
Input
l
SULIN
Ensure that the Input signal line is as far as possible
from noise sources such as High Tension Cable,
Horn relay,Motor etc.
l Ensure that sealed wire are used for input line of O2
Sensor and Crank Angle Sensor, and the wiring is as
far as possible from the noise sources similar to the
ones above (Unsealed wire may be used for O2 sensor
if the noise level is small enough so as not to affect
the Air/Fuel control).
Output
l Take care to avoid dead - short (solenoid short - circuit
etc.) and similar circuit misconnection while checking
( to avoid any damage to the Output Power Transistor).
Use a solenoid which does not use a fly - back diode
(reverse polarity m ay dam age the Output Pow er
Transistor).
Installation
l Ensure that the ECU is secured firmly to the body
using screws.
l Ensure that there is no water seepage into the ECU.
l Do not use an ECU which has been dropped once.
36
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 OR ENGINE
of engine to ascertain whether an engine overhaul is
Drive the car with weight equal to GVW in 3rd gear
necessary and to w hat extent.
on level ground and let the speed drop down to
Most common reasons for which engine is overhauled approximately 15 kmph. Now press accelerator pedal
are : fully.With slipping clutch,the car speed will not pick
up and also clutch burning smell will be noticed. If
1. Loss of power
t his does not occur and car picks up speed, it
2. Excessive engine oil consumption indicates that clutch does not slip.
3. Extrem ely low engine oil pressure e. BRAKE BINDING
4. Mechanical failures During driving apply brake number of times and then
shift the gear to neutral position Check brake drums
To know exact reason and general condition of engine,
for over-heating and if necessary jack up the car and
proceed as follow s :
check the wheels for free rotation.
1. LOSS OF POWER f. CHECKING ENGINE COMPRESSION PRESSURE
Loss of engine power may be due to : If loss of power is not on account of defective fuel
a. Defective Ignition system 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
b. Defective Fuel system compression as follows :
c. Clogged air cleaner/ choked cat alyt ic convert er 1. Warm up engine preferably by road drive to get
d.
exhaust silencer
Clut ch slippage
SULIN 2.
a temperature of about 75 to 85 0C.
Remove all spark plugs.
e. Brake binding 3. Rem ove air cleaner filter elem ent.
f. Loss of engine compression 4. Install Compression gauge (Range about 0 to 25
a. IGNITION SYSTEM kg/ cm 2) into one of the spark plug hole.
Check all the sensors for proper function by Note :

using diagnostic m onitor. Replace defective Use adaptor w hich is available com m ercially to
sensors. suit the size of the spark plug threads.
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
ENGINE 475 SI MPFI
5. Disengage clutch (to reduce starting load on engine) 4. Take a clean vessel, place it below the drain plug of
and depress accelerator pedal all the way to make oil sump.
throttle valve open fully.
ENGINE
5. Drain the hot oil into the clean vessel. Drain it fully.
6. Crank engine with fully charged battery, and read
6. Screw in oil sump drain plug and tighten it.
the highest pressure on compression gauge.
7. Weigh the vessel along with oil let this weight be
7. Carry out steps 5 to 7 on each cylinder to obtain
‘w1’, gms.
co m p ressio n p ressu res. Th e sp ecif ied
compression pressure is 9.5 bar minimum. 8. Refill the weighed oil into the oil sump. Do not spill
any oil. The vessel used for draining should not be
8. Variation in compression pressure between cylinders
used for any other purposes.
should not be more than 0.5 bar.
9. Drive the vehicle approx. 200 - 300 km. This drive
9. Low compression pressure may be due to leakage
should include at least 30 - 40 kms. of highway
past valves / piston rings/blown cylinder head gasket.
or similar road, vehicle running at about 60 kmph.
To ascertain the point of leakage,spray small quantity
Let this drive distance be ‘D’ kms.
of clean engine oil in to the cylinder showing low
pressure and re-check compression pressure. If it 10. Immediately after the test drive, place the vehicle
im proves, w ear in pist on rings/ cylinder bore is at the same spot from where it started.
indicated. If it does not, leakage past the valves is
indicat ed. If com pression pressure of adjacent 11. Place the same previously used vessel below the
cylinder is also on lower side, it may be due to blown oil sum p, unscrew t he drain plug and drain off
cylinder head gasket. oil into the vessel. Drain the sump fully.
2. EXCESSIVE ENGINE OIL CONSUMPTION 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.
High engine oil consumption may also lead to overhauling
following points : SULIN

of the engine but before proceeding to overhauling, check 13. Find out standard oil consumption as -
Std. oil consumption

=
(w1 - w2)(wt. of oil consumed, gms) x 1000
1. Make sure that there is absolutely no external oil ‘C’ (litres/ 1000km) sp. wt. of oil (gm/ cm 3) x ‘D’ (drive dist. in km.)
leak (i. e. from the camshaft oil seal, crankshaft oil
w1 - w2
seal, oil sump gasket, oil pump gasket, cylinder head ‘C’ = litres/ 1000km
0.88 x D
cover gasket etc.)
3. EXCESSIVE LOW OIL PRESSURE EXTREMELY
2. If no external leakage is found, determine the exact
engine oil consumption, as per following procedure. 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.
Do not make a rough estimate of engine oil consumption by
noting the kilometerscovered by the car at any random stage c. Oil pressure transducer for proper functioning.
and finding oil consumed from the topped up position
d. Functioning of pressure relief valve on oil pump.
taking into consideration dipstick level and oil sump
capacity. e. Oil pump performance using a suitable pressure
gauge.
PROCEDURE :
Oil pressure found to be less than 2.8 bar at maximum
1. Once it is doubted that engine oil consumption is sp eed and 1.2 b ar at id ling sp eed , m ay b e d ue t o
higher, place the car on a level ground. im p rop er funct ioning of oil p um p or d efect ive oil
2. Top up oil sump to its capacity of 4 litres. pum p relief valve.
3. Warm up the engine so that oil temperature is 75 - If low oil pressure is not on account of above factors,
800 C. 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
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
ENGINE
40
ENGINE 475 SI MPFI

SR. NO. 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
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
SULIN
®
MAIN INDEX
5.5 #

GROUP INDEX
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 13-a BOLT (FOR CONNECTING ROD)
(FOR CLUTCH ON FLYWHEEL)
03 PULLEY CRANKSHAFT-ALT.DRIVE (4-GROOVES) 13-b NUT (FOR CONNECTING ROD)
10 HEX.BOLT (FOR FLYWHEEL)
04 PULLEY (4 GROOVE)(ON CRANKSHAFT FOR AC) 13-c SET BRG.HALF NORMAL (CON.ROD) (BIMETAL)
11 SET MAIN BEARING SHELLS NORMAL
05 HEX FL BOLT M8X38 14 PISTON SET WITH RINGS GRADE A (IP)
(BIMETAL)
06 HEX.BOLT (FOR CRANKSHAFT GEAR) 14-a PISTON SET WITHOUT RINGS GRADE A (IP)
12 SET THRUST WASHERS (BIMETAL)
07 WASHER (FOR CRANKSHAFT GEAR) 14-b SET PISTON RINGS ABC STD (IP)
41
ENGINE
ENGINE
42
ENGINE 475 SI MPFI

- Specified Torque in Kgm MOVING PARTS (For 75 PS engine)
# Allowed Tolerance of ±5%
SULIN
®
MAIN INDEX
5.5 #

GROUP INDEX
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 13-a BOLT (FOR CONNECTING ROD)
(FOR CLUTCH ON FLYWHEEL)
03 PULLEY CRANKSHAFT-ALT.DRIVE (4-GROOVES) 13-b NUT (FOR CONNECTING ROD)
10 HEX.BOLT (FOR FLYWHEEL)
04 PULLEY (4 GROOVE)(ON CRANKSHAFT FOR AC) 13-c SET BRG.HALF NORMAL (CON.ROD) (BIMETAL)
11 SET MAIN BEARING SHELLS NORMAL
05 HEX FL BOLT M8X38 14 PISTON SET WITH RINGS GRADE A (IP)
(BIMETAL)
06 HEX.BOLT (FOR CRANKSHAFT GEAR) 14-a PISTON SET WITHOUT RINGS GRADE A (IP)
12 SET THRUST WASHERS (BIMETAL)
07 WASHER (FOR CRANKSHAFT GEAR) 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
1 TIMING BELT
2 OIL SEAL (CAMSHAFT-FRONT)
3 TIMING GEAR (CAMSHAFT)
4 WASHER (FOR CAMSHAFT GEAR)
5 HEX BOLT (CAMSHAFT GEAR MTG.)
6 ASSY.TENSIONER (TIMING BELT)
SULIN
7 SPACER(TIMING BELT TENSIONER)
8 HEX FL BOLT M10X65
9 ASSY.IDLER (FOR TIMING BELT)

MAIN INDEX
10 SPACER
12 CAM SHAFT * 1.0
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

GROUP INDEX
19 SCREW-ROCKER SHAFT HOLDER.
20 CAM THRUST PLATE (FRONT)
21 CAP SCREW M6X20

4.5

- Specified Torque in Kgm
43
ENGINE
ENGINE
44
ENGINE 475 SI MPFI

FUEL INJECTION EQUIPMENT (same for 85 PS & 75 PS engines)
SULIN
MAIN INDEX

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
07 CANISTER PURGE VALVE
08 RUBBER SLEEVE (CANISTER PURGE VALVE)
GROUP INDEX
09 CLAMP - CANISTER PURGE VALVE

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 - Specified Torque in Kgm
ENGINE 475 SI MPFI
CYLINDER BLOCK ASSY. (same for 85 PS & 75 PS engines)
# Allowed Tolerance of ±5% 1.0 #

® 3.5
®
5.5 # ®
1.0
®
2.0
SULIN
1.0 #
MAIN INDEX
1.0 ®
®
1.0
0.6 to 0.7#
1.0
®
3.5
®
SR. PART DESCRIPTION 1.0

NO. 06 ASSY.DIPSTICK
GROUP INDEX
01 ASSY.CYLINDER CRANKCASE 07 ASSY.OIL SUMP COMPLETE

20 HEX SCREW M6X20
01-a HOLLOW DOWEL 14h6x10.5x14L 07-a ASSY.OIL SUMP W/O DRAIN PLUG
21 WASHER A6.4 IS5370
01-b DOWEL SLEEVE (FRONT HALF TO INT.PLATE (2) ) 07-b MAGNETIC DRAIN PLUG
22 RUBBER BUFFER (FOR MTG.TIMING COVER)
01-c HOLLOW DOWEL 10h6x8.4x8L 07-c SEALING WASHER (OIL SUMP DRAIN PLUG)
23 INSERT TUBE (FOR MTG.TIMING COVER)
01-d HOLLOW DOWEL 8h6x6.5x8L 08 OIL SUMP GASKET
24 ASSY.OIL PUMP
01-e SEALING PLUG M14X1.5 09 HEX FL SCREW M6X14 (for oil sump)
25 GASKET (FOR OIL PUMP)
01-f SEALING WASHER 14X20 IS3175-CU 10 ASSY.TIMING COVER - REAR (LH BOTTOM)
26 ASSY HEX SCREW M6X25
01-g HEX.BOLT (FOR M.B.CAP) 11 ASSY.TIMING COVER - REAR (RH BOTTOM)
27 OIL SEAL-CRANKSHAFT (FRONT)
01-h DOWEL 6h6x10 (1-no screw behind) 12 HEX FL SCR M10X14 (for timing cover)
28 ASSY.STRAINER (FOR OIL PUMP)
01-i HOLLOW DOWEL 8h6X6.5X8L (6) 13 ASSY.FRONT COVER(LOWER)(TIMING COVER)
29 GASKET (FOR OIL PUMP STRAINER)
02 .ASSY.REAR COVER CRANKCASE WITH OIL SEAL 14 HEX FL SCREW M6X14
30 STUD CM6X16
02-a REAR COVER - CRANKCASE (HOLLOW DOWEL) 15 COVER (TIMING BELT-FRONT)
31 HEX FL NUT BM6
02-b 0IL SEAL-CRANKSHAFT (REAR) 16 SEALING STRAP
32 ADAPTOR (OIL FILTER)
03 GASKET (REAR COVER CRANKCASE) 17 SHOULDER BOLT (FOR TIMING COVER)
33 ASSY.OIL FILTER
04 ASSY HEX SCREW M6X20 (6-for rear cover) 18 BRIGHT WASHER 10.5
45
05 ASSY.DIPSTICK TUBE 19 RUBBER BUSH (TIMING COVER)
ENGINE
ENGINE
46
ENGINE 475 SI MPFI

CYLINDER HEAD & COVER (same for 85 PS & 75 PS engines)
SR. PART DESCRIPTION

NO.
01 ASSY.CYL.HEAD COMP(WITH VAL,RO.ARM,SP.PL
01-a VALVE GUIDE SEAL
01-b INTAKE VALVE 1.0
01-c EXHAUST VALVE
01-d SPRING SEAT
01-e VALVE SPRING
01-f VALVE SPRING RETAINER
01-g LOCK HALF
01-h SPARK PLUG ASSEMBLY.(M/S CHAMPION)
01-i ASSY.CYLINDER HEAD (WITHOUT VALVES)
01-i-a CYLINDER HEAD
01-I-B STUD CM8X25 (FOR INTAKE MANIFOLD)
01-I-C STUD CM8X20 (FOR PURGE VALVE MTG. BRACKET.)
01-I-D STUD CM8X25 (FOR EXHAUST MANIFOLD)
02 GASKET (FOR CYL.HEAD)(1.1THK.)
SULIN
03 HEX BOLT (FOR CYL.HEAD)
04 WASHER (FOR CYL.HEAD BOLT)
05 ASSY.CYLINDER HEAD COVER COMPLETE (LMM)
05-a BAFFLE GASKET
05-b BAFFLE PLATE
05-c SCREW 6.5
MAIN INDEX
06 RUBBER HOSE (BLOWBY) (HEADCOVER-AIR FIL)

07 HOSE CLAMP 25
08 HOSE CLAMP 16 08
09 'T' - CONNECTOR
®
10 RUBBER HOSE-BLOW
BY-HD.COVER TO MANIFOLD
11 HOSE CLAMP 25 1.0
12 HOSE CLAMP 20 1-i-d 09
13 GASKET (FOR CYL.HEAD COVER) 1.0 07
14 STUD (FOR CYL.HD.COVER)
15 SPACERTUBE 11
(FOR CYL.HD.COVER)
16 ASSY.RUBBERBUSH
(FOR CYL.HD.COVER)
17 DOMED CAP NUT
(FOR CYL.HEAD COVER MTG.) 10
®
18 SEALING WASHER
GROUP INDEX
(FOR CYL.HEAD COVER)

19 OIL FILLER CAP
20 GASKET 12
21 VALVE GUIDE 21
22 VALVE INSERT
®
®
22

ENGINE 475 SI MPFI
GASKET KIT (same for 85 PS & 75 PS engines)
®
®
®
®
®
SULIN
®
®
MAIN INDEX
®
NO.
1 Rear Gasket
®
2 Oil Sump Gasket
3 Cylinder Head Gasket
®
®
4 Cylinder Head Cover Gasket
5 Oil Filler Cap Gasket
6 Throttle Body Gasket
®
7 Inlet Manifold Gasket
®
8 Exhaust Manifold Gasket
GROUP INDEX
®
9 Front Cover Gasket
®
10 Oil Pump Strainer Gasket

11 Water Pump Gasket
12 Gasket
13 Gasket Elbow
14 Rear Crankshaft Oil Seal
(Rear Crankcase Cover)
15 Camshaft Front Oil Seal
16 Front Crankshaft Oil Seal
47
ENGINE
ENGINE
48
ENGINE 475 SI MPFI

AIR INTAKE SYSTEM (same for 85 PS & 75 PS engines)
®
®
NO.
®
01 ASSY AIR FILTER MPFI
02 ASSY.FILTER ELEMENT
03 ASSY.ISOLATOR (FOR AIR FILTER)
SULIN
04 ISOLATOR (FOR AIR FILTER)
05 ASSY.ADAPTER (BLOWBY CONN.ON AIR FILTER)
06 SEALING WASHER 14X18 CU
07 SEALING WASHER 12X15.5 CU
MAIN INDEX
08 ASSY.BRACKET FRONT (FOR AIR FILTER MTG.)

09 BRACKET REAR (A/ F MTG.ON BATTERY TRAY)
12 ASSY.BRACKET (FOR RESONATOR BOX MTG.)
14 RESONATOR BOX
15 ASSY.ISOLATOR (FOR RESONATOR)
16 RUBBER GROMMET (FOR RESONATOR BOX)
18 AIR INTAKE SNORKEL
19 ASSY.CLAMP (FOR SNORKEL MTG.)
20 HEX FL SCREW M6X14 (FOR SNORKEL MOUNTING)
21 HOSE (RESONATOR BOX)
GROUP INDEX
22 HOSE CLAMP (42 DIA.)

23 INTAKE DUCT (FROM AIR INTAKE SYSTEM)
24 HOSE (AIR FILTER TO INTAKE DUCT)
25 HOSE CLAMP (72 DIA.)
26 HEX FL NUT AM6 8C (FOR SNORKEL MOUNTING)
27 PLUG (ON THROTTLE BODY)
28 GASKET (FOR INTEGRATE THROTTLE BODY)
29 HEX FL NUT AM6 8C
30 RUBBER BELLOW (AIR FILTER TO THRO.BODY)
31 HOSE CLAMP ( 53 DIA.)
32 HOSE CLAMP (72 DIA.) ® -Non Reusable Part
ENGINE 475 SI MPFI
INTAKE & EXHAUST MANIFOLDS (same for 85 PS & 75 PS engines)
06
21
21
1
21
1
32
32
SULIN
3
3
43
4
4
4
4
®
MAIN INDEX

NO.
01 ASSY.INTAKE MANIFOLD COMPT (FOR LTRS)
®
02 BRACKET (FOR ACC.CABLE MTG) (LTRS)

03 CYL PIN 4m6X8 IS2393
GROUP INDEX
05 ASSY.CABLE LEVER COMPLETE (FOR LTRS) 2.0

06 STICKER (FOR SPARK PLUG CONNECTION)
®
07 STUD CM6X45 (FOR THROTTLE BODY)

08 GASKET (FOR INLET MANIFOLD)
09 SELF LOCKING NUT
10 EXHAUST MANIFOLD
11 GASKET EXHAUST MANIFOLD
12 .ASSY.HEAT SHIELD (FOR EXHAUST MANIFOLD) ® -Non Reusable Part
14 STUD CM8X32
49
ENGINE
ENGINE
50
ENGINE 475 SI MPFI

® -Non Reusable Part ENGINE ELECTRICAL EQUIPMENT (75 PS)
2.0
2.0
3.0
1.5
SULIN
®
MAIN INDEX
4.0
2.5
2.0
8.0
GROUP INDEX
SR. PART DESCRIPTION 11 HEX THIN NUT M12

NO. 08-a ASSY.CLAMP ROD (COMPLETE) 172 mm 12 LOW OIL PRESSURE SWITCH
01 BRACKET (FOR 75 AMP ALT.& PSTG.) 08-a-a ASSY.CLAMP ROD WITH SILENT BLOCK 13 POLY-V BELT (4 GROOVES-875)
02 STUD (FOR A.C. & ALT. BRACKET) 08-a-b ASSY.CLAMPING PIECE 14 ALTERNATOR 12V 75A W/ IEM W/ O VP-OFFER
03 HEX FL SCREW M8X18 08-a-b-a CLAMPING PIECE 22 POWER STEERING PUMP
04 HEX FL NUT AM8 08-a-b-c CYL PIN 8m6X25 IS2393 23 HEX FL SCREW M8X18
05 HEX FL BOLT M8X125 08-b ASSY.BRACKET (ALTERNATOR - UPPER) 24 PULLEY (POWER STG.PUMP) 4 GROOVES
06 BRIGHT WASHER 8.4 08-c HEX FL BOLT M10X40 25 HEX FL.NUT AM12X1.25
07 NYLOC NUT M8 9 HEX FL SCREW M8X18
08 ASSY.CLAMP ROD COMP.WITH BRACKET (172mm) 1 0 HEX FL BOLT M8X45
ENGINE 475 SI MPFI
ENGINE ELECTRICAL EQUIPMENT (85 PS)
NO.
01 BRACKET (ALTERNATOR,IDLER & PSTG.MTG.)
04 SUPPORT BKT.(FOR ALT.BKT.& TOP SUPPORT)
06 BRACKET (FOR ALT.TOP SUPPORT) 2.0

08 SLIDER (FOR TENSIONER MTG.) (ALUMINIUM)
SULIN
09 WASHER (FOR AC COMPRESSOR IDLER)
2.0
10 SLIDER SCREW (FOR TENSIONER)
11 ASSY.SHAFT W/ H DUST SHIELD-

FOR TENSIONER
MAIN INDEX
12 ASSY.TENSION PULLEY.
(FOR A/ C COMP.)(INA) 2.0
13 HEX.NUT(FOR MTG.70 DIA.INA-TENSIONER)
14 POLY VEE BELT (5 PK-1095)

2.0
15 ALTERNATOR 12V 90A W/ VP W/ IEM
2.3
16 PULLEY-PSTG.PUMP (5-GROOVES)
4.0
GROUP INDEX
2.3

51
ENGINE
ENGINE
52
ENGINE 475 SI MPFI

ENGINE ELECTRICAL/A.C. EQUIPMENT
2.4
SULIN
Sr. Part Description
No.
MAIN INDEX
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
5.0 16-a BRACKET(MTG.A/ C COMPRESSOR)(HALLA-110CC)
2.5 16-b ASSY.AIR COMPRESSOR (w ith sealed connector)
®
2.5 16-c HEX FL SCREW M8X30

17 STUD (FOR A.C. & ALT. BRACKET)
GROUP INDEX
18 HEX FL NUT AM8

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)
- Specified Torque in Kgm 21-e NYLOC NUT M8
ENGINE 475 SI MPFI
EMS KIT COMPONENTS
- Specified Torque in Kgm 1.0
12
11
SULIN
1.0
08 09
MAIN INDEX
10
GROUP INDEX
1.4
NOTE : Vehicles speed sensor, one of EMS component, is a part of instrument cluster. (not shown)

NO. 04 BRACKET (FOR CRANK ANGLE SENSOR)
01 KIT-EMS BHARAT STAGE-II FE (HITACHI) 05 CR CSK SCREW M6X16
01-a ASSY.COIL WITH IGNITOR (HITACHI) 01-e-b INSULATOR (FOR FUEL INJECTOR) 06 CYL PIN 6m6X14
01-b ENGINE CONTROL UNIT (BS-II) FE (HITACHI) 01-e-c RUBBER RING (FOR FUEL INJECTOR) 07 HEX FL BOLT M6X20
01-b ENGINE CONTROL UNIT (BS-II) FE (HITACHI) 01-f INTEG.THROTTLE BODY(HITACHI) NEW PR.SEN. 08 MANIFOLD AIR PRESSURE SENSOR
01-c CRANK ANGLE SENSOR (HITACHI) 01-g ASSY.PRESSURE REGULATOR (HITACHI). 09 THROTTLE POSITION SENSOR
01-d WATER/ AIR TEMP.SENSOR (HITACHI) 01-g-a O-RING (FOR PR.REGULATOR) 10 ISC VALVE
01-e ASSY.FUEL INJECTOR (HITACHI) 02 HEX FL SCREW M5X12 11 WATER TEMPERATURE SENSOR
01-e-a O-RING (FOR FUEL INJECTOR) 03 ASSY HEX SCREW M6X25 (Ignition coil) 12 LAMBDA SENSOR
53
ENGINE
ENGINE
54
ENGINE 475 SI MPFI

ENGINE COOLING SYSTEM (same for 85 PS & 75 PS engines)
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 TO AUX. TANK
SULIN
1.5
MAIN INDEX
®
®
®
48 1.5
®
2.0
1.0
GROUP INDEX
SR. PART DESCRIPTION TO HEATER

NO.
10 ASSY.ADAPTER (FOR HEATER CONNECTION) 39 THERMOSTAT HOUSING 49 SEALING WASHER 14X18
11 WASHER (18X22X2-Cu) 40 O-RING 42.52X2.62 A NITRILE 50 STUD CM6X16
12 ASSY.BANJO BOLT WITH NIPPLE (FOR HEATER) 41 HEX FL NUT AM8 51 ASSY.TUBE WATER BYPASS
13 HOSE (FROM CYL.HEAD TO HVAC UNIT) 42 STUD CM6X25 52 GASKET (FOR WATER BYPASS TUBE)
14 SPRING BAND CLAMP FORM A 12X23D TS17665 43 ASSY.COVER (THERMOSTAT) 53 HEX FL NUT BM6
15 ASSY.TUBE(CYL.HEAD VENT) 44 ASSY.THERMOSTAT (82 DEG.SOT ) 54 ASSY.HOSE (WATER BYPASS) (SPR.BAND)
16 SPRING BAND CLAMP FORM A 12X14D TS17665 45 SEAL THERMOSTAT 55 HOSE CLAMP 35
36 ASSY.WATER PUMP (OFFER DRG.) 46 HEX FL NUT AM6 56 ASSY.ELBOW (FOR WATER INLET
37 GASKET (FOR WATER PUMP) 47 SEALING WASHER 12X15.5 57 GASKET (FOR WATER INLET ELBOW)
38 ASSY HEX SCREW M6X20 48 TEMPERATURE TRANSDUCER-M/ S PRICOL 58 HEX FL SCREW M8X18
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.
FROM HEATER 06
TO WATER ELBOW
08
*
07 1.0 17
Fitted on Body 08 18
19
1.5
1.0
Fitted on Body
09
OCK
TO BL
SULIN
MAIN INDEX
*
To Heater
1.5
T
TA
OS
M
ER
TH
1.5
TO
NO.
GROUP INDEX
01 ASSY.INT.RUBBER HOSE
02 RUBBER HOSE (INTEGRAL HOSE TO AUX.TANK)
03 HOSE CLAMP (53 DIA.) 18 CLAMP FRONT (CYL.HEAD VENT HOSE) 29 ASSY.RADIATOR W/ H TH.SW.(AC/ NON AC) TOYO
04 SPRING BAND CLAMP FORM-A 12X28D 19 HEX FL SCREW M8X12 29-a ASSY.THERMOSWITCH
05 SPRING CLIP (25) 20 RUBBER HOSE (RADIATOR VENT)TOYO RAD.ONLY 29-b DRAIN PLUG WITH WASHER
06 HOSE CLAMP (26 DIA.) 21 SPRING BAND CLAMP FORM A 12X14D 30 ASSY.SHROUD WITH FAN & MOTOR
07 HEX FL NUT BM6 22 SPRING BAND CLAMP FORM A 12X19D 31 HEX FL SCREW M6X14
08 ASSY.CLAMP (FOR INT.HOSE AUX.TANK BR.) 23 RUBBER HOSE-COVER THERMOSTAT TO RADIATOR 32 RUBBER GROMET (RAD MOUNT)
09 HEX FL SCREW M6X10 24 SPRING BAND CLAMP FORM A 15X49D 33 ASSY.BKT.RAD.MTG.TOP RH COMPL
14 SPRING BAND CLAMP FORM A 12X23D 25 ASSY.AUX.WATER TANK W/ H PR.CAP 34 ASSY.BKT.RAD.MTG.TOP LH COMPL
15 ASSY.TUBE(CYL.HEAD VENT) 26 ASSY.BRACKET-REAR (FOR AUXILLIARY TANK) 35 HEX FL SCREW M6X12
16 SPRING BAND CLAMP FORM A 12X14D 27 HEX FL SCREW M6X12 59 SCREW FOR TOP MOUNTING BRACKET (AUX. TANK)
17 HEX FL SCREW M6X10 28 ASSY HEX SCREW M6X16
55
ENGINE
ENGINE 475 SI MPFI
ENGINE SUSPENSION (85 PS)

ENGINE
®
4.0
2.5
2.5
c
b
®
a
4.5
2.5
2.5
3.5
SULIN 2.0
a
® b
3.0
NO.
01 LIFTING HOOK (FRONT)
03 ASSY.BRACKET ENG MTG. WITH STUDS 8.0
03-a BRACKET (FOR ENG.MTG.ARM)
03-b STUD BM10X50
03-c STUD BM10X60
NO.
06 ENGINE MTG.ARM (FRONT) 19 ASSY.BRACKET ENGINE STOPPER (FABRICATED)
07 HEX FL NUT AM10 20 HEX FL SCR M12X30
08 ASSY.ENGINE MOUNT-A(HYDRAULIC) 21 HEX FL BOLT M8X38
09 NYLOC NUT M10 22 ASSY.RUBBER STOPPER
10 BRIGHT WASHER 10.5 23 HEX NUT M12
11 ASSY.MOUNTING PLATE (B-MOUNT) 24 ASSY.C LINK & BODY MTG BKT COMPLETE
12 ASSY.STOPER(ON B-MOUNT PLATE) 24-a ASSY.MOUNT INTERMEMEDIATE LINK (REAR)
13 HEX FL BOLT M8X25 24-b ASSY.BODY MTG.BRACKET (FOR C-MOUNT)
14 ASSY.ENG.MOUNT-B (ON GEAR BOX) 25 HEX FL BOLT M10X55
15 NYLOC NUT M12X1.5 26 NYLOC NUT M10
16 WASHER (FOR B-MOUNT) 27 ASSY HEX SCR M12X1.25X30
17 .HEX FL NUT BM8 28 HEX FL BOLT M10X75
18 ASSY.ENGINE MOUNT-C (TC) 29 HEX FL NUT AM10
56
ENGINE 475 SI MPFI
ENGINE SUSPENSION (75 PS)

® ENGINE
4.0
2.5
2.5 c
b
®
a
4.5
2.5
2.5
3.5
SULIN 2.0
a
® b
3.0
NO.
01 LIFTING HOOK (FRONT)
03 ASSY.BRACKET ENG MTG. WITH STUDS 8.0
03-a BRACKET (FOR ENG.MTG.ARM)
03-b STUD BM10X50
03-c STUD BM10X60
NO.
06 ENGINE MTG.ARM (FRONT) 19 ASSY.BRACKET ENGINE STOPPER (FABRICATED)
07 HEX FL NUT AM10 20 HEX FL SCR M12X30
08 ASSY.ENGINE MOUNT-A(HYDRAULIC) 21 HEX FL BOLT M8X38
09 NYLOC NUT M10 22 ASSY.RUBBER STOPPER
10 BRIGHT WASHER 10.5 23 HEX NUT M12
11 ASSY.MOUNTING PLATE (B-MOUNT) 24 ASSY.C LINK & BODY MTG BKT COMPLETE
12 ASSY.STOPER(ON B-MOUNT PLATE) 24-a ASSY.MOUNT INTERMEMEDIATE LINK (REAR)
13 HEX FL BOLT M8X25 24-b ASSY.BODY MTG.BRACKET (FOR C-MOUNT)
14 ASSY.ENG.MOUNT-B (ON GEAR BOX) 25 HEX FL BOLT M10X55
15 NYLOC NUT M12X1.5 26 NYLOC NUT M10
16 WASHER (FOR B-MOUNT) 27 ASSY HEX SCR M12X1.25X30
17 .HEX FL NUT BM8 28 HEX FL BOLT M10X75
18 ASSY.ENGINE MOUNT-C (TC) 29 HEX FL NUT AM10
57
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.
Fig.51
Disconnect exhaust pipe from exhaust manifold
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 :
l
l
Air filter SULIN
Gear shift linkages from transaxle Fig. 52
l Radiator (if required)
Drain transaxle oil, Fig. 53.
Fig. 52
Fig. 53
58
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. 2702 5890 24 01
Remove starter motor.
Fig. 54
Disconnect transaxle Assembly from engine. (Ref. transaxle
group)
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 :
l
l
if necessary. SULIN
Check engine mounting pads for wear.Replace them
Install the engine in reverse sequence of removal

l Tighten engine mounting bolts to specified torque
l Connect all pipes, hoses and electrical connections
FRONT
l Fill sp ecif ied q u an t it y o f o il in en g in e o f
recommended brand.
‘A’ MOUNT ‘B’ MOUNT
l Fill coolant in the cooling system through aux. tank
l Crank the engine momentarily. Let oil and coolant Fig. 55
circulate through the system. Remove air trapped in
cooling system with the air venting screw provided
on outlet hose from cylinder head to radiator top.
l Confirm whether engine oil pressure indicator light
is switching off when engine is started.
l Check for leakage, rectify if any.
l Top up coolant upto FULL mark in auxiliary tank, if
necessary.
Fig. 56
59
ENGINE 475 SI MPFI
REMOVAL OF RADIATOR FROM CAR

1.
(Front bum p er, Splash guard already rem oved - For
procedure refer Body group of this manual) 2.
ENGINE
1. Drain the coolant.
2. Remove all the hose connections i. e.
i. From the thermostat
ii. From the auxiliary tank. 3.
iii. To the outlet elbow.

3. Disconnect the electrical connections,
1. ASSY. RADIATOR COMPLETE
i. To the condenser fan (For AC version)
ii. To the temperature sensor of cooling fan. 2. CROSS MEMBER RADIATOR MOUNTING
4. i. Unscrew the 2 M8 bolts & remove the radiator 3. RUBBER GROMET

bottom m ounting m em ber along w ith the
radiator.Fig 57
ii. Remove upper support bracket. Fig. 57
SPECIFICATIONS
AUXILLIARY TANK AUXILLIARY TANK CAP
Leakage testing pressure : 1.5 bar
Auxillary Tank Cap Fig. 58
Pressure valve opening : 1 bar
Vacuum valve opening : 0.05 bar (max)
(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. Fit the radiator along with the radiator bottom
mounting member on to the car & tighten the
Fig. 58
mounting bolts.
ii. Fit upper mounting bracket.
a. Fill branded premixed ready to use coolant in the
2. Fit back the 3 hose connections. auxiliary tank after ensuring all the hoses are secured
3. Connect the electrical connections for temperature and leak proof.
sensor & condenser fan (For AC version)
b. Du rin g fillin g , keep t h e h ose clam p loose at
Fill branded coolant as per specification. thermostat housing.
Top up coolant through auxiliary tank cap upto ‘Full” mark.
c. During coolant filling, ensure that the air in the
Fit Auxillary tank cap. system is removed from this then tighten the hose,
Run engine for short durat ion and t op up coolant if using a screwdriver.
necessary. Rem ove t he t rap p ed air t hough vent ing d. Start the engine & slowly raise the engine speed &
screw . wait for the temperature to reach 850 C to 900 C to
Bleeding procedure for cooling system : allow the thermostat to open up. Engine running at
idling speed, open the bleeding screw by using a
(For refilling or during reconditioning after complete
screwdriver to allow any trapped air in the system to
draining)
escape. Tighten the bleeding screw & top up with
coolant to max. level.
60
ENGINE 475 SI MPFI
ALTERNATOR / POWER STEERING PUMP BELT (specific to 85 PS engine)
Removal : ENGINE
l Lo o sen b o t h t h e slid er m o u n t in g screw s o n

alternator bracket.
l Slide the slider to reduce the belt tension by rotating
the slider screw at the bottom. Fig. 59.
l Remove the alternator belt.
Inspection :
l Inspect the alternator belt for wear,cracks and signs
of failure. Replace, if necessary.
Fitment :
l Adjust the slider at the higher most position and
keep the screws loose but engaged.
l Install alternator belt over Crankshaft, Alternator,
Power Steering pump and the tensioner pulley.
l Slide the slider by rotating the bottom slider screw
till correct belt tension is set.
l Retighten the slider screws.
l SULIN
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 SLIDER SCREWS
thumb pressure applied. 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.
SPAN
2. Inspect pulley grooves.
ALTERNATOR BELT TENSIONER BOLT
Fig. 60
61
ENGINE 475 SI MPFI
FITMENT
SPAN
1. Install the belt over crankshaft and A. C. compressor
ENGINE pulleys.
2. Press the tensioner against the belt and tight the
tension bolt to specified torque.
3. Check belt tension.
BELT
4. The belt tension to be adjusted such that on the TENSIONER
ROLLER
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. BELT TENSION
ADJUSTING SCREW
Fig. 61
SULIN
62
ENGINE 475 SI MPFI
ALTERNATOR / POWER STEERING PUMP BELT (specific to 75 PS engine)
ALTERNATOR / POWER STEERING PUMP BELT 3

4 5 6
ENGINE
Crankshaft
Removal :
Pulley
l Loosen alternator upper mounting Bolt and bottom
2
m ount ing bolt Fig. 61a. For vehicles w it h pow er 10 -1 1mm
steering please refer 61b.
l Slightly loosen banjo bolt connections on vacuum
pump
l Reduce alternator belt tension by loosening of tension
Alternator
adjust ing nut and by pushing alt ernat or t ow ards 1
engine.
l Remove alternator belt.
Inspection :
Engine with Alternator (without power steering)
l Inspect alternator belt for wear, cracks and signs of
failure. Replace, if necessary.
1. Alternator mounting bottom bolt
Fitment : 2. Alternator mounting upper bolt
l Install alternator belt over crank shaft, power steering 3. Clamping piece
pully and alternator pulleys (Fig. 61b). 4. Clamping bolt
Note : incase of vehicle without power steering, power 5. Adjusting nut
steering pulley will not be there Fig-61a). 6. Lock nut
l Pull alternator away from engine for specified tension
& tighten the nut to specified torque. Fig. 61a
l
SULIN
ALTERNATOR BELT TENSION IS CORRECT IF IT CAN BE
DEPRESSED BY 10-11 mm (for engine with alternator)
& 8-9 mm (for engine with A.C., Alternator and Power
steering) WITH THUMB PRESSURE (1O KG APPROX.)
APPLIED IN THEMIDDLEOF ITSLENGTH Fig.61a & 61b.
l Tighten alternator top mounting screw and bottom
mounting bolt.
l Tighten banjo bolt connections on vacuum pump
A.C. COMPRESSOR BELT
REMOVAL
1. Loosen b elt t ensioner b olt . (Fig. 61b ) on id ler /
tensioner.
2. Release tension load on the belt and remove the belt
from the pulleys.
Alt ern at or
INSPECTION Crankshaft Pulley
1. Inspect the A. C. compressor belt for wear cracks, and
signs of failures. Replace if necessary.
8-9 mm
FITMENT
1. Install the belt over crankshaft and A. C. compressor
pulleys.
2. Press the tensioner againsts the belt and tight the Com pressor
tension bolt to specified torque. Tensioner Tensioner
8 -9
3. Check belt tension. Bo lt mm
Pow er St eering
4. A. C. Compressor belt tension is correcrt if it can be
Pum p
depressed by 8-9 mm with thumb pressure applied in
the middle of its length between compressor and Fig. 61b
crankshaft pulleys.
63
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
ENGINE 475 SI MPFI
Fit lock plate for camshaft gear washer on cylinder head

as shown in Fig.65
Slacken the camshaft gear fixing bolt.
ENGINE
Slacken t he m ount ing b olt of b elt t ensioner roller

assembly and rotate the belt tensioner in anticlockwise
direction to loosen the belt. Fig. 66
Remove timing belt.
Inspection :
Check belt in detail. If following flaws are evident, replace
belt with new one.
l Back surface glossy,non elastic and so hard that even
if finger nail is forced into it, no mark is produced.
l Cracked back surface rubber
l Cracked or exfoliated canvas Fig. 65
l Cracked tooth bottom

l Side of belt cracked
l Side of belt excessively worn
l Excessively worn teeth
l Missing tooth
NOTE :
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.
Fitment : Fig. 66
Ensure that timing pin is in flywheel locked position. Slacken the camshaft gear fixing bolt so that the camshaft
Check that the cam gear is “Just ” freely rotating on the gear is“Just ” freely rotating on camshaft.Fit the camshaft
cam sh af t w it h m o u n t in g b o lt in h an d lo o se gear washer lock plate as shown in Fig. 65
condit ion. Check now that both the flywheel and camshaft are in
locked in timing position.
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 Fit timing belt on Crank shaft gear,water pump, tensioner
riding on the valve tips & tighten the locknuts. roller and camshaft gear.
NOTE : 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
This is to reduce the valve spring load on Camshaft, while t ig ht ening t he m ount ing screw ensuring t hat t he
rotating the camshaft. t ensioner roller does not rot at e furt her in clockw ise
Using appropriate spanner on camshaft gear fixing bolt, direct ion. This w ill prevent overtensioning of t im ing
rotate camshaft in clockwise direction with timing pin b elt .
placed on the cylinder head reference hole, until the Tighten the cam shaft gear fixing bolt to a lower tightening
camshaft is locked in timing position. (Fig. 116) torque of 1 mkg.
65
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.,
Fig. 67
Inlet - 3 & 4 and Exhaust - 2 & 4
Rot at e cran ksh aft in clockw ise d irect ion b y m ore bolt. This is to prevent severe damage to cylinder head,
revolution and check whether flywheel and camshaft camshaft timing slot and subsequent problem of very low
are in locked timing position. oil pressure (due to increased bearing clearance on bearing
No. 5 of cylinder. head).
NOTE :
Special ‘C’ tool should be used whenever cam gear fixing
In t his procedure t im ing pin locking t he cam shaft is bolt is to be tightened or loosened.
rem oved from t he cylind er head t im ing reference
SULIN
hole, w henever cam shaft is sub ject ed t o very high
looserning and tightening torque through the gear fixing
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 ARM Cylinder Head Ex-
ROCKER SCREW
SPRING RETAINER
ploded
LOCK
HALF
SPRING
VALVE GUIDE SEAL
VALVE
GUIDE
ROCKER
SHAFT
CYLINDER HEAD
CAM SHAFT
TIMING
GEAR
EXHAUST VALVE
INTAKE VALVE
Fig. 68
66
ENGINE 475 SI MPFI
CYLINDER HEAD : (Engine on workstand)

Disassembly:
Remove electrical cable connections for : ENGINE
l Spark plug leads. Fig. 69
Fig. 69
Remove
l Fuel pressure regulator
l Canister purge valve
l Bracket supporting fuel lines. Fig. 70
SULIN
Fig. 70
l Coolant bypass line. Fig. 71
Fig. 71
67
ENGINE 475 SI MPFI
l Blowby hose connection to cylinder head cover.

Fig. 72
ENGINE
Fig. 72
l Vacuum pipe from intake manifold to brake booster.

l Vacuum pipe to canister purge valve Fig. 73.
SULIN
Fig. 73
l Inlet manifold with throttle body Fig. 74.
Fig. 74
68
ENGINE 475 SI MPFI
l Exhaust manifold Fig. 75

l Timing Cover
ENGINE
Fig. 75
l Cylinder head cover Fig. 76
SULIN
Fig. 76
Keep crankshaft rotating by socket spanner simultenously,

Insert flywheel locking pin and lock fly wheel.
Fit lock plate for camshaft gear washer & loosen cam shaft
gear mounting bolt. (Fig. 77)
Fig. 77
69
ENGINE 475 SI MPFI
Also remove
l Timing belt Fig. 78
l Dip stick clamping screw
ENGINE
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
ENGINE 475 SI MPFI
NOTE :
1) To ease the dismantling of rocker shaft relieve
the valve spring load by slackening the tappet ENGINE
setting screws. In this condition do not attempt
to rotate the cam shaft, if you do so valve tips
will be damaged. (Fig. 81)
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
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
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
ENGINE 475 SI MPFI
2. Pull out the spark plug cables by gripping at the

connector.
ENGINE 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 Fig. 90
damage the threads in the cylinder head. A loose spark
plug can affect combustion and cause engine damage.
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
Fig. 91 Fig. 92
(stationary engine). Replace spark plugs.
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
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
ENGINE
misfire. Replace spark plugs.
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 : Over-
ad 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
Remove :
SULIN
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
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
ENGINE 475 SI MPFI
CYLINDER HEAD TOP AND BOTTOM SURFACE

REMACHINING, IN SERVICE IS NOT PERMITTED.
Permissible unevenness of cyl. head overall mating surface ENGINE
(150 x 150) : cross wise 0.015 mm
lengt h w ise 0.030 mm.
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
ENGINE 475 SI MPFI
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
ENGINE
straighten bent valves. If valve is free from any other
d efect s excep t w orn out seat , t hen only it can b e
rematched on valve grinding machine as follows.
l Clamp valve on grinding machine jaws as close as
possible to valve head.
l Adjust grinding angle on graduated scale to achieve
correct valve seat angle.
l Feed valve slowly towards grinding wheel until wheel
just touches valve head.
l Grind at low feed until valve seat is just clean all
around.
NOTE : After grinding, valve head thickness should not Fig. 102
be less than 0.85 mm.
INLET VALVE EXHAUST VALVE

VALVE STEM
SULIN C C
VALVE SEAT
C
B
D
D A
0
A
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
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 0.2 0.2

to valve steam mm
Valve seat dia C mm 35 29.2
Valve seat end distance from valve face D mm 2.65+0.1 2.82+0.1
Maximum run out of valve seat with 0.030 0.030

respect to valve steam
Valve seat dia in cylinder head mm 34 28.0
Distance between cylinder head mating

surface with crank case to valve seat in
cylinder head mm
SULIN 14.4+0.05 14+0.05
Maximum run out of valve seat in cylinder 0.030 0.030

head with respect to valve guide axis mm
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
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 Valve guide Valve guide Valve guide

bore in cyl. head OD,mm ID,mm length, mm
+ 0.015
Normal 12.99+0.008/-0.01 13.0 + 0.046 7 - 0 (Inlet)
+ 0.016
+ 0.028 7 + 0.004 (Exhaust) 39.5 (Inlet)
+ 0.015
Normal 1 13.09+0.008/-0.01 13.1 + 0.046 7 - 0 (Inlet) 46 (Exhaust)
VALVE SEAT MUST BE ABSOLUTELY FAULTLESS AND

SULIN + 0.028 7
+ 0.016
+ 0.004 (Exhaust)
suitable puller. In order to avoid damaging machined

WITHOUT ANY CHATTERMARKS cylinder head mating surface with crank case, place any
If necessary lap valve seats to a smooth and even finish by soft protective sheet metal under supports of puller.
using suitable hand pump grinder or a lapping paste and Measure valve seat insert bore in cylinder head & then
valve itself. 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
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
l 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 :

Valve seat insert thickness
Inlet - 6.5 + 0.05
SULIN
mm
Valve seat inside dia in insert
Inlet - 32 + 0.1
mm
+ 0.05 + 0.1
Exhaust - 6.5 mm Exhaust - 26 mm
Valve seat insert & bore dia. in cyl. head
Stage Valve seat insert bore Valve seat insert

diameter in cyl. head (mm) out side diameter (mm)
INLET
- Normal 38/ 38.03 38.13/ 38.155
- Normal 1 38.23/ 38.28 38.43/ 38.455
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 : Check hardness of cam shaft journals and cam lobes. It
l Overall heating of journals, which is indicated by should be 40 HRC min.
bluish/brown colour Check cam shaft runout at 2nd, 3rd & 4th journal by
l Deep scoring marks on journals and cam lobes supporting it on V-block at 1st and 5th journal. Fig. 108
l Cracks, which should be checked on a magnetic Check cam shaft journal dimensions.
crack detector.
81
ENGINE 475 SI MPFI
Cam shaft journal & bearing bore dimensions (mm) :

Journal No. Cam shaft bearing journal Cam shaft bearing
ENGINE
bore diameter in cylinder head journal diameter.
1 42.000 - 42.025 41.925 - 41.950
2 41.500 - 41.525 41.425 - 41.450
3 41.000 - 41.025 40.925 - 40.950
4 40.500 - 40.525 40.425 - 40.450
5 40.000 - 40.025 39.925 - 39.950
Maximum permissible run out of cam shaft bearing journal 0.025 mm
Maximum permissible axial play of cam shaft in installed condition 0.1/ 0.25 mm
Runout of oil seal mating diameter. 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
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 ENGINE
different).
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:
- 0.016
Rocker shaft dia. :15 mm
+ 0.011
Rocker bore dia. : 15 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
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 GASKET
PROJECTION THICKNESS, Fig. 112
mm mm
0.04 - 0.26 1.1
MAXIMUM DIFFERENCE BETWEEN PISTON PROJECTIONS

OF ANY TWO PISTONS IN CRANK CASE SHOULD NOT
EXCEED SPECIFIED VALUE.
Fig. 113
83
ENGINE 475 SI MPFI
Ensure that cylinder head locating hollow dowel is in

position on crank case (Block).
Ensure t hat flyw heel locking pin 2702 5890 0605 is
ENGINE
installed in position Fig. 114.
Place cylinder head gasket of pre-determined thickness.
Install cylinder head and tighten cylinder head mounting
screws to 3 mkg torque in the correct sequence i.e. from
9 5 1 4 8
1 2 3 4
10 6 2 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
Fitment :
Fit camshaft gear
SULIN
Ensure that timing pin is in flywheel locked position.
Check that the cam gear is “Just ” freely rotating on the
camshaft with mounting bolt in hand loose condition.
Slacken all valve tappet clearance setting screws to such
an extent that the screw bottom radius is just riding on
the valve tips & tighten the locknuts. (Refer fig. 68) Fig. 115
NOTE :
This is to reduce the valve spring load on camshaft, while
rotating the camshaft.
Using an appropriate spanner on camshaft fixing bolt,
rotate in camshaft in clock direction with timing pin placed
on the cylinder head reference hole, until the camshaft is
locked in timing position. Fig. 116
Slacken the fixing bolt so that the camgear is“Just ” freely
rotating on camshaft. Fit the camshaft gear washer locking
plate. (Fig. 65)
Check now that both the flywheel and camshaft are in
locked timing position.
Fig. 116
84
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 ENGINE
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. 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.
l Adjust the valve clearances of cylinder No. 1 & 2 on
inlet valves and cylinder No. 1 & 3 on exhaust valves
Fig. 119
l Remove the camshaft locking pin and fly wheel
locking pins.
Fig. 119
85
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.
ENGINE
l Adjust the valve clearances of cylinder No. 3 & 4 on
Fig. 120
INLET EXHAUST
Specified 0.20 0.30
Assemblies Fig. 120
l Spark plug. Fig. 121
SULIN
Fig. 121
l Exhaust manifold Fig. 122
Fig. 122
86
ENGINE 475 SI MPFI
l Inlet m anifold w it h t hrot t le b od y and gasket .

Fig. 123
l Spacer tube on cylinder head cover mtg. studs. ENGINE
l Cylinder head cover along with camshaft gear rear

cover. Replace the gasket if required.
l Timing belt gear cover Fig. 124.
l Thermostat cartridge
l Thermostat cover with gasket
l Bypass line
l Dip stick clamp screw
l Vacuum pipe canister purge valve to intake manifold.
l Hoses from intake manifold to cylinder head cover
and brake booster. Fig. 123
l Bracket supporting fuel lines.
l Spark plug leads.
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
ENGINE 475 SI MPFI
Remove :
l Vibration damper Fig. 126.
ENGINE
Fig. 126
l Crankshaft gear Fig. 127.

l Water pump
l Timing belt tensioner
l Timing belt rear cover
SULIN
Fig. 127
l Oil filter by using spanner (2702 5890 1802)

Fig. 128
l Engine mtg. bkt. (intermediate)
Fig. 128
88
ENGINE 475 SI MPFI
l Oil sump by extended socket (2702 5890 0603)

Fig. 129
ENGINE
Fig. 129
l Oil pump strainer Fig. 130a

l Oil pump Fig. 130b
Carefully remove combustion residues towards top end
of cylinder bores, preferably by a broken piston ring or by
a ridge cutter.
SULIN
Turn the crank shaft and bring a pair of piston to BDC
Unscrew connecting rod bearing cap mounting nuts

Fig. 131
Fig. 130a
Fig. 130b Fig. 131
89
ENGINE 475 SI MPFI
Remove connecting rod bearing caps with bearing shells.

Push these piston assemblies out of cylinders using the
ENGINE 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
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
ENGINE 475 SI MPFI
PISTON AND PISTON RINGS :

PISTON AND CYLINDER BORE SIZES :
ENGINE
Type Grade Cylinder bore Piston
Diameter mm Diameter mm
A 75.00/ 75.01 74.96
Standard B 75.01/ 75.02 74.97
C 75.02/ 75.03 74.98
PISTON RINGS :
Type of ring Axial clearance Butt clearance

in piston groove in cylinder bore
1st Compression 0.03 / 0.07 mm 0.15 / 0.3 mm
ring
Fig. 138
2nd Compression 0.02 / 0.06 mm 0.2 / 0.35 mm

ring
3rd Oil control - 0.2 / 0.6 mm
ring
Remove piston rings from piston using ring expander.Fig.

138
Remove the carbon deposits from the piston
Clean the piston and piston rings thoroughly
SULIN
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. 20.00/ 19.996 mm

Piston Pin length 59.00/ 58.7 mm
Piston Pin bore in piston 19.998/ 20.003 mm
Height of Piston 52.5 mm
Piston to bore clearance 0.040 - 0.050 mm
Max. permissible difference in
weights of pistons with pin &
rings of an engine 3 gm s.
Fig. 140
92
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,
ENGINE
com plete 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.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 Fig. 141
plier.Ensure‘TOP’marking istowardsthe piston crown.
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
necessary, replace it . SULIN

In sp ect co n n ect in g ro d sm all en d b u sh an d if
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. Fig. 142
Ensure that centre distance between small end & big
end is maintained within specified limit.
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
ENGINE 475 SI MPFI
CONNECTING ROD (DIMENSIONS) :

Connecting rod small end
ENGINE Stage parent bore bush outside

diameter mm 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 0.004 mm

small end parent bore and cylindricity 0.008 mm
Connecting rod small end bush inside diameter 20.0+ 0.020/ 0.007 mm
finished after installation) (Piston pin oiled has
thumb push fit in small end bush).
Maxim um perm issible out of parallelism (bend) betw een 0.050 mm

connecting rod small end and big end parent bores.
Centre to centre distance betw een connecting rod sm all 141.65+ -0.3 mm
end and big end parent bores.
Maximum permissible tw ist of connecting rod 0.050 mm
Connecting rod big end parent bore diameter
big end parent bore and cylindricity

SULIN
Maximum permissible taper and ovality of connecting rod
48.655 / 48.671
0.005
0.01
mm
mm
mm
Bearing shells to be selected such that clearance is maintained as 0.024 to 0.075 mm
Pre-tension of connecting rod big end bearing shells 0.013-0.051 mm
Maxim um perm issible difference in w eight of 5 gms

connecting rods in one engine
Connecting rod big end axial play 0.05 - 0.35 mm
94
ENGINE 475 SI MPFI
NOTE :
Ensure that the identification numbers for connecting rod
& connecting rod bearing cap are matched & notches for ENGINE
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
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 Fig. 144
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.
If d ifference is not iced in connect ing rod b ig end
parent bore dim ension, connect ing rod bearing cap
SULIN
can be centralised by lightly tapping it with mallet in
required direction after slightly loosening connecting
rod bearing cap mounting nuts.
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
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
SULIN
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. 148
96
ENGINE 475 SI MPFI
Crank shaft (dimensions)
Stage Crank case main bearing bore Crank shaft main bearing journal
ENGINE
diameter with bearing shell mm 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 Crank pin journal diameter mm
diameter with bearing shell (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 Thickness of 4th main
journal (mm) 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 SULIN
24.252 / 24.200 2.52(2.50-2.55)
End play of crank shaft 0.06 - 0.226 mm Pre-tension of main bearing shells 0.018-0.040 mm
Fillet radius of main bearing journals 2.5-0.5 mm Hardness of crank shaft main 50-60 HRC
bearing and crank pin journals
Fillet radius of crank pin journals 2.5-0.5 mm
Main bearing parent bore dia in 53.8 +0.019 mm
Width of 1st, 2nd, 3rd and 5th 24.0+0.2 mm
crank case + 0.00 mm
main bearing journals
Maximum permissible taper of 0.005 mm
Width of crank pin journals 24.0+0.2 mm
main bearing parent bore
Maximum permissible cylindricity 0.0025 mm
Maximum permissible ovality of 0.005 mm
Ovality of main brg. journal 0.005 mm main bearing parent bore.
Max. permissible ovality of crank pin 0.005 mm Crank shaft journal to main 0.026 / 0.085 mm
Maximum permissible run out of 0.02 mm bearing clearence
2nd, 3rd and 4th main bearing journals
when supported at 1st and 5th main
bearing journals
Maximum permissible out of parallelism 0.010 m m
between crank pin and main
bearing journal axis
97
ENGINE 475 SI MPFI
4th main bearing journal
CRANK SHAFT :
Clean and carry out visual inspection of crankshaft for the
following
ENGINE
l Overheating of journals, which is indicated by bluish

brown colour.
l Scoring marks on journals.
l Cranks, which should be checked on magnetic crack
detector.
Check crank shaft run out by supporting it on V-block at
1st and 5th main bearing journals. Fig. 149
If run out exceeds permissible limits, straighten crank
shaft in cold condition on press carefully.
Similarly check lateral and radial run outs of flywheel
mounting flange.
Fig. 149
Check crank shaft main bearing and crank pin journal
dimension.
If necessary,grind crank shaft main bearing and crank pin
journals to next under size.
MAINTAIN CORRECT FILLET RADII FOR JOURNALS
Care must be taken during grinding to ensure that width
of journals is not increased.
SULIN
Should it be necessary to grind sides of 4th main bearing
journal, grind it to next over size.
Re-chamfer oil holes on journals to avoid scoring of new
bearing shells.
Finish journals by lapping them with 320 grit lapping cloth
of suitable width.
After grinding recheck main bearing and crank pin journal
dimensions.
Fig. 150
Also recheck run out of crank shaft.
Thoroughly clean crank shaft with kerosene. Use wire
brush for cleaning oil holes.
IT IS ESSENTIAL TO RECHECK CRANK SHAFT FOR CRACKS
AND BALANCE AFTER GRINDING
Apply grease to all machined surfaces, if crank shaft is
t o b e st ored. Crank shaft m ust alw ays b e st ored in
vert ical posit ion.
CYLINDER BLOCK
Check cylinder block for cracks by pressure t est ing
m et hod.
Check crank case m at ing surface w it h cylinder head
for unevenness with help of straight edge and feeler
gauge. Fig. 150 & 151
Fig. 151
98
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. 152
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.
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
ENGINE 475 SI MPFI
Measure the main bearing bore.

BOLT TIGHTENED BOLT LOOSENED
IF M AIN BEARING PARENT BORE DIM ENSION IS
ENGINE
MAINTAINED WITHIN SPECIFIED LIMITS, PROPER MAIN
BEARING BOREDIMENSION ISAUTOMATICALLY 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 PRETENSION
GAP
on opposite side of bearing shell lug (This is to be done on
ÞÞ
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), SURFACE PLATE
change & select new shell.
MAIN BEARING SHELLS ARE PRECISION FINISHED AND
SHOULD NOT BE BORED OR SCRAPED. Schematic Sketch : Main bearing shell pretension checking
Select a new pair of thrust washer according to crank Fig. 155

shaft 4th main journal width. Refer Fig. 149
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
SULIN
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.
Fig. 156a
100
ENGINE 475 SI MPFI
REM OVAL, INSTALLATION AND M ACHINING OF approximately at 100-120 rpm and approx. 50 double
CYLINDER LINERS strokes per minute. Under these conditions leave about
0.02 mm materials for second stage honing. Anticlock
REMOVAL
wise direction of rotation of tool will be prefered if possible. ENGINE
1. Keep cylinder block upside down on hydraulic press

Stage II
such that bore from which liner is to be removed lies
clear in machine table slot. Base honing
The honing should be approx. 50-60 rpm & 25 double strokes
2. Ensure that the block is resting squarely on machine per minute.The opration should be completed in 5 to 8 double
bed. strokes with low pressure of 2.0 to 3.0 kg/cm 2.
3. Press out liners individually using drift, (Pt. No. 2702 Anticlock wise rotation will be preferred if possible.
5890 0201 and a suitable distance piece between press
ram and the drift. Make sure that the distance piece is
Note : Adjust honing stick travel project by approx. 20-25
also seating squarely between the drift and the ram. mm from top and bottom of bore during honing. Use plenty
of kerosene during honing operation. At bottom 20 mm
INSTALLATION OF LINERS IN CYLINDER BLOCK overtravel, care must be taken that stick holder will not hit
Thoroughly clean bores of the cylinder block. to MB faces.
Thoroughly clean liners. Clean cylinder block thoroughly and if engine assembly is
not to be taken up immediately,apply grease on machined
Place cylinder block on hydraulic press ensuring that oil surface of cylinder block.
sump mating face is resting evenly and squarely on the
Special Tools Required :
horizontal bed.
Drift for installation of cylinder liner - 2702 5890 02 01
DO NOT SMEAR CYLINDER BORE OF BLOCK OR LINER Drift for removal of cylinder liner - 2702 5890 02 02
OUTSIDE SURFACE WITH OIL.
Place liner with proper orientation (matching minimum /
SULIN
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.
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.
Similarly,press all other liners. 75+0.01
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
ENGINE 475 SI MPFI
Cylinder Block (Dimensions) - in mm

C
Height of crank case 265.8/ 265.6 D
ENGINE
(Dimension A&B) Fig. 157
Maximum permissible unevenness

of crank case mating surface with cylinder
B
head 150x150 : cross wise ‘D’ Fig. 157 0.015
A
: length wise ‘C’ Fig. 157 0.030
Maximum permissible out of 0.2

parallelism between crank case top and
bottom machined surface
Maximum permissible shift in 0.25 mm

perpendicularity of cylinder bore Fig. 157
from crank shaft axis when
checked from crank shaft centre line
Maximum permissible taper and 0.007

ovality of cylinder bore
SULIN
102
ENGINE 475 SI MPFI
LUBRICATION SYSTEM : Pump rpm Minimum flow rate in Ipm

OIL PUMP 4000 28
ENGINE
Unscrew screws holding oil pump to cyl. block and remove 2000 14
the oil pump assembly Check oil pump for flow rate at
specified rpm. Check for any leakage at sealing plugs. 800 5.6
Ch eck fu n ct io n in g o f Pressu re relief valve. If t h e Engine oil pressure with coolant temperature of 700 C at
performance of the pump is not satisfactory, then replace idling speed
the oil pump assembly.
800+50 rpm - 1 bar
Fit oil pump assembly with new gasket. at 5000 rpm - 3 bar
Flow rate measured against back pressure of 3kg/ cm 2 Oil Pressure Switch
should be as follows using SAE-30 oil.
NC contact opening pressure : 0.9 / 0.6 bar
ENGINE LUBRICATION COMPONENTS
SULIN
MAINOIL
GALLERY
OILFILTER
OILPUMP
GASKET
OILSUMP
STRAINER
DRAINPLUG
Fig. 158
103
ENGINE
Fig. 159
104
ENGINE 475 SI MPFI

COOLING CIRCUIT
RADIATORVENT HOSE
AUXILIARYWATERTANK
SULIN
INTEGRAL HOSE
MAIN INDEX
RADIATOR
WATERINLET ELBOW
HEATER RETURN HOSE
CYLINDER HEAD VENT LINE

GROUP INDEX
BYPASSLINE
UPPERCOOLINGLINE CAB HEATER FEEDER HOSE
THERMOSTATCOVER
WATERTEMP.SENSOR
THERMOSTATHOUSING
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 Fig. 160
5000 5250 100

THEMOSTATE OPEN
5500 5775 110
Thermostat
l Start opening temperature - 87 0C ± 2
l
l
Full open temperature - 93 0C ± 2
By pass port closed at or before SULIN
l Leakage through main valve (including seepage
hole) at room temperature and pressure of 1 kg/
cm 2 : 150-250 ltrs/ hr
l Maximum leakage through by pass at full open
t em p erat u re or m ain f lo w rat e of
130 + 5 lpm : 1.5 lpm
Fig. 161
Thermostat is installed in cooling system between cyl.
head & radiator inlet tank.
3. As t h e en g in e co o lin g t em p erat u re reach es
The working principle of thermostat : thermostat full open temperature, thermostat valve
opens fully and thermostat by-pass valve closes
1. For cold engine (im m ed iat ely aft er st art ing) :
completely.Under such condition maximum quantity
Thermostat does not allow coolant to flow to radiator
of engine coolant flows to radiator Fig. 161.
(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.
105
ENGINE 475 SI MPFI
Satisfactory operation of thermostat is very much essential

for :
ENGINE
l Efficient engine operation
l Longer engine life.
Defective thermostat may cause
l Over cooling due to thermostat valve sticking in full
open position
l Over heating due to thermostat valve sticking in
partial/ full closed condition
When above defects are observed, thermostat needs
checking.
Checking of thermostat element
1. Rem ove t herm ost at elem ent from t herm ost at Fig. 162
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. SULIN
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.
If t hey do not m eet t he sp ecificat ions, rep lace t he
Fig. 163
t herm ost at elem ent .
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
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
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 Fig. 168
piston with piston rings can slide inside it. Fig. 169
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 VALVE POCKETS
same side Fig. 170.
JET
LUGS
Fig. 170
108
ENGINE 475 SI MPFI

Assemble other connecting rods with piston in same ENGINE
manner.
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
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
ENGINE 475 SI MPFI
Lock flywheel with timing pin Fig. 177
ENGINE
Fig. 177
Screw in crankshaft pulley mounting bolt with spacer and

tighten it to specified torque. Fig. 178
Fit
l Alternator top mounting bracket
l Alternator bottom mounting bracket
l Alternator
SULIN
Fig. 178
l NEW oil filter Fig. 179

l Fit coolant inlet elbow with gasket.
Fig. 179
111
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
Fig. 182
ENGINE 475 SI MPFI

AIR INTAKE SYSTEM
AIRTEMPRATURESENSOR
SNORKEL
SULIN
T- HOSE
MAIN INDEX
AIRFILTER
RESONATORBOX
GROUP INDEX
INTAKEMANIFOLD
CYLINDERHEAD
113
ENGINE
ENGINE 475 SI MPFI
AIR CLEANER Fig. 182

For regular cleaning as per maintenance schedule :
ENGINE
l Unscrew and remove housing cover, and remove
element. Fig. 183
l Clean it gently by tapping on clean table.
l Use com pressed air, at a very low pressure, for
cleaning the element
l Check the condition of rubber sealing
l Check element for major rupture or puncture of
paper pleats.
l Replace elem ent if any rupt ure or punct ure is

observed.
Fig. 183
l Check condition of air hose / resonator box
l Check condition of rubber cuff on air filter and replace

it if necessary.
l Always use GENUINE air filter element to ensure

long engine life.
l Install paper filter element
l SULIN
Fit housing cover and clamp it firmly with the screws.
114
ENGINE 475 SI MPFI
ACCELERATOR CABLE
ENGINE
9 11 10
1 ASSY.ACC.CABLE-RHD
2 CLIP
3 HOSE
4 GROMMET
6 CABLE TIE 4.7X110
SULIN 7
8
9
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 1. Insert accelerator cable plastic end (10) inside the
accelerator cable at throttle body end. firewall hole.
2. Remove Hex FL screws (5) & remove cable from clip 2. Insert inner cable end (11) in accelerator pedal.
(2).
3. Locate accelerator cable in clip (2). Ensure that rubber
3. Remove inner cable end from throttle body sector sleeve (3) on accelerator cable are located inside the
after disengaging the threaded end of the cable in clip.
throttle body bracket (7).
4. Loosen the top side nut (8) from threaded end of the
4. Remove inner cable end (11) from accelerator pedal cable. Engage the threaded end of the cable in body
(9). bracket (7). Insert inner cable end in throttle body
sector.
5. Remove accelerator cable plastic end (10) through
firewall hole. 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
ENGINE
116
ENGINE 475 SI MPFI

ASSY. FOOT CONTROL
4.0
SULIN
®
MAIN INDEX

NO.
1 ASSY FOOT CONTROL MODULE -RHD
2 ASSY.CONTROL MOUNTING
BRACKET (WELDED)
3 ASSY CLUTCH PEDAL LEVER COMPLETE.
4 ASSY ACC PEDAL (RHD)
5 SLEEVE (FOR BRAKE & CLUTCH)
6 CLUTCH PEDAL ASSISTANCE SPRING
7 BRIGHT WASHER 10.5
8 HEX BOLT M10X125
GROUP INDEX
9 ASSY BRAKE PEDAL LEVER COMPLETE

10 TORSION SPRING (FOR BRAKE PEDAL RETURN)
11 NYLOC NUT M10
12 TORSION SPRING FOR ACC.PEDAL RETURN.
13 BUSH
14 CIRCLIP E9X1.1
15 STOP LIGHT SWITCH
16 CLUTCH PEDAL STOPPER
17 HEX SCREW M8X45
18 HEX NUT M8 Fig. 185 ® -Non Reusable Part
19 RUBBER COVER (PEDAL PLATE)
20 RUBBER COVER (ACC.PEDAL)
ENGINE 475 SI MPFI
ENGINETESTING 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 Loosen cylinder head mounting bolt by quarter turn and ENGINE
manner. retighten immediately to 7 mkg torque in the correct

sequence.
Connect oil pressure gauge and temperature gauge.
Complete cylinder head tightening operation in the same
Connect coolant hose to and from radiator. Fill coolant in sequence and with the same torque.
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 Tim e (m inutes) Torque (m kg)
(rpm)
800 5 0.0
2000 5 2.3
2500 5 4.6
3000 5 5.8
3500 5 4.9
2500 5 8.2
After running in test of the engine, reduce dynamometer

load to zero and allow engine to run at idling speed for
about 5 minutes and then stop it.
117
ENGINE 475 SI MPFI
EVAPORATIVE EMISSION CIRCUIT :

ENGINE
SULIN
Fig. 186
118
ENGINE 475 SI MPFI
8. TROUBLE SHOOTING
NOTE : BEFORE CHANGING ANY SENSOR PLEASE CHECK THE WIRING HARNESS CAREFULLY.
ENGINE
Sr. Problem Observed Probable Cause Action to be taken
no.
1. Engine not cranking Low battery voltage Clean and tighten the connectors
Jump start using another battery
Get battery charged or changed
Faulty starter Rectify or replace
Worn out piston rings/seized pistons Overhaul & replace affected parts
Faulty immobiliser Check and rectify
2. Engine cranks but

doesnot start Clogged air filt er Clean as per the instructions
Incorrect valve timing Set valve timing / check & reset
Fault y spark plugs Clean, check gap/ replace if necessary
Fault y crank angle signal Check & correct the gap
Faulty water tem p erature sensor Check & replace if necessary
Fault y MAP signal Check & replace if necessary
Fault y throttle position signal Check & replace if necessary
Fault y ISC valve Check & replace if necessary
SULIN
Clogged inject ors
Fault y fuel regulator
Check & replace if necessary
Clogged fuel filt er Rep lace
Fault y ignition coil Check and replace
Fault y firing order/ injector Check and replace
(connect ion) order
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
3. Erratic idling Inlet manifold leakage/

vacuum connections Check and rectify
Valve timing incorrect Set valve timing / check & reset
Vehicle speed signal fault y Check & replace
ISC valve faulty Check & replace
Vacuum line to presure
regulat or connect ions Check & t ight en/ replace
Fault y firing order/
inject or(connect ion) order Check and rectify
4. Does not idle Fault y MAP signal Check & replace

Fault y ISC Valve Check & replace
Fault y fuel regulator Check & replace
119
ENGINE 475 SI MPFI

no.
5. Maximum RPM low Battery voltage low Check and tighten connections
ENGINE
Jump start using good battery
Get battery charged/changed
Clogged air filt er Clean as per instruction
Valve timing incorrect set valve timing / check & reset
Spark plugs defect ive Clean an d ch eck g ap / rep lace if
necessary
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
injector (connection) order Check and rectify
6. Poor Low battery voltage Check and tighten connections

acceleration/Power
Get bat t ery charged/ changed
Clogged air filt er Clean as per instructions
Inlet manifold leakage/
SULIN
vacuum connections
Fault y ISC valve
Check and rectify
Check & replace
Clogged inject ors Check & replace
Fault y fuel regulator Check and replace
Fault y ignition coil Check and replace
Fault y firing order/ injector Check and replace
(connect ion) order
Incorrect t appet clearances Check and reset
Worn out piston rings/ seized pistons Overhaul / replace affect ed part s
necessary
Adult rat ed fuel Flush the system and refill
Fault y fuel regulator Check and Replace
Fuel pump fault y Check and Replace
inject or(connect ion) order Check and rectify
120
ENGINE 475 SI MPFI

no.
7. Knocking Spark plugs defective Clean and check gap/replace if necessary
ENGINE
Adultrated fuel Flush the system and refill
regulat or connect ions Check and t ight en/ replace
Incorrect valve timing Check and adjust.
8. Misfiring Inlet manifold leakage/ Check and Replace

necessary
Faulty crank angle signal Check and rectify the gap
inject or(connect ion) order Check and Rectify
9. Whitish/Bluish smoke Clogged air filt er Clean as per instructions

Worn out piston irings/ seized pistons Overhaul / replace affected parts
SULIN
Valve guide seals leaking
Adult et at ed fuel
Check and Replace
Flush the system and refill
10. High fuel Low battery voltage Check and tighten connections
consumption
Get bat t ery charged/ changed
Inlet manifold leakage/ Set valve timing / check & reset
Worn out piston rings/ seized pistons Overhaul / replace affect ed part s
Spark plugs defect ive Clean and check gap/ replace if
necessary
Faulty lambada signal Check and Replace
Fault y fuel regulator Check and Replace
regulat or connect ions Check and t ight en/ replacet
Fault y firing order/ injector Check and rectify
(connect ion) order
11. High oil consumption Clogged Air Filter Clean/ replace

Worn out piston rings/ siezed pistons Overhaul / replace affect ed part s
Valve guide seals leaking Check and Replace
121
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.
i
ENGINE 475 SI MPFI
CONTENTS
Sr. No. Description Page No.
1. Technical specifications 1
2. List of special tools 2
3. Tightening torques 3
4. 475 MPFI Euro III engine 5
5. 475 SI MPFI engine advantages 6
6. 475 MPFI Euro III system : Schematic representation 7
7. Exploded view of : EMS Kit Components 8
8. Engine Management System (EMS) Overview 9
9. MPFI sensors / actuators 11
10. Integrated Intank fuel pumpwith pressure regulator 31
11. Ignition Coil Assembly 32
12. ECU 34
13. ECU Handling & care 40
14. Schematic wiring diagram of power relay 41
15.
16.
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Schematic wiring diagram of some other EMS components
Preliminary inspection of engine
42
45
17. Exploded Views:
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
ENGINE 475 SI MPFI
Sr.No. Description Page No.
21. Timing belt Removal / Fitment 63

22. Cylinder Head (Engine on Workstand) 66
23. Cylinder block sub assembly 86
24. Lubrication system 100
25. Cooling system 102
26. Air intake system 111
27. Accelerator Cable 113
28. Engine Testing 115
29. Trouble Shooting 116
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v
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
Ignition system
:
:
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Sequential Injection with close loop Air / Fuel control
Grouped Ignition
Emission compliance : EURO III with EOBD
Engine oil capacity : 4.5 Litres
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
1
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.
11.
Valve spring compressor
Support rail
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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
2
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.

No.
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 2.5
4. Cylinder head cover bolts M6 1.0 #
5. Oil sump Screw M6 x 1 0.6 to 0.7 #
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.
10. Timing belt cover M6 x 1
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Rear timing cover to head cover M6 x 1 1.0
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 4+60 0 #
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 4.5 #
19. Camshaft gear to camshaft screw M12 x 1.25 8.0
20. Lock Nut (Rocker adjusting screw) M9 x 1 2 Kgm
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
3
ENGINE 475 SI MPFI

No.
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 1.0 #
30. Assembly Strainer to oil pump M6 x 1 1.0
31. Assembly oil filter to cylinder crankcase M12 x 1.5 Ref. Note @ #
32. Oil pressure switch on cylinder crankcase M20 x 1.5 3.0
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.
41. Engine mounting bracket to arm
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Engine mounting bracket to block M10 x 1.5 4.5
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 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.
4
ENGINE 475 SI MPFI
475 MPFI EURO III ENGINE
OIL FILLER CAP
IGNITION COIL
INTAKE
EXHAUST MANIFOLD
MANIFOLD
THROTTLE BODY
PHASE SENSOR
AC ENGINE RPM
COMPRESSOR
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MAP
SENSOR
OIL FILTER
DIPSTICK TUBE
ALTERNATOR
POWER STEERING PUMP
5
ENGINE 475 SI MPFI
INTAKE MANIFOLD WITH THROTTLE BODY
IAC VALVE
MAP SENSOR
THROTTLE
CYLINDER HEAD COVER BODY
BLOWBY HOSE
CYLINDER HEAD
FUEL RAIL
CANISTER
INTAKE PURGE
MANIFOLD VALVE
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475 SI MPFI ENGINE ADVANTAGES of Water and Air temperature inputs to the ECU.
475 MPFI engine uses JCAE multipoint fuel • Emission :
injection system. Various sensors located at
The petrol injection engine has low emissions
various points in the engine, sense important
because the air fuel ratio is controlled to
parameters of the engine operation & send signals
stoichiometric using lambda sensor. Faster warm
to a ECU located in egine compartment.Based on
up from cold start ensures early operation of
predetermined engine mapping, the ECU precisely
catalytic converter in turn reducing the emission.
controls the fuel delivery injection timing to ensure
optimum fuel utilisation with minimum emission. • Fuel Economy :
MPFI engine provides the following advantages The petrol injection engine has a better fuel
economy because the engine is optimised at each
• Better Engine Performance :
operating point, discretly.
Optimum fuel quantity and Spark timing is
calculated by ECU for any operating condition.
• Quick Response :
The petrol injection engine will have a better
• Better Cold Starting and Warm up :
driveability and better acceleration since the fuel
ECU identifies cranking condition and quick delivery and spark timing are controlled by ECU,
startingis ensured by providing sufficient fuel which quickly responds to engine/Driver demands.
quantity and optimum spark timing. For quicker
warm up, idling speed is increased as a function
6
ENGINE 475 SI MPFI
475 MPFI EURO III SYSTEM: SCHEMATIC REPRESENTATION
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7
ENGINE 475 SI MPFI
EMS KIT COMPONENTS
1
7
1
8 2
1.4
0.8
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3
11
4
10
5
- SPECIFIED TORQUE IN Kgm 1.5
Sr.No. PART DESCRIPTION Sr.No. PART DESCRIPTION

1 Crank Angle and Shaft RPM 6 Sensor Plate (Cam Shaft Gear)
Sensor 7 Knock Sensor
2 Bracket (Crank Angle Sensor) 8 MAP Sensor
3 Cam Sensor 9 Coolant Temperature Sensor
4 Bracket (for Cam Sensor) 10 Throttle Body
5 Rubber Grommet (Dust seal) 11 Ignition Coil
8
ENGINE 475 SI MPFI
ENGINE MANAGEMENT SYSTEM (EMS) • Canister Purge Control Valve

OVERVIEW : • Integrated Fault –tolerant System
• Immobilizer (Anti theft) management
• Air Conditioning and Fan Control
Indica MPFI - Euro III is powered with 475–SI Multi
Point Fuel Injected (MPFI) engine, which • Keyword 2000 (ISO 9141)interface
• Electrical diagnostic and protection (Short and
generates 85Hp. The JCAE (Johnson Controls
open circuits, signals)
Automotive Electronics) S2000 Engine Management
System combined with the suitable hardware meets
Additional Features
the EURO – III regulations.
• Warm Up Corrections
The Engine Management System is modular with a • Model Based transient injection control
• Model based transient ignition control
basic core group of essential sensors, actuators and
• Model based air/water temperature compensation
strategies(refer block diagram below). The strategies
are derived from physical modeling of the engine and • Limp home and recovery
• Adaptive fuel injection control
vehicle. The S 2000 PL 4 is dedicated for EURO III /
• Catalyst light-off control during engine warm up
Engine On Board Diagnostics(EOBD) Engine
management systems. It benefits from new • Altitude compensation
technologies includes a 256Kbit flash memory, • Deceleration fuel cut-off
• Engine Knock Control
allowing a downloading of the engine parameters and
has a 12MIPS (Million Inputs Per Second) • Fuel Pump relay Control
processing capability. The following matrix identifies • Post Ventilation – Fan control
• Accessory Load based Idle Speed regulation
the features used on Indica MPFI - Euro III application
• Distributorless Grouped Ignition ( Wasted Spark GENERAL SYSTEM OVERVIEW
•
Ignition)
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Sequential Multi point (MPI) Injection engine
control
Refer page No. 7 + Block Diagram of JCAE EMS
(below)
» Starting:
• Engine Phase detection
Dual (Up stream & Downstream) O2 Sensor The Idle Air Control Valve is opened to allow the
Interfaces with independent monitoring and heater correct amount of extra air into the engine for starting.
The Ignition timing and the amount of the fuel are
drivers
• Idle Speed Control by Stepper motor adjusted according to the engine temperature, giving
• EOBD Functions (Catalyst Monitoring, Mis-fire quick starts regardless of the different ambient
conditions.
detection ,Oxygen sensors, Fuel system etc)
INPUTS
OUTPUTS
9
ENGINE 475 SI MPFI
» Idle Air Control: depends largely on the engine load and speed.
Proper Idling of the engine is ensured irrespective of Further adjustments are to account for the variations
different operating conditions with help of closed loop in the operating conditions (e.g. Engine temperature).
control. The Idle Air control valve (IACV) that allows air To maximise the engine performance the fuelling is
to bypass the throttle controls idle air. The activation enriched to give maximum power at wide-open throttle
of the IACV occurs in three strategies: (WOT) conditions.
Not all the fuel injected by the Injectors enters the
1. During Starting to provide correct amount of engine directly, some amount is deposited on the Inlet
air to the engine port walls as a puddle whose size varies with the throttle
2. During engine Idle. Depending upon the position, engine speed and engine temperature. The
engine coolant temperature, the amount of the puddle evaporates over the time and its effect is
air inducted through the valve is varied by the particularly significant during transients. To account
varying the position of the valve, ensuring a for these transient effects, the puddle dynamics are
closed loop control to a target Idle Speed. modelled and the fuelling is adjusted accordingly.
3. During engine running to enhance driveability Overrun fuel cut-off is provided for fuel economy and
by controlling engine torque changes on improved emissions performance.
closing throttle (depression limiting). A closed loop fuelling system is used – a further
correction is applied to the open loop pulse time to
» Engine Load Determination: maintain a stoichiometric air fuel ratio under certain
Fuelling and Ignition timing requirements of the operating conditions. The closed loop system also
engine are dependent on the Engine load. The Load provides adaptive (‘Learning’) fuelling to compensate
determination is done using the Model Based for the wear of the intake system, component
Fuelling (MBF) strategy. tolerances and vehicle to vehicle variations.
The strategy uses the estimated temperature and
speed to estimate the amount of air entering the

cylinder at the next induction stroke.
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pressure at the intake port together with the engine » Ignition:
The optimum ignition timing depends largely upon the
engine speed and load. Further small corrections are
To calculate the airflow as precisely as possible, a applied to improve driveability and to account for the
thermal model of the Intake manifold is used, which is variations in the operating conditions (e.g. engine
a correction factor applied to the load equation to temperature, Inlet air temperature).
determine the correct amount of the fuel to deliver to The ignition timing is also adjusted in conjunction with
the engine. the Idle Air Control Valve to control the idle speed of
This model also serves as a backup strategy if either the Engine.
the Throttle Position or Manifold Absolute Pressure
Sensors fails. » Throttle Position and Adaptation:
The MBF model or Thermo model is a heat transfer The throttle position potentiometer output may differ
model, which use the heat exchange between the air between vehicle and can also change over time due to
and the manifold walls. The manifold also takes into component aging. A corrective term is applied to
account of all temperature variations (E.g.: purging) compensate for this effect; this is an adaptive
that will occur during the running. (‘learning’) value that is updated throughout the vehicle’s
life.
» Fuelling:
The Fuel is injected into the Inlet ports (Port Fuel » Knock Control:
Injection) by the solenoid operated Fuel Injectors which A sensor mounted on the engine detects when the
are driven by ECU. The amount of the fuel delivered knock occurs and allows the ECU to determine on
during each engine cycle is proportional to duration of which cylinder knock is occurred. Then the Ignition
the Injector open time. Injector timing (phasing) is and fuelling corrections are applied to prevent further
controlled to optimise performance. The injection is knock and thus protecting the engine from any
sequential i.e., each injector is opened relative to its damages. Further an intelligent software strategy
own cylinder timing. enables a ‘Cylinder selective’ knock control, despite
Amount of the fuel required (i.e. the Injector pulse time) the ignition is ‘grouped’.
10
ENGINE 475 SI MPFI
» Gear Ratio Determination:

Employing different calibrations for open loop Idle
control and fuel cut off depending on which gear is
currently selected can enhance Driveabilty. Gear ratio,
and hence the gear engaged, is calculated from the
vehicle’s measured engine speed and road speed. This
input is further synchronised with the ‘Anti- surge’
functions for a smoother driveability during the
transients (accelerations and decelerations).
» Purge Control:
Fuel vapours generated in the fuel tank is stopped in a
canister, in order to limit the hydrocarbon emissions
into the atmosphere. The vapours stored in the
canister are purged into the engine under controlled
conditions via a Purge valve to minimise any
detrimental effects on driveability or on the emissions.
» Engine Speed Limiting:

A rev-limiter protects the engine from over revving. The
cut off is introduced progressively to make the
operation smooth to the driver.
» Vehicle Speed Limiting:
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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.
» 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
ENGINE 475 SI MPFI
MPFI SENSORS / ACTUATORS

CRANK ANGLE SENSOR : (Fig.1 & 2).
Type :
03VR
Inductive pick up (Variable reluctance)
3 Pin connector
Working Principle :
The sensor is positioned near the flywheel mounted
toothed wheel. An A.C. voltage is induced in sensor
coil, when the flywheel tooth projection pass through
the sensor. This A.C. voltage is directly proportional
to the speed of rotation. This sensor signal is first
processed by an ASIC and then by the ECU.
Fig. 1 Crank angle sensor
The sensor provides the speed and crank angle input

to the ECU. The system uses a 60 -2 = 58 tooth
spaced at 6º intervals. The tooth wheel (target wheel)
is integral part of the flywheel. This wheel has 2 tooth
missing (at 114º ATDC of cylinder1) to allow the engine
position to be determined.
& crank angle position.(Fig. 3 & 4).

Fitment Data :
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The sensor signal is used to calculate engine speed
This sensor is mounted on the cylinder block over the

flywheel (Fig. 1).
Sensor Gap = 1.5 ± 0.75 mm
Installation Guideline :
Fig. 2 Crank angle sensor
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
1 : ECU pin M2B1: +ve
2 : ECU pin M2B2: -ve
3 : Shield
12
ENGINE 475 SI MPFI
PMH 1-4
Physical
Teeth
VR
sensor
signal
Processed
Signal
1 3 1
PMH 2-3 PMH = TDC, Top Dead Centre
Fig. 3 Fig. 4
SCHEMATIC WIRING DIAGRAM :
+ VE
M2B1
- VE SULIN M2B2
CRANK ANGLE SENSOR
13
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.
Fitment Data : Fig. 5 Water temperature sensor
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 @ 20º C
833.9 ohm @ 50º C
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1 : ECU M1D4: -ve
2 : ECU M1E4: +ve
Measure the resistance
across pins 1 & 2.
System Diagnosis :
Use Tata Diagnostic Tool.
Check for ‘Water Temp’ values.
SIG M1E4
- VE
M1D4
14
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 Fig. 6Manifold air pressure sensor
output increases with increase in absolute manifold
vacuum.
Air temp :
Semiconductor material changes resistance when
exposed to variable temperature source.
System Integration : 4 3 2 1 PIN Nos.
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This provides manifold vacuum (abs.) signal & air
temperature input to ECU. The sensor is activated by
excitation voltage supplied by ECU.
Fitment Data :
This sensor is fitted on Inlet manifold pleanum.(Fig. 6)

Installation Torque : 1Kgm
Stand Alone Diagnosis : Fig. 7Manifold air pressure sensor
Use Multimeter
With ignition “ON”. Characteristic of MAP Sensor
Supply volt = 5.00 vdc 5

4.65
Signal volt = 0.4 V @ 10 kpa (abs)

Output Voltage Uout in V
= 4.65 V @ 115 kpa (abs)

Pin assignment (Fig.7)
1 : M2A2 : Ground
2 : M1A2 : Temp. Signal
3 : M2E1 : Supply 5V 0.4
0
0 10 115
Absolute Pressure Pabs in kPa
4 : M2C1 : Pressure Signal
Measure signal volt at pin1 and pin3 with sensor
15
ENGINE 475 SI MPFI
connected to wiring harness.

Characteristic of Temperature Sensor
System Diagnosis : 100000
Use Tata Diagnostic Tool

10000
Resistance R in ohm
Check for ‘Intake manifold pressure’ and air
temperature value. 1000
100
10
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130
Temperature t in ºC
2 M1A2
+
SIG
-
3
4
SULIN M2E1
M2C1
1 M2A2
MAP & T
16
ENGINE 475 SI MPFI
THROTTLE POSITION SENSOR (TPS)

Fig. 8 & 9.
Type :
06TP
Linear Potentiometer type
2 Pin Connector Blade drive with integral 3-way
connector
Working Principle :
A fixed input DC volt to a potentiometer provides a
variable output DC volt when the circuit resistance is
varied externally.
Output voltage increases when circuit resistance
reduces.
System Integration : Fig. 8 Throttle Position Sensor (TPS)
Sensor provides variable signal Input to ECU when
throttle lever is operated (opened / closed). This
requires a supply volt of 5.00 Vdc from ECU.
Fitment Data :
is fitted on inlet manifold upstream side. Throttle lever
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shaft is extended to a crank lever which operates the
sensor (varies the circuit resistance). Fig. 8
Installation Guidelines :
Diameter of screws used to fix potentiometer = 12mm
Tightening Torque = 2.5 + 0.5 Nm
Use Multimeter
With ignition “ON”. Fig. 9 Throttle Position Sensor
Supply volt = 5.00 vdc
Signal volt = 0.5 vdc at Idle position Sensor Characteristics
= 4.5 + 0.15 vdc at WOT position
4.25 + 0.225
Sensor end Pin Assignment

1 : ECU pin M1A3 : Gnd.
Volts
2 : ECU pin M1B4 : Signal

3 : ECU pin M2C3 : 5V
supply 0.68 + 0.1
Measure signal voltage across pin 2 and pin 3 with 0 5

Degrees
91 98
sensor connected to wiring hamess.

System Diagnosis :
Note :
Use Tata Diagnostic Tool. The broken lines represent acceptable divergence limits <S>
Check for ‘Throttle sensor’ voltage by pressing the
accelerator pedal in and out.
17
ENGINE 475 SI MPFI
+ VE
3 M2C3
SIG 2 M1B4
1
M1A3
- VE
THROTLE POSITION SENSOR
FROM POWER RELAY (BASE PIN NO 8)
FUSE 15A
+ VE
- VE
1
2
SULIN M1E2
SIG M2A3
4
- VE M2B3
3
UPSTREAM LAMBDA (O2 )SENSOR
FUSE 15A
+ VE
1
- VE
2 M1D2
SIG
4 M1E3
- VE
3 M1D3
DOWNSTREAM LAMBDA (O2 )SENSOR
18
ENGINE 475 SI MPFI
LAMBDA SENSOR (O2 Sensor) Fig. 10 & 11

Type :
Heated Ceramic Oxygen Sensor

4 Pin Connector
08LS Down Stream Oxygen Sensor
09LS Up Stream Oxygen Sensor
Working princple (See Illustration) :
A special ceramic body with gas permeable platinum
electrodes on its surface, operates, depending upon
ceramic material’s porosity which allows oxygen in
the air to diffuse when the ceramic body is exposed to
temperatures above 3500C. Voltage is generated
across the electrodes which are exposed to gas with
different levels of oxygen contents.
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 :
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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
ENGINE 475 SI MPFI

Use Multimeter
Heater function
Heater Resistance
For Pin nos. please refer
08LS : 6.0 ± 1ohm ( 23 ± 5º C) to marking on casing.
09LS : 3.3 (+0.7ohm/-0.3ohm) ( 23 ± 5º C)
Pin assignment (Fig. 12)

Up Stream Oxygen Sensor (Green colour)
1 : Supply 12V
2 : ECU pin M1E2 : Heater
3 : ECU pin M2B3 : Signal -ve
4 : ECU pin M2A3 : Signal +ve
Fig. 12
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 :
Check for the signal voltages.
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● For Upstream O2 sensor :
Voltage > 0.500V or < 0.400V &
Switching frequency > 0.2Hz
● Downstream O2 sensor :
Voltage > 0.500V or < 0.400V
20
ENGINE 475 SI MPFI
LAMBDA SENSOR :
• Lambda oxygen sensor located in exhaust pipe
Fig. 13. 5 7 6 4 8
1. Special ceramic coat
2. Electordes
3. Contact
4. Housing
5. Exhaust pipe
3
6. Shield (porous)
7. Exhaust gas.
8. Air 1 2
Fig. 13 Lambda Sensor
• Lambda (oxygen) sensor voltage curve at 6000C

operating temperature Fig. 14
mV
a) Rich mixture (air deficiency) a b
1000
Oxygen-sensor voltage
b) Lean mixture (excess air)
800
SULIN 600
400
200
0
0.8 0.9 1 1.1 1.2
Excess-air factor
Fig. 14 Lambda Sensor Voltage Curve
• Heated Lambda (oxygen) sensor Fig. 15

1. Probe housing
2. Ceramic Shield tube 1 2
5 3
3. Electrical connections
4. Shield tube with slits
5. Active ceramic sensor layer
6. Contact
7. Shield
8. Heating lement
9. Clamp connections for heater element 4 6 7 8 9
Fig. 15 Heated Lambda Sensor
21
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 Fig. 16 Location of VSS on Transaxle
on speedo output location.Fig. 16.
Use Multimeter
Pin assignment
1 : Supply
2 : Ground
3 : ECU pin CPG2 : Signal
SULIN
Manually rotate the speedometer cable and check for
contact make & break pulses 8 times/rev.
With Ignition ‘ON’,
Pulse volt in ‘ON’ condition = 12 Volt DC 3 2 1 PIN NOS.
Measure pulse volt across ECU pin no. 6 and car body
as ground with wiring harness connected to ECU. Fig. 17 Vehicle Speed Sensor (VSS)
System Diagnosis :
Check for Vehicle speed sensor ‘Value’ during driving.
SCHEMATIC WIRING DIAGRAM : FROM POWER RELAY (BASE PIN NO 8)
FUSE 15A
+ VE 1
SIG 3 CPG2
2
- VE
VEHICLE SPEED SENSOR
22
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.
Fitment Data :
Mounted on the cylinder block.
SULIN
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
1
M1C3
KNOCK
2 SENSOR
M1B3
KNOCK SENSOR
23
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 Fig.20

the phasing. The software reads the state of the
Camshaft sensor on each engine revolution, by the
signal provided by the sensor.
Fitment Data :
This sensor is mounted near the Camgear on the

cylinder head.
Sensor Gap : 1.5 ± 0.5mm
Installation Guidelines : 6 - 10 Nm
SULIN PIN Nos. 1 2 3

Pin Assignment
1 : Ground
2 : ECU pin M1F3 : Signal Fig.21
3 : Supply 12V (From relay - pin 8 of base)
SCHEMATIC WIRING DIAGRAM : FROM POWER RELAY (BASE PIN NO 8)
FUSE 10A
+ VE 3
SIG 2 M1F3
1
- VE
CAM SHAFT POSITION SENSOR
24
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
Fig. 22 Throttle Body showing Idle Air control valve
e.g. :A/C idle speed = 800 rpm fitted
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.
used to prevent loosening.
SULIN
Torque : 4+ 0.4 Nm - Thread locking adhesives can be
Use Multimeter
Single Phase coil resistance = 53 ± 5.3 ohm
A ECU pin M2E3 : Coil A
B ECU pin M2D2 : Coil B
C ECU pin M2D3 : Coil B Fig. 23 Idle Air control valve (IAC)
D ECU pin M2D1 : Coil A
Measure the coil resistance across pins M2E3 &
M2D1, M2D2 & M2D3.
Throttle Body
System Diagnosis :
Check for IAC valve steps
For normal idling at hot condition
IAC valve steps = 12 ± 3 steps. (typical value)
Air Cleaner Air Outlet

M2D1
D Stepper
M2D3 C
M2D2
B
A
M2E3
Air Inlet Throttle Plate Intake Manifold
Fig. 24 IAC valve illustration
25
ENGINE 475 SI MPFI
INTEGRAL THROTTLE BODY

Type :
09TB
Ø 44 mm throttle valve, integrated with throttle position
sensor, IACV (Idle Air Control Valve).
Working Principle :
Air flow into the engine is varied by varying the cross
section area. In addition, flow rate is dependent on
engine speed.
This Integral Throttle Body is with a butterfly valve
(See Illustration) in the air flow path (of ø 44mm). The
throttle is actuated by the lever (Fig.27)and the shaft
assembly which in turn operates Throttle position Fig. 25
sensor to provide engine load signal.
Fitment Data :
Fitted on the upstream of the inlet manifold. Fig. 25
Manifold mounting flange screw torque : 6Nm
Tightening Torques :
Item Dimension
SULIN
Torque(NM)
Throttle Screw 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
Fig. 26 Integral throttle body
Idle adjusting screw M5 x 0.5 ---

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
ENGINE 475 SI MPFI
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 Fig. 28 Location of purge valve
manifold) at appropriate speed and load of engine as
decided by ECU. This valve is kept open (to purge)
depending upon the duty cycle ratio drive signal from
ECU.
Fitment Data :
This valve is mounted on the engine block. In petrol
vapour circuit this valve connects canistor purge line
SULIN
to intake manifold, downstream side of integrated
throttle body. Fig. 28
Use Multimeter
Solenoid coil resistance = 26 ohm ± 4 ohm @ 200 C
1 : ECU pin M2F2
Fig. 29 Purge valve
2 : Supply
Measure the resistance across pin 1 and 2.

System Diagnosis :
27
ENGINE 475 SI MPFI
CANISTER PURGE VALVE - ILLUSTRATION :

1. HOSE CONNECTION
1
2. NON RETURN VALVE
3. LEAF SPRING 2
4. SEALING ELEMENT 3
5. SOLENOID ARMATURE
4
6. SEALING SEAT
5
7. SOLENOID COIL.
6
Fig. 30 SULIN
M2B1 1
FUSE 10A
PURGE VALVE
28
ENGINE 475 SI MPFI
FUEL INJECTOR Fig. 31, 32 & 33

Type :
F type short
2 Pin Connector
Working Principle :
A solenoid valve, normally closed, opens when the
electromagnetic core is energised. Fuel under pressure
flows through metering orifice.This ensures fine
atomisation and consistent flow rate for a given Injector
opening time. The ball type seating valve acts as a
good anti-deposit.
ECU provides drive signal to Injector (normally closed Fig. 31 Fuel Injectors location in the engine
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 :
SULIN
Four numbers of injectors are fitted on inlet manifold
and fuel is fed by a common fuel rail(Fig.32) so that
the fuel spray from each injector is directed towards
the inlet valve, inside the inlet port.
Stand Alone Diagnosis : Injectors
Use multimeter
Injector coil resistance 12.25 ohm ± 0.50 ohm
Actuator end Pin assignment Fig.32 Fuel Injectors
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
System Diagnosis :
Fig. 33 Fuel Injector
29
ENGINE 475 SI MPFI
FUSE 15A
1 INJECTOR
CYLINDER 1
1 INJECTOR
CYLINDER 2
SULIN 1 INJECTOR
CYLINDER 3
1 INJECTOR
CYLINDER 4
INJECTORS
30
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 Fig. 34
return line.
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.
Fitment Data :
SULIN
This Intank pump is fitted inside the fuel tank by
immersing the pump’s suction end in the fuel.
Pressure regulator is fitted on the return line of the
pump.
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
ENGINE 475 SI MPFI
M
FUSE 15A
FUEL PUMP
FROM POWER RELAY

(BASE PIN NO 5)
FUSE 15A 3 2
M1H3
SULIN 3
2
M1G3 1
4 1
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
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
Fig. 36 Ignition coil
possible interferance w.r.t. the functioning of ECU.
Fig. 36 & 37
Use Multimeter
Check for 12 V power supply P/G on wiring harness
Firing order (1,3,4,2) & HT cable connections
(See Illustration)
Primary coil resistance = 0.6 ohm
SULIN
1 : ECU pin M1G3 : cylinder1&4
2 : ECU pin M1H3 : cylinder 2&3
3 : Supply
4 : Ground (through supressor) Fig. 37
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).
System Diagnosis :
Check for ‘Ignition timing value’ during idling.
Cylinder nos. marked for HT cable fitment.

Fig. 38
33
ENGINE 475 SI MPFI
ENGINE CONTROL UNIT (ECU) :

Fig. 39,40 & 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 micro-
processor and control signals are provided for various
activators (e.g. ISC valve, Injectors etc.) for
satisfactory engine performance. Various control
algorithms (software) are used in conjuction with the
map/table data to provide various control functions for
optimum functioning of the engine, which in turn
provides best fuel consumption/emissions.
Fitment Data : (Fig. 39)

SULIN
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 Fig. 40
Use multimeter.
Perform continuity check on the ECU connection at
wiring harness end to any sensor/actuator depending
upon engine symptom.
SPECIFICATIONS :
Type :
S2000PL4
CPU Make :
SIEMENS
CPU Type :
SAK 167
Processor Speed :
Over 12 MIPS
Fig. 41
34
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 : 204 mm
• Grouped Ignition
• Sequential Injection
SULIN
35
ENGINE 475 SI MPFI
CONNECTOR CLM1(BLACK) :
(VIEW SEEN FROM CABLE ENTRY SIDE)
PIN NO PIN ASSIGNMENT CABLE CODE(Please Refer Page 39)

M1 A1 NOT USED -
M1 A2 AIR TEMPERATURE SENSOR BR
M1 A3 SENSOR GROUND 2 LgW
M1 A4 Vbatt SWITCH BR
M1 B1 NOT USED -
M1 B2
M1 B3
M1 B4
NOT USED
KNOCK SENSOR -
THROTTLE POSITION
SULIN -
B
BrG
M1 C1 NOT USED -
M1 C2 NOT USED -
M1 C3 KNOCK SENSOR + W
M1 C4 ALTERNATOR CURRENT BrY
M1 D1 NOT USED -
M1 D2 DOWNSTREAM LAMBDA SENSOR HEATER BrG
M1 D3 DOWNSTREAM LAMBDA SENSOR - B
M1 D4 WATER TEMPERATURE INPUT - Rg
M1 E1 NOT USED -
M1 E2 UPSTREAM LAMBDA HEATING DRIVER PB
M1 E3 DOWNSTREAM LAMBDA SIGNAL INPUT + W
M1 E4 WATER TEMPERATURE INPUT + BrW
M1 F1 NOT USED -
M1 F2 MAIN RELAY DRIVER P
M1 F3 CAM SENSOR INPUT W
M1 F4 NOT USED -
M1 G1 NOT USED -
M1 G2 NOT USED -
M1 G3 COILS 1 AND 4 WL
M1 G4 NOT USED -
M1 H1 NOT USED -
M1 H2 NOT USED -
M1 H3 COILS 2 AND 3 G
M1 H4 POWER GROUND n3 BR
36
ENGINE 475 SI MPFI
CONNECTOR CLM2 (GREY) :

M2 A1 NOT USED -
M2 A2 MAP SENSOR GROUND 1 BrR
M2 A3 UPSTREAM LAMBDA SENSOR + B
M2 A4 NOT USED -
M2 B1 ENGINE SPEED SENSOR + W
M2 B2
M2 B3
M2 B4
SULIN
ENGINE SPEED SENSOR -
UPSTREAM LAMBDA SIGNAL INPUT -
NOT USED
W
B
-
M2 C1 INLET AIR PRESSURE WO
M2 C2 NOT USED -
M2 C3 SENSOR +5V_2 VR
M2 C4 NOT USED -
M2 D1 ICS STEPPER DRIVER OUTPUT D LGO
M2 D2 ICS STEPPER DRIVER OUTPUT B WV
M2 D3 ICS STEPPER DRIVER OUTPUT C RL
M2 D4 NOT USED -
M2 E1 SENSOR +5V_1 WY
M2 E2 NOT USED -
M2 E3 ICS STEPPER DRIVER OUTPUT A GR
M2 E4 NOT USED -
M2 F1 NOT USED -
M2 F2 PURGE CANISTER YL
M2 F3 POWER RELAY WG
M2 F4 NOT USED -
M2 G1 CHECK ENGINE LAMP LR
M2 G2 INJECTOR CYLINDER 3 YL
M2 G3 INJECTOR CYLINDER 2 YL
M2 G4 NOT USED -
M2 H1 POWER GROUND n4 Br
M2 H2 INJECTOR CYLINDER 1 LG
M2 H3 INJECTOR CYLINDER 4 LgP
M2 H4 NOT USED -
37
ENGINE 475 SI MPFI
CONNECTOR CP (BROWN) :
AC PRESS SW
FUEL LEVEL
FAN2
LO SPEED

CP A1 NOT USED -
CP A2 NOT USED -
CP A3 NOT USED -
CP A4 NOT USED -
CP B1 NOT USED -
CP B2 NOT USED -
CP B3 L-LINE RG
CP B4
CP C1
CP C2
IGNITION SWITCH INPUT
NOT USED
NOT USED
SULIN GR
-
-
CP C3 AIR CON O/P (Relay Driver) GP
CP C4 ONBOARD DIAGNOSTIC FAULT INDICATOR(MIL) WP
CP D1 NOT USED -
CP D2 NOT USED -
CP D3 AC REQUEST INPUT BY
CP D4 NOT USED -
CP E1 NOT USED -
CP E2 COOLING FAN - HIGH SPEED GY
CP E3 POWER STEERING STOP INPUT GrW
CP E4 NOT USED -
CP F1 NOT USED -
CP F2 NOT USED -
CP F3 ANTI THEFT LINK WG
CP F4 NOT USED -
CP G1 NOT USED -
CP G2 VEHICLE SPEED SENSOR INPUT V
CP G3 NOT USED -
CP G4 NOT USED -
CP H1 NOT USED -
CP H2 K LINE YR
CP H3 NOT USED -
CP H4 NOT USED -
38
ENGINE 475 SI MPFI
PIN NO PIN ASSIGNMENT CABLE CODE

CP J1 NOT USED -
CP J2 NOT USED -
CP J3 NOT USED -
CP J4 COOLING FAN 1 (RELAY DRIVER) Y
CP K1 NOT USED -
CP K2 NOT USED -
CP K3 NOT USED -
CP K4 FAN 2 RELAY DRIVER YB
CP L1 NOT USED -
CP L2 NOT USED -
CP L3 NOT USED -
CP L4 POWER GROUND1 Br
CP M1 NOT USED -
CP M2 NOT USED -
CP M3 LOW FUEL LEVEL INPUT VR
CP M4 POWER GROUND2 Br
2. FOR VERSION : NON AC WITH POWER STEERING
ALL PINOUT ARE AS PER REFERENCE VERSION EXCEPT
CP D3 AC REQUEST INPUT BY NOT CONNECTED

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

CP C3 AC COMPRESSOR DRIVER GP 12 V SUPPLY
CP E2 COOLING FAN HIGH SPEED GY NOT CONNECTED
CP E3 POWER STEERING STOP INPUT GrW NOT CONNECTED
CABLE CODE CABLE COLOUR

B BLACK
Br BROWN
G GREEN
Gr GREY
L BLUE
O ORANGE
P PINK
R RED
W WHITE
Y YELLOW
V VIOLET
Lg LIGHT GREEN
Sb SKY BLUE
39
ENGINE 475 SI MPFI
ECU HANDLING CARE : • Ensure that the connector is inserted in the end
after all the installation is complete.
Earth (Ground) Connection
• To carry out welding job on the car the ECU
• Ensure all the ground connections are fixed should be disconnected.
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
SULIN
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
• 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
ENGINE 475 SI MPFI
SCHEMATIC WIRING DIAGRAM OF POWER RELAY :
BAT
30A (EMS ECU

MAXI FUSE)
POWER
MAIN RELAY
RELAY NC (2 NO CONTACTS)
NO 2
4
M1F2
P
INERTIA
M1A4 SWITCH
6 8 5 IMMOBILISER
6
M2F3
SULIN 26
IMMOBILISER PIN
15A
FUSE
15A
5
FUEL
FUSE PUMP
• IGNITION COIL
• UPSTREAM O2 SENSOR • INJECTORS
• 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
ENGINE 475 SI MPFI
SCHEMATIC WIRING DIAGRAM OF SOME OTHER EMS COMPONENTS :
MIC4
SULIN
CPE3
42
ENGINE 475 SI MPFI
3 CAN_H
11 CAN_L
7 ISO 9141k
15 ISO 9141L
16 12V+ve
0.5 mm
1 GND
CPB4
SULIN
10A FUSE
IGN SUPPLY
IGNITION KEY
CEL (1.4W)
M2G1 IGN
10A FUSE SUPPLY
MIL (14W)
CPC4
MALFUNCTION INDICATOR LAMP CHECK ENGINE LAMP
43
ENGINE 475 SI MPFI
CKT. IN THE CLUSTER

15 16
CPM3
2
TANK UNIT FUEL

GAUGE
FUEL LEVEL SENSOR
80 A (MAXI FUSE)
RADIATOR
CONDENSOR
RELAY
CPJ4 SULIN RELAY
TO COOLING FAN
SERIES
RELAY
CPK4 COOLING FAN
(LOW SPEED)
COOLING FAN 1 AND 2
44
ENGINE 475 SI MPFI
PRELIMINARY INSPECTION OF ENGINE OR

Drive the car with weight equal to GVW in 3rd
Before proceeding to carry out actual overhauling of gear on level ground and let the speed drop down
engine it is desirable to have a preliminary inspection to approximately 15 kmph/10 mph. Now press
of engine to ascertain whether an engine overhaul is accelerator pedal fully. With slipping clutch, the
necessary and to what extent. car speed will not pick up and also clutch burning
Most common reasons for which engine is overhauled smell will be noticed. If this does not occur and
are : car picks up speed, it indicates that clutch does
not slip.
1. Loss of power
e. BRAKE BINDING
2. Excessive engine oil consumption
During driving apply brake number of times and
3. Extremely low engine oil pressure then shift the gear to neutral position Check brake
4. Mechanical failures 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 : f. CHECKING ENGINE COMPRESSION
PRESSURE (Fig. 42)
1. LOSS OF POWER
If loss of power is not on account of defective fuel
Loss of engine power may be due to : system, lack of air, choked exhaust silencer,
a. Defective Ignition system clutch slipping and brake binding. check engine
compression as follows :
b. Defective Fuel system
1. Warm up engine preferably by road drive to get a
c. Clogged air cleaner/choked catalytic converter temperature of about 75 to 85 0C.
d.
exhaust silencer
Clutch slippage
SULIN 2. Remove all spark plugs.
3. Remove fuel connection to fuel rail (after relieving
fuel pressure as indicated in fuel section) &
e. Brake binding suitably prevent fuel from spilling from open
f. Loss of engine compression connection.
4. Remove air cleaner filter element.
a. IGNITION SYSTEM 5. Install Compression gauge (Range about 0 to 25
Check all the sensors for proper function by using kg/cm2) into one of the spark plug hole.
Note :
diagnostic monitor. Replace defective sensors.
Use adaptor which is available commercially to
b. FUEL SYSTEM suit the size of the spark plug threads.
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 Fig. 42
does not slip.
45
ENGINE 475 SI MPFI
is higher, place the car on a level ground.

5. Disengage clutch (to reduce starting load on 2. Top up oil sump to its capacity of 4.5 litres.
engine) and depress accelerator pedal all the way
3. Warm up the engine so that oil temperature is
to make throttle valve open fully.
75 - 800 C.
6. Crank engine with fully charged battery, and read
4. Take a clean vessel, place it below the drain plug
the highest pressure on compression gauge.
of oil sump.
7. Carry out steps 5 to 7 on each cylinder to obtain
5. Drain the hot oil into the clean vessel. Drain it
compression pressures. The specified
fully.
compression pressure is 9.5 bar minimum.
6. Screw in oil sump drain plug and tighten it.
8. Variation in compression pressure between
cylinders should not be more than 0.5 bar. 7. Weigh the vessel along with oil let this weight be
‘w1’, gms.
9. Low compression pressure may be due to leakage
past valves / piston rings/blown cylinder head 8. Refill the weighed oil into the oil sump. Do not
gasket. To ascertain the point of leakage, spray spill any oil. The vessel used for draining should
small quantity of clean engine oil in to the cylinder not be used for any other purposes.
showing low pressure and re-check compression
pressure. If it improves, wear in piston rings/ 9. Drive the vehicle approx. 200-300 km/125 - 185m.
cylinder bore is indicated. If it does not, leakage This drive should include at least 30-40 kms/
past the valves is indicated. If compression 20-25m of highway or similar road, vehicle running
pressure of adjacent cylinder is also on lower at about 60 kmph/ 40mph. Let this drive distance
side, it may be due to blown cylinder head be ‘D’ miles.
gasket. 10. Immediately after the test drive, place the vehicle
2. EXCESSIVE ENGINE OIL CONSUMPTION
Maximum limit for Oil Consumption = 100 cc/ 1000km
SULIN at the same spot from where it started.
11. Place the same previously used vessel below
the oil sump, unscrew the drain plug and drain
= 100 cc/ 625miles
off oil into the vessel. Drain the sump fully.
High engine oil consumption may also lead to
12. Weigh the vessel along with oil, now for the
overhauling of the engine but before proceeding to
second time. Let this weight be ‘w2’ gms.
overhauling, check following points :
13. Find out standard oil consumption as -
1. Make sure that there is absolutely no external
oil leak (i. e. from the camshaft oil seal, crankshaft Std.oil consumption(w1-w2)(wt.ofoil consumed,gms)x1000
oil seal, oil sump gasket, oil pump gasket, cylinder ‘C’ (litres/1000km) =
sp. wt. of oil (gm/cm3) x ‘D’ (drive dist. in
head cover gasket etc.)
miles.)
2. If no external leakage is found, determine the
w1 - w2
exact engine oil consumption, as per following ‘C’ = litres/1000miles
0.88 x D
procedure.
3. EXCESSIVE LOW OIL PRESSURE
DETERMINING EXACT ENGINE OIL
EXTREMELY
CONSUMPTION :
Check the following :
CAUTION :
a. External leakages.
Do not make a rough estimate of engine oil consumption
by noting the kilometers covered by the car at any random b. Oil level in sump upto maximum mark on dipstick.
stage and finding oil consumed from the topped up
c. Oil pressure transducer for proper functioning.
position taking into consideration dipstick level and
oil sump capacity. d. Functioning of pressure relief valve on oil pump.
PROCEDURE : e. Oil pump performance using a suitable pressure
gauge.
1. Once it is doubted that engine oil consumption
46
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. 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.
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
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
ENGINE 475 SI MPFI
AIR - INTAKE SYSTEM
5
7
6
4
11
1
22
2
21
3
8 20
17
9 10
16
12 19
SULIN 14
18
13
15

1 Gasket (for Throttle Body) 12 Assembly Bracket (for Resonator
2 Throttle Body Mtg.)
3 Rubber Bellow 13 Resonator Box
4 Hose Clamp (72 Dia) 14 Assembly Isolator
5 Assembly Air Filter 15 Rubber Grommet(for Resonator
6 Sealing Plug M12 Box)
7 Sealing Washer 16 Air Intake Snorkel
8 Isolator (for Air Filter) 17 Assembly Clamp(for Mtg. Snorkel)
9 Assembly Bracket Front (for Air 18 Hose (Resonator Box)
Filter Mtg.) 19 Hose Clamp (42 Dia)
10 Assembly Isolator (for Air Filter) 20 Intake Duct
11 Bracket Rear (for Air Filter Mtg.) 21 Hose (Air Filter to Intake Duct)
22 Hose Clamp (72 Dia)
49
ENGINE 475 SI MPFI
ENGINE SUSPENSION ENGINE MOUNTING

ARM (FRONT)
LIFTING HOOK (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 MOUNTING ASSY ENGINE MOUNT C

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
ENGINE 475 SI MPFI
INLET AND EXHAUST MANIFOLD

NIPPLE (RESTRICTION)
CORE PLUG
TUBE (FOR VACCUM BOOSTER)
STUD
INTAKE MANIFOLD
NIPPLE (TPV)
SULIN
GASKET (FOR INLET MANIFOLD)
GASKET (FOR EXHAUST MANIFOLD)
-- SPECIFIED TORQUE IN Kgm STUD

-- NON-REUSABLE PART
2.0
51
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
OIL SEAL
TIMING BELT
SULIN
ASSY TIMING GEAR
8.0
ASSY TENSIONER
ASSY IDLER PULLEY
4.5
SPACER
4.0
52
ENGINE 475 SI MPFI
MOVING PARTS - BLOCK

16
17
18
15
19
11 7
20 5.0#
2
14
13
12
5.25#
2.5
SULIN 1
9 10
4+60º# 4
-- SPECIFIED TORQUE IN Kgm # = + 5% Tolerance on Torque value

1 Crankshaft 11 Connecting Rod
2 Cylinder Pin 8m 6 X 16 12 Con Rod Cap
3 Assembly Gear(for crankshaft) 13 Con Rod Bush
4 Assembly Integral Vibration 14 Bearing Half Normal
Damper 15 Piston Grade A (IP)
5 Washer 16 Top Ring A (IP)
6 Key 17 Taper Faced Ring (IP)
7 Assembly Flywheel Complete 18 Assembly Oil Control Ring
8 Main Bearing Half Shell 19 Piston Pin (IP)
9 Thrust Washer Upper 20 Internal Circlip 20
10 Thrust Washer Lower
53
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 HOSE CLAMP
RUBBER HOSE (THERMOSTAT COVER TO RAD) SULIN 1.5
RUBBER HOSE
HOSE CLAMP
O-RING
THERMOSTAT
HOUSING
ASSY THERMOSTAT
1.5
COOLANT TEMP
SENSOR HOSE CLAMP
SEAL THERMOSTAT 0.8
GASKET
ASSY HOSE
ASSY WATER BYPASS TUBE

1.0
54
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
ASSY FUEL RAIL SULIN RUBBER HOSE (CPV

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

SPRING CLIP
SPRING CLIP
ASSY CARBON CANISTER
ASSY BRACKET (FOR

CARBON CANISTER)
1.0
55
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
LOCK HALF
SULIN
VALVE SPRING
6.5
CYLINDER HEAD
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
ENGINE 475 SI MPFI
GASKETS
Throttle Body Gasket
Gasket Oil Filter Gasket
Gasket (Cyl. Head Cover)

Exhaust Manifold
Gasket
SULIN Intake manifold Gasket
Gasket Elbow
Rear Gasket
Front Cover Gasket
Water Pump Gasket
Oil Sump Gasket
Oil Pump Strainer Gasket
57
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
ALTERNATOR 2.0
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 BRACKET

(FOR A/C COMPONENTS)
58
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
SULIN
Gear shift linkages from transaxle Fig. 44
Radiator (if required)
Remove Battery.
Fig.44
Drain transaxle oil, Fig. 45.
Fig. 45
59
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 2702 5890 24 01
recommended to use two pole hoist to lift the car)
Remove the engine alongwith transaxle. Fig.46
Remove starter motor.
Disconnect transaxle Assembly from engine. (Ref.
‘C’ MOUNT
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
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 FRONT
• Connect all pipes, hoses and electrical

connections ‘A’ MOUNT ‘B’ MOUNT
• Fill specified quantity of oil in engine of Fig.47

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.
Fig.48
60
ENGINE 475 SI MPFI
REMOVAL OF RADIATOR FROM CAR : 1.

(Front bumper, Splash guard already removed - For
procedure refer Body group of this manual) 2.
1. Drain the coolant.

2. Remove all the hose connections i. e.
i. From the thermostat
3.
ii. From the auxiliary tank.
iii. To the outlet elbow.
3. Disconnect the electrical connections,
i. To the condenser fan (For AC version) 1. ASSY. RADIATOR COMPLETE
ii. To the temperature sensor of cooling fan. 2. CROSS MEMBER RADIATOR MOUNTING
4. Unscrew the 2 M8 bolts & remove the radiator 3. RUBBER GROMET

bottom mounting member along with the radiator.
Fig.49
SPECIFICATIONS Fig. 49
Leakage testing pressure : 1.5 bar
AUXILLIARY TANK AUXILLIARY TANK CAP
Auxillary Tank Cap Fig.50
Pressure valve opening : 1 bar
Vacuum valve opening : 0.05 bar (max)
(suction)
INSPECTION
SULIN
Check radiator for damages / leakages. Straighten
bent fins if any.
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.
Fig. 50
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.
61
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 :
SLIDER SCREWS
• Adjust the slider at the higher most position and
keep the screws loose but engaged. Fig. 51
• 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
SULIN
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.
SPAN
Alternately belt can be depressed by 11 to 13
mm (for only Alternator configuration) & 9 to 11
mm (for alternator and power steering ALTERNATOR BELT TENSIONER BOLT
configuration) with thumb pressure applied.
A.C. COMPRESSOR BELT Fig. 52
Removal :
1. Loosen belt tensioner bolt (Fig. 53) on idler / SPAN
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, BELT
TENSIONER
cracks, and signs of failures. Replace if
ROLLER
necessary.
Fitment : BELT TENSION
ADJUSTING
1. Install the belt over crankshaft and A.C. SCREW
Fig. 53
62
ENGINE 475 SI MPFI
compressor pulleys.
2. Press the tensioner against the belt and tight
the tension bolt to specified torque.
3. Check belt tension.
4. The belt tension to be adjusted such that on the
span shown in Fig. 53, 200 +10/-5 Hz is measured
by CLAVIS gauge.
Alternately belt can be depressed by 11 to 13
mm with thumb pressure applied.
Fig. 54
TIMING BELT :
Removal :
Remove alternator and AC belt
Unscrew the mounting screws & remove front timing
gear train cover Fig.54
Keep crank shaft rotating with socket spanner
SULIN
simultaneously pressing camshaft timing pin till it locks
camshaft Fig. 55.
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
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 Fig. 57
• Cracked or exfoliated canvas
• Cracked tooth bottom
• Side of belt cracked
• Side of belt excessively worn
• Excessively worn teeth
• Missing tooth
NOTE : 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
riding on the valve tips & tighten the locknuts.
64
ENGINE 475 SI MPFI
NOTE : Cam gear
This is to reduce the valve spring load on Camshaft, White Mark

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.
Slacken the fixing bolt so that the camshaft gear is Cam plate
“Just” freely rotating on camshaft. Fit the camshaft
White Mark
gear washer lock plate as shown in Fig. 57
locked in timing position.
Fit timing belt on Crank shaft gear, water pump
Cam plate
tensioner roller and camshaft gear.
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 Fig. 60
fixing bolt. This is to prevent severe damage to Set the flywheel and cam shaft in No.1 cylinder firing
cylinder head, camshaft timing slot and subsequent position.
problem of very low oil pressure (due to increased
bearing clearance on bearing No. 5 of cylinder Adjust the valve clearances of cylinder No. 1 & 2 on
head). inlet valves and cylinder No. 1 & 3 on exhaust valves
Fig. 60.
Special ‘C’ tool should be used whenever cam gear Remove the camshaft and crankshaft locking pins.
fixing bolt is to be tightened or loosened.
Rotate the crankshaft by one rotation in the
clockwise direction and insert the flywheel locking
Never use the timing pin in locked timing position to
pin.
hold the camshaft during tightening or loosening
process. Adjust the valve clearances of cylinder No. 3 & 4 on
Re-tighten the cam gear fixing bolt to the specified
torque. INLET EXHAUST
Remove camshaft gear washer lock plate and flywheel
Specified 0.20 0.30
locking pin.
65
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
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
ENGINE 475 SI MPFI
• Exhaust manifold Fig. 67

• Timing Cover
Fig. 67
• Cylinder head cover Fig. 68
SULIN
Fig. 68
Insert flywheel locking pin, fit camshaft gear washer

lockplate and loosen camshaft gear mounting bolt.
Fig. 69
Fig. 69
68
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
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
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
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. Fig. 78
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.
Repeat the procedure for the other spark plugs.
Fig. 79
72
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 Fig. 82
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.
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
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. 84
Fig. 86
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.
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Fig. 85
Fig. 87 Fig. 86
74
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
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Fig. 89
75
ENGINE 475 SI MPFI
VALVES Fig. 90
Check valve leakages by pouring gasoline on valve
head. Gasoline must not seep past valve seat.
Valves with burnt heads, excessive scoring and wear
on stem should be replaced.
Check valve seat run out with respect to valve stem.
Fig. 91. If it exceeds specified limit replace valve. No
attempt should be made to straighten bent valves. If
valve is free from any other defects except worn out
seat, then only it can be rematched on valve grinding
machine as follows:
ROCKER SHAFT
16º
SULIN ROCKER SCREW
ROCKER ARM
CAM VALVE RETAINER

SHAFT
LOCK HALF
VALVE GUIDE
SEAL
SPRING
VALVE GUIDE
INTAKE PORT
CYLINDER HEAD
16º
VALVE VALVE SEAT
Fig. 90 Valve Arrangement
76
ENGINE 475 SI MPFI
• Clamp valve on grinding machine jaws as close

as possible to valve head.
• Adjust grinding angle on graduated scale to
achieve correct valve seat angle.
• Feed valve slowly towards grinding wheel until
wheel just touches valve head.
• Grind at low feed until valve seat is just clean all
around.
NOTE : After grinding, valve head thickness should
not be less than 0.85 mm.
Fig. 91
INLET VALVE EXHAUST

VALVE
B
B
SULIN C C C C
D
D A
0
A
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
ENGINE 475 SI MPFI
Valve dimensions : Fig. 92

INLET EXHAUST
Valve head dia. ‘A’ mm 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 0.2 0.2

to valve stem mm
Valve seat dia ‘C’ mm 35 29.2
Valve seat end distance from valve face ‘D’ mm 1.37/1.47 1.48/1.58
Maximum run out of valve seat with 0.030 0.030

respect to valve steam
Valve seat dia in cylinder head mm 35±0.05 28.88±0.05
Distance between cylinder head mating

SULIN
surface with crank case to gauge diameter in
cylinder head mm
11.8±0.05 11.75±0.05
Maximum run out of valve seat in cylinder 0.030 0.030

head with respect to valve guide axis mm
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
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 Valve guide Valve guide Valve guide

bore in cyl. head OD,mm ID,mm length, mm
+ 0.015
Normal 12.99+0.008/-0.01 13.0 + 0.046 7 - 0 (Inlet)
+ 0.020
+ 0.028 7 + 0.005 (Exhaust) 39.5 (Inlet)
+ 0.015
Normal 1 13.09+0.008/-0.01 13.1 + 0.046 7 - 0 (Inlet) 46 (Exhaust)
VALVE SEAT MUST BE ABSOLUTELY FAULTLESS

SULIN + 0.028 7
+ 0.020
+ 0.005 (Exhaust)
groove into valve seat insert and then pull it out with a
AND WITHOUT ANY CHATTER MARKS suitable puller. In order to avoid damaging machined
If necessary lap valve seats to a smooth and even cylinder head mating surface with crank case, place
finish by using suitable hand pump grinder or a lapping any soft protective sheet metal under supports of puller.
paste and valve itself. 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
ENGINE 475 SI MPFI
If boring and prying is done carefully without damaging

valve seat insert bore in cylinder head, fitment of an
over size valve seat insert will not be necessary.
Remachined valve seat insert bore in cylinder head
must be at 16º angle from vertical,Refer Fig.90. All
specified dimensions should be strictly maintained to
ensure proper interference of valve seat insert in its
bore.
Clean the valve seat insert and its bore in cylinder
head thoroughly.
Just before installation :
• Place valve seat insert in a mixture of Methanol
and dry ice for about 20-30 minutes to bring
its temperature down to -150 deg. C. Fig. 97
• Heat cylinder head to approximately 80 deg. C
in water bath. • Deep scoring marks on journals and cam lobes
Install valve seat insert in cylinder head bore quickly • Cracks, which should be checked on a magnetic
by using mallet. crack detector.
Machine valve seat in cylinder head. Check hardness of cam shaft journals and cam lobes.
It should be 40 HRC min.
CAM SHAFT INSPECTION
Carry out visual inspection of cam shaft for :
•
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Overall heating of journals, which is indicated
Check cam shaft runout at 2nd, 3rd & 4th journal by
supporting it on V-block at 1st and 5th journal.
Fig. 97
by bluish/brown colour Check cam shaft journal dimensions.
Cam shaft journal & bearing bore dimensions (mm) :

Journal No. Cam shaft bearing journal Cam shaft bearing
bore diameter in cylinder head journal diameter.
1 42.000 - 42.025 41.925 - 41.950
2 41.500 - 41.525 41.425 - 41.450
3 41.000 - 41.025 40.925 - 40.950
4 40.500 - 40.525 40.425 - 40.450
5 40.000 - 40.025 39.925 - 39.950
Maximum permissible run out of cam shaft bearing journal 0.025 mm
Maximum permissible axial play of cam shaft in installed condition 0.1/0.25 mm
Runout of oil seal mating diameter. 0.02 mm
Valve seat insert :

Valve seat insert thickness Valve seat inside dia in insert
Inlet - 7.1 + 0.05 mm Inlet - 32.5 + 0.1mm
Exhaust - 7.34 + 0.05 mm Exhaust - 25.7 + 0.1mm
80
ENGINE 475 SI MPFI
Valve seat insert & bore dia. in cyl. head
Stage Valve seat insert bore Valve seat insert

diameter in cyl. head (mm) out side diameter (mm)
INLET
- Normal 38 / 38.03 38.13 / 38.155
- Normal 1 38.23 / 38.28 38.43 / 38.455
EXHAUST
- Normal 32.99 / 33.021 33.13 / 33.155
- Normal 1 33.29 / 33.321 33.43 / 33.455
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
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
+ 0.018
Rocker bore dia. : 15 - 0.000 mm
CAUTION :
While inserting rocker arm shaft on inlet valves, ensure Fig. 100
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.
Check cam shaft axial play. It should be within
specified limits Fig. 102
Check camshaft for rotation.
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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 GASKET
PROJECTION THICKNESS,
mm 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
ENGINE 475 SI MPFI
Ensure that cylinder head locating hollow dowel is in

position on crank case.
Ensure that timing pin 2702 5890 0605 is installed in
position Fig. 103.
Place cylinder head gasket of pre-determined
thickness.
Install cylinder head and tighten cylinder head
9 5 1 4 8
1 2 3 4
10 6 2 3 7
Fig. 103
mounting screws to 3 mkg torque in the correct
sequence i.e. from centre to outwards. Then retighten
screws to 5 mkg torque in the same sequence - Then
loosen each screw by quarter turn and retighten to
6.5mkg. torque Fig. 104
Valve clearance adjustment.
VALVE CLEARANCES SHOULD BE CHECKED
ONLY WHEN ENGINE IS COLD.
• Fit camshaft gear
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Fitment :
Check that the cam gear is “Just” freely rotating on
the camshaft with mounting bolt in hand loose
condition.
Fig. 104
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.
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
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
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
INLET EXHAUST
Specified 0.20 0.30
Fig. 109
Assemble
• Spark plug. Fig. 110
SULIN
Fig. 110
• Exhaust manifold Fig. 111
Fig. 111
85
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.
Fig. 112
• Hoses from intake manifold to cylinder head cover
and brake booster.
• Bracket supporting fuel lines.
• Spark plug leads.
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
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
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
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
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
ENGINE 475 SI MPFI
PISTON AND PISTON RINGS :

PISTON AND CYLINDER BORE SIZES :
Type Grade Cylinder bore Piston
Diameter mm Diameter mm
A 75.00/75.01 74.96
Standard B 75.01/75.02 74.97
C 75.02/75.03 74.98
PISTON RINGS :
Type of ring Axial clearance Butt clearance
in piston groove in cylinder bore
1st Compression 0.03 / 0.07 mm 0.15 / 0.3 mm
ring
Fig. 127
2nd Compression 0.02 / 0.06 mm 0.2 / 0.35 mm
ring
3rd Oil control - 0.2 / 0.6 mm
ring
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. 20.00/19.996 mm

Piston Pin length 59.00/58.7 mm
Piston Pin bore in piston 19.998/20.003 mm
Height of Piston 52.5 mm
Piston to bore clearance 0.040 - 0.050 mm
Max. permissible difference in
weights of pistons with pin &
rings of an engine 3 gms.
Fig. 129
91
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
Inspect connecting rod small end bush and if
necessary, replace it.
SULIN
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 Fig. 131
axes are parallel to each other within specified limits.
Ensure that centre distance between small end & big
end is maintained within specified limit.
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
ENGINE 475 SI MPFI
CONNECTING ROD (DIMENSIONS) :

Connecting rod small end
Stage parent bore bush outside

diameter mm diameter mm
Normal 23.021/23.000 23.086/23.111
Normal I 23.221/23.200 23.286/23.311
Maximum permissible taper and ovality of connecting rod 0.004 mm

small end parent bore and cylindricity 0.008 mm
Connecting rod small end bush inside diameter 20.0+0.020/0.007 mm

finished after installation) (Piston pin oiled has
thumb push fit in small end bush).
Maximum permissible out of parallelism (bend) between 0.050 mm

connecting rod small end and big end parent bores.
Centre to centre distance between connecting rod small 141.65±0.03 mm

end and big end parent bores.
Maximum permissible twist of connecting rod 0.050 mm
big end parent bore and cylindricity

SULIN
Connecting rod big end parent bore diameter
Maximum permissible taper and ovality of connecting rod

48.655 /48.671
0.005
0.01
mm
mm
mm
Bearing shells to be selected such that clearance is maintained as 0.024 to 0.075 mm
Pre-tension of connecting rod big end bearing shells 0.013-0.051 mm
Maximum permissible difference in weight of 5 gms

connecting rods in one engine
Connecting rod big end axial play 0.05 - 0.35 mm
93
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 Fig. 133
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.
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
SULIN
direction after slightly loosening connecting rod bearing
cap mounting nuts.
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 Fig. 134
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 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
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
ENGINE 475 SI MPFI
Crank shaft (dimensions)
Stage Crank case main bearing bore Crank shaft main bearing journal
diameter with bearing shell mm 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 Crank pin journal diameter mm
diameter with bearing shell (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 Thickness of 4th main
journal (mm) 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 SULIN
24.252 / 24.200 2.52(2.50-2.55)
End play of crank shaft 0.06 - 0.226 mm Pre-tension of main bearing shells 0.018-0.040 mm
Fillet radius of main bearing journals 2.5-0.5 mm Hardness of crank shaft main 50-60 HRC
bearing and crank pin journals
Fillet radius of crank pin journals 2.5-0.5 mm
Main bearing parent bore dia in 53.8 +0.019 mm
Width of 1st, 2nd, 3rd and 5th 24.0+0.2 mm
crank case + 0.00 mm
main bearing journals
Maximum permissible taper of 0.005 mm
Width of crank pin journals 24.0+0.2 mm
main bearing parent bore
Maximum permissible cylindricity 0.0025 mm
Maximum permissible ovality of 0.005 mm
Ovality of main brg. journal 0.005 mm main bearing parent bore.
Max. permissible ovality of crank pin 0.005 mm Crank shaft journal to main 0.026 / 0.085 mm
Maximum permissible run out of 0.02 mm bearing clearence
2nd, 3rd and 4th main bearing journals
when supported at 1st and 5th main
bearing journals
Maximum permissible out of parallelism 0.010 mm
between crank pin and main
bearing journal axis
96
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.
Fig. 138
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.
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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. 139
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 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
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
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 PRETENSION
gauge after loosening main bearing cap mounting bolt GAP
on opposite side of bearing shell lug (This is to be SURFACE PLATE
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
Schematic Sketch : Main bearing shell pretension
MAIN BEARING SHELLS ARE PRECISION FINISHED checking
AND SHOULD NOT BE BORED OR SCRAPED. 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 265.8/265.6 D
(Dimension A&B) Fig. 146
Maximum permissible unevenness
of crank case mating surface with cylinder
B
head 150x150 : cross wise ‘D’ Fig. 146 0.015 A
: length wise ‘C’ Fig. 146 0.030
Maximum permissible out of 0.2

parallelism between crank case top and
bottom machined surface
Fig. 146
99
ENGINE 475 SI MPFI
SULIN
OIL PATH
RETURN OIL PATH
Fig. 147a
100
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 0.25 mm replace the oil pump assembly.
perpendicularity of cylinder bore Fit oil pump assembly with new gasket.
from crank shaft axis when Flow rate measured against back pressure of 3kg/
checked from crank shaft centre line cm2 should be as follows using SAE-30 oil.
Maximum permissible taper and 0.007 Pump rpm Minimum flow rate in Ipm
ovality of cylinder bore
4000 28
LUBRICATION SYSTEM :Fig. 147a & 2000 14
147b.
800 5.6
OIL PUMP
Engine oil pressure with coolant temperature of 700 C
Unscrew screws holding oil pump to cyl. block and at idling speed
remove the oil pump assembly Check oil pump for
800+50 rpm - 1 bar
flow rate at specified rpm. Check for any leakage at
sealing plugs. at 5000 rpm - 3 bar
Check functioning of Pressure relief valve. If the Oil Pressure Switch
performance of the pump is not satisfactory, then NC contact opening pressure : 0.9 /0.6 bar
101
ENGINE 475 SI MPFI
102
Fig. 148
COOLING CIRCUIT
RADIATOR VENT HOSE
RADIATOR AUXILARY WATER TANK
RADIATOR FAN
SULIN
MAIN INDEX
INTEGRAL WATER HOSE
UPPER COOLING LINE
Flow of coolant
THERMOSTAT HOUSING
GROUP INDEX
BYPASS LINE
HEAD VENT LINE
CAB HEATER FEEDING HOSE

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
TO
3000 3150 60 ENGINE
4000 4200 80 Fig. 149
5000 5250 100
THERMOSTAT OPEN
5500 5775 110 TO
RADIATOR
Thermostat
• Start opening temperature : 82 0C ± 2
•
•
Full open temperature : 96 0C Max.
SULIN
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 TO
ENGINE
Thermostat is installed in cooling system between cyl.
head & radiator inlet tank. Fig. 150
The working principle of thermostat :
3. As the engine cooling temperature reaches
1. For cold engine (immediately after starting) : thermostat full open temperature, thermostat valve
Thermostat does not allow coolant to flow to opens fully and thermostat by-pass valve closes
radiator (Thermostat valve in closed position) completely. Under such condition maximum
instead coolant flows through thermostat by-pass quantity of engine coolant flows to radiator
outlet to engine. Thus short circuiting of radiator Fig. 150.
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.
103
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
Fig. 151
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 SULIN
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.
If they do not meet the specifications, replace the Fig. 152
thermostat element.
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
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
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.
Fig. 157
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
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,
SULIN
simultaneously pushing piston till crank pin journal
reaches BDC position.
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
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
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
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
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
Fig. 171
ENGINE 475 SI MPFI

AIR INTAKE SYSTEM
AIR FILTER
SNORKEL
SULIN
MAP SENSOR
MAIN INDEX
THROTTLE BODY
CYLINDER HEAD
GROUP INDEX
INTAKE MANIFOLD RESONATOR BOX

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.
Fig. 172
• 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
• SULIN
Fit housing cover and clamp it firmly with the
screws.
Fig. 173
Fig. 174
112
ENGINE 475 SI MPFI
ACCELERATOR CABLE :
RHD :
2
1
1 CABLE PLASTIC END
2 INNER CABLE END
3 PLASTIC CLAMP
4 PLASTIC CLAMP
5 TOP SIDE NUT
6 THROTTLE BODY BRACKET
8 7 THROTTLE BODY SECTOR
8 ACCELERATOR PEDAL RHD
9 CABLE CLIP
10 RUBBER STOPPER
6 11 ASSEMBLY ACCELERATOR
7 CABLE RHD
5 12 ASSEMBLY ACCELERATOR
10
9 CABLE LHD
13 ACCELERATOR PEDAL LHD
4
3
11
1
LHD :
12 2
5
SULIN
13
Fig . 175
Removal : Installation :
1. Loosen the top side nut (5) from threaded end of 1. Insert accelerator cable plastic end (1) inside the
accelerator cable at throttle body end. firewall hole.
2. Remove inner cable end from throttle body sector 2. Insert inner cable end (plastic flower) (2) in
after disengaging the threaded end of the cable in accelerator pedal.
throttle body bracket (6). 3. Locate accelerator cable in plastic clamp (3) and
3. Remove accelerator cable from plastic clamp (3,4). (4). Ensure that rubber sleeve on accelerator cable
are located inside the plastic clamps.
4. Remove inner cable end (plastic flower) (2) from
4. Loosen the top side nut (5) from threaded end of
accelerator pedal (8).
the cable. Engage the threaded end of the cable
5. Remove accelerator cable plastic end (1) through in throttle body bracket (6). Insert inner cable end
firewall hole. 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
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
SLEEVE ASSY CONTROL MTG
BRACKET
CIRCLIP
RUBBER STOPPER
SULIN
STOP LIGHT SWITCH
ASSY CLUTCH PEDAL

LEVER
SLEEVE ASSY ACC PEDAL

WITH BUSH
ASSY BRAKE PEDAL

LEVER
RUBBER COVER RUBBER COVER
PEDAL PLATE RUBBER GRIP
RUBBER GRIP
ACC PEDAL PLATE
RUBBER COVER TORSION SPRING (FOR BRAKE PEDAL RETURN)
114
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 Loosen cylinder head mounting bolt by quarter turn
following manner. and retighten immediately to 7 mkg torque in the correct
sequence.
Connect oil pressure gauge and temperature gauge. Complete cylinder head tightening operation in the
Connect coolant hose to and from radiator. Fill coolant same sequence and with the same torque.
in the cooling system. Fit radiator cap. Start the engine and check for any fuel leakages.
Rectify, if necessary.
Fill required quantity of recommended 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.
SULIN
Allow oil to be circulated through the system. Check
and ensure that oil pressure indicated by gauge is
satisfactory.
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 Time (minutes) Torque (mkg)
(rpm)
800 5 0.0
2000 5 2.3
2500 5 4.6
3000 5 5.8
3500 5 4.9
2500 5 8.2
After running in test of the engine, reduce dynamometer

load to zero and allow engine to run at idling speed for
about 5 minutes and then stop it.
115
ENGINE 475 SI MPFI
TROUBLE SHOOTING
NOTE : BEFORE CHANGING ANY SENSOR PLEASE CHECK THE FUSES,RELAYS & WIRING HARNESS CAREFULLY.
no.
1. Engine not cranking Low battery voltage Clean and tighten the connectors
Jump start using another battery
Get battery charged or changed
Faulty starter Rectify or replace
Worn out piston rings/seized pistons Overhaul & replace affected parts
Faulty immobiliser Check and rectify
2. Engine cranks but

doesnot start Clogged air filter Clean as per the instructions
Incorrect valve timing Set valve timing /check & reset
Faulty spark plugs Clean, check gap/replace if necessary
Faulty crank angle signal Check & correct the gap
Faulty water temperature sensor Check & replace if necessary
Faulty MAP signal Check & replace if necessary
Faulty throttle position signal Check & replace if necessary
Faulty ISC valve
Clogged injectorsSULIN
Faulty fuel regulator
Clogged fuel filter Replace
Faulty ignition coil Check and replace
Faulty firing order/ injector Check and replace
(connection) order
Faulty E C U Replace
Faulty inertia switch Reset if tripped off or replace
Faulty Fuel Pump Check and replace if necessary
3. Erratic idling Inlet manifold leakage/

Valve timing incorrect Set valve timing /check & reset
Vehicle speed signal faulty Check & replace
ISC valve faulty Check & replace
regulator connections Check & tighten/replace
Faulty firing order/
injector(connection) order Check and rectify
4. Does not idle Faulty MAP signal Check & replace

Faulty ISC Valve Check & replace
Faulty fuel regulator Check & replace
116
ENGINE 475 SI MPFI

no.
5. Maximum RPM low Battery voltage low Check and tighten connections
Clogged air filter Clean as per instruction
Valve timing incorrect set valve timing /check & reset
Spark plugs defective Clean and check gap/replace if
necessary
Adulterated fuel Flush the system and refill
Faulty crank angle signal Check and rectify the gap 1.5 + 0.5 mm
Clogged injectors Check and Replace
Fuel pump faulty Check and Replace
injector (connection) order Check and rectify
6. Poor Low battery voltage Check and tighten connections

acceleration/Power
Clogged air filter Clean as per instructions
SULIN
vacuum connections
Faulty ISC valve
Check and rectify
Check & replace
Clogged injectors Check & replace
Faulty fuel regulator Check and replace
Faulty ignition coil Check and replace
Faulty firing order/ injector Check and replace
(connection) order
Incorrect tappet clearances Check and reset
Worn out piston rings/seized pistons Overhaul /replace affected parts
necessary
Faulty fuel regulator Check and Replace
Fuel pump faulty Check and Replace
injector(connection) order Check and rectify
117
ENGINE 475 SI MPFI

no.
7. Knocking Spark plugs defective Clean and check gap/replace if necessary
regulator connections Check and tighten/replace
Incorrect valve timing Check and adjust.
8. Misfiring Inlet manifold leakage/ Check and Replace

necessary
Faulty crank angle signal Check and rectify the gap
injector(connection) order Check and Rectify
9. Whitish/Bluish smoke Clogged air filter Clean as per instructions

Worn out pistonirings/seized pistons Overhaul /replace affected parts
Adultetated fuelSULIN
Flush the system and refill
10. High fuel Low battery voltage Check and tighten connections
consumption
Inlet manifold leakage/ Set valve timing /check & reset
Worn out piston rings/seized pistons Overhaul /replace affected parts
necessary
Faulty lambada signal Check and Replace
Faulty fuel regulator Check and Replace
regulator connections Check and tighten/replacet
Faulty firing order/ injector Check and rectify
(connection) order
11. High oil consumption Clogged Air Filter Clean/replace

Worn out piston rings/siezed pistons Overhaul /replace affected parts
118
ENGINE 475 SI MPFI
ENGINE INSPECTION SHEET 50--6

CYLINDER BLOCK AND PISTONS
Engine No. ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Reason for dismantling ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Chassis No. ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Kilometres ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Kilometres since last overhaul ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
COMPRESSION READING
Cyl. 1 2 3 4
Pressure
Kg/cm2
CYLINDER BORE
A = Non thrust side B = Thrust side Dial gauge set at .....mm. Piston size (Stamped)..... mm
Cyl. No. 1 2 3 4
Pistons A B Ovality A B Ovality A B Ovality A B Ovality
aa
bb
cc
dd
SULIN
dd
ee
ff
Taper
Max. taper .....mm Max. ovality .....mm Rebore to size .....mm
Piston Rings
Piston PISTON RING BUTT CLEARANCE (mm) PISTON RING LATERAL CLEARANCE (mm)
Ring PISTON NO. PISTON NO.
No. 1 2 3 4 1 2 3 4
1
2
3
*Check butt clearance at unworn portion of cyl. bore Piston rings and grooves should be properly cleaned
(bottom) of carbon and other deposits.
PISTON RING GROOVES Conclusions/Recommendations :
N.B. - Check lateral clearance of new piston
rings in grooves
Piston New piston ring lateral clearance
Ring No. 1 2 3 4
1
2
3 Checked by ○ ○ ○ ○ ○ ○ ○ ○ ○ Date ○ ○ ○ ○ ○ ○
119
ENGINE 475 SI MPFI
ENGINE INSPECTION SHEET SHEET II

CYLINDER BLOCK & PISTONS
Chassis No. ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Kilometres ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
C C
B
B
A A
WITH BEARING SHELL WITHOUT BEARING SHELL
Measuring
Direction
Measuring with bearing shells :
SULIN CRANK SHAFT BEARING NO.
Dial gauge set at ...mm
1 2 3 4 5
A mm
B mm
C mm
OVALITY mm
Measuring without bearing shells : Dial gauge set at ...mm

Measuring
Direction PARENT BORE NO.
1 2 3 4 5
A mm
B mm
C mm
OVALITY mm
Conclusions/Recommendations :
Checked by ○ ○ ○ ○ ○ ○ ○ Date ○ ○ ○ ○ ○ ○ ○
120
ENGINE 475 SI MPFI
ENGINE INSPECTION SHEET SHEET III

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

supported on journal Nos. 1 and 7
○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ mm
width of 4th main journal ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ mm
Max MAIN JOURNAL BIG END JOURNAL
DIRECTION aa AND cc AT THE DIRECTION A,B & C
SECTION WHERE FILLET RADIUS 120o APART
Taper
ENDS DIRECTION bb NEAR THE CENTRE Ovality
MEASUREMENTS IN DIRECTION
JOURNAL MAIN JOURNAL GAUGE SET AT .....mm BIG END JOURNAL GAUGE SET AT .....mm
No.
1
aa
bb
A B
SULIN C Ovality A B C Ovality
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
ENGINE 475 SI MPFI
ENGINE INSPECTION SHEET

CONNECTING ROD BEARING AND PARENT BORES SHEET IV
Chassis No. ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Kilometres ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
MEASURING BIG END BEARING BORE DIA. (WITH SHELLS INSTALLED) GAUGE SET AT.....mm
DIRECTION 1 2 3 4
A mm
B mm
C mm
OVALITY mm
WEIGHT GROUP SMALL END :
COLOUR MARKS
} BIG END :
B
C
SULIN A
MEASURING CONNECTING ROD BIG END PARENT BORE GAUGE SET AT.....mm
DIRECTION 1 2 3 4
A mm
B mm
C mm
OVALITY mm
CONNECTING ROD SMALL END PARENT BORE GAUGE SET AT.....mm
1 2 3 4
A mm
B mm
OVALITY mm
ALIGNMENT
1 2 3 4
TWIST
BEND
Conclusions/Recommendations :
Checked by ○ ○ ○ ○ ○ ○ ○ ○ ○ Date ○ ○ ○ ○ ○ ○ ○ ○ ○
122
ENGINE 475 SI MPFI
ENGINE INSPECTION SHEET

CAMSHAFT JOURNAL AND BEARING BORE SHEET V
Chassis No. ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Kilometres ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
CAMSHAFT JOURNAL
NO. 1 Journal Measuring Direction

CAMSHAFT JOURNAL No. Dia Dia Ovality Remarks
A(mm) B(mm) (mm)
aa
1
bb
aa
2
MEASURING bb
DIRECTION
aa
3
bb
4
SULIN aa
bb
Run-out of intermediate Camshaft re-ground

journals when supported to repair size
on journal Nos. 1 & 4
2 3 4 1 2 3 4 5
Conclusions/
Recommendations :
CAMSHAFT BEARING BORE

(Bearing Shells installed)
Measuring Direction
Bearing Remarks
No. A-Dia B-Dia Ovality
(mm) (mm) (mm)
Checked by ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 3
Date ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 4
123

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ENGINE 475 SI MPFI

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

Sr. No. Description Page No. 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

Max. engine output

Compression ratio : 9.5 : 1 SULIN

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

LIST OF SPECIAL TOOLS

1. Box spanner (16 A/ F) for spark plug 2702 5890 06 01

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

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

Serial 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 2.5

4. Cylinder head cover bolts M6 1.0 #

5. Oil sump Screw M6 x 1 0.6 to 0.7 #

7. Oil sump drain plug M12 x 1.5 3.5

8. Rear timing cover to block M6 x 1 1.0

10. Timing belt cover M6 x 1

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 4+60 0 #

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

19. Camshaft gear to camshaft screw M12 x 1.25 8.0

20. Lock Nut (Rocker adjusting screw) M9 x 1 3.5

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

Serial Description Torque in mkg.

Cylinder Oil Filling

Vibration Damper Vibration Damper Alternator

Power Steering Power Steering

CARBURETTED ENGINE V/s MPFI ENGINE Prim ary m ain jet

Petrol Injected Engine :

for Single p oint and Mult ip oint fuel inject ion

Fig. 3 Intake Manifold with throttle body

Divided fine injection Further total pulse width is Low Emissions

Fuel is cut if Throttle When throttle valve is Good startability in all

ECU 31 supply, VCC

Typical values at 3500C: = 0.95 840 + 70mv (rich)

ECU 2 Coil A STEPPING MOTOR

2 P1 3 P1 Supply (+) TYPE ISC VALVE