CNG - ENGINE CONTROL SYSTEM

ENGINE SENSORS AND ACTUATORS

SECTION EC

CONTENTS
1.1 ENGINE SENSORS ...................................................................................................................... 3
1.1.1 PRECAUTIONS AND PREPARATION............................................................................... 3
1.1.2 ENGINE CONTROL MODULE ......................................................................................... 7
1.1.3 TEMPERATURE MANIFOLD ABSOLUTE PRESSURE SENSOR ...................................... 8
1.1.4 CRANK SENSOR ............................................................................................................ 9
1.1.5 CAM SENSOR ................................................................................................................ 10
1.1.6 COOLANT TEMPERATURE SENSOR ............................................................................. 11
1.1.7 VEHICLE SPEED SENSOR ............................................................................................. 12
1.1.8 ACCELERATOR PEDAL SENSOR ................................................................................... 13
1.1.9 RAIL PRESSURE SENSOR ............................................................................................. 14
1.1.10 FUEL LOCKOFF SOLENOID ........................................................................................... 15
1.1.11 TANK PRESSURE SENSOR ........................................................................................... 16
1.1.12 ELECTRONIC THROTTLE POSITION SENSOR .............................................................. 17
1.1.13 LAMBDA SENSOR .......................................................................................................... 18
1.1.14 INJECTOR ...................................................................................................................... 20
1.1.15 IGNITION COIL ............................................................................................................... 21

EC - 1
 ENGINE SENSORS

1.1 ENGINE SENSORS

1.1.1 PRECAUTIONS AND PREPARATION
PRECAUTION

CAUTION

1. Check voltage / resistance at Sensor or ECU with recommended instruments only.

2. Care to be taken not to short the supply voltage with Negative.
3. Connectors of the ECU must be connected or disconnected only when ignition
switch is in OFF position.
4. Never repair wiring harness or sensors. Always replace it.
SENSORS CHECK PROCEDURE
1. Few test to be carried out with Ignition “OFF / ON” and Engine running mode condition to
confirm the fault and after erasing the error.
2. Measure resistance of the sensor between sensor pin.
3. Input voltage at connector is measured at the connector end.
Do’s
1. The ECU should be disconnected from the harness and a dummy cap should be put on
the ECU connector to avoid dust or water ingress.
2. Always trouble shoot ECU system first with diagnostic tool.
Don’ts
1. Electrical tapping is not allowed from ECU wiring.
2. Avoid falling of weld spatters on wiring harness and sensors.
3. Diagnostic connector should not be left hanging loose and should be handled with care.
4. Do not touch the pins of the ECU to avoid damage due to electrostatic discharge.
5. Do not test ECU pins without multimeter.
6. Do not remove or cut wires of the wiring harness.

EC - 3
 ENGINE SENSORS

ECU Pin configuration (Engine)

ECU Pin configuration (Vehicle)

EC - 4
 ENGINE SENSORS

81 way connector

Pin Number Function Description

1 BATTERY POWER (+12V)
3 KEYED POWER (+12V)
5 BATTERY GROUND
6 CAN HIGH
8 CAN LOW
15 ETB SIGNAL-2
18 LAMBDA SENSOR-1 SIGNAL
20 ECU RELAY CONTROL
29 VSS SIGNAL
30 CAM SENSOR SIGNAL
34 ETB SIGNAL-1
35 TMAP PRESSURE SIGNAL
36 IGNITION KILL FEEDBACK
37 LAMBDA SENSOR-2 SIGNAL
38 SENSOR POWER-2 (+5V)
40 SENSOR POWER-1 (+5V)
47 CRANK SENSOR SIGNAL -VE
48 CRANK SENSOR SIGNAL +VE
49 K-LINE
51 SENSOR GROUND-1
52 ACC. PEDAL SENSOR-1 SIGNAL
53 TANK PRESSURE SENSOR SIGNAL
55 COOLANT SENSOR SIGNAL
61 OVERHEAT LAMP
65 ECU RELAY FEEDBACK
66 CLUTCH SWITCH
67 BRAKE SWITCH
70 SENSOR GROUND-2
71 ACC. PEDAL SENSOR-2 SIGNAL
72 FUEL PRESSURE SIGNAL
73 FUEL TEMPERATURE SIGNAL

EC - 5
 ENGINE SENSORS

81 way connector

Pin Number Function Description

74 TMAP TEMPERATURE SIGNAL
78 CHECK ENGINE LAMP
80 SPEEDO SIGNAL
82 LAMBDA SENSOR-1 CONTROL
84 MIL / OBD-II
85 LAMBDA SENSOR-2 CONTROL
86 FUEL GAUGE CONTROL
87 INJECTOR-2 CONTROL
97 COOLING FAN HIGH SPEED
98 STARTER RELAY CONTROL
99 LOW FUEL LAMP
100 COOLING FAN LOW SPEED
102 INJECTOR-1 CONTROL
104 ETB M- SUPPLY
105 ETB M+ SUPPLY
109 CRANK REQUEST
112 ETB M- SUPPLY
113 ETB M+ SUPPLY
115 BATTERY GROUND
116 IGNITION COIL-1 CONTROL
117 IGNITION COIL-2 CONTROL
118 IGNITION COIL-3 CONTROL

EC - 6
 ENGINE SENSORS

1.1.2 ENGINE CONTROL MODULE

Disassembly
Engine Control Module, or ECM, is a
microprocessor controlled computer which takes
information from sensors to determine current
engine operating conditions, and uses it to control
a number of configurable outputs, most notably
fuel injectors and spark plugs.

WARNING

REMOVE BATTERY NEGATIVE CONNECTOR

AND ECU CONNECTOR BEFORE DOING
ANY WELDING OPERATION ON VEHICLE.

1. Remove the connector bunch from the ECM.

2. Remove the screws (3) holding the ECM clamp (5) to the ECM bracket (2).
3. ECM bracket (2) is welded on the cabin inner side of the rear panel (4) behind the
co-driver’s seat.
4. Remove the ECM clamp (5) while holding the ECM carefully with one hand.

Inspection

1. Check for any pin bend on ECU.

2. After Ignition ON, check for relay actuating
noise.
3. Check for the supply voltage of any sensor.

Assembly

1. Assemble the ECM (1) to the bracket (2) using

the ECM clamp with M6 screws.
2. Tightening torque for M6 screw 9 – 13 Nm.

EC - 7
 ENGINE SENSORS

1.1.3 TEMPERATURE MANIFOLD ABSOLUTE PRESSURE SENSOR

This sensor measures the intake manifold
pressure and temperature.
Location
It is located on the intake manifold duct and with
O-ring to ensuring leak proof.
Specifications
Nominal Voltage - From ECU: 5V DC
Operating Temp: – 40 °C to + 130 °C
Tightening Torque of Screw : 4-6 Nm.
Inspection
Sensor
• Nominal Resistance = 2.5 kΩ ± 5 % @ 20 °C
• Measure the resistance between Pin 1 & 2 at
sensor end for temperature sensor.
Refer the table for resistance value with respect
to temperature.
If any value is faulty, replace the sensor.

Pin1 – Ground
Pin2 – Temp signal
Pin3 – Supply Voltage
Pin4 – Pressure signal
Connector
• Ensure the connection to the sensor is made and
measure the value using back-probe PIN 1 and
PIN 4 (GND) for pressure signal.
Check continuity between the following sensor
connector and ECU connector.

SENSOR ECU
CONNECTOR CONNECTOR
Pin 1 Pin 70
Temp ºC Resistor Ω
Pin 2 Pin 74
0 5671-6118
Pin 3 Pin 40
10 3656-3927
Pin 4 Pin 35
20 2416-2583
• Check the input voltage in the connector end of 30 1653-1760
the sensor when ignition is ON and connector
40 1139-1209
removed condition between PIN 1 and PIN 3
(GND) = 5 V. 50 8105-8570
If faulty replace the wiring harness. Resistance of sensor (Temperature)

EC - 8
 ENGINE SENSORS

1.1.4 CRANK SENSOR

Crank sensor mounted on the cylinder block and
measures engine speed.
Location
Crank sensor is mounted on the cylinder block and
is facing towards the flywheel. Standard shims are
used during sensor installation.
Specifications
Operating Temperature: – 30 °C to + 130 °C
Functional Air Gap: 0.5 to 1.5 mm.
Tightening torque : 5-8 Nm

Inspection
Sensor
• Measure the resistance between Pin 1 & 2 at
sensor end male connector.
• Resistance = 860 ± 10% Ω
• Measure output voltage pin 1 (In sensor fitted
condition) to be >700mV during cranking.
If any value is faulty, replace the sensor.

Pin1 – Signal (+)

Pin2 – Signal (-)
Pin3 – Shield
Connector
• Remove the ECU connector and check the
continuity in wiring harness.

SENSOR ECU CONNECTOR

CONNECTOR
Pin 1 Pin 48
Pin 2 Pin 47
Pin 3 Pin 5 & 115

EC - 9
 ENGINE SENSORS

1.1.5 CAM SENSOR

Cam speed sensor is a Hall Effect type. It signals
the TDC condition of first cylinder.

Location
Cam sensor is placed in the Cambox housing.
Specifications
Operating Temp: – 40°C to + 130°C
Camshaft Rotational speed: up to 1750 rpm
Air Gap: 0.3-2 mm
Tightening Torque: 8-10 Nm
Operating Voltage: 12V DC
Pin1 – Power Supply
Pin2 – Signal
Pin3 – Ground
Inspection
Connector
• Remove the ECU connector and check the
continuity in the wiring harness.

SENSOR ECU
CONNECTOR CONNECTOR
Pin 1 Pin 03
Pin 2 Pin 30
Pin 3 Pin 70

• Connect ECU connector and switch on the ignition and measure the input voltage in pin 1
for sensor supply Voltage (12V).
• Output voltage = ~12V DC (Pin 2).
If faulty replace the wiring harness.
If fault is not found and problem still persists, then replace the cam sensor.

EC - 10
 ENGINE SENSORS

1.1.6 COOLANT TEMPERATURE SENSOR

The sensor measures the temperature of the
coolant.
Location
Mounted on the cylinder head near the thermostat
cover.
Specifications
Operating Voltage: 5V DC
Operating Temp: – 30 °C to + 140° C
Output voltage: ~5V DC.
Tightening Torque: 15-20 Nm
Inspection
Sensor
• Measure the resistance between Pin 1 & 2 at
sensor. Refer the table for resistance against
temperature.
• If any value is incorrect, replace the sensor.

Pin1 – Signal
Pin2 – Sensor Ground
Connector Re a r Vie w
• Remove the ECU connector and check the
continuity in the wiring harness.

SENSOR ECU
2 1
CONNECTOR CONNECTOR
Pin 1 Pin 55
Pin 2 Pin 70
SAEM0037-0213

• Connect ECU connector and switch on the

ignition and measure the input voltage in pin 1
for sensor supply Voltage.
Temp °C Resistance Ω
• Output voltage = ~5V DC.
15 2706 – 3457
If faulty replace the wiring harness.
20 2220 – 2817
80 299.7 – 357.1
130 80.4 – 101.1
140 64.5 – 80.4

Resistance with respect to Temperature

EC - 11
 ENGINE SENSORS

1.1.7 VEHICLE SPEED SENSOR

It senses the speed of the vehicle.
Location
Vehicle speed sensor is mounted on the gearbox
at speedo drive output shaft.
Specifications
Operating Voltage: 12 V DC
Supply current: 13 mA
Operating Temp: – 40 °C to + 140 °C
Output voltage = ~12V DC.
Inspection
Sensor
Disconnect the connector and apply 12V supply in
Pin 1. Measure the output supply at pin 2. It must
be 12V.
If any value is incorrect, replace the sensor.

Connector Rear Vie w

• Remove the ECU connector and check the
continuity in the wiring harness.

SENSOR ECU
3 2 1
CONNECTOR CONNECTOR
Pin 1 Pin 03
Pin 2 Pin 29
SAEM0095(0213)
Pin 3 Pin 5 & 115
Pin1 – Power Supply
• Connect ECU connector and switch on the
ignition and measure the input voltage in pin 1 Pin2 – Signal
& pin 3 for sensor supply Voltage. Pin3 – Ground
• Output voltage = ~12V DC.
If faulty replace the wiring harness.

EC - 12
 ENGINE SENSORS

1.1.8 ACCELERATOR PEDAL SENSOR

The Sensor measures accelerator pedal travel and
communicates to the ECU.
Location
The accelerator pedal sensor is mounted on
accelerator pedal module as shown.
Specifications
Operating Voltage: 5V DC
Temperature Range: – 40 °C to + 85 °C

Inspection
Connector
• Remove the ECU connector and check the
continuity in the wiring harness.

SENSOR ECU
CONNECTOR CONNECTOR
Pin 1 Pin 52
Pin 2 Pin 51
Pin 3 Pin 38
Pin 4 Pin 40 Pin1 – Sensor 1 signal
Pin 5 Pin 70 Pin2 – Sensor 1 Ground
Pin 6 Pin 71 Pin3 – Sensor 1 Power
Pin4 – Sensor 2 Power
Pin5 – Sensor 2 Ground
Pin6 – Sensor 2 signal
• Measure the input voltage (5V) by connecting the ECU connector and disconnecting the
connector from sensor.
• At Connector end, between PIN 2 and PIN 3 gives track 1 input voltage and between PIN
4 and PIN 5 gives track 2 input voltage.
Sensor
• Connect the connector and check the voltage between PIN 1 and PIN 2 for track 1 Signal
Voltage and between PIN 5 and PIN 6 for track 2 Signal voltage
• Pedal not pressed track 1 = 0.74 V and track 2 = 0.37 V.
• Pedal 100% pressed track 1 = 4.55 V and track 2 = 2.25 V.
• If any value is faulty, replace the sensor.

EC - 13
 ENGINE SENSORS

1.1.9 RAIL PRESSURE SENSOR

This sensor is combination of pressure and
temperature sensor.
It detects the rail pressure and temperature in the
rail and sends a feedback to the ECU.
Location
It is installed on one end of the common rail. The
sensor cannot be dismantled.
Specifications:
Supply Voltage : 5.0 ± 0.1 V DC
Supply Current : 10 mA Max Pin 1 – Ground
Operating Temp: – 40 °C to + 85 °C Pin 2 – Pressure Signal
Output Voltage Range for Pressure : 0.5 to 4.5 V Pin 3 – Temp Signal
Output Resistance Range for Temperature : Pin 4 – Supply Voltage
316181 to 271 Ω
Inspection Rear V iew

Connector
• Remove the ECU connector and Rail pressure
sensor connector and check the continuity in the
2
wiring harness. 4
3 1

SENSOR ECU
CONNECTOR CONNECTOR
Pin 1 Pin 51 SAEM0036-0213

Pin 2 Pin 72
Pin 3 Pin 73
Pin 4 Pin 38
Measure the input voltage across Pin-1 & Pin-4 by
connecting the ECU connector and disconnecting
the connector from sensor.
If faulty replace the wiring harness.

SAEM0097-0213

Sensor
Measure the resistance between Pin-1 & Pin-3 at
sensor. Temp° C Resistance Ω
10 19691 – 19346
Refer the table for resistance against temperature.
20 12474 – 12315
If value is faulty, replace the sensor.
30 8080 – 7977
40 5372 – 5282
50 3661 - 3585

EC - 14
 ENGINE SENSORS

1.1.10 FUEL LOCKOFF SOLENOID

Fuel Lockoff Solenoid is located as shown in the
Pressure regulator.

Inspection
Connector Rear V iew

Remove the ECU connector and check the

continuity in the wiring harness.

2 1
SENSOR ECU CONNECTOR
CONNECTOR
Pin 1 Pin 5 & 115
Pin 2 Pin 65
SAEM0034-0213

Pin1 – Ground
Pin2 – Supply Voltage
Measure the supply Voltage (VS=12V) between the pins 1 & 2 in wiring harness side, by
connecting the ECU connector and disconnecting the connector from sensor. Also ensure
that Ignition key in ON position
If faulty replace the wiring harness.
If fault is not found and problem still persists, then replace the Solenoid.

EC - 15
 ENGINE SENSORS

1.1.11 TANK PRESSURE SENSOR

The pressure measurement from the regulator or
tank valve is used to calculate the amount of fuel
in the tank for dashboard fuel gauge indication.
Specifications
Operating Temperature: – 40 °C to + 125 °C
Supply Voltage: 5.0 ± 0.25 V DC
Supply Current: 20 mA Max
Output Voltage: 4% to 96% of VS
Tightening torque: 30-35 Nm
Inspection
Connector
Remove the ECU connector and check the
continuity in the wiring harness.
Measure the supply Voltage (5V) between the pins
1 & 3 in wiring harness side, by disconnecting the
connector from sensor, ensure that the Ignition key
in ON position
Rear V iew

SENSOR ECU CONNECTOR

CONNECTOR
Pin 1 Pin 51
2
Pin 2 Pin 53 3 1
Pin 3 Pin 38

If faulty replace the wiring harness.

If fault is not found and the problem still persists, SAEM0039-0213

then replace the tank pressure sensor.

Pin1 – Ground
Pin2 – Pressure Signal
Pin3 – Power Supply

EC - 16
 ENGINE SENSORS

1.1.12 ELECTRONIC THROTTLE POSITION SENSOR

Specifications
Operating Temperature: – 40 °C to + 140 °C
ETB Control device (DC Motor)
Operating voltage range: 6 to 16 V
Supply current IMAX: 10 A
Typical resistance: 1.6Ω ± 0.3Ω

Sensor (Potentiometer) Pin1 – Motor -VE Supply

Supply Voltage: 12 V ± 0.2 V Pin2 – Ground
Supply current: 10 µA Pin3 – Power Supply
Resistance of parallel IP1/IP2: 0.625 to 3 kΩ Pin4 – Motor +VE Supply
Pin5 – Sensor 2 signal
Pin6 – Sensor 1 signal
Connector Rear V iew

Remove ECU Connector and check continuity in

the wiring harness.
Measure the supply Voltage (12V) across the Pin-1
3 2 1
& Pin-4 and also sensor supply (5V) across Pin-2
& Pin-3 in wiring harness side, make sure that 6 5 4

Ignition key in ON position.

If faulty replace the wiring harness.

SAEM0088-0213

SENSOR ECU CONNECTOR

CONNECTOR
Pin 1 Pin 104 & 112
Pin 2 Pin 51
Pin 3 Pin 38
Pin 4 Pin 105 & 113
Pin 5 Pin 15
Pin 6 Pin 34
SAEM0098-0213

Sensor
• Measure the typical resistance of control device between Pin-1 & Pin-4 at sensor.
• Measure the resistance of sensor (Parallel IP1/IP2) between Pin-2 & Pin-3 at sensor.
If the values are faulty, replace the sensor.

EC - 17
 ENGINE SENSORS

1.1.13 LAMBDA SENSOR

WARNING

DO NOT CONNECT 12V DIRECTLY FROM

THE BATTERY.

CAUTION

Use only sensor safe silicone sealants on the

engine. Failing to do so can damage the Oxy-
gen Sensor
Location
Lambda sensor to be assembled on exhaust pipe.
Specifications
Tightening torque: 40-50 Nm
Supply voltage: 12 V
Output voltage range: 0.2 to 0.8 V
Nominal heater resistance @ room temperature: 9
Ω
Inspection
Sensor
Measure the heater coil resistance between Pin-1
& Pin-2 at sensor.
Connector
Remove the ECU connector and check the
continuity in the wiring harness.
If value is faulty replace the sensor.

Sensor 1 Pin1 – Power Supply

SENSOR ECU CONNECTOR Pin2 – Ground
CONNECTOR
Pin3 – Sensor Ground
Pin 1 Pin 03
Pin 2 Pin 82 Pin4 – Sensor Signal

Pin 3 Pin 70
Pin 4 Pin 18

EC - 18
 ENGINE SENSORS

Rear V iew
Sensor 2
SENSOR ECU CONNECTOR
CONNECTOR
Pin 1 Pin 03

2
4

1
Pin 2 Pin 85
Pin 3 Pin 51
Pin 4 Pin 37

SAEM0038-0213

Measure the input voltage (12V) across Pin-1 & Pin-3 by disconnecting the connector from
sensor. If faulty replace the wiring harness.

EC - 19
 ENGINE SENSORS

1.1.14 INJECTOR

WARNING

DO NOT CONNECT 12V DIRECTLY FROM

THE BATTERY.
Location
Injector is assembled on the fuel rail.
Specifications
Operating temperature range : – 20 °C to + 125 °C
Coil Resistance : 15 Ω
Inspection
INJECTOR 1
Pin 1 – Control Signal
Pin 2 – Coil Power
INJECTOR 2
Pin 1 – Control Signal
Pin 2 – Coil Power
Connector Re a r Vie w
• Remove the ECU connector and check the
continuity in the wiring harness.

SENSOR ECU
CONNECTOR CONNECTOR
2 1
INJECTOR 1
Pin 1 Pin 102
Pin 2 Pin 65
SAEM0037-0213

INJECTOR 2
Pin 1 Pin 87
Pin 2 Pin 65
If faulty replace the wiring harness.
Sensor
Measure the resistance between Pin-1 & Pin-2 at sensor.
If value is faulty, replace the sensor.

EC - 20
 ENGINE SENSORS

1.1.15 IGNITION COIL

Location
Assemble the ignition coil with bracket mounted on
the engine cylinder head.
Specification
Operating temperature range: – 40 °C to +120 °C
Primary Coil Resistance: 1.07 Ω ± 10 %
Secondary Coil Resistance: 12.5 kΩ ± 12%

Inspection
Connector Rear V iew

Remove the ECU connector and check the

continuity in the wiring harness.

Coil-1
2 1
SENSOR ECU CONNECTOR
CONNECTOR
Pin 1 Pin 03
Pin 2 Pin 116
SAEM0035-0213

Coil – 1
Coil-2
Pin1 – Coil Power
SENSOR ECU CONNECTOR
CONNECTOR Pin2 – Control Signal
Pin 1 Pin 03 Coil – 2
Pin 2 Pin 117
Pin1 – Coil Power
Pin2 – Control Signal
Coil-3
Coil – 3
SENSOR ECU CONNECTOR
CONNECTOR Pin1 – Coil Power
Pin 1 Pin 03 Pin2 – Control Signal
Pin 2 Pin 118
Sensor
Measure the Primary coil resistance between Pin-1 & Pin-2 at sensor and Secondary coil
resistance between Pin 1 and spark plug tip.
If the values are faulty, replace the sensor.

EC - 21
CNG - ENGINE INTAKE AND EXHAUST SYSTEM

ENGINE INTAKE AND EXHAUST SYSTEM

SECTION IE

CONTENTS
1.1 AIR FILTER .................................................................................................................................. 3
1.1.1 REMOVAL ....................................................................................................................... 3
1.1.2 REPLACEMENTS ............................................................................................................ 3
1.1.3 INSPECTION................................................................................................................... 3
1.1.4 ASSEMBLY ..................................................................................................................... 4
1.2 ELECTRONIC THROTTLE BODY ASSEMBLY ............................................................................... 4
1.3 ELECTRONIC THROTTLE BODY ASSEMBLY PARTS.................................................................... 6
1.4 EXHAUST PIPE ........................................................................................................................... 8
1.5 CATALYTIC CONVERTER ............................................................................................................ 9
1.6 MUFFLER .................................................................................................................................... 10
1.7 SERVICE DATA AND SPECIFICATION .......................................................................................... 11

IE - 1
 AIR FILTER

1.1 AIR FILTER

1.1.1 REMOVAL
1. Disconnect hose connection between air filter and snorkel.
2. Remove the mounting bolts of snorkel.
3. Disconnect the hose connection from turbocharger and air filter.
4. Un-clip the air filter housing and remove the element from inside.
5. Remove the filter housing from Cab.
1.1.2 REPLACEMENTS
Replace the air filter element on appearance of red band on the service indicator or 40000
Kms.
1.1.3 INSPECTION

1. Inspect the condition of the hoses for any

damages.
2. Inspect the choke indicator, incase of red band
appearing, reset the air filter service indicator
by pressing it on the top.
3. Run the engine and check for any leaks through
the hoses. Tighten clamps if necessary.

IE - 3
 ELECTRONIC THROTTLE BODY ASSEMBLY

1.1.4 ASSEMBLY

1. Mount the air filter housing and tighten the bolts to the specified torque.
Tightening torque for air filter bolt is: 2.5 – 3.5 Nm (0.25 – 0.35 kgf-m).
2. Mount the snorkel and tighten bolts.
Torque: 2.5 – 3.5 Nm (0.25 – 0.35 kgf-m)
3. Assemble the hoses and tighten the clips.

1.2 ELECTRONIC THROTTLE BODY ASSEMBLY

Disassembly

CAUTION

Before any intervention on the CNG instal-

lation, it is obligatory to close the manual
shut-off of the valve. Do not try to set or ad-
just throttle flap.

1. Keep vehicle ignition OFF during electronic

throttle body disassembly.
2. Remove the hose connecting the Air filter outlet
to throttle body (4).
3. Disconnect the connector cables connecting to
the throttle body sensors.
4. Remove the gas supplying hose connecting to the throttle body.
5. Dismantle the air duct (3) from the intake manifold (1) and the gasket (2) by loosening the
M6 flange nuts.
6. Dismantle the throttle body (4) from the air duct (3) by loosening the M6 nuts.

Inspection

1. Shine a flashlight into the part to examine the

carbon buildup on the inner body.
2. Check for crack and damage on the throttle
body.
Check that the throttle flap is not stuck open.
3. While servicing the electronic throttle body
assembly, avoid introducing contaminants to
the threads, or to the new element.

IE - 4
 ELECTRONIC THROTTLE BODY ASSEMBLY

Assembly

1. Place the gasket (1) in throttle body (2) and

assemble the air duct (3) using M6 nut (4).
2. Tightening torque for nut is 8 - 10 Nm.
3. Assemble the air duct (3) in intake manifold (5)
along with air duct gasket.
4. Replace the gaskets whenever the unit is
dismantled.
5. Do not re-use old O-ring
6. Tightening torque for air duct mounting M8 bolt
(6) is 18 - 22 Nm.

IE - 5
 ELECTRONIC THROTTLE BODY ASSEMBLY PARTS

1.3 ELECTRONIC THROTTLE BODY ASSEMBLY PARTS

Rail Pressure Sensor Replacement

1. Unscrew the two allen screws (3) holding the 1

3
fuel rail (2) to the injection manifold (4).
3
2. Unscrew the Rail Pressure Sensor (1) from
Fuel Rail body (2). 2

3. Replace Rail Pressure Sensor with O-Ring.

4. Tightening torque for Rail Pressure Sensor is 6
to 8 Nm on the Fuel Rail body.
4
SAEM0079-0213

Fuel Rail Replacement

1. Unscrew the two allen Bolts (1) from Fuel Rail

1
(2).
1
2. Pull out the Fuel Rail (2) from the Injection
Manifold Assembly (3).
2
3. Replace the Fuel Rail on the Injection Manifold
Assembly and tighten the allen bolts at 18 Nm.

3
SAEM0080-0213

Injector Replacement

1. Unscrew the two allen Bolts (1) from Fuel Rail

1
(2).
1
2. Pull out the Fuel Rail (2) from the Injection
Manifold Assembly (3).
2
3. Pull out the Injector mounting clips (4) from the
Injectors (5). 5

4. Pull out the Injectors straight out from the

Injector Adapters (6) mounted on Injection
Manifold (3). 3 6 7 4
SAEM0081-0213
5. Replace the Injectors (5) along with Injector
O-rings (7) by pushing it straight on the Injector
Adapters (6).
6. Push the Injectors mounting clips (4) to lock the injectors (5) with Injector adapters (6).
7. Push the Fuel Rail Assembly (2) along with O-ring Injectors by pushing it straight on the
Injectors.
8. Tightening torque for allen bolts on fuel Rail is 18 Nm.

IE - 6
 ELECTRONIC THROTTLE BODY ASSEMBLY PARTS

Fuel Rail Inlet Adaptor Replacement

1. Unscrew Inlet Adaptor (1) from Fuel Rail Body

(2).
1
2. Replace Inlet Adaptor (1) along with O-Ring (3).
3
3. Tightening torque for Inlet Adaptor is 19 – 21 2
Nm on the Fuel Rail body.

SAEM0082-0213

Electronic Throttle Body Replacement

1. Unscrew the 4 Mounting Nut (1) from Injection 1

3
Manifold Assembly (2).
2. Pull out the Electronic Throttle Body (3) from
Injection Manifold Assembly (2). 4

3. Replace O-ring (4) by pulling it out from the

groove inside the Injection Manifold.
4. Replace Electronic Throttle Body by pushing
it straight on the groove inside the Injection
Manifold. 2
SAEM0083-0213
5. Tightening torque for mounting nuts is 14 Nm
on the Engine Flange.

CAUTION

After removal, replacement and refitment of any ETB part, ensure to do proper leak
testing before fitment to vehicle due to high possibility of fire hazard.

IE - 7
 EXHAUST PIPE

1.4 EXHAUST PIPE

Disassembly

CAUTION

Adequate care should be taken to ensure that

the engine is cold before proceeding to han-
dle the exhaust area. Apply temperature re-
sistance grease before assembly and disas-
sembly of lambda sensor.

1. Remove the bolts holding the catalytic

converter to the exhaust pipe.
2. Remove the connectors from the Lambda
sensor mounted on the exhaust pipe (2).
3. Remove the three nuts (4) holding the exhaust
pipe to the exhaust manifold (3).
4. Remove the exhaust pipe.

Inspection

1. Check for crack and damage on the exhaust

pipe and heat shield.
2. If damaged or cracked, change the respective
damaged components.
3. Inspect the flatness of the exhaust pipe (1) on
a surface table using feeler gauge (2).
4. Flatness to be checked on both sides.
5. Change the exhaust pipe gasket on both ends.
Limit: 0.2 mm
If the limit exceeds, replace the components.

Assembly

1. Gasket (1) to be assembled in between

exhaust pipe (2) and exhaust manifold (3).
2. Assembling gasket to exhaust manifold.
3. Now assemble the exhaust pipe and tighten
the exhaust pipe faces exactly the mark on the
gasket.
4. Follow the sequence (1–2–3) to tighten the nuts
for exhaust pipe to mount on exhaust manifold.
5. Use self lock M8 nuts (4) to assemble and
tighten the components.
6. Tightening torque for nut is 18 – 22 Nm.

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 CATALYTIC CONVERTER

1.5 CATALYTIC CONVERTER

CAUTION

Apply temperature resistance grease (MOS2) before assembly and disassembly of

lambda sensor.

Disassembly
The catalytic converter is a very important part of
the emissions control system on your vehicle.
1. Remove the connector from the Lambda
sensor on the catalytic converter.
2. Remove lambda sensor (2) from catalytic
converter.
3. Remove the catalytic convertor (4) mounting
bolts from the flywheel housing (3).

4. Remove the mounting bolts fastening the catalytic converter to the exhaust pipe (1).

CAUTION

Be very careful when working on or near the catalytic converter. External tempera-
tures can reach 1,500°F (816°C) and more, causing severe burns. Removal or instal-
lation should be performed only on a cold exhaust system.

Inspection
Here are some signs that show something may be
wrong with your catalytic converter
1. Vehicle’s fuel efficiency suddenly drops.
2. Vehicle doesn’t accelerate when you step on
the Accelerator pedal.
3. Vehicle fails to start.
4. MIL will glow ON.
5. Exhaust gas back pressure will increase and
result in poor pick up.

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 MUFFLER

Assembly

1. Assemble the mounting bolts (5) fastening the

catalytic converter (1) to the exhaust pipe (2).
2. Assemble the catalytic convertor (1) to the
flywheel housing bracket (3) using M10 bolts
and nuts (4).
3. Tightening torque for M10 bolt is 35 – 43 Nm.
4. Tightening torque for M10 nut is 24 – 46 Nm.
5. Tightening torque for exhaust pipe bracket bolt
is 18 – 22 Nm.

1.6 MUFFLER

Disassembly
• Remove the flange nuts (3) on the both ends of tube assembly (4).
• Remove the muffler (1) by removing the exhaust mounting rubber (5).

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 SERVICE DATA AND SPECIFICATION

Assembly
Assemble in the reverse order of removal.

CAUTION

• Always replace exhaust gaskets with new ones while assembling.

• If insulator is badly deformed replace it.
• Connect sealing surface securely to avoid gas leakage.
• When installing mounting rubber, avoid twisting.
• Assemble muffler pipe till the stopper on catalytic converter before clamping

Tightening torque for hex flange nut is 24–32 Nm.

1.7 SERVICE DATA AND SPECIFICATION

TIGHTENING TORQUE FOR SPECIAL BOLTS AND NUTS

Unit Nm Kgf-m
Air Filter bolt 2.5-3.5 0.25-0.35
Snorkel mounting bolts 2.5-3.5 0.25-0.35
Exhaust Manifold flanged nut 18-22 1.8-2.2
Exhaust Manifold stud 13 1.3
Exhaust outlet pipe stud 12-15 1.2-1.5
Exhaust outlet pipe self lock nut 18-22 1.8-2.2
Heat shield M6 screw 7-9 0.7-0.9
Bracket exhaust pipe M10 screw 35-43 3.6-4.4
Cat – Con Hex nut M10 24-46 2.4-3.6
Exhaust pipe bracket bolt 18-22 1.8-2.2
Cat – Con exhaust pipe screw M10 24-46 2.4-3.6
Exhaust pipe mounting screw 18-22 1.8-2.2
Air duct flanged screw 18-22 1.8-2.2
Throttle body M6 nut 8-10 0.8-1.0
Tail Pipe - hex flange nut 24-32 2.4-3.2

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