Mahindra THAR Service Repair Manual

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INDEX EURO IV ENGINE AIR INTAKE SYSTEM FUEL SYSTEM CRDe COOLING SYSTEM EMISSION CONTROL SYSTEM CLUTCH NGT 530 2WD NGT 530 4WD TRANSFER CASE - ELECTRICAL SHIFT TRANSFER CASE - MECHANICAL SHIFT PROPELLER SHAFT REAR AXLE STEERING BRAKES FRONT SUSPENSION REAR SUSPENSION WHEELS & TYRES THAR

Euro IV Engine Contents Description Trouble Shooting Care of the System In Car Repairs Working principle of various sub systems of the Engine Dismantling & overhauling of the Engine. Specifications & Wear Data Lubricants & Sealants Tightening Torques List of the MST Main Menu Search Print EXIT Index Automotive Sector All copyrights reserved by Mahindra & Mahindra Ltd THAR Engine CRDe - IV July 09

Automotive Sector All copyrights reserved by Mahindra & Mahindra Ltd THAR Engine CRDe - IV July 09 Description The 2.49 -liter Turbocharged and intercooled common rail direct injected diesel engine with a bore 94 mm and stroke of 90 mm develop 113 BHP at 3800 RPM and a torque of 260 Nm at 1800 RPM. A waste gated turbocharger controls the boost to 2.2 bar. The compressed air is cooled by the charge intercooler which is mounted upstream of the turbocharger. The cooled air enters the inlet manifold’s plenum and it enters the Cast iron cylinder head through the inlet valves having a 45- degree angle. A boost pressure sensor is incorporated in the system to measure the air boost. The piston features re-entrant type combustion chamber and having ferrous ring insert in the Top ring groove. A 3-ring pack is used. The top ring is asymmetrical barrel face and with CKS coating and keystone shape. The 2 nd ring is taper faced. The 3 rd is Conformable Oil Ring. The piston is having an offset of 0.5 mm. The forged connecting rod is connected to induction-hardened crankshaft. The small end of the connecting rod is trapezoidal shaped to reduce the mass as well as to ensure higher loading. The crankshaft is induction hardened with the filets hardened & ground. The flywheel has a shrunk fit ring gear and also a ball bearing to act as pilot for the gearbox input shaft. The front end is having a rubber moulded dampener pulley The high pressure pump & camshaft are chain driven. Boost Pressure Sensor Main Menu Search Print EXIT Index

Automotive Sector All copyrights reserved by Mahindra & Mahindra Ltd THAR Engine CRDe - IV July 09 Trouble Shooting Refer to the Service diagnosis chart. Additional tests & diagnostic procedures may be necessary for specific engine complaints that can not be isolated using only the diagnostic chart. Information concerning the additional checks is provided within the following diagnostic. Cylinder compression pressure Test The results of the cylinder compression test can be utilized to diagnose several engine malfunctions. Before carrying out the compression test ensure that the battery is in good working condition. Otherwise the indicated pressures may not be valid for diagnostic purpose. Remove all the injectors. Fit the dummy injector (MST Tool) and connect it with the compression gauge. Disconnect the engine RPM sensor or phase sensor connector so that the engine does not start. Crank the engine. Note the compression value should be 30 bars. Repeat the procedure for the other cylinder. Refer to the Specification for the value. Engine cylinder Head Gasket Failure Diagnosis A leaking engine cylinder head gasket usually results in loss of power, loss of coolant and engine misfiring, overheating and poor fuel economy. An engine cylinder head gasket leak can be: A. Between adjacent cylinders Or B. Between a cylinder and adjacent water jacket. Cylinder head gasket failure between cylinders is indicated by Loss of power and /or engine misfiring. Main Menu Search Print EXIT Index

Automotive Sector All copyrights reserved by Mahindra & Mahindra Ltd THAR Engine CRDe - IV July 09 Cylinder head gasket leaking between a cylinder and coolant passage results in coolant foaming or overheating and loss of coolant indicate an engine water jackets. Cylinder to Cylinder Leakage Test Check the cylinder compression pressure as already explained. Leakage between cylinders will be result in drop of compression pressure by nearly 50 to 70% in the affected cylinders. Cylinder to Water jacket Leakage Test • Remove the radiator cap. • Warm up the engine and allow it to warm up until the engine thermostat opens. • If large combustion /combustion pressure leak exist, bubbles will be visible in coolant. • If bubbles are not visible, install a radiator pressure tester and pressurize the cooling circuit. If a cylinder is leaking combustion pressure into the water jackets then the tester’s needle will pulsate with every combustion stroke of the cylinder. Symptom Causes Remedial action Engine will not start & emit black smoke 1. Air intake obstructed 2. Defective injectors 3. Lack of compression. 4. Cylinder head gasket failure 5. Engine timing- Valve 6. CR system Replace the element. Check for free operation of Turbocharger. Replace Check compression pressure.- if low check for valve seat ,rings & liner wear Replace the cyl. head gasket. Check timing chain. Refer diagnostic manual. Main Menu Search Print EXIT Index

Automotive Sector All copyrights reserved by Mahindra & Mahindra Ltd THAR Engine CRDe - IV July 09 Noisy engine & black smoke. 1. Faulty injectors. 2. Loose main bearings 3. Broken parts 4. Rockers loose or out of adjustment. Replace injectors Tighten the main bearings. Inspect and replace the broken parts. Adjust tappet. Engine does not give full power. 1. Air intake restricted. 2. Clogged fuel filter. 3. Incorrect tappet clearance 4. Defective injectors. 5. Air leaks in pressure line after turbocharger( Turbo to intercooler, intercooler & intercooler to intake manifold) 6. Air leak in pipe – manifold to FIP 7. Fuel return pipe to tank blocked. 8. Boost pressure pipe/hose Replace air cleaner element if required. Replace filter. Adjust tappets in cold condition. Replace Plug the leaks, replace hose or clip if required. Replace the hose or tighten Locate the kink/block in return pipe and rectify. Check the pipe, washer Main Menu Search Print EXIT Index

Automotive Sector All copyrights reserved by Mahindra & Mahindra Ltd THAR Engine CRDe - IV July 09 assembly damaged. 9. Valve leak 10. Turbocharger damaged. 11. Gas leaks between exhaust manifold & cylinder head. 12. Restricted exhaust system. 13. Exhaust gas leak between turbo & manifold. 14. Gas leak between EGR pipe joints 15. EGR pipe leak. 16. Fuels supply line kink creating restriction. 17. EGR valve improper functioning. 18. Compression leak. 19. Jammed piston rings 20. Viscous fan & rectify. Check the compression, relap if required. Get the Turbocharger repaired at authorized TEL dealer. Replace gaskets. Replace Turbocharger Tighten the TC mounting bolts. Replace gasket if required. Remove the restriction in exhaust system. Change the gasket or the hose. Replace the pipe. Remove the restriction. Check the EGR using the blink codes. Proceed appropriately. Check compression. Replace piston rings. Check the VFD as Main Menu Search Print EXIT Index

Automotive Sector All copyrights reserved by Mahindra & Mahindra Ltd THAR Engine CRDe - IV July 09 continuously engaged. Check CR system outlined in cooling. Replace if required. Refer the diagnostic manual Noisy engine & high smoke ( White/ Grey) 1. Cylinder head gasket defective. 2. Worn out or damaged valve seats. 3. Leaking injector holder Replace the cylinder head gasket. Lap the valve seats or regrind. Tighten the injector holder. Black smoke. 1. Air intake restricted. 2. Incorrect tappet setting. 3. Defective injectors 4. Air leaks. 5. EGR valve stuck open 6. Restricted exhaust system. 7. Gas leak between exhaust manifold & cylinder head. 8. Worn out rings, liners & valves. Check for hoses, replace air cleaner element. Adjust tappets. Check injectors. Check for leaks between Turbocharger to intercooler, intercooler & intercooler to inlet manifold. Check the EGR valve Remove restriction or replace parts. Replace manifold gasket or parts. Overhaul engine. Excessive oil consumption 1. Cracked vacuum line hoses. Check the vacuum line from the alternator to the EGR valve - check for Main Menu Search Print EXIT Index

Automotive Sector All copyrights reserved by Mahindra & Mahindra Ltd THAR Engine CRDe - IV July 09 2. Clogged air filter element. 3. Restriction in air intake to compressor duct. 4. Restrictions in turbocharger oil drain line. 5. Restriction in crankcase breather. 6. Damaged oil separator 7. Turbocharger damaged. 8. Worn out rings, liners, and valves. 9. External oil leaks 10. Leakages through inlet manifold mounting face leaks, crack. Replace cracked hoses. Replace element. Locate & remove restriction. Remove the restriction in the drainpipe. Check the crankcase ventilation & rectify. Replace the oil separator Change oil, filter, service the Turbocharger & use recommended oils & drain intervals. Follow the recommended procedure while shutting down. Repair Turbocharger. Overhaul engine. Stop the external oil leakages. Change the vacuum hoses. Change the manifold gasket or replace the Main Menu Search Print EXIT Index

Mahindra THAR Service Repair Manual

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