xd3p bolero.pdf

7/21/2019 XD3P BOLERO.pdf

1/107

Mahindra institute of learmingexcellence, Nasik

XD 3P ENGINE


2/107

Side view


3/107

Front view


4/107

Indirect injection

Heater

Plug

Nozzle

Pre combustion chamber


5/107

The model XD 3P engine is a 4-cylinder, in-line, overheadvalve, water-cooled, indirect injection engine.

Engine is used on following vehicles

BOLERO MM OTHERSBOLERO GLX / SLX MM 550 XDB VOYAGER

BOLERO LX / XLS MM550 XD/4WD ARMADA GRAND

BOLERO SPORTZ ARMY AMBULANCE

INVADER DX EXPORT MODELS

SERIES [ BS 1 & BS 2 MODEL]


6/107

Model : XD 3P

Type : In-line, Four stroke

Number of Cylinders : 4

Combustion system : In direct injection

Bore mm (in) : 94

Stroke mm (in) : 90

Displacement cc (cu. In) : 2498Compression ratio : 23 : 1

Firing order : 1-3-4-2

Timing : By chain

Power : 50.50kW 4000 rpm

Torque : 137.50nm at 2000-2500 rpm

Low idle : 770 to 820 rpm

Specification


7/107

MAINTENANCE SCHEDULE

Change engine oil & filter [ with Maximile 6k oil ]4000km,10000km & then every 6000km

Refill fresh water with sodium chromate [Vehicle w/o degassingtank], Maximile coolant [ Vehicle with Aluminium radiator &

de-gassing tank]once in a year / after every 64000 kms

Change primary fuel filter4000km, 16000kms & then every 12000kms

Change secondary fuel filter16000km, 40000kms & then every 24000kms

Check nozzles opening pressure & reset it52000kms, 100000kms & then 48000kms.

Adjust fan belt tensionduring every service Clean air filter

during every service

Change air cleaner cartridgeat every 40,000kms [ Old type - 20000kms ]


8/107

Oil & lubricants

Oil recommended for XD 3P engine is maximile 6K

Oil sump capacity : 5 lit.


9/107

Oil f ilter recommended :

Maximile filter for DP engine

Diesel fi lter recommended :Lucas diesel filter


10/107

Maximile premium [10k] oil can be used for XD 3P engine.

With this oil, the drain interval is 10,000 kms .

Multi grade APICG4 15W/40 oil


11/107

General construction


12/107

Block

Integral cylinder liners, inline arrangement. Diameter grading

A or B is punched on block.

A or B


13/107

Piston

Weight

Grading

Diameter

Grading

Max weight diff allowed is : +/- 10 gms

Grade Piston BoreA 93.900 - 93.909 94.010 to 94.022 mm

B 93.100 - 93.109 94.022 to 94.033 mm


14/107

Piston pin

Diameter : 30.0 mm

Length : 78.8 mm

Piston pin circlip of XD 3P & XDP 4.90 engines are different.

Identif ication of Circlip


15/107

Piston rings[ PCVL ]- old

Top : Asymmetrical barrel

Middle : Scrapper ring-Napier groove

Bottom : Oil ring with chrome plated coil expander

Ring gap

Top : 0.35 to 0.50mm ( 14 to 20 thou)

MIDDLE : 0.35 to 0.55mm ( 14 to 22 thou)

BOTTOM : 0.15 to 0.30mm ( 06 to 12 thou)


16/107

Piston rings PCVL


17/107

New piston rings [ IPL ] :

Top : Chrome inlaid positive twist symmetrical barrelMiddle : Taper face ring [ Ring gap 0.80 to 1.00mm]

Bottom : Profile ground with increase in tangential load

[From 4-6Kg to 6- 8 kg]New piston ring set part no- 9420001228

To address oil consumption / Blow bye problem, following

modifications are done in XD 3P engine

Piston : New piston with low piston to liner clearance

[ 0.11-0.14mm to 0.11- 0.12mm & low top land [ From 15mm to

12mm ]( Part no 9420001222- Qty 4- BS I application. No change

in BS II application - 9420001172-Qty 4)

Block :

Plateau honed cylinder block in place of normal honed to reduce

the initial ring wear to enhance the life of engine.


18/107


19/107

Connecting rod

Central distance

Big end to small end : 150 + 0.025

Big end dia. : 58.737 + 0.013Big end width : 35.90 -0.05

Small end width : 30 + 0.20

Radial clearance : 0.040 0.092Side clearance : 0.10 0.25

Small end dia. : 33 0.025

Bushing outer dia. : 33.09 - 33.13Bushing inner dia. : 30 +0.020/+0.007


20/107

Connecting rod

Maximum allowed weight difference of 4 connecting rod : 20gms

Weight grading mark Identification number


21/107

Connecting rod side play: 0.10mm TO 0.25mm

( 4 to 10 thou )


22/107

Connecting rod bearings

Std. Size : 1.832 1.838

1st o/s 0.30 : 1.982 1.988

2nd

o/s 0.50 : 2.082 2.0883rd o/s 0.80 : 2.232 2.238

Std size of crank pin journal : 55.00 0.021/-0.006mm

1st u/s 0.30 crank pin journal : 49.70 0.021/-0.006mm

2nd u/s 0.50 crank pin journal : 49.50 0.021/-0.006mm

3rd u/s 0.80 crank pin journal : 49.20 0.021/-0.006mm


23/107

Crank shaft

Std size of main journal : 60.00 0.021/-0.006mm

1st u/s 0.30 main journal : 59.70 0.021/-0.006mm

2nd u/s 0.50 main journal : 59.50 0.021/-0.006mm

3rd u/s 0.80 main journal : 59.20 0.021/-0.006mm


24/107

Crank shaft

No 4 cap of main journal can be identify by O mark punched

on it.


25/107

Crankshaft end float : 0.08 mm TO 0.29mm ( 3 to 12 Thou )

End float is adjusted by using thrust washer

Thrust washer on cap have locating lips.

Oil grooves face towards out side


26/107

Cam shaft

Oil pump drive gear teeth : 13

Axial clearance of cam shaft : 0.05 to 0.15 mmRadial clearance of cam shaft : 0.05 to 0.11 mm

Tappets

Cast iron with hardened bearing surfaces

Oil return slot


27/107

Flywheel

Ring gear teeth

: 146

Temperature for ring

Gear fitment

: 1700 c

Flywheel clutch surface

Regrinding

: 0.5max


28/107

Cylinder head

Height of cylinder head : 90.00 mm

Min. Cylinder head height after machining : 89.45 mm

90.00mm


29/107

Cylinder head warpage : max. 0.15mm ( 6 thou )


30/107

Valve & guide

Check the clearance between valve & valve guide. If i t is

more than 0.15mm ( 6 thou ), replace valve guide

Check valve depression from cylinder head surface.

Inlet valve : 1.05 to 1.45mm

Exhaust valve : 0.85 to 1.25mm

Depth of valve guide from cylinder head surface 28 +/- 0.5 mm


31/107

Valve depression from head surface. [BS I]

Inlet valve : 1.05 to 1.45mmExhaust valve : 0.85 to 1.25mm


32/107

Pre combustion chamber projection: 0 - 0.03mm

0 to 0.03 max.


33/107

Lubrication circuit

Cam shaft slot


34/107

Extension tube : Connected from main oil gallery to FIP

bracket. Lubricate FIP sprocket journal.

Ensure correct assembly of extension tube.

If rubber sleeve is misplaced

during assembly, will cause low

oil pressure & subsequentlydamage to FIP sprocket & FIP

bracket.


35/107

Oil filter & bracket

Bypass valve

Filter paper

BI function

Switch

Pressure

Sensor

Oil filterBracket

Oil retaining

Seal


36/107

Ensure that the oil retaining seal is present inside the filter.

Oil retaining seal retained oil inside the filter even after engine

is switch off

Oil filter


37/107

Oil pump

Full flow with gear type pump

Oil pressure :

Idling [ 770 / 820 ] : 1.5 kg / cm2

At 3000 rpm : 3.0 kg / cm2

Bypass valve operates from 0.8 - 1.0

bar

With three gauge instrument

cluster , pressure gauge is eliminated


38/107

Install the pump and mount it in its position with the allenscrew and its cap.

Hand tighten the buffer plug and measure the gap ( X ) asshown in the fig. By using fi ller gauge.

Oil pump shaft end play


39/107

Calculate the shim thickness by adding 0.1 mm to the value ( X )

Shim thickness = X + 0.1 mm

With shim in position, tighten the plug to a torque of 8.00 kg-m .

XX + 0.1 mm

0.1mm

Bi f ti it h


40/107

Bi-function switch

Ignition on , engine off :- Pressure warning l ight on

+

P1: Oil pressure before filtration

P2: Oil pressure after f iltration

Positive

Warning lightIs on

P1 = P2 = 0

Earthing through filter bracket


41/107

Ignition on , engine on :- Pressure warning light off

+

Positive

Warning lightIs off

P2 > P1

No earthing

P2

P1


42/107

Ignition on , engine on, filter choked :- Pressure warning light on

+

Positive

Warning light

Is on

P2 < P1

P2

P1

Earthing through filter bracket


43/107


44/107

Check the clearance between gears. The clearance should not

be more than 0.15 mm ( 6 Thou).


45/107

Important

adjustments & setting


46/107

Match white dot mark on chain with crank sprocket


47/107

Match white dot mark on chain with crank sprocket

Mark & white line mark with cam & FIP sprocket mark

orMatch no 1 link with crank sprocket mark

Match no 13 link with cam sprocket mark

Match no 26 link with FIP sprocket mark

1

13 26

Chain tensioning


48/107

Chain tensioning

Chain should be tensioned by turning eccentric in anticlockwise direction ( with use of MST 251 ) and keepingautomatic slack tensioner in its bottom lock posit ion.


49/107

Adjust the clearance between chain tensioner shoe and its

support from 0.5 to 1.00 mm. After tensioning the chainrelease the tensioner lock by turning it in clockwise posit ion.

Chain tensioner fixture

[ MST 250 ]0.50 mm to 1.00mm


50/107


51/107

Lock position

Unlock position


52/107

Eccentric sprocket on ball bearing must be secured with a class

of 10.9 bolt.

Tappet setting


53/107

Tappet setting

In cold condition

Inlet : 0.15 to 0.20 ( 6 to 8 thou )Exhaust : 0.25 to 0.30 ( 10 to 12 thou )

Valve layout :

In1 Fx1 Ex2 In2 In3 Ex3 Ex4 In4

It is recommended to do the tappet setting in cold condition

FR

O

N

T

Procedure for tappet setting


54/107

Set the no. 1 piston at T.D.C on the compression stroke byturning the engine until the no. 4 inlet valve is just beginning

to open and the no. 4-exhaust valve is just beginning to

close.

Adjust the tappet clearance of following valve as per given

specifications.

In1, Ex1, In2, Ex3

Turn the engine to one full revolution so that no 4 piston is

at compression

Adjust the tappet clearance of following valve as per given

specifications.

Ex2, In3, Ex4, In4

Tappet setting-cold condition


55/107

Inlet : 0.15 to 0.20mm ( 6 TO 8 thou )

Exhaust : 0.25 to 0.30mm ( 6 TO 8 thou )

Cylinder head gasket


56/107

Cylinder head gasket

Head gasket are available in three sizesThickness Identification

1.53mm 2 Notch

1.63mm 3 Notch

1.73mm 4 Notch


57/107

Head gasket selection


58/107

Maximum piston projection out of 4 should be consideredfor gasket selection

Gasket thickness Piston projection [ mm ]

BS I BS II

Two cut 0.70 to 0.79 0.77 to 0.86

Three cut 0.80 to 0.89 0.87 to 0.96

Four cut 0.90 to 0.98 0.97 to 1.05

Piston top

Cylinder head tightening


59/107

TorquingTighten each bolt in sequence : 3.00 kg-m ( 20-25 lbs. -Ft)

Tighten each bolt in sequence : 9.00 kg-m ( 60-65 lbs. -Ft )

Retorquing

Loose the bolt by 90o & retighten the same in sequence: 7.00 kg-m ( 50-55 lbs.-Ft )

Rotate each bolt in the same sequence further by

: 1200

No retorquing is required of cylinder head at 1500/2500 kms if

followed above method

Run the engine upto 10min at 3000rpm & allow it to cool down

for 3-4 hrs.

Cylinder head tightening sequence


60/107

Spread molykote grapid on bolt

The cylinder head bolt must be position according to their


61/107

length.

07 long bolt ( KSL)

15 short bolt ( KL )


62/107


63/107

Idling setting


64/107

Anti stalling screw

Idling screw


65/107


66/107

Keep 5 Rs coin in between thrott le lever & its minimum stop.

Adjust anti stalling screw with 5 Rs coin untill rpm starts just


67/107

Adjust anti stalling screw with 5 Rs coin untill rpm starts just

increasing.


68/107


69/107

India 2000 timing mark ( line)

XD 3P engine FIP sprocket


70/107

India 2000 timing mark ( line)

Third teeth from keyway

1

23

XD 3P engine BS II timing mark ( dot mark )


71/107

Fourth teeth from keyway

1234

Setting & checking- Lucas FIP


72/107


73/107

Pump timing values for lucas FIP- BS I engine


74/107

[With variable timing method]Piston posit ioned pump reading

A] With new chain 190 BTDC As per individual

with chain tensioned [3.17mm valve drop] Marking on pump

B] With old chain 180 BTDC As per individual

w/o chain tensioned [2.85mm valve drop] Marking on pump


75/107


76/107


77/107


78/107

3] Rotate engine in either direction to set TDC of no.1 piston.

& Give some preload say 7.00mm.


79/107

4] Fit FIP with gasket on mounting bracket & align it with mark

punched on mounting bracket & FIP.

5] Remove timing chimney

Cap & insert t iming pin

[ MST 241 for variable

timing & MST 257 forConstant timing ]

6] Fit dial gauge holder

[ MST 240] & dial gauge ontiming chimney.


80/107


81/107


82/107

9] Now see the reading of dial gauge mounted on FIP, it should

be:-


83/107

For variable timing method

Preload + as per marking on FIPi e 4.00mm + as per marking on FIP

[ As we had given 4.00 mm preload.]For constant timing method

Preload + 0.90

I.E. 4.90mm.If not, adjust it for above reading.

[ If the reading is more than above value first retard the FIP &

then advanced it for above reading to eliminate errorsoccurring due to backlash ]

10] complete the assembly


84/107


85/107


86/107

1] R k & t 1 i t t th d f

Pump timing procedure with TDC pointer


87/107

1] Remove rocker arm cover & set no 1 piston at the end ofcompression. [No.4-dancing]

2] Set no one piston to TDC with the help of TDC pointer

On the vehicleView




88/107

4] Remove timing chimney cap & insert timing pin.

[ MST 241 for variable

timing & MST 257

for constant timing ]

5] Fit dial gauge holder

[MST 240] & dial gauge

on timing chimney.


89/107

7] Rotate engine in normal running direction & set no.One

piston to TDC* with the help of TDC pointer


90/107

On the vehicle

View

* Always ensure TDC by rotating engine in normal running

direction to eliminate error occurring due to backlash.

8] Now see the reading of dial gauge mounted on FIP, it should

be:


91/107

be:-

Preload + 4.5i.e. 4.00mm + 4.5

[ As we had given 4.00 mm preload.]If not, adjust it for above reading.

[ If the reading is more than above value first retard the FIP &

then advanced it for above reading to eliminate errorsoccurring due to backlash ]

9] Complete the assembly


92/107


93/107


94/107


95/107

3] rotate engine in either direction to set TDC of no.1 piston. &

Give some preload say 7.00mm.


96/107



5] Remove bleeding screw &fit pump timing adapter

[MST166] with dial gauge.

Ensure at least 4mm travel

of dial needle.

Mst 166


97/107

7] Rotate engine in normal running direction* until dial gauge

mounted on valve shows following reading: -

** ] With h i / ith h i t i d 6 68


98/107

**a] With new chain / with chain tensioned: - 6.68 mm[Preload -valve drop]

(7.00mm - 0.32 mm)

B] With old chain / without chain tensioned: - 6.78 mm[Preload -valve drop]

(7.00mm - 0.22 mm)

* Always ensure above reading by rotating engine in normal

running direction to eliminate error occurring due to backlash.** The term chain tensioned refers, when we are adjusting the

tightness of chain by adjusting the gap between the hydraulic

chain tensioner shoe & its support by 0.5 to 1.00mm.


99/107


100/107


101/107


102/107


103/107


104/107


105/107


106/107


107/107

xd3p bolero.pdf

Documents