Repair Manual MAN-00190
THAR CRDe BS-IV MAY 2012/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2012 Mahindra & Mahindra Ltd.
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.
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.
Follow the chart below for various problem, causes and their remedies -
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