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.
Inspection:
All the components should be inspected for wear. Any components, which are beyond the wear limits,
have to be replaced.
Over & above the wear limits: The following points also need to be ensured.
Piston: Check for scuffing/scoring on the skirt. A hard thick layer of carbon lacquer on top land is
acceptable. (If the thick layer is present on the piston check that the liner does not have scuffing)
However scuffing of the top land and skirt giving indication of overheating which is not acceptable.
Liner: Any scoring on the liner is not acceptable.
Crankshaft: Check for scoring on the main as well as connecting rod journal. If scoring is nominal and
will not the increase the oil clearance then the crankshaft can be used in, as it is condition.
However if it is unacceptable then the journal has to be ground up to service limits only.
Any deep groove in the rear end oil seal seating area is unacceptable. It will result in oil leaks.
Valve: If valve tip is worn out/ ridged then not acceptable
Main bearing and connecting rod bearing — If the scoring is nominal and oil clearance is not affected,
then it can be reused. However if flaking /peeling of the bimetal in any particular zone only is present
then use new shell. Look for foreign particle embedded, deep scratches.
Dampener pulley rubber bonding – inspect for any gap between the rubber ring and the outer/inner
ring, Cracks on ring. Any deep groove in the front oil seal seating area is unacceptable. It will lead to
leakages.
If any deterioration of rubber or gap noticed between the ring and the rubber replace the dampener
pulley.
It is suggested that the dampener pulley be replaced at every 3,00,000 Kms.
Caution:
While measuring the inner diameter of the connecting rod big end and main journal please take the
measurements after torque tightening only. For measurement purpose the torque should be 85±8
Nm. Do not reuse this bolt.
If line boring of the crankshaft’s journal in the block is done to rectify any oval, then ensure that the
material from block half is not removed. In absence of taking this precaution the piston will move
up. It will change the compression, influencing the performance. In the worst case the valves can hit
the piston.
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