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.
Assembly –
The assembly sequence is the reverse of the dismantling procedure.
To obtain a good life of the rebuilt unit absolute cleanliness of the parts is taken as a prerequisite and
also the fact that all the parts have been inspected.
The additional points which are mentioned are necessary to give you the engine life same as the
original engine.
Bolts
The following bolts are recommend to be replace every time they are opened-if the Maximum length
exceeds the specification. However the connecting rod bolt has to be changed every time without
exception.
The bolts have to be tightened by base torque then 2 stage angular torque. The angular torque’s
ensures that the bolts are torque tightened up to yield point. And the 2 stage ensures that the
clamping load for each bolt is within a very close tolerance.
Cylinder head bolts - 10 nos. Maximum length 136.6/135.4 mm
Main Bearing Bolts - 10 nos. Maximum length 90.6/89.4mm
Connecting rod bolts- 08 nos. Replace every time.
Flywheel bolts - 06nos. Maximum length 29.58/30.42 mm
Cylinder block – Top face –
Ensure that the tapping for the cylinder head bolt as well as the crankshaft’s main journal is fine.
Ensure that no water or oil after cleaning is in the bolt holes (esp. the cylinder heads.). If found please
remove them, if necessary using cotton cloth (not cotton waste).
If the oil /water is not removed then it is possible that while tightening the bolt. It may not allow
complete tightening of the bolts and one will get a false reading.
Cylinder head gasket –
It is a multi layer steel gasket type. Do not use any oil or shellac on the cylinder head gasket or on the
block face or the cylinder head face. The gasket has to be fitted dry.
The gasket can be assembled any face up or down. However it is suggested that the face with the
numbers should be facing up.
Piston & Rings –
While fitting the piston rings ensure that the rings end gap are staggered in 120°.
The first ring end gap should not be on the thrust axis but the minor axis i.e. on the gudgeon pin axis.
Please note that the first ring is keystone shaped hence the top mark has to face up. The 2
nd
ring is
taper faced. The face, which should be on the top, has to be facing up. The 3
rd
ring is the conformable
type oil ring. It can be assembled either way.
While assembling the piston on to the liner- apply clean oil liberally on the liner surface.
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