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.
♦ If the turbocharger parts are damaged, wheel rubbing marks present, shaft not rotating freely
or binding or excessive journal clearance then the Turbocharger should be serviced.
Do not attempt to service or overhaul the Turbocharger. It should be done only at the authorized
Turbo Energy Ltd service center. Any attempts to attend without the use of special tools or
procedure can damage to turbocharger or personnel!
Turbocharger Installation –
• Do not mishandle, tumbled, dropped or keep any ports open.
• Do not use the actuator control rod for lifting or carrying.
• Do not disturb the setting of the actuator.
Check
The inlet connection & outlet exhaust connection to turbocharger for foreign material, cracks,
blockages, sand particles, loose nuts etc. This check should be done more thoroughly if any damage
has been noticed in compressor or turbine blades as under normal operating conditions the blades
can damaged only if a foreign object hits them.
Check all the hoses and pipes from turbocharger outlet to intercooler and intercooler to inlet manifold
for crack, aging, leaks. Check the hose clips for proper functioning. If in doubt – replace.
The oil supply pipe should be checked carbon deposits, crack, distortions etc. Clean the supply pipe
before fitting.
Do not attempt to change the orientation of turbocharger and ensure the correct gaskets are used.
Do not reuse any of metallic gaskets even if they appear to be good. It will lead to leakage & drop in
the performance of the engine.
Installation –
Once a new turbocharger is being installed,
i. Fill fresh clean oil from the oil supplies port and after that give the shaft few rotations.
ii. Fit the supply pipe.
iii. Crank the engine till a steady stream of oil comes out through the drainpipe. (CAUTION: Do not
crank the engine for too long. Excessive cranking will result in emptying of the pump cavity
causing the plunger to run dry.)
This will ensure that the oil supply line to Turbocharger is purged of any air pocket.
After this, fit the return line from turbocharger to sump, taking care to avoid any kinks.
With engine running condition, check the air, exhaust and oil connections for leaks.
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