Mahindra institute of learming

excellence, Nasik
XD 3P ENGINE
Side view
Front view
Indirect injection
Heater
Plug
Nozzle
Pre combustion chamber
The model XD 3P engine is a 4-cylinder, in-line, overhead
valve, water-cooled, indirect injection engine.
Engine is used on following vehicles
BOLERO MM OTHERS
BOLERO 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]
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) : 2498
Compression 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
MAINTENANCE SCHEDULE
Change engine oil & filter [ with Maximile 6k oil ]
4000km,10000km & then every 6000km
Refill fresh water with sodium chromate [Vehicle w/o degassing
tank], Maximile coolant [ Vehicle with Aluminium radiator &
de-gassing tank]
once in a year / after every 64000 kms
Change primary fuel filter
4000km, 16000kms & then every 12000kms
Change secondary fuel filter
16000km, 40000kms & then every 24000kms
Check nozzles opening pressure & reset it
52000kms, 100000kms & then 48000kms.
Adjust fan belt tension
during every service
Clean air filter
during every service
Change air cleaner cartridge
at every 40,000kms [ Old type - 20000kms ]
Oil & lubricants
Oil recommended for XD 3P engine is maximile 6K
Oil sump capacity : 5 lit.
Oil filter recommended :
Maximile filter for DP engine
Diesel filter recommended :
Lucas diesel filter
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
General construction
Block
Integral cylinder liners, inline arrangement. Diameter grading
A or B is punched on block.
A or B
Piston
Weight
Grading
Diameter
Grading
Max weight diff allowed is : +/- 10 gms
Grade Piston Bore
A 93.900 - 93.909 94.010 to 94.022 mm
B 93.100 - 93.109 94.022 to 94.033 mm
Piston pin
Diameter : 30.0 mm
Length : 78.8 mm
Piston pin circlip of XD 3P & XDP 4.90 engines are different.
Identification of Circlip
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)
Piston rings PCVL
New piston rings [ IPL ] :
Top : Chrome inlaid positive twist symmetrical barrel
Middle : 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.
Piston rings [IPL]- New
Top : Chrome inlaid positive twist symmetrical barrel
Middle : Taper face ring
Bottom : Profile ground with increase in tangential load
[From 4-6Kg to 6- 8 kg]
Ring gap
Top : 0.30 to 0.55mm ( 12 to 22 thou)
Middle : 0.80 to 1.00mm ( 32 to 40 thou)
Bottom : 0.30 to 0.55mm ( 12 to 22 thou)
Connecting rod
Central distance
Big end to small end : 150 + 0.025
Big end dia. : 58.737 + 0.013
Big end width : 35.90 -0.05
Small end width : 30 + 0.20
Radial clearance : 0.040 0.092
Side clearance : 0.10 0.25
Small end dia. : 33 0.025
Bushing outer dia. : 33.09 - 33.13
Bushing inner dia. : 30 +0.020/+0.007
Connecting rod
Maximum allowed weight difference of 4 connecting rod : 20gms
Weight grading mark Identification number
Connecting rod side play: 0.10mm TO 0.25mm
( 4 to 10 thou )
Connecting rod bearings
Std. Size : 1.832 1.838
1
st
o/s 0.30 : 1.982 1.988
2
nd
o/s 0.50 : 2.082 2.088
3
rd
o/s 0.80 : 2.232 2.238
Std size of crank pin journal : 55.00
0.021/-0.006mm
1
st
u/s 0.30 crank pin journal : 49.70
0.021/-0.006mm
2
nd
u/s 0.50 crank pin journal : 49.50
0.021/-0.006mm
3
rd
u/s 0.80 crank pin journal : 49.20
0.021/-0.006mm
Crank shaft
Std size of main journal : 60.00
0.021/-0.006mm
1
st
u/s 0.30 main journal : 59.70
0.021/-0.006mm
2
nd
u/s 0.50 main journal : 59.50
0.021/-0.006mm
3
rd
u/s 0.80 main journal : 59.20
0.021/-0.006mm
Crank shaft
No 4 cap of main journal can be identify by O mark punched
on it.
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
Cam shaft
Oil pump drive gear teeth : 13
Axial clearance of cam shaft : 0.05 to 0.15 mm
Radial clearance of cam shaft : 0.05 to 0.11 mm
Tappets
Cast iron with hardened bearing surfaces
Oil return slot
Flywheel
Ring gear teeth
: 146
Temperature for ring
Gear fitment
: 170
0
c
Flywheel clutch surface
Regrinding
: 0.5max
Cylinder head
Height of cylinder head : 90.00 mm
Min. Cylinder head height after machining : 89.45 mm
90.00mm
Cylinder head warpage : max. 0.15mm ( 6 thou )
Valve & guide
Check the clearance between valve & valve guide. If it 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
Valve depression from head surface. [BS I]
Inlet valve : 1.05 to 1.45mm
Exhaust valve : 0.85 to 1.25mm
Pre combustion chamber projection: 0 - 0.03mm
0 to 0.03 max.
Lubrication circuit
Cam shaft slot
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 & subsequently
damage to FIP sprocket & FIP
bracket.
Oil filter & bracket
Bypass valve
Filter paper
BI function
Switch
Pressure
Sensor
Oil filter
Bracket
Oil retaining
Seal
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
Oil pump
Full flow with gear type pump
Oil pressure :
Idling [ 770 / 820 ] : 1.5 kg / cm
2
At 3000 rpm : 3.0 kg / cm
2
Bypass valve operates from 0.8 - 1.0
bar
With three gauge instrument
cluster , pressure gauge is eliminated
Install the pump and mount it in its position with the allen
screw and its cap.
Hand tighten the buffer plug and measure the gap ( X ) as
shown in the fig. By using filler gauge.
Oil pump shaft end play
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 .
X
X + 0.1 mm
0.1mm
Bi-function switch
Ignition on , engine off :- Pressure warning light on
+
P1: Oil pressure before filtration
P2: Oil pressure after filtration
Positive
Warning light
Is on
P1 = P2 = 0
Earthing through filter bracket
Ignition on , engine on :- Pressure warning light off
+
Positive
Warning light
Is off
P2 > P1
No earthing
P2
P1
Ignition on , engine on, filter choked :- Pressure warning light on
+
Positive
Warning light
Is on
P2 < P1
P2
P1
Earthing through filter bracket
Oil pump
Check the oil pressure regulating valve spring. Check the oil
pressure regulating valve and seat for wear, pitting, or
corrosion.
Check the clearance between the gear & pump body. It should
not be more than 0.15 mm ( 6 Thou).
Check the clearance between gears. The clearance should not
be more than 0.15 mm ( 6 Thou).
Important
adjustments & setting
Chain timing
Chain
FIP
Sprocket
Crank
Sprocket
Idler
Sprocket
Cam
Sprocket
Chain
tensioner
Match white dot mark on chain with crank sprocket
Mark & white line mark with cam & FIP sprocket mark
or
Match 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
Chain should be tensioned by turning eccentric in anti
clockwise direction ( with use of MST 251 ) and keeping
automatic slack tensioner in its bottom lock position.
Adjust the clearance between chain tensioner shoe and its
support from 0.5 to 1.00 mm. After tensioning the chain
release the tensioner lock by turning it in clockwise position.
Chain tensioner fixture
[ MST 250 ]
0.50 mm to 1.00mm
Chain tensioner
Chain tensioner shoe
Chain tensioner shoe support
Ratchet
Lock position
Unlock position
Eccentric sprocket on ball bearing must be secured with a class
of 10.9 bolt.
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 :
In
1
Fx
1
Ex
2
In
2
In
3
Ex
3
Ex
4
In
4
It is recommended to do the tappet setting in cold condition
F
R
O
N
T
Procedure for tappet setting
Set the no. 1 piston at T.D.C on the compression stroke by
turning 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.
In
1
, Ex
1
, In
2
, Ex
3
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.
Ex
2
, In
3
, Ex
4
, In
4
Inlet : 0.15 to 0.20mm ( 6 TO 8 thou )
Exhaust : 0.25 to 0.30mm ( 6 TO 8 thou )
Tappet setting-cold condition
Cylinder head gasket
Head gasket are available in three sizes
Thickness Identification
1.53mm 2 Notch
1.63mm 3 Notch
1.73mm 4 Notch
Gasket notch
1
2
3
4
1
2
3
1
2
1.73 mm Thick 1.63 mm Thick 1.53 mm Thick
Head gasket selection
Maximum piston projection out of 4 should be considered
for 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
Torquing
Tighten 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 90
o
& retighten the same in sequence
: 7.00 kg-m ( 50-55 lbs.-Ft )
Rotate each bolt in the same sequence further by
: 120
0
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
Spread molykote grapid on bolt
The cylinder head bolt must be position according to their
length.
07 long bolt ( KSL)
15 short bolt ( KL )
KL (short bolts )
KL (Shorter bolts )
KSL ( Longer Bolts )
Idling setting
Anti stalling screw
Idling screw
Screw-in the anti stalling screw (Away from lever)
Idling rpm : 770 TO 820 rpm
To be set when engine is hot & AC is off [if fitted]
Setting procedure
Slacken the lock nut & turn the idling screw to set idling speed
as specified.
Keep 5 Rs coin in between throttle lever & its minimum stop.
Adjust anti stalling screw with 5 Rs coin untill rpm starts just
increasing.
Remove 5 Rs coin. Depress accelerator pedal to run engine at
2500~3000 rpm . then release accelerator pedal instantly.
If the engine speed falls below the idling speed & engine jerks
severely or stalls or if the deceleration is too slow repeat
above procedure.
If the engine die down
time is too long, screw
in antistalling screw
towards the throttle
lever by 1/4 turn.
If the engine speed falls
below idling, screw out
away from the throttle
lever, by 1/4 turn
Pump timing -XD 3P engine
With lucas FIP
[Valve drop method]
India 2000 timing mark ( line)
XD 3P engine FIP sprocket
Third teeth from keyway
1
2
3
XD 3P engine BS II timing mark ( dot mark )
Fourth teeth from keyway
1 2 3 4
Setting & checking- Lucas FIP
FIP mounting bracket
[NON BS II ENGINE]
For MICO pump
For LUCAS pump
Pump timing values for lucas FIP- BS I engine
[With variable timing method]
Piston positioned pump reading
A] With new chain 19
0
BTDC As per individual
with chain tensioned [3.17mm valve drop] Marking on pump
B] With old chain 18
0
BTDC As per individual
w/o chain tensioned [2.85mm valve drop] Marking on pump
Lucas has introduced constant timing method from
Following pumps:-
Lucas TVS Sr.no. G 8473 B 121 B
All bharat stage II engine.
Pump reading value is 0.90 mm.
Pump timing values for lucas FIP-BS I engine
[With constant timing method]
Piston positioned pump reading
A] with new chain 19
0
BTDC 0.90mm
With chain tensioned [3.17mm valve drop]
B] With old chain 18
0
BTDC 0.90mm
w/o chain tensioned [2.85mm valve drop]
Pump timing values for lucas FIP- BS II engine
[With constant timing method]
Piston positioned pump reading
A] with new chain 18
0
BTDC 0.90mm
With chain tensioned [2.85mm valve drop]
B] with old chain 17
0
BTDC 0.90mm
w/o chain tensioned [2.54mm valve drop]
Constant & Variable Timing Method
Constant timing method :- pump reading is fixed
[0.90mm]
Variable timing method :- pump reading is variable
[Mark on individual pump]
Variable method Fixed timing method
1] Remove rocker arm cover & set no 1 piston at the end of
compression. [No.4-dancing]
2] Free exhaust valve of no.1 cylinder & fit dial gauge holder
[MST 164] with dial gauge. [Ref. Fig-2]
Pump Timing procedure with valve drop method
3] Rotate engine in either direction to set TDC of no.1 piston.
& Give some preload say 7.00mm.
4] Fit FIP with gasket on mounting bracket & align it with mark
punched on mounting bracket & FIP.
5] Remove timing chimney
Cap & insert timing pin
[ MST 241 for variable
timing & MST 257 for
Constant timing ]
6] Fit dial gauge holder
[ MST 240] & dial gauge on
timing chimney.
7] Rotate engine in reverse direction i.e. anticlockwise from
fan side until dial gauge mounted on FIP stops.
[ Do not rotate engine further, this may damage timing pin &
pump]
This will ensure the BDC of cam ring. At this point give some
preload say 4.00mm.
8] Rotate engine in normal running direction* until dial gauge
mounted on valve shows following reading: -
For BSI engine
**A] with new chain / with chain tensioned: - 3.83mm
[preload -valve drop]
(7.00mm - 3.17mm)
b] with old chain / without chain tensioned: - 4.15mm
[preload -valve drop]
(7.00mm - 2.85mm)
* 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.
For BS-II engine
**A] with new chain / with chain tensioned
: 4.15 mm
[ Preload -Valve drop ]
( 7.00 mm - 2.85 mm )
B] With old chain / without chain tensioned
: 4.46 mm
[ Preload -Valve drop ]
( 7.00 mm - 2.54 mm )
9] Now see the reading of dial gauge mounted on FIP, it should
be:-
For variable timing method
Preload + as per marking on FIP
i 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 errors
occurring due to backlash ]
10] complete the assembly
Pump timing-XD 3P engine
With lucas FIP
[ With TDC pointer ]
TDC pointer
TDC mark on pulley
On the vehicle
View
Pump timing values for lucas FIP
[ with TDC pointer]
Piston positioned pump reading
TDC 4.50+/- 0.02mm
Note: this timing procedure is not very accurate method. To
get optimum performance & emission results the pump to be
set with valve drop method
1] Remove rocker arm cover & set no 1 piston at the end of
compression. [No.4-dancing]
2] Set no one piston to TDC with the help of TDC pointer
Pump timing procedure with TDC pointer
On the vehicle
View
3] Fit FIP with gasket on mounting bracket & align it with mark
punched on mounting bracket & FIP.
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.
6] Rotate engine in reverse direction i.e. anticlockwise from fan
side until dial gauge mounted on FIP stops.
[ Do not rotate engine further, this may damage timing pin &
pump]
This will ensure the BDC of cam ring. At this point give some
preload say 04.00 mm.
On the vehicle
View
7] Rotate engine in normal running direction & set no.One
piston to TDC* with the help of TDC pointer
* 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:-
Preload + 4.5
i.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 errors
occurring due to backlash ]
9] Complete the assembly
Pump timing-XD 3P engine
With MICO FIP-BS I
[Valve drop method]
Setting & Checking- MICO FIP
Pump timing values for MICO FIP- BS I engine
Piston positioned plunger lift
A] With new chain 06
0
BTDC 0.50mm +/- 0.02
With chain tensioned [0.32 mm VALVE DROP]
B] with old chain 05
0
BTDC 0.50mm +/- 0.02
W/o chain tensioned [0.22mm VALVE DROP]
Note:-Automatic injection advance mechanism should be
disconnected while checking the pump timing for MICO pump.
1] Remove rocker arm cover & set no 1 piston at the end of
compression.[ No.4-dancing ]
2] Free exhaust valve of no.1 cylinder & fit dial gauge holder
[MST 164] with dial gauge.
Pump timing procedure with valve drop method
MST 164
3] rotate engine in either direction to set TDC of no.1 piston. &
Give some preload say 7.00mm.
4] Fit FIP with gasket on mounting bracket & align it with mark
punched on mounting bracket & FIP.
5] Remove bleeding screw &
fit pump timing adapter
[MST166] with dial gauge.
Ensure at least 4mm travel
of dial needle.
Mst 166
6] Rotate engine in reverse direction i.e. anticlockwise from fan
side until dial gauge mounted on FIP stops. This will ensure the
BDC of plunger. At this point give some preload say 4.00mm.
7] Rotate engine in normal running direction* until dial gauge
mounted on valve shows following reading: -
**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.
8] Now see the reading of dial gauge mounted on FIP, it should
be:- Preload + 0.50 mm
i.e. 4.00mm + 0.50mm = 4.50 mm
[ As we have 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 error occurring
due to backlash ]
9] Complete the assembly
Cooling System
Fuel System
Important Clearances - Standard
Piston projection : 0.70 to 0.98mm [ BS I ]
0.78 to 1.05mm [ BS II ]
End float of oil pump gear : 0.05 to 0.10mm
Exhaust cam lobe lift : 6.07 to 6.17mm
Inlet cam lobe lift : 6.07 to 6.17mm
Valve stem & guide : 0.15mm (max)
Crank shaft & main bearing : 0.04 to 0.09mm
Crank shaft run out : 0.03mm [max]
Crank shaft end float : 0.08 to 0.29mm
Connecting rod & crank pin : 0.04 to 0.09mm
Connecting rod side clearance : 0.10 to 0.25mm
Cam shaft side clearance : 0.05 to 0.15mm
Axial clearance of cam shaft : 0.05 to 0.15mm
Radial clearance cam shaft : 0.05 to 0.11mm
Clearance between chain tensioner shoe
& support : 0.50 to 1.00mm
Cylinder head height : 90.00mm
Transverse deflection of head : 0.15 mm [max]
Tappet setting - inlet : 0.15 to 0.20mm
Tappet setting - exhaust : 0.25 to 0.30mm
Depth of valve guide from Cylinder head
surface : 28.00mm
Projection of pre combustion chamber
above head surface : 0.03mm [max]
Nozzle opening pressure-Lucas : 117-124 bar
Nozzle opening pressure-Mico : 115+5 bar
Important Torques
Kg-m lbs-ft
Cylinder head : [ Refer procedure]
Connecting rod bolts : 6.0 45-50
Crankshaft main bearing caps : 10 - 12 70-85
Crank shaft pulley : 5.5 +60
0
40+ 60
0
Fly- wheel bolt : 1.5 +60
0
10+ 60
0
Nut-rocker shaft bracket : 4.5 35
Rocker shaft end support : 2.0 15
Injector : 9.0 65
Buffer plug : 8.0 - 10.0 58- 72
Eccentric sprocket bolt : 3.5 25
Mst no
Special wrench for comp. Of piston ring : 168
Rope seal dolly : 175
Setting gauge for Lucas DPC pump : 240
Plunger for FIP setting CAV / DPC [BS I] : 241
Special tool for bosh FIP : 244
Holder to cut seal bearing cap : 247
Chain tensioner fixture : 250
Holder Assy. For chain tensioner : 251
Plate to Arrest flywheel rotation : 252
Gauge for tappet clearance : 253
Mandrel for rope seal fitting : 254
Special push rod : 255
Gauge to check piston projection : 301
Important MST
Tool common with XD 4.90 engine
Drift for removing pre combustion chamber: 140
Adjusting shim for rocker shaft : 142
Tool for installing & removing valve : 146
Spanner for cylinder head : 148
Cylinder head guide : 149
Tool for installing side packing seal : 154
Tool for removing oil filter : 163
Pump timing adapter : 166
Engine mounting gear box & adapter : 177
Tool to rotate crankshaft : 302
Plate for locking fly wheel : 303
Pre combustion chamber seat
reconditioning : 305
THANK YOU