XD 3P ENGINE
Mahindra institute of learming excellence, Nasik
Side view
Front view
Indirect injection
Nozzle
Heater Plug
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
SERIES [ BS 1 & BS 2 MODEL] BOLERO MM BOLERO GLX / SLX MM 550 XDB BOLERO LX / XLS MM550 XD/4WD BOLERO SPORTZ INVADER DX
OTHERS VOYAGER ARMADA GRAND ARMY AMBULANCE EXPORT MODELS
Specification Model Type Number of Cylinders Combustion system Bore mm (in) Stroke mm (in) Displacement cc (cu. In) Compression ratio Firing order Timing Power Torque Low idle
: : : : : : : : : : : : :
XD 3P In-line, Four stroke 4 In direct injection 94 90 2498 23 : 1 1-3-4-2 By chain 50.50kW 4000 rpm 137.50nm at 2000-2500 rpm 770 to 820 rpm
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 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 Diameter Grading Weight Grading
Piston pin Diameter Length
: :
30.0 mm 78.8 mm
Piston pin circlip of XD 3P & XDP 4.90 engines are different.
Identification of Circlip
Piston rings[ PCVL ]- old Top Middle Bottom
: : :
Asymmetrical barrel Scrapper ring-Napier groove Oil ring with chrome plated coil expander
Ring gap Top MIDDLE BOTTOM
: : :
0.35 to 0.50mm ( 14 to 20 thou) 0.35 to 0.55mm ( 14 to 22 thou) 0.15 to 0.30mm ( 06 to 12 thou)
Piston rings PCVL
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) 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 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 Middle Bottom
: Chrome inlaid positive twist symmetrical barrel : Taper face ring : Profile ground with increase in tangential load [From 4-6Kg to 6- 8 kg]
Ring gap Top Middle Bottom
: : :
0.30 to 0.55mm ( 12 to 22 thou) 0.80 to 1.00mm ( 32 to 40 thou) 0.30 to 0.55mm ( 12 to 22 thou)
Connecting rod Central distance Big end to small end Big end dia. Big end width Small end width Radial clearance Side clearance Small end dia. Bushing outer dia. Bushing inner dia.
: 150 + 0.025 : 58.737 + 0.013 : 35.90 -0.05 : 30 + 0.20 : 0.040 – 0.092 : 0.10 – 0.25 : 33 –0.025 : 33.09 - 33.13 : 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 )
Std size of crank pin journal 1st u/s 0.30 crank pin journal 2nd u/s 0.50 crank pin journal 3rd u/s 0.80 crank pin journal
: : : :
55.00 49.70 49.50 49.20
0.021/-0.006mm 0.021/-0.006mm 0.021/-0.006mm 0.021/-0.006mm
Connecting rod bearings Std. Size 1st o/s 0.30 2nd o/s 0.50 3rd o/s 0.80
: : : :
1.832 – 1.838 1.982 – 1.988 2.082 – 2.088 2.232 – 2.238
Crank shaft Std size of main journal 1st u/s 0.30 main journal 2nd u/s 0.50 main journal 3rd u/s 0.80 main journal
: : : :
60.00 59.70 59.50 59.20
0.021/-0.006mm 0.021/-0.006mm 0.021/-0.006mm 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 Axial clearance of cam shaft Radial clearance of cam shaft
: : :
13 0.05 to 0.15 mm 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 : 1700 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 • Depth of valve guide from cylinder head surface 28 +/- 0.5 mm • Check valve depression from cylinder head surface. Inlet valve : 1.05 to 1.45mm Exhaust valve : 0.85 to 1.25mm
Valve depression from head surface. [BS I] Inlet valve Exhaust valve
: :
1.05 to 1.45mm 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 Oil retaining Seal
Filter paper
Oil filter Bracket
Pressure Sensor
BI function Switch
Oil filter
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 pump Full flow with gear type pump Oil pressure : Idling [ 770 / 820 ] : At 3000 rpm :
1.5 kg / cm2 3.0 kg / cm2
Bypass valve operates from 0.8 - 1.0 bar With three gauge instrument cluster , pressure gauge is eliminated
Oil pump shaft end play 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.
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 Earthing through filter bracket
Positive
+
Warning light Is on P1 = P2 = 0
Ignition on , engine on :- Pressure warning light off
P1
No earthing Positive
P2
+ Warning light Is off
P2 > P1
Ignition on , engine on, filter choked :- Pressure warning light on Earthing through filter bracket P1
Positive
P2
+ Warning light Is on
P2 < P1
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
Cam Sprocket
Idler Sprocket
Chain tensioner Crank Sprocket
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 26
13
1
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 It is recommended to do the tappet setting in cold condition
Inlet Exhaust Valve layout In1 – Fx1 F R O N T
In cold condition : 0.15 to 0.20 ( 6 to 8 thou ) : 0.25 to 0.30 ( 10 to 12 thou ) : Ex2– In2
In3 – Ex3
Ex4 – In4
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. In1, Ex1, In2, Ex3 •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. Ex2, In3, Ex4, In4
Tappet setting-cold condition
Inlet Exhaust
: :
0.15 to 0.20mm ( 6 TO 8 thou ) 0.25 to 0.30mm ( 6 TO 8 thou )
Cylinder head gasket Head gasket are available in three sizes Thickness 1.53mm 1.63mm 1.73mm
Identification 2 Notch 3 Notch 4 Notch
Gasket notch
1 2
1
3
2
1
4
3
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 Two cut Three cut Four cut
Piston projection [ mm ] BS I BS II 0.70 to 0.79 0.77 to 0.86 0.80 to 0.89 0.87 to 0.96 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 ) Run the engine upto 10min at 3000rpm & allow it to cool down for 3-4 hrs.
Retorquing Loose the bolt by 90o & retighten the same in sequence : 7.00 kg-m ( 50-55 lbs.-Ft ) Rotate each bolt in the same sequence further by : 1200 No retorquing is required of cylinder head at 1500/2500 kms if followed above method
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 Idling screw
Anti stalling screw
Idling rpm : 770 TO 820 rpm To be set when engine is hot & AC is off [if fitted] Setting procedure Screw-in the anti stalling screw (Away from lever)
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]
XD 3P engine FIP sprocket India 2000 timing mark ( line)
2
1
3
Third teeth from keyway
XD 3P engine BS II timing mark ( dot mark )
4
3
2
Fourth teeth from keyway
1
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 190 BTDC with chain tensioned [3.17mm valve drop]
As per individual Marking on pump
B] With old chain 180 BTDC w/o chain tensioned [2.85mm valve drop]
As per individual Marking on pump
Pump timing values for lucas FIP-BS I engine [With constant timing method] Piston positioned
pump reading
A] with new chain With chain tensioned
190 BTDC [3.17mm valve drop]
0.90mm
B] With old chain w/o chain tensioned
180 BTDC [2.85mm valve drop]
0.90mm
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 II engine [With constant timing method] Piston positioned
pump reading
A] with new chain With chain tensioned
180 BTDC [2.85mm valve drop]
0.90mm
B] with old chain w/o chain tensioned
170 BTDC [2.54mm valve drop]
0.90mm
Constant & Variable Timing Method Constant timing method :-
pump reading is fixed [0.90mm]
Variable timing method :-
pump reading is variable [Mark on individual pump]
Fixed timing method
Variable method
Pump Timing procedure with valve drop 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]
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 mark on pulley
On the vehicle View
TDC pointer
Pump timing values for lucas FIP [ with TDC pointer] Piston positioned TDC
pump reading 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
Pump timing procedure with TDC pointer 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 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.
7] Rotate engine in normal running direction & set no.One piston to TDC* with the help of TDC pointer On the vehicle View
* 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 With chain tensioned
060 BTDC [0.32 mm VALVE DROP]
0.50mm +/- 0.02
B] with old chain W/o chain tensioned
050 BTDC [0.22mm VALVE DROP]
0.50mm +/- 0.02
Note:-Automatic injection advance mechanism should be disconnected while checking the pump timing for MICO pump.
Pump timing procedure with valve drop 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.
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
:
End float of oil pump gear : Exhaust cam lobe lift : Inlet cam lobe lift : Valve stem & guide : Crank shaft & main bearing : Crank shaft run out : Crank shaft end float : Connecting rod & crank pin : Connecting rod side clearance : Cam shaft side clearance : Axial clearance of cam shaft :
0.70 to 0.98mm [ BS I ] 0.78 to 1.05mm [ BS II ] 0.05 to 0.10mm 6.07 to 6.17mm 6.07 to 6.17mm 0.15mm (max) 0.04 to 0.09mm 0.03mm [max] 0.08 to 0.29mm 0.04 to 0.09mm 0.10 to 0.25mm 0.05 to 0.15mm 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
Crankshaft main bearing caps : 10 - 12
45-50 70-85
Crank shaft pulley
: 5.5 +600
40+ 600
Fly- wheel bolt
: 1.5 +600
10+ 600
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
Important MST Special wrench for comp. Of piston ring Rope seal dolly Setting gauge for Lucas DPC pump Plunger for FIP setting CAV / DPC [BS I] Special tool for bosh FIP Holder to cut seal bearing cap Chain tensioner fixture Holder Assy. For chain tensioner Plate to Arrest flywheel rotation Gauge for tappet clearance Mandrel for rope seal fitting Special push rod Gauge to check piston projection
Mst no : : : : : : : : : : : : :
168 175 240 241 244 247 250 251 252 253 254 255 301
Tool to rotate crankshaft Plate for locking fly wheel Pre combustion chamber seat reconditioning
: :
302 303
:
305
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
THANK YOU
