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7/21/2019 XD3P BOLERO.pdf
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Mahindra institute of learmingexcellence, Nasik
XD 3P ENGINE
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Side view
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Front view
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Indirect injection
Heater
Plug
Nozzle
Pre combustion chamber
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The model XD 3P engine is a 4-cylinder, in-line, overheadvalve, water-cooled, indirect injection engine.
Engine is used on following vehicles
BOLERO MM OTHERSBOLERO 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]
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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) : 2498Compression 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
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MAINTENANCE SCHEDULE
Change engine oil & filter [ with Maximile 6k oil ]4000km,10000km & then every 6000km
Refill fresh water with sodium chromate [Vehicle w/o degassingtank], Maximile coolant [ Vehicle with Aluminium radiator &
de-gassing tank]once in a year / after every 64000 kms
Change primary fuel filter4000km, 16000kms & then every 12000kms
Change secondary fuel filter16000km, 40000kms & then every 24000kms
Check nozzles opening pressure & reset it52000kms, 100000kms & then 48000kms.
Adjust fan belt tensionduring every service Clean air filter
during every service
Change air cleaner cartridgeat every 40,000kms [ Old type - 20000kms ]
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Oil & lubricants
Oil recommended for XD 3P engine is maximile 6K
Oil sump capacity : 5 lit.
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Oil f ilter recommended :
Maximile filter for DP engine
Diesel fi lter recommended :Lucas diesel filter
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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
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General construction
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Block
Integral cylinder liners, inline arrangement. Diameter grading
A or B is punched on block.
A or B
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Piston
Weight
Grading
Diameter
Grading
Max weight diff allowed is : +/- 10 gms
Grade Piston BoreA 93.900 - 93.909 94.010 to 94.022 mm
B 93.100 - 93.109 94.022 to 94.033 mm
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Piston pin
Diameter : 30.0 mm
Length : 78.8 mm
Piston pin circlip of XD 3P & XDP 4.90 engines are different.
Identif ication of Circlip
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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)
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Piston rings PCVL
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New piston rings [ IPL ] :
Top : Chrome inlaid positive twist symmetrical barrelMiddle : 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.
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Connecting rod
Central distance
Big end to small end : 150 + 0.025
Big end dia. : 58.737 + 0.013Big end width : 35.90 -0.05
Small end width : 30 + 0.20
Radial clearance : 0.040 0.092Side clearance : 0.10 0.25
Small end dia. : 33 0.025
Bushing outer dia. : 33.09 - 33.13Bushing inner dia. : 30 +0.020/+0.007
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Connecting rod
Maximum allowed weight difference of 4 connecting rod : 20gms
Weight grading mark Identification number
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Connecting rod side play: 0.10mm TO 0.25mm
( 4 to 10 thou )
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Connecting rod bearings
Std. Size : 1.832 1.838
1st o/s 0.30 : 1.982 1.988
2nd
o/s 0.50 : 2.082 2.0883rd o/s 0.80 : 2.232 2.238
Std size of crank pin journal : 55.00 0.021/-0.006mm
1st u/s 0.30 crank pin journal : 49.70 0.021/-0.006mm
2nd u/s 0.50 crank pin journal : 49.50 0.021/-0.006mm
3rd u/s 0.80 crank pin journal : 49.20 0.021/-0.006mm
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Crank shaft
Std size of main journal : 60.00 0.021/-0.006mm
1st u/s 0.30 main journal : 59.70 0.021/-0.006mm
2nd u/s 0.50 main journal : 59.50 0.021/-0.006mm
3rd u/s 0.80 main journal : 59.20 0.021/-0.006mm
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Crank shaft
No 4 cap of main journal can be identify by O mark punched
on it.
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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
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Cam shaft
Oil pump drive gear teeth : 13
Axial clearance of cam shaft : 0.05 to 0.15 mmRadial clearance of cam shaft : 0.05 to 0.11 mm
Tappets
Cast iron with hardened bearing surfaces
Oil return slot
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Flywheel
Ring gear teeth
: 146
Temperature for ring
Gear fitment
: 1700 c
Flywheel clutch surface
Regrinding
: 0.5max
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Cylinder head
Height of cylinder head : 90.00 mm
Min. Cylinder head height after machining : 89.45 mm
90.00mm
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Cylinder head warpage : max. 0.15mm ( 6 thou )
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Valve & guide
Check the clearance between valve & valve guide. If i t 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
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Valve depression from head surface. [BS I]
Inlet valve : 1.05 to 1.45mmExhaust valve : 0.85 to 1.25mm
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Pre combustion chamber projection: 0 - 0.03mm
0 to 0.03 max.
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Lubrication circuit
Cam shaft slot
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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 & subsequentlydamage to FIP sprocket & FIP
bracket.
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Oil filter & bracket
Bypass valve
Filter paper
BI function
Switch
Pressure
Sensor
Oil filterBracket
Oil retaining
Seal
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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
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Oil pump
Full flow with gear type pump
Oil pressure :
Idling [ 770 / 820 ] : 1.5 kg / cm2
At 3000 rpm : 3.0 kg / cm2
Bypass valve operates from 0.8 - 1.0
bar
With three gauge instrument
cluster , pressure gauge is eliminated
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Install the pump and mount it in its position with the allenscrew and its cap.
Hand tighten the buffer plug and measure the gap ( X ) asshown in the fig. By using fi ller gauge.
Oil pump shaft end play
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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 .
XX + 0.1 mm
0.1mm
Bi f ti it h
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Bi-function switch
Ignition on , engine off :- Pressure warning l ight on
+
P1: Oil pressure before filtration
P2: Oil pressure after f iltration
Positive
Warning lightIs on
P1 = P2 = 0
Earthing through filter bracket
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Ignition on , engine on :- Pressure warning light off
+
Positive
Warning lightIs off
P2 > P1
No earthing
P2
P1
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Ignition on , engine on, filter choked :- Pressure warning light on
+
Positive
Warning light
Is on
P2 < P1
P2
P1
Earthing through filter bracket
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Check the clearance between gears. The clearance should not
be more than 0.15 mm ( 6 Thou).
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Important
adjustments & setting
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Match white dot mark on chain with crank sprocket
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Match white dot mark on chain with crank sprocket
Mark & white line mark with cam & FIP sprocket mark
orMatch 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
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Chain tensioning
Chain should be tensioned by turning eccentric in anticlockwise direction ( with use of MST 251 ) and keepingautomatic slack tensioner in its bottom lock posit ion.
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Adjust the clearance between chain tensioner shoe and its
support from 0.5 to 1.00 mm. After tensioning the chainrelease the tensioner lock by turning it in clockwise posit ion.
Chain tensioner fixture
[ MST 250 ]0.50 mm to 1.00mm
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Lock position
Unlock position
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Eccentric sprocket on ball bearing must be secured with a class
of 10.9 bolt.
Tappet setting
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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 :
In1 Fx1 Ex2 In2 In3 Ex3 Ex4 In4
It is recommended to do the tappet setting in cold condition
FR
O
N
T
Procedure for tappet setting
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Set the no. 1 piston at T.D.C on the compression stroke byturning 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
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Inlet : 0.15 to 0.20mm ( 6 TO 8 thou )
Exhaust : 0.25 to 0.30mm ( 6 TO 8 thou )
Cylinder head gasket
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Cylinder head gasket
Head gasket are available in three sizesThickness Identification
1.53mm 2 Notch
1.63mm 3 Notch
1.73mm 4 Notch
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Head gasket selection
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Maximum piston projection out of 4 should be consideredfor 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
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TorquingTighten 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 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
Run the engine upto 10min at 3000rpm & allow it to cool down
for 3-4 hrs.
Cylinder head tightening sequence
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Spread molykote grapid on bolt
The cylinder head bolt must be position according to their
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length.
07 long bolt ( KSL)
15 short bolt ( KL )
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Idling setting
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Anti stalling screw
Idling screw
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Keep 5 Rs coin in between thrott le lever & its minimum stop.
Adjust anti stalling screw with 5 Rs coin untill rpm starts just
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Adjust anti stalling screw with 5 Rs coin untill rpm starts just
increasing.
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India 2000 timing mark ( line)
XD 3P engine FIP sprocket
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India 2000 timing mark ( line)
Third teeth from keyway
1
23
XD 3P engine BS II timing mark ( dot mark )
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Fourth teeth from keyway
1234
Setting & checking- Lucas FIP
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Pump timing values for lucas FIP- BS I engine
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[With variable timing method]Piston posit ioned pump reading
A] With new chain 190 BTDC As per individual
with chain tensioned [3.17mm valve drop] Marking on pump
B] With old chain 180 BTDC As per individual
w/o chain tensioned [2.85mm valve drop] Marking on pump
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3] Rotate engine in either direction to set TDC of no.1 piston.
& Give some preload say 7.00mm.
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4] Fit FIP with gasket on mounting bracket & align it with mark
punched on mounting bracket & FIP.
5] Remove timing chimney
Cap & insert t iming pin
[ MST 241 for variable
timing & MST 257 forConstant timing ]
6] Fit dial gauge holder
[ MST 240] & dial gauge ontiming chimney.
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9] Now see the reading of dial gauge mounted on FIP, it should
be:-
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For variable timing method
Preload + as per marking on FIPi 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 errorsoccurring due to backlash ]
10] complete the assembly
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1] R k & t 1 i t t th d f
Pump timing procedure with TDC pointer
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1] Remove rocker arm cover & set no 1 piston at the end ofcompression. [No.4-dancing]
2] Set no one piston to TDC with the help of TDC pointer
On the vehicleView
3] Fit FIP with gasket on mounting bracket & align it with mark
punched on mounting bracket & FIP.
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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.
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7] Rotate engine in normal running direction & set no.One
piston to TDC* with the help of TDC pointer
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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:
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be:-
Preload + 4.5i.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 errorsoccurring due to backlash ]
9] Complete the assembly
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3] rotate engine in either direction to set TDC of no.1 piston. &
Give some preload say 7.00mm.
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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
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7] Rotate engine in normal running direction* until dial gauge
mounted on valve shows following reading: -
** ] With h i / ith h i t i d 6 68
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**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.
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