Mahindra QUANTO Repair Manual Part 1 of 4 MAN 00209 Rev 1 PDF

REPAIR MANUAL
Part 1 of 4
MAN-00209
RELEASED BY –
TECHNICAL PUBLICATION CELL

MAHINDRA & MAHINDRA LTD.
Rev1 – SEPTEMBER 2012

www.teknetmahindra.com
ALL INFORMATION CONTAINED IN THIS MANUAL IS MOST UP-TO-DATE AT THE TIME OF PUBLICATION.
HOWEVER, SPECIFICATIONS AND PROCEDURES ARE SUBJECT TO CHANGE WITHOUT NOTICE. THIS
MANUAL
© 2012IS STRICTLY
Mahindra MEANTLtd.
& Mahindra FOR RESTRICTED
All rights INTERNAL
reserved. This CIRCULATION
book may not be reproducedWITHIN
or copied,M&M AUTHORIZED
in whole or in
DEALER SERVICE CENTERS.
part, without the written permission of Mahindra & Mahindra Ltd.
Part 1 of 4
Table of Content
• How to use this manual…………………………………………………………………………………………

• General Information…………………………………………………………………………….………………..
• Vehicle Specification…………………………………………………………….…………….…………………
• Vehicle Maintenance……………………….…………………………………….……………………………..
• Engine……………………………………………………………….................…………………………………..
Engine Chain Timing Procedure (2D Animation)……………………………………………………
Twin Turbocharger Working Principle (2D Animation)………………………………………….
© 2012 Mahindra & Mahindra Ltd. All rights reserved. This book may not be reproduced or copied, in whole or in
part, without the written permission of Mahindra & Mahindra Ltd.
Repair Manual MAN-00209
QUANTO Sept’2012/ Rev1
About the Repair Manual
This Repair Manual is published for the information and guidance of the service technician of
authorized MAHINDRA & MAHINDRA dealers to help them provide efficient and correct
service and maintenance on Mahindra vehicle. It contain information on the operation and
maintenance of the QUANTO mCR100 as well as descriptions of the major units and their
functions in relation to the other components of the System.
To ensure customer satisfaction with Mahindra products, proper service and maintenance by
Mahindra Dealer Technicians is essential. Technician should know and understand the content of
this manual before starting actual work on the vehicle. The copy of this manual should be kept in
a handy place on the shopfloor for quick and easy reference.
This manual includes special notes, important points, service data, precautions that are needed for
the maintenance, adjustments, service, removal and installation of Engine and other aggregate
components.
All information, illustrations and specifications contained in this manual are based on the latest
product information available at the time of publication. Dealers will be provided Technical
Service Bulletins or Supplementary Notes in case modifications done in future.
All rights are reserved to make changes at any time without prior notice.
Pictures, photographs used in this manual are illustrations only and may pertain to some variation
than actual in the vehicle.
The repair methods given by the manufacturer in this document are based on the technical specifications, current 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 of 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.
Table of Content
• How to use this manual…………………………………………………………………………………………

• General Information…………………………………………………………………………….……………….
• Vehicle Specification…………………………………………………………….…………….…………………
• Vehicle Maintenance……………………….…………………………………….……………………………..
• Engine……………………………………………………………….................…………………………………..
• Air Intake System……………………………………………………………………..…………………………..
• Cooling System………………………………………………………………………….………………………….
• Fuel System…….………………………………………………………………………..…………………………..
• Emission Control System………………………………………………………….……………………………
• Clutch……………………………………………….………………................……………………………………
• Transmission………………………………………………………………………………………………………..
• Propeller Shaft…………………………………………………………………….. …………..…………………
• Rear Axle……………..………………………………………………………………………………………………..
• Steering System…………………………………………………………………….…………….………………..
• Front Suspension…………………………………………………………………………………………………..
• Rear Suspension……………………………………………………………………..…………………………….
• Brake System………………………………………………………………………..……………………………..
• Anti Lock Brake System………………………………………………………..……………………………..
• Wheels and Tyres…………………………………………………………………..……………………………..
• Chassis…………………………………………………………………………………….…………….……………..
• HVAC……..……………………………………………………………………………………………..………………
• SRS (Airbag)………………………………………………………………………………………….……………….
• NVH…………………………………………………………………………………………….…………….............
• Appendices…………………………………………………………………………………………….……………..
Table of Content
Engine Chain Timing Procedure….…………………….........
Working Principle of Twin Turbo Charger…............………
Clutch System Air Bleeding………………….…………………
Wheel Alignment Procedure ……….................................…
Brake System Air Bleeding………….……….…………………
Parking Brake Check and Adjustment…………….………….
LSPV Setting………..…………………………………………..
DAB and Clock Spring Removal……………………...……..
Head Lamp Alignment..………..……………………………..
How to use this manual
There is table of contents for the whole manual on the second page of this manual, where the required
section can be easily found. Also, there is Table of content on the first page of each section, where the
main objects in that section are listed. Each section is further divided in to sub-sections –
• Description section gives an overview of the functioning of the system.

• Construction, Operation and Identification section gives details of construction of System, its
operation and serial number identification.
• Care of the system details the maintenance and adjustments, if any, to be carried out on the system to
keep it functioning at its best performance level.
• Trouble shooting section details a generic trouble shooting for major problems.
• In-car repair outlines the procedure to carryout minor repairs/adjustments without removing the
aggregate from the vehicle.
• Dismantling/overhauling section covers the detailed process and procedures to be followed, while
repairing the system. This is generally carried out after removing the aggregate/system from the
vehicle.
• Inspection section gives information on how and what are all components to be inspected.
• Assembly section covers the detailed process and procedures to be followed, while repairing the
system.
• Repair & maintenance data provides information on the dimensions of a new part as well as how
much wear can be tolerated on a specific part, respectively.
• Technical Specification section provides information on the dimensions; service and wear data of
system components.
• Torque Specification is the specified torque values for all crucial fasteners in the Component/ vehicle
system.
• Special Tools List (MST) lists out the special tools should be used for the service and repair work
described in that section.
• Appendices are provided in the last section of this manual. It includes of Abbreviations, measuring
units, Lubrication chart, Greasing points, Do’s & Don’ts, Vehicle preservation notes and List of MST’s
applicable to this model.
The proper performance of service is essential for both the safety of the technician and the efficient
functioning of the system. The service methods in this repair manual are described in such a manner that
the service may be performed safely and accurately. Service varies with the procedures used, the skills of
the technician and the tools & Parts available. Accordingly, anyone using service procedures, tools or parts
which are not specifically recommended by MAHINDRA & MAHINDRA must first completely satisfies
himself that neither his safety nor the vehicle’s safety will be jeopardized by the service method selected.
Repair Procedures - 2D Animation
2D Animation SOP’s –
Some of the critical Operations in this Manual (pdf copy) are embedded with 2D
Animations and voice modulation.
It is suggested to play these Animations in Adobe 9 reader and above version.
Refer below information on the structure of Animated SOP’s and Animation Play guideline
to use this Maintenance Manual effectively. The option of Full Screen Mode is also
provided while playing these Animations.
1. Animated SOP’s –
Animation SOP Title
2D Animation Play Screen Area Standard Procedure Step Display Area
2. Animation Play Guidelines –
Refer below diagram which explains about options available while playing
animations. Callout comes automatically when curser moves on those buttons.
PLAY
REPLAY
PREVIOUS
PLAY/ PAUSE
NEXT
OFF/ ON
General Information
1. Health and Safety Precautions –
Toxic Substances
Many liquids and other substances used are poisonous, so care should be taken while handling the same. It
is also advisable to keep all the substances away from open wounds. These substances include anti-freeze,
brake fluid, fuel, windscreen washer additives, air conditioning refrigerant, lubricants and various
adhesives. These toxic substances are irritant to the skin, eyes, nose and throat. They can cause burns and
destroy ordinary protective clothing. Wear a suitable protective apron, gloves and goggles. Do not breathe
the mists. Make sure that the access to eye wash bottles, soap and shower are readily available.
Air Conditioning Refrigerant
Instructions given by the manufacturer must be followed. The air conditioning system contains refrigerant
under high pressure. Severe personal injury may result due to improper service procedures. Repairs should
only be performed by a qualified service personnel. Avoid breathing the refrigerant or refrigerant oil vapor
or mist. Exposure may irritate the eyes, nose and throat. Wear suitable protective gloves and goggles for
eye protection while servicing the air conditioning refrigerant system. If eye contact occurs, immediately
seek medical attention.
Adhesives and Sealers
A number of renowned products are recommended in this manual for use during maintenance and repair
work. They should be available locally at garage equipment suppliers. If there is any problem in obtaining
the supplies, contact the company for advice and the nearest dealer. Cleanliness should be observed where
necessary, for example disposable paper covering benches should be dispensed from applicators and
secondary containers should be labeled appropriately.
Antifreeze
Antifreeze is an ethylene glycol base coolant, which is harmful if swallowed or inhaled. If swallowed, drink
two glasses of water and induce vomiting. If inhaled, move to fresh air area. Seek medical attention
immediately. Do not store in open or unmarked containers. Wash skin and clothing thoroughly after
coming in contact with ethylene glycol. Keep out of reach of children. To dispose the glycol base coolant
properly, contact your dealer or government agency for the location of collection center in your area. Do
not open a cooling system when the engine is at operating temperature or hot under pressure, which may
result in personal injury. These products should not be used in any cooling or industrial water system that
is connected or linked to general, food preparation or drinking water supplies.
Asbestos
Breathing asbestos dust may cause lung problems or in some cases, cancer. Asbestos is used in brake &
clutch linings, transmission brake bands and gaskets. The use of drum cleaning units, vacuum cleaning or
damp wiping is preferred. Asbestos dust waste should be dampened first, and placed in a sealed container
and marked for safe disposal. If any cutting or drilling is attempted on materials containing asbestos the
item should be dampened and only hand tools or low speed power tools are to be used.
Chemical Materials
Chemical materials such as solvents, sealers, adhesives, paints, resin foams, battery acids, antifreeze, brake
fluids, fuels, oils and grease should always be stored and handled with care. They may be poisonous,
harmful, acidic or highly flammable and give rise to harmful vapors and dust. The effects of excessive
exposure to chemicals may be immediate or delayed, temporary or permanent, life threatening or may
decrease life expectancy.
Corrosion Protection Materials
These materials are varied and the manufacturer‘s instructions must be followed. They may contain
solvents, resins or petroleum products. Skin and eye contact should be avoided. They should only be
sprayed in conditions of adequate ventilation and not in confined spaces.
Engine Oil
Prolonged and frequent contact with the engine or motor oil will result in removal of natural fats from the
skin, leading to dryness and irritation. An used engine oil contains potentially harmful contaminants which
may cause skin cancer. Adequate means of skin protection and washing facilities should be provided.
Transmission Fluids
Transmission and power steering fluids contain additives which have the potential to cause irritation or
even skin disease when prolonged or repeated skin contact with the fluid occurs. These fluids are used for
vehicle initial fill and service purposes. Draw attention to the existence of Material Safety Datasheets
(MSDS's) for the fluids. These MSDS's contain detailed information on hazards and appropriate controls.
Fuel Handling Precautions
This information is issued only for basic guideline. Fuel vapor is highly flammable, and in restricted spaces it
is highly explosive and poisonous. The vapor is heavier than air and will always fall to the lowest level,
which flows throughout the workshop by air current. Even a small spillage of fuel is very dangerous. Always
have fire extinguisher containing foam CO2 gas or powder close at hand while handling fuel or dismantling
fuel systems, and in areas where the fuel containers are stored.
• Always disconnect the vehicle battery before working on the fuel system.
• Avoid prolonged and frequent skin contact with oils, particularly engine oils.
• Properly ventilate the area so that the flammable fumes do not become concentrated.
• Never smoke or have an open flame in the work area.
• Always check for leaks after fuel system repairs.
• Clean up fuel spills immediately with absorbent materials, by using proper disposal procedures.
• Wear protective clothing, including resistant gloves wherever required.
• Do not put oily rags in your pockets.
• Avoid wearing contaminated clothes.
• Overalls must be cleaned regularly.
• First-aid treatment must be given immediately for open cuts and wounds.
Do not operate the engine for unlimited period of time without proper exhaust ventilation. Keep the work
area well ventilated and free of any flammable materials.
Special care should be taken when handling any flammable or toxic materials such as gasoline, refrigerant
gas, etc.
Fuel Transfer
The transfer of fuel from the vehicle fuel tank must be carried out in a well ventilated area. An approved
transfer tank must be used according to the transfer tank manufacturer’s instructions and local regulations,
including attention to grounding of tanks.
Fuel Tank Repair
The fuel tank should not be repaired in case of damage and has to be replaced with a new tank.
Fire
Many materials related with the repair of vehicles are highly flammable. Some give off poisonous or
dangerous fumes if burnt. Observe strict fire safety standards while storing and handling flammable
materials or solvents particularly near the electrical equipment or during welding processes. Make sure a
suitable fire extinguisher is available before using the welding or heating equipment.
To avoid severe burns:
• Avoid contact with hot metal parts. Do not remove the degassing tank cap, when the engine is hot.
• Dispose or recycle drained oil or solvent used for cleaning parts in a proper manner.
• Do not try to top off the fuel tank after the fuel pump nozzle shuts off automatically.
• Continued refueling may cause fuel overflow, resulting in fuel spray and possibly fire.
• Clean all disassembled parts in the designated liquid or solvent prior to inspection or assembly.
• Replace oil seals, gaskets, packing’s, O-rings, locking washers, cotter pins, self-locking nuts, etc.
with new ones.
• Replace the inner and outer races of tapered roller bearings and needle bearings as a set.
• Arrange the disassembled parts in accordance with their assembled locations and sequence.
• Do not touch the terminals of electrical components which use microcomputers.
• Static electricity may damage internal electronic components.
• After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection.
• Use only the fluids and lubricants specified in this manual.
• Use approved bonding agent, sealants or their equivalents when required.
• Use hand tools, power tools (disassembly only) and recommended special tools which are specified
for safe and efficient service repairs.
• When repairing the fuel, oil, and water, vacuum or exhaust systems check all affected lines for
leaks.
First Aid
It is desirable for someone in the workshop to be trained in first-aid procedures. Splashes to the eye should
be flushed carefully with clean water for at least ten minutes. Soiled skin should be washed with soap and
water. In case of cold burns from alternative fuels place the affected area in cold water. Individuals
affected by inhalation of gases and fumes should be immediately moved to fresh air area. If there is no
improvement, consult a doctor immediately. If liquids are swallowed accidentally, consult a doctor giving
him the information on the container or label.
Health Protection
• Avoid extended and repeated contact with oils, particularly used engine oils.
• Wear protective clothing, including resistant gloves where possible.
• Do not put oily rags in your pockets.
• Avoid contaminating clothes, particularly underpants with oil.
• Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be
cleaned regularly.
• First aid treatment should be obtained immediately for open cuts and wounds.
• Use barrier creams, applying them before each work period removes oil from the skin.
• Wash with soap and water to ensure that all oil is removed (skin cleansers and nail brushes will
help).
• Preparations containing lanolin replace the natural skin oils which have been removed.
• Do not use gasoline, kerosene, diesel fuel, gas oil, thinners or solvents for cleaning skin.
• If skin disorders develop, obtain medical advice without delay.
• Where practical, degrease components prior to handling.
• Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles
or face shields and an eye wash facility should be provided.
Guidance to safe working
Always follow the safety instructions provided by the respective manufacturers for all the equipment,
tools, safety gears etc. used in the workshop.
2. Precautions for repairing a vehicle in the workshop
When working on the vehicle in the workshop, always follow the below mentioned procedure:
• Make sure the work area is ventilated and well lit. When it is necessary to run the engine indoors,
make sure that the the area has adequate ventilation to disperse exhaust gases such as carbon
monoxide and other fumes.
• Do not perform service work in areas where combustible materials can come in contact with a hot
exhaust system. When working with toxic or flammable materials, make sure that the area you
work in is well-ventilated.
• Make sure that the work area such as floors, workbenches, tools are clean and free from debris and
clutter. Keep work area clean, dry and well organized.
• Be sure that all necessary tools and measuring equipment are available before starting any work.
Keep tools and parts off the floor or in a trolley.
• Use Mahindra Special Tools where ever applicable and recommended.
• Do not allow other people near the vehicle during servicing.
• When it is necessary to do service work with the engine running, make sure that the parking brake
is set fully and the transmission is in Neutral. Keep hands, hair, clothing, tools, etc. away from the
fan and belts when the engine is running.
• Do not let fuel, coolant and other fluids spill over electrical and hot vehicle parts.
• Avoid repeated contact with fluids.
• The battery should be disconnected while, working on the engine, underneath the vehicle or if the
vehicle is raised.
• Cover seats and carpets, wear clean overalls and wash hands or wear gloves before working inside
the vehicle.
• Avoid spilling hydraulic fluid or battery acid on paint work. Wash off with water immediately if this
occurs. Use Polythene sheets to protect carpets and seats.
• While using the welding equipment on the vehicle, keep a suitable fire extinguisher readily
available. Follow the recommended standard procedure before doing welding job.
• Make sure that the Transmission, Transfer Case, Oil/ Exhaust system has cooled down sufficiently
before attempting to remove any components, for your safety.
• Use correct lifting devices whenever raising a vehicle for service. Follow the instructions.
• Wear proper safety equipment as recommended and authorized for the job. Wear proper hearing
protection.
• Wear protective safety glasses/ goggles or face shields. Wear safety shoes.
• Wear correct work clothing, do not wear wrist watches, jewelry, rings, loose or hanging apparel,
such as ties, torn clothing, unzipped jackets that can catch on moving parts.
• New and used engine oil, Brake or Clutch oil, Radiator Coolant, Transmission and Differential oils
can be hazardous. Continuous contact with used engine oil has been found to cause [skin] diseases.
Brief contact with used oil may irritate skin. To minimize your exposure to used engine oil, wear a
long-sleeve shirt and moisture-proof gloves (such as dish washing gloves) when changing engine oil.
If engine oil contacts your skin, wash thoroughly with soap and water.
• Recycle or properly dispose the used Coolant, oil and filters.
• Make sure that charged fire extinguishers are available in the workshop.
• Make sure a first Aid Kit is available in workshop.
Preparation before dismantling the vehicle parts
• Clean components and surrounding area prior to removal.

• Blank-off any openings exposed by component removal using masking tape.
• Using plastic caps or plugs immediately seal fuel, oil or hydraulic lines when separated to prevent
loss of fluid and entry of dirt.
• Close the open ends of oil ways, exposed by component removal with tapered hardwood plugs or
readily visible plastic plugs.
• Before dismantling the component, clean it thoroughly with a recommended cleaning agent. Check
that agent is suitable for all materials of the component.
• After a component is removed, place it in a suitable container/tray. Use a separate container/tray
for each component and its associated parts.
Dismantling of the vehicle parts
• Observe cleanliness while dismantling the components, particularly brake, fuel or hydraulic system
parts. A particle of dirt or cloth fragment can cause dangerous malfunction if trapped inside the
system.
• Blow out all tapped holes, crevices, oil ways and fluid passages with an air line. Ensure that any O-
rings used for sealing are correctly replaced or renewed.
• Use marking ink to identify mating parts and ensure correct reassembly. If a centre punch or
scriber is used they may initiate cracks or distortion of components.
• Label and separate the mating parts to prevent accidental interchange.
• Label parts which are to be renewed and requiring further inspection before being passed for
reassembly. Place these parts in separate containers.
• Do not discard a part due for renewal until it has been compared with the new part, to ensure that
its correct replacement has been obtained.
Environmental protection precaution
It is illegal to dispose used engine oil, engine coolant, brake fluid, transmission fluid, battery and electrolyte
transfer case oil, differential oil and power steering fluid in to the sewers, drains or into waterways.
Dispose the used oil through authorized waste disposal contractors, licensed waste disposal sites or to the
waste oil reclamation trade. Rubber and plastic parts should be disposed through the authorized recycle
centers and/or agencies. If you have doubt on disposal of any of the above mentioned materials, contact
your local authority for advice for disposal facilities.
Noise
Several operations may produce high noise levels, which might damage hearing. In these cases, proper ear
protection must be worn.
Accessories and Conversions
Do not fit unapproved accessories or conversions, as they could affect the safety of the vehicle.
Mahindra will not accept liability for death, personal injury or harm to property which may occur as a direct
effect of fitting non-approved accessories or conversions to the vehicle.
Fitment of non-approved accessories could lead to vehicle not performing as intended resulting in
personal injury or death in case of an accident.
Workshop Tools and Equipment
It is essential that all tools and equipment are maintained in good condition. Never use tools or equipment
for any purpose other than that for which they were designed. Never overload equipment such as hoists,
jacks, axle and chassis stands or lifting slings. Damage caused by overloading is not always immediately
apparent and may result in fatal failure when the equipment is used another time. Do not use damaged
tools or equipment, mainly high-speed equipment such as grinding wheels. The damaged grinding wheel
can break up without warning and cause serious injury. Wear suitable eye protection when using the
grinding or sand blasting equipment. Wear a suitable breathing mask when using the abrasive blasting
equipment, working with asbestos-based materials or while using the spraying equipment. Make sure
there is adequate ventilation to control dusts, mists and fumes. Always maintain the tools in a neat and
good condition for quality repairs. Always keep the tools and equipment calibrated.
Hose Removal and Installation
• To prevent damage to rubber hoses, do not force open rubber hoses with the screwdriver.
• To reinstall rubber hoses securely, make sure that the hose length and direction is correct.
Hose Clamping
• If old rubber hose is re-used, install the hose clamp in its original position (at the groove in which
the old clamp is fixed). If there is a trace of tube bulging on the old rubber hose, align the rubber
hose accordingly.
• Discard old clamps, and replace with new ones.
Removal of Parts
While correcting a problem, try to determine its cause. Begin to work only after first learning which parts &
subassemblies need to be removed and disassembled for replacement or repair. After removing the part,
plug all holes and ports to prevent entering of foreign materials.
Disassembly of Parts
If the disassembly procedure is complex and requires many parts to be disassembled, all parts should be
temporarily marked in a place that will not affect their performance or external appearance and identified
so that reassembly can be performed with ease and efficiency.
Inspection during Removal/ Disassembly
When removed, each part should be carefully inspected for malfunctioning, deformation, damage, and
other problems.
Arrangement of Parts
All disassembled parts should be carefully arranged for reassembly. Be sure to separate or otherwise
identify the parts to be replaced from those that will be reused.
Cleaning of Parts
All parts to be reused should be carefully and thoroughly cleaned by using the appropriate cleaning agent
and method.
Using compressed air will cause dirt and other particles to fly out, and cause injury to the eyes, wear
protective goggles to avoid probable injury.
Reassembly
• Standard values, such as torques and certain adjustments, must be strictly adhered to while
reassembling the parts.
• If removed, these parts should be replaced with new ones:
1. Oil seals 4. Lock washers

2. O-rings 5. Nylon nut
3. Cotter pins
• Specified oil/lubricant should be applied to the moving components of parts.

• Specified oil or grease should be applied at the prescribed locations such as oil seals before
reassembly.
Adjustment
Use recommended/appropriate gauges and testers while making adjustments.
Rubber Parts and Tubing
Prevent fuel or oil from spilling on rubber parts or tubing.
Hose clamps
When reinstalling, position the hose clamp in the original location on the hose, and squeeze/tighten/
compress the clamp lightly to ensure better fit.
Bench Vise
When using a bench vise, use protective padding in the jaws of the vise to prevent damage to parts.
Component Cleaning
To prevent the ingress of dirt, accumulation of loose dirt and greasy deposits should be removed
before disconnecting or dismantling components or assemblies. Components should be thoroughly
cleaned using appropriate cleaning agent before inspection and prior to reassembly. Use Mahindra
recommended cleaning agents only.
Cleaning Methods:
• Dry cleaning.
• Removal of loose dirt with brushes.
• Scraping off dirt with metal/wood scraper.
• Wiping off dirt with a rag.
Wear eye protection while cleaning vehicle components with compressed air, a steam cleaner or
power washer. Failure to follow this instruction will result in personal injury.
• Various solvents are available which are suitable for component cleaning. All the components
should be cleaned only with appropriate solvents. Ensure that the solvent does not affect the
performance of the component as intended. Always follow the safety precautions
recommended by respective solvent manufacturer.
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of 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.
3. General Inspection
• Never inspect a component for wear or dimensional check unless it is absolutely clean.
• Slight smear of grease can conceal an incipient failure.
• When a component is to be checked dimensionally against figures quoted for it, use correct
equipment (surface plates, micrometers, dial gauges, etc.) in serviceable condition. Makeshift
checking equipment is dangerous.
• Reject a component if its dimensions are outside the quoted limits, or if damage is apparent. A
part may however be refitted if it’s critical dimensions are given to the prescribed size limits,
and is otherwise satisfactory.
• Legend of the Standard Operating Procedure Symbols
Symbol Denotation
Set / Place / Check here
Locate / Show
Move forward / Fit
Rotate / Turn Clockwise
Rotate / Turn anti-clockwise
• Legend of the Safety Symbols
Carefully read, understand and follow the safety symbols/ instructions given in this manual.
To emphasize information and procedures regarding safety, use, maintenance, etc., the following
symbols are used throughout the manual. DANGER, WARNING, CAUTION and NOTICE symbols are
given in this manual to alert the service technician to an area of potential hazard or to note
something of importance.
Any repairs related to safety or critical items such as the steering, brakes, suspension or the
supplementary restraint system should be carried out by a Mahindra dealer/ certified technician only.
Following correct service methods and repair procedures are essential for the safe, reliable operation
of vehicle as well as the personal safety of the individual while carrying out the work. This manual
cannot possibly predict all such variations and offer warning or cautions as to each. Deviation from the
instructions provided in this manual could lead to personal injury or damage to the vehicle.
Term/ Symbol Denotation

DANGER indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
WARNING indicates a potentially hazardous

situation which, if not avoided, could result in
death or serious injury.
CAUTION indicates a potentially hazardous

situation which, if not avoided, may result in
minor or moderate injury.
CAUTION used without the safety alert

symbol indicates a potentially hazardous
situation which, if not avoided, may result in
property damage.
Indicates important information relevant to

the vehicle, the vehicle's use or to sections of
this manual to which particular attention
must be paid for optimum use of the vehicle.
If you see this symbol, it indicates “no”, “do

not,” “do not do this,” or “never”.
Vehicle Specification
Refer following chart for QUANTO mCR100 vehicle general specifications –
Engine
Make and Country of origin (if imported) MAHINDRA & MAHINDRA LTD.
Model mHawk 3cyl 1.5L
Type 4 Stroke, Turbocharged, DI engine.
Bore x stroke, (mm) 83.0 x 92.0
No. of cylinders 3
Displacement 1493 CC
Compression ratio 18.5 (+/ - 0.5) : 1
Max. Engine output, (kW @ rpm) 73.5+/ -2 % kW @ 3750 rpm
Max. Torque, (Nm @ rpm) 240 Nm @ 1600 to 2800 rpm
Air cleaner type Foam Type
Clutch
Type Single plate, Dry type
Gear box
Make & model Mahindra & Mahindra Ltd.
5MT320
Type Synchromesh in all gears
No. of gears 5 Forward, 1 Reverse
Gear ratio
1st 3.78:1
2nd 2.21:1
3rd 1.42:1
4th 1.00:1
5th 0.79:1
6th Not Applicable
Rev. 3.56:1
Drive Axle (Front / Rear / All) Rear
Front axle ratio Not Applicable
Rear axle ratio 3.73 : 1
Steering
Type / Description Rack & Pinion Type,
Power Assisted - Hydraulic
Steering wheel diameter, mm 395 mm Opt. 391 mm
Ratio Power Steering - 17.8 : 1
Frame
Long member size, mm 75.0 X 75.0 X 2.8 - minimum,

147.4 X 82.0 X 3.2 - maximum,
L=3700, W=836.5mm at Front, 1175mm at Middle
and 1168mm at Rear
Number of cross members 8
Suspension Front - Double Wish-Bone Type IFS
Rear - Multi Link (5 Link) Rear Suspension
Type / Description Front - Double Wish-Bone Type IFS
Rear - Multi Link (5 Link) Rear Suspension
Spring Front -Coil Spring
Rear - Coil Spring
Anti-roll bar Provided in front
Shock absorbers Hydraulic, Double Acting, Telescopic
Brake
Service brake (Brief description) Hydraulic Circuit, Assisted by Vacuum Booster with
LSPV acting on Rear Wheels and with Auto-adjuster
Auto Slack Adjuster Fitted (Yes / No / Optional) Auto adjuster fitted
ABS Fitted (Yes / No / Optional ) No

Front (Disc / Drum) Disc
Rear (Disc / Drum) Drum
Total braking area cm2 Frt Axle - 220, Rr Axle - 533
Parking brake Reaction Type
Secondary brake Parking Brake

Wheels and tyres
Wheel rim size 6J x 15
Tyre size designation including ply rating P 205/65 R15 Radial.
Speed index S - For Bridgestone & JK,
T - For Apollo.
Load index / Load rating 94
Tyre Type (Radial / Cross / Tube / Tubeless) Radial, Tubeless P 205/65 R15
Laden Tyre pressure (front & rear), (kg/cm2) Front - 2.3 Kg/cm2, Rear - 2.3 kg/cm2
Electrical system
System voltage, V 12
Battery rating, Ah 72 Opt.80 Opt.64
Wiper motor Continuous & Intermittent Operating and Link type.
Wiping system (Brief description) Power operated, Two wiper, 2 Speed & Intermittent
Wash and Wipe type
Fuel tank
Material CRCA Steel - EDD (Al - Si Coated)
Capacity, l 55
Dimensions
Wheel base, mm 2760
Overall width, mm 1850
Overall length, mm 3985
Overall height, mm 1868(w/o Shi Rack) & 1880(with Ski Rack)
Front track, mm 1500
Rear track, mm 1500
Min. ground clearance, mm 180
Cargo box dimensions, mm Not Applicable
Load body platform area Not Applicable
Weights
Maximum GVW, kg (for rigid vehicles) 2220
Maximum GCW, kg (for articulated / combination Not Applicable
vehicles)
Maximum FAW, kg 1090
Maximum RAW, kg 1130
Kerb weight with 90% fuel(with spare 1640
wheel,tools,etc),(kg)
Maximum gradeability in 1st gear 10.3°

Seating
Seating capacity Driver+6
Vehicle Maintenance
Refer following chart for QUANTO mCR100 vehicle maintenance schedule –
Refer below chart for QUANTO mCR100 vehicle lubrications recommendations –
The repair methods given by the manufacturer in this document are based on the technical specifications, current 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 of 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.
QUANTO Sept 2012/ Rev1
ENGINE
mCR100
Table of Content
Description………………………………………………………………………………………………………
Trouble Shooting……………………………………………………………………………………………..
Care of the System…………………………………………………………………………………………..
In Car Repairs…………………………………………………………………………………………………..
Dismantling & overhauling of the Engine………………………………………………………….
Engine Chain Timing Procedure (2D Animation)……………………………………………….
Working Principle of Twin Turbocharger (2D Animation)…………………..…………….
Specifications & Wear Data……………………………………………………………………………..
Lubricants & Sealants……………………………………………………………………………………….
Sealant Application Pattern……………………………………………………………………………..
Tightening Torques………………………………………………………………………………………….
Tightening Sequence………………………………………………………………………………………..
List of the MST…………………………………………………………………………………………………
The repair methods given by the manufacturer in this document are based on the technical specifications, current 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 of 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.
Overview
Refer below illustrations for Engine accessory & component location -
Engine Accessory and Components Location – Isometric View A
A. Intake Manifold and Pipe F. Power Steering Pump

B. Oil Filter G. Damper Pulley
C. Alternator H. A/C Compressor
D. Oil Dip Stick Guide Tube I. Water Pump
E. Oil Sump J. Front Cover
Refer below illustrations for engine accessory & component location -
Engine Accessory and Components Location – Isometric View B
K. EGR Valve O. Flywheel

L. EGR Cooler P. Cylinder Block
M. Drive Belt Q. Twin Turbo Charger
N. Auto Tensioner R. Oil Filling Neck
Description
The 1.493 Lit Twin Turbocharged and intercooled common rail direct injected diesel engine with a
bore 85 mm and stroke of 96 mm develop 100 BHP (73.5 ± 2 kW) @ 3750 rpm and a torque of 240
Nm @ 1600 to 2800 rpm.
A twin turbocharger controls the boost to 2.2 bars. The compressed air is cooled by the charged
intercooler which is mounted upstream of the turbocharger. The cooled air enters the inlet
manifold’s plenum and it enters the Aluminium cylinder head through the inlet valves having an
angle.
The piston features re-entrant type combustion chamber and having ferrous ring insert in the Top
ring groove. A 3-ring pack is used. The top ring is asymmetrical barrel face and with CKS coating and
keystone shape. The 2ndring is taper faced. The 3rd is conformable Oil Ring.
The forged connecting rod is connected to induction-hardened crankshaft. The small end of the
connecting rod is trapezoidal shaped to reduce the mass as well as to ensure higher loading. The
crankshaft is induction hardened with the filets hardened & ground. The flywheel has a shrunk fit
ring gear and also a ball bearing to act as pilot for the gearbox input shaft. The front end is having a
rubber molded dampener pulley.
There are two overhead camshafts (Inlet and exhaust). Inlet camshaft is chain driven whereas the
exhaust camshaft is gear driven, input given by inlet camshaft gear. High pressure fuel pump is
mounted on inlet camshaft back end and vacuum pump mounted on exhaust camshaft back end.
The valves are actuated through HLA (hydraulic tappets). There are four valves per cylinder. This
ensures that the charge fill as well as the purging is optimum.
Refer below illustrations for mHawk engine accessory & component location -
Engine Accessory and Components Location – Engine Front View Schematic
Engine Accessory and Components Location – Engine Side View Schematic
The repair methods given by the manufacturer in this document are based on the technical specifications, current 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 of 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
Engine Accessory & Component Location – Engine Top & Bottom View Schematic
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of 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.
Trouble Shooting
Refer to the Service diagnosis chart. Additional tests & diagnostic procedures may be necessary for
specific engine complaints that cannot be isolated using only the diagnostic chart.
Information concerning the additional checks is provided within the following diagnostic.
Cylinder compression pressure Test
The results of the cylinder compression test can be utilized to diagnose several engine malfunctions.
Before carrying out the compression test ensures that the battery is in good working condition.
Otherwise the indicated pressures may not be valid for diagnostic purpose.
 Remove all the injectors.

 Fit the dummy injector (MST Tool) and connect it with the compression gauge.
 Disconnect the engine RPM sensor or phase sensor connector so that the engine does not start.
 Crank the engine.
 Note the compression value should be 30 bars.
 Repeat the procedure for the other cylinder.
 Refer to the Specification for the value.
Engine cylinder Head Gasket Failure Diagnosis
A leaking engine cylinder head gasket usually results in loss of power, loss of coolant and engine
misfiring, overheating and poor fuel economy.
An engine cylinder head gasket leak can be:

A. Between adjacent cylinders
Or
B. Between a cylinder and adjacent water jacket.
Cylinder head gasket failure between cylinders is indicated by Loss of power and /or engine misfiring.
Cylinder head gasket leaking between a cylinder and coolant passage results in coolant foaming or
overheating and loss of coolant indicate leakage in engine water jackets.
Cylinder to Cylinder Leakage Test
Check the cylinder compression pressure as already explained. Leakage between cylinders will be result
in drop of compression pressure by nearly 50 to 70% in the affected cylinders.
Cylinder to Water jacket Leakage Test
• Remove the radiator cap.

• Warm up the engine and allow it to warm up until the engine thermostat opens.
• If large combustion /combustion pressure leak exist, bubbles will be visible in coolant.
• If bubbles are not visible, install a radiator pressure tester and pressurize the cooling circuit. If a
cylinder is leaking combustion pressure into the water jackets then the tester’s needle will pulsate
with every combustion stroke of the cylinder.
Refer below chart for various symptoms, causes and there remedial actions -
Symptom Causes Remedial action
Engine will not start & 1. Air intake obstructed  Replace the element.
emit black smoke 2. Defective injectors  Check for free operation of
Turbocharger.
3. Lack of compression.  Replace
4. Cylinder head gasket  Check compression pressure.- if
failure low check for valve seat ,rings &
liner wear
5. Engine timing- Valve  Replace the cylinder head gasket.
6. CR system  Check timing chain.
 Refer diagnostic manual.
Noisy engine & black 1. Faulty injectors.  Replace injectors
smoke. 2. Loose main bearings  Tighten the main bearings.
3. Broken parts  Inspect and replace the broken
parts.
4. EGR valve stuck open  Check the EGR valve & replace if
mechanically required
Engine does not give 1. Air intake restricted.  Replace air cleaner element if
full power. required.
2. Clogged fuel filter.  Replace filter.
3. Defective injectors.  Replace
4. Air leaks in pressure line  Plug the leaks, replace hose or clip
after turbocharger( Turbo if required.
to intercooler, intercooler
& intercooler to intake
manifold)
5. Fuel return pipe to tank  Locate the kink/block in return
blocked. pipe and rectify.
6. Valve leak  Check the compression, re-lap if
required.
7. Turbocharger damaged.  Get the Turbocharger repaired at
authorized TEL dealer.
8. Gas leaks between exhaust  Replace gaskets.
manifold & cylinder head.
9. Leaking exhaust system.  Tighten the TC mounting bolts.
Replace gasket if required.
10. Exhaust gas leak between  Correct the leak
turbo & manifold.
11. Gas leak between EGR  Change the gasket or the hose.
pipe joints
12. EGR pipe leak.  Replace the pipe.
13. Fuels supply line kink  Remove the restriction.
creating restriction.
14. Compression leak.  Check compression.
15. Jammed piston rings  Replace piston rings.
16. Viscous fan continuously  Check the VFD as outlined in
engaged. cooling. Replace if required.
17. Vacuum leak to the VGT  Check the vacuum leak and rectify.
actuator causing the Please note that the VGT
delayed VGT operation operation is sensitive to vacuum
leak.
18. Check CR system  Refer the diagnostic manual
Noisy engine & high 1. Cylinder head gasket  Replace the cylinder head gasket.
smoke ( White/ Grey) defective.
2. Worn out or damaged  Lap the valve seats or regrind.
valve seats.
3. Leaking injector holder  Tighten the injector holder.
Black smoke. 1. Air intake restricted.  Check for hoses, replace air
cleaner element.
2. Defective injectors  Check injectors.
3. Air leaks.  Check for leaks between
Turbocharger to intercooler,
intercooler & intercooler to inlet
manifold.
4. EGR valve stuck open  Check the EGR valve
5. Restricted exhaust system.  Remove restriction or replace
parts.
6. Gas leak between exhaust  Replace manifold gasket or parts.
manifold & cylinder head.  Overhaul engine.
7. Worn out rings, liners &
valves.
8. Improper vacuum  Check & correct
connection for EGR valve
Excessive oil 1. Cracked vacuum line  Check the vacuum line from the
consumption hoses. alternator to the EGR valve - check
for leaks, crack. And vacuum line
to the VGT actuator. Replace
cracked hoses.
2. Clogged air filter element.  Replace element.
3. Restriction in air intake to  Locate & remove restriction.
compressor duct.
4. Restrictions in  Remove the restriction in the
turbocharger oil drain line. drainpipe.
5. Restriction in crankcase  Check the crankcase ventilation &
breather. rectify.
6. Damaged oil separator  Replace the oil separator
7. Turbocharger damaged.  Change oil, filter, service the
Turbocharger & use recommended
oils & drain intervals. Follow the
recommended procedure while
shutting down.
8. Worn out rings, liners, and  Repair Turbocharger.

valves.
9. External oil leaks  Overhaul engine.
10. Leakages through inlet  Stop the external oil leakages.
manifold mounting face
allowing dust entry.  Change the vacuum hoses.
11. Bend/kink in any of the oil
return pipe’s/vacuum  Change the manifold gasket or
hoses. replace the manifold.
12. Defective vacuum pump.  Remove the bend or kinks.
 Replace the vacuum pump.
Blue smoke. 1. Clogged air filter element.  Replace element.

2. Restriction in air intake to  Locate & remove restriction.
compressor duct.
3. Air leak between the  Locate the leaks, change hose or
Turbocharger to intake clamp if required.
manifold.
4. Excess oil.  Correct the oil level.
5. Wear in valve seal.  Check the valve stem seals,
replace if required.
6. Wear in piston rings &  Check the compression pressure,
liner. replace rings & liners.
7. TC oil seal leaks  Check the Turbocharger if
defective get it attended.
White smoke. 1. Improper timing  Check sprockets & chain for wear.
Rectify
2. Defective cylinder head  Replace the cylinder head gasket.
gasket.
3. Restriction in fuel supply  Remove the restrictions.
Starter will not work or 1. Electrical complaints.  Refer the electrical section.
only cranks slightly 2. Check water level.  If water level reduced drastically
then check for hydrostatic lock.
3. Hydrostatic lock  Remove the water in the cylinder
and find the cause for water entry.
Starter will not crank 1. Weak battery.  Check the battery specific gravity.
the engine. 2. Corroded or loose  Clean & tighten battery
battery connection connections.
3. Faulty starter.  Repair starter.
4. Improper earthing.  Rectify earthing.
Noisy valves 1. Thin or diluted oil.  Change oil.

2. Low oil pressure.  Check the oil level.
3. Worn HLA  Replace the HLA.
4. Worn valve guides.  Replace the valve guides.
5. Excessive run out of valves  Grind valve seats and valves.
seats
6. Oil thickening  Replace oil & find the reasons of
thickening, rectify.
7. Aeration in oil  Follow the de-aeration procedure.
Oil pressure drop 1. Low oil level.  Check engine oil level.
2. Defective oil pressure  Install new sensor.
sensor.
3. Clogged oil filter.  Replace filter.
4. Clogged oil cooler  Clean the oil cooler.
5. Clogged oil strainer.  Clean the strainer.
6. Pressure relief valve in oil  Clean the valve & bore and
filter bracket stuck. assemble.
7. Oil leaks- internal  Check the gasket between the
block & front cover or any of the
MOG plugs
8. Worn parts in oil pump.  Replace the worn parts or pump.

9. Excessive bearing  Check bearing clearances.
clearances
10. Thin or diluted oil.  Change oil to correct viscosity.
11. Excessive bearing  Replace the bearing
clearance.
12. Oil pump relief valve stuck. Remove the valve, inspect, clean &
refit.
13. Oil pump suction tube  Remove sump, inspect the parts &
loose, bent or cracked. replace.
14. Sealant blocking the  Check for sealant at the face of the
suction suction pipe.
15. Oil pump cover warped or  Install new pump.
cracked
Oil leaks 1. Worn oil seals  Replace seals.

2. Misaligned or deteriorated  Replace gasket.
gaskets.
3. Loose fastener, broken or  Tighten fastener
porous metal parts  Repair or replace.
Care of the System
Service Tips and Precautions

Observe the following precautions when disassembling or servicing the engine system and its
components.
• Ensure a dust free environment before starting the work on the engine.
• Carefully assemble the disassembled parts in the correct order. If work is interrupted, the
disassembled parts must be covered with clean cover/paper cloth.
• Carefully disconnect all the electrical connection in the engine compartment before
commencing the work.
• Carefully unscrew the high pressure pipe nut from the high pressure connector. Always use two
spanners or socket wrench set while tightening it.
• Ensure that there are no contacts between hard materials and critical head’s, eccentric shaft, LP
connectors and flange.
• Handle the High Pressure Pump (HPP) with extreme care. If the HPP falls down it must be
changed though it is not damaged.
 Do not work on the cooling system until the engine is OFF and cooled down considerably,
because the pressure within the system is extremely high and will cause personal injury
 Eye protection must be worn while working near the engine system, failure to follow this may
cause personal injury.
 Use Extreme Caution while the engine is running. Do not put your hands near hot
components, near the turbocharger in the engine compartment. Failure to follow these
instructions may lead to serious personal injury.
 Care to be taken while working with heavy parts, failure to follow this instruction will lead to
personal injury and damage to the parts.
Recommended Engine Oil –

Always use MAHINDRA "MAXIMILE Feo" New Generation Genuine Engine Fluid. Quantity 05 Liters. For
other than specified brand, the oil change interval has to be reduced to 6000 km if the oil meets
minimum of API CH-4 SAE 15W-40 specification.
Recommended Engine Oil Filter –

Always Mahindra "MAXIMILE UNIVERSE" Genuine Oil Filter.
Recommended Coolant –
Always use MAHINDRA "MAXIMILE ULTRA COOL" genuine coolant (Ready to use coolant. No need to
mix water) Quantity is 07 Liters. Brand Specific. Don’t use other coolants for top up. In case of
emergency, coolant meeting JIS K2234 specification should be used (30% concentration diluted with
distilled water) and coolant change period to be reduced as 30,000 km
Accessory Drive Belts and Auto Tensioner

Removal
Pre removal and Post Installation –

• NVH Cover and Intercooler assy.
• Degassing Tank.
• Electric fan and shroud assembly.
• Top up coolant level in Degassing
Tank.
Removal Steps –
• Loosen the auto tensioner (2) and
remove steering and alternator
drive belt.
• Loosen and lock the auto
tensioner (1) and remove AC
comp and water pump drive belt.
Removal
Drive belts and Auto tensioner – Replace
[A] Alternator/Power Steering Pump Drive Belt
[B] AC Compressor /Water Pump Drive Belt
Refer illustration.
1. Use the no. 6 allen key, rotate the Auto

Tensioner in the direction shown in the
illustration.
2. Remove the Alternator, steering pump drive

belt.
3. Release the Auto Tensioner.
4. Loosen the mounting bolt and remove auto

tensioner assembly.
5. Using the 12mm spanner, rotate the Auto

Tensioner in clockwise direction shown in the
illustration.
6. Lock the Auto Tensioner in that position using a

lock pin. Refer illustration.
7. Remove the accessory drive belt.
8. Take the locking pin out and release the Auto

Tensioner.
9. Remove auto tensioner assembly by removing

one allen bolt and one 12mm bolt.
Auto Tensioner Inspection:

Inspect automatic tensioner carefully for symptoms such as cracked arms, excessive vibration during
idle speeds, looseness, noise (clatter or rattling) and sticking or seized operation. These can all be signs
that a tensioner needs replacing.
Alternator, Steering pump drive belt tensioner –
Inspect
Refer slots/ marking shown by arrow marks on

Auto tensioner in illustration.
The tensioner lug should always match to the left

side or centre of the coil hub slot.
If it travels towards right side, beyond centre of

the coil hub, it is recommended to replace the
auto tensioner.
Water pump, AC Comp drive belt tensioner –

Inspect
Refer marking shown by arrow marks on Auto

tensioner in illustration.
The tensioner lug should always be positioned in

these marks of the coil hub.
If it travels towards left side, beyond last mark of

the coil hub, it is recommended to replace the
auto tensioner.
Accessory Drive Belt Specification –

1. Water Pump, AC Compressor Drive Belt : 4PK/ 1220 mm Length.
2. Alternator, Power Steering Pump Drive Belt : 4PK/ 1060 mm Length.
Accessory Drive Belts to be Inspected for –

Abrasion
1. Abrasion 2. Cracking
Cracking
3. Improper Install 4. Uneven Rib Wear
Improper Install
5. Misalignment 6. Chunk-out
Uneven Rib Wear
7. Gravel Penetration 8. Pilling
Misalignmenttion
1. Abrasion – Each side of belt appears shiny or

glazed. In advanced stages, fabric becomes
exposed.
2. Cracking – Small, yet visible cracks along the

length of a rib or ribs.
3. Improper Install – A belt rib begins

separating from the joined strands. If left
unattended, the cover will often separate,
causing the belt to loosen.
4. Uneven Rib Wear – Belt shows damage to

the side with the possibility of breaks in the
tensile cord or rough edged ribs. A thumping
noise may also be heard when running.
5. Misalignment – Sidewalls of the belt may

appear glazed or the edge cord may become
frayed and ribs removed. A noise may result.
In severe cases, the belt can jump off the
pulley.
6. Chunk Out – Pieces or chunks of rubber

material have broken off from the belt.
When chunk-out has occurred, a belt can fall
at any moment.
7. Gravel Penetration – Small pinholes are

visible on the backside of the belt. Bumps
may be visible and the fabric around the
holes can be frayed.
8. Pilling – Belt material is sheared off from the

ribs and builds up in the belt grooves.
It is recommended to remove & check the drive belts thoroughly if any abnormality noticed.
Engine Oil Checking

1. Park the vehicle on a level surface and apply the parking brake.
2. Start the engine and let it idle until reaches operating temperature.
3. Turn off the engine. Wait a few minutes for the oil to drain back into the oil pan.
4. Remove the dipstick and wipe it clean. Reinsert it all the way.
5. Remove the dipstick again and check the Oil level. It should be between the maximum (MAX)
and minimum (MIN) marks. If the oil level is below the MIN mark, remove the oil filler cap and
pour recommended oil through the opening. Do not overfill.
6. Recheck oil level with the dipstick. It is normal to add some oil between oil maintenance
intervals or during the break-in period, depending on the severity of operating conditions.
Oil level should be checked regularly. Operating the engine with an insufficient amount of oil can
damage the engine and such damage is not covered by warranty.
Use only recommended MAHINDRA "MAXMILE FEO" oil of specification Exceeds - APICH-4; SAE 15W-
40.
Engine Oil Draining Procedure
1. Park the vehicle on a level surface and apply the parking brake.
2. Run the engine until it reaches operating temperature, and then turn it off.
3. Disconnect the negative terminal of the battery.
4. Remove the oil filler cap.
5. Lift the vehicle.
6. Remove all 10 mm mounting bolts of engine underbody cover.
7. Place a large drain pan below the drain plug.
Be careful not to burn yourself. The engine oil may be hot.
8. Remove the 22 mm drain plug and completely drain the oil from oil pan.
Engine oil filling procedure
1. Clean and reinstall the drain plug and a new washer. Tighten the drain plug to the specified
torque:
2. Refill the engine with recommended oil and securely tighten the filler cap.
Use MAHINDRA "MAXMILE FEO" oil of recommended quantity of 5 liters.
3. Connect the negative terminal of the battery.

4. Start the engine. Check for leakage around the drain plug and oil filter. Correct as required.
5. Turn the engine off and wait several minutes.
Check the oil level with the dipstick. Add engine oil if necessary.
Prolonged and repeated contact with used engine oil may cause skin disease. Try to avoid direct skin
contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as
possible.
Engine Oil Filter

Removal
Pre removal –
• Park the vehicle on certified post.
• Disconnect the battery negative terminal.
Engine Oil filter is located on LH side of the

engine.
To access the oil filter remove the engine top

encapsulation/ NVH Cover.
Lift the vehicle.
Remove all 10 mm mounting bolts of engine

underbody cover/ encapsulation.
Place a large drain pan below the oil filter.
Remove the oil filter using a suitable tool in

anticlockwise direction.
Installation:
Wipe the engine oil filter mounting surface with a
clean rag.
Coat the gasket on the new filter with clean

engine oil.
NOTE:
Tighten the Oil filter by hand only and do not use

tool while tightening Oil filter.
Tighten the oil filter in clockwise direction until a

slight resistance is felt, then tighten an additional
2/3 turn.
Post Installation -
• Connect the negative terminal of the battery.

• Start the engine and check for leakage around the oil filter. Correct as required.
• Turn the engine off and wait several minutes. Check the oil level. Add engine oil if necessary.
• Install the engine underbody cover and tighten all 10 mm mounting bolts to the underbody
cover.
In Car Repairs
Tests and inspection procedures are necessary for specific engine malfunctions that cannot be is
isolated with the Service Diagnosis charts. In-formation concerning tests and Inspection is provided
within the following:
1. Cylinder Compression Pressure Test

2. Engine Cylinder Head Gasket Failure Test.
3. Engine Oil Leak Test.
4. Inspection for oil seal area leaks
Cylinder Compression Pressure/ Dry Test:
1. Remove all the injectors

2. Fit the dummy injector and connect it with the compression gauge
3. Disconnect the crankshaft position sensor electrical connector.
4. Crank the engine.
5. Note down the max value the gauge indicates.
6. Repeat the procedure for all the other cylinders.
7. Tabulate the results.
Cylinder Compression Pressure/ Wet Test:
1. Spray 10 to 20 ml of fuel inside the bore through the injector port with the help of oil can.
2. Fit the dummy injector and connect it with the compression gauge
3. Disconnect the crankshaft position sensor electrical connector.
4. Crank the engine.
5. Note the maximum value the gauge indicates.
6. Repeat the procedure for all the other cylinders.
7. Tabulate the results.
Compare both the dry and the wet values with the specifications. The wet test values should always be
higher than the dry test values. If the reading does not change during wet test, this can hint towards
compression leakage from cylinder head or through the valves. If the wet and dry test values vary
considerably between cylinders then the piston rings can be suspected.
Engine Cylinder Head Gasket Failure Test
A leaking engine cylinder head gasket causes power loss, coolant loss and engine misfiring, overheating
and poor fuel economy. The engine cylinder head gasket leakage occurs between adjacent cylinders or
between a cylinder and adjacent water jacket. The cylinder head gasket failure between cylinders is
indicated by power loss and engine misfiring. The cylinder head gasket leaking between the cylinder and
coolant passage results in coolant foaming or overheating and loss of coolant indicate an engine water
jacket.
Cylinder to Cylinder Leakage Test
Check the cylinder compression pressure as already explained. Leakage between cylinders will be result
in drop of compression pressure by nearly 50 to 70% in the affected cylinders.
Cylinder to Water jacket Leakage Test
• Remove the degassing pressure cap.

• Warm up the engine and allow it to warm up until the engine thermostat opens.
• If large combustion pressure leak exist, bubbles will be visible in coolant.
• If bubbles are not visible, install a radiator pressure tester and pressurize the cooling circuit. If a
cylinder is leaking combustion pressure into the water jackets then the tester’s needle will
pulsate with every combustion stroke of the cylinder.
Engine Oil Cooler

Removal
Pre removal and Post Installation – Removal Steps –

• NVH Cover and Engine top encapsulation. 1. Oil Filter assembly
• Dip stick guide bracket. 2. Oil cooler hoses
• Vehicle Battery, to get better access. 3. Oil cooler assembly
• Oil cooler body mounting Gasket. 4. Oil cooler mounting body and
Check oil level and leak and top up if gasket.
required.
Correct Procedure for Oil Filter Removal and Installation -
Engine Chain Timing - Procedure
• This job cannot be performed when engine is assembled on vehicle.

• Engine chain timing has to be carried during engine assembly.
Ensure proper fitment of HLA assemblies in all

places.
Place both camshafts with lobe facing upward.
Apply sealant (Locktite 5900) on the cylinder

head. (Refer sealant application pattern in RM)
Align and fit the camshaft lock tool on the rear

side.
Fix the tool on cylinder head using two

mounting bolts.
Assemble cam cover over camshafts.
Tight the mounting bolts to the recommended

torque values following tightening sequence.
Insert TDC position lock pin in crankshaft.
NOTE:
Rotate the engine in such a way that the 1st

piston should be at 90 dg. ATDC and
Crankshaft key comes at 3 O’ Clock position.
Assemble the cam sprocket and chain

assembly along with hydraulic tensioner.
Assemble the cam gears and its mounting

bolts.
Assemble the crankshaft locking tool;
Assemble the crankshaft lock tool with the

help of mounting bolt on cylinder block.
Tighten the camshaft gear mounting bolts.
Turn and hold the intake camshaft gear against

the tightening direction with the help of the
tool as shown in the illustration and tighten
the bolt of intake camshaft gear to the
specified torque.
Remove –
 Camshaft holding tool.
 The camshaft locking tool mounted on cylinder head back.
 Crankshaft locking tool.
Post installation –
• Assemble the front cover and assemble the bolts. Tighten the front cover bolts to the specified
torque with following the specified sequence.
• Assemble the flywheel. Torques tightens the flywheel bolts following the specified sequence.
• Remove the crankshaft TDC locating pin from the block.
• Fit the damper pulley and tighten the bolt to the specified torque.
Crankshaft Front Oil Seal

Removal

• NVH Cover and engine top and
bottom encapsulation.
• Radiator coolant drain and refill.
• Degassing tank assembly.
• Cooling system hoses on radiator.
• Cooling fan assembly.
• Alternator, steering pump drive belt.
• Water pump, AC Comp drive belt.
Removal Steps –
1. Alternator, steering pump drive
belt.
2. Water pump, AC comp drive belt.
3. Damper pulley.
4. Timing cover oil seal.
2
3
1
4
Removal
Install the crankshaft locator pin.
Remove the accessory drive belts.
For additional information refer to Accessory

Drive Belt removal and installation section.
Remove the 24mm mounting bolts of the

crankshaft damper pulley.
Using a suitable tool, remove the oil seal from

the timing cover.
Inspection
1. Check and clean the oil seal seating area thoroughly for any damage.
The oil seals should never be reused.
Installation:
Install the new oil seal on front end of the
crankshaft.
Insert the dolly for front cover oil seal (Special

Tool No: 0311DAM0001ST) on the timing cover
and tap it using a mallet.
Visually inspect the oil seal for proper seating.
• Visually check if the oil seal is seated properly in the slot.

• Install the damper pulley on the timing cover. Align the damper pulley flat surfaces with the oil
pump.
• Tighten the 24mm crankshaft damper pulley mounting bolt to the specified torque.
• Remove the crankshaft lock pin tool from the block.
Install the accessory drive belts. For additional information refer to Accessory Drive Belt removal and
installation section.
Crankshaft Rear End Oil Seal

Removal

• Transmission oil drain and refill.
• Transmission assembly.
• Clutch assembly.
Removal Steps –
1. Flywheel assembly.
2. Rear oil seal.
3. Rear oil seal retainer.
1 3
2
Torque Sequence - Sealant Application Pattern -
Removal
Remove the transmission. For more details refer to Transmission removal and installation section.
Remove the flywheel. For additional information refer to Flywheel removal and installation section.
Using a suitable tool, pull out the oil seal from rear end of the crankshaft.
• Care should be taken while pulling out the oil seal from the crankshaft, to avoid damage to
the oil seal seating edge of the crankshaft.
• The oil seal should never be reused.
Using a suitable tool (A), remove the oil seal (B)
from the timing cover.
Inspection
1. Check the oil seal seating area for any damage,
and clean it thoroughly.
Installation:
Install the new oil seal on rear end of the
crankshaft.
Clean the oil seal seating edge of the crank shaft,

before installing the oil seal.
Insert the rear oil seal pressing dolly

(Special Tool No: 0301BM007ST) on the rear end
crankshaft and tap it using a mallet.
• To install, reverse the removal procedure.

• Tighten all bolts to the specified torque.
Engine
Removal
Park the vehicle on certified post.
Make sure that parking brake is pulled ON and

engine is switched OFF.
Pull the lever which is located in the driver side to

open the bonnet.
Press the bonnet lock as shown in arrow direction,

to open the bonnet.
Open the bonnet and fix the stay rod in position to

support the bonnet.
Remove the battery terminals and remove

battery.
Remove the two 12mm inches mounting bolts on

the bonnet RHS.
Similarly remove two 12mm inches mounting bolts

on bonnet LHS.
Detach the bonnet assembly.
Remove the NVH cover, top encapsulation and

intercooler assembly from the engine.
Remove the degassing tank.
Drain the engine oil before engine removal.

Drain the engine coolant from the radiator and engine block. For additional information refer to Engine
Coolant Replacement/ Filling and Bleeding Procedure Section.
Remove engine bottom encapsulation.
Remove starter motor assembly.
Remove the Air filter assembly.
Ensure to remove HFM sensor WH connector and

air filter hoses before removing assembly.
Press the lock and pull out the fuel suction hose
from the fuel pump.
Remove the wiring harness socket from HP fuel

pump.
Press the lock and pull out the vacuum hoses of

the EGR valve.
Remove the EGR valve and pipe.
Press the lock and pull out the vacuum hoses on

the turbocharger.
Press the lock and pull out the fuel return hose.
Pull out the vacuum pump outlet hose from the
vacuum pump.
Recover A/C gas from the HVAC system.

Drain the power steering fluid.
Remove the power steering suction hose. For additional information refer to Power Steering Suction
Hose removal and installation section.
Avoid spillage of power steering fluid on other components and wipe off immediately if any spillage is
noticed.
Plug the inlet & outlet hole of the power steering pump to avoid entry of foreign particles.
Remove the air filter housing. For additional information refer to Air Filter Housing removal and
Pull the lock and remove the clutch slave cylinder inlet hose. For additional information refer to
Concentric Slave Cylinder removal and installation section.
Disconnect the neutral, reverse switch and vehicle speed sensor electrical connectors. For additional
information refer to Transmission removal and installation section.
Remove 12mm battery ground cable mounting bolt connected to the Transmission. For additional
information refer to Transaxle removal and installation section.
• Press the lock and pull out the heater core inlet and outlet hoses.
• Unlock the engine wiring harness clips mounted on the engine room body and place it aside.
• Press the clip, and pull out the radiator top, bottom and by-pass hoses from the radiator.
• Press the lock, and disconnect the A/C compressor electrical connector.
• Remove the 13mm A/C low and high pressure pipe mounting nuts.
Plug the inlet & outlet hole of the A/C compressor to avoid entry of foreign particles.
• Remove the two 12 mm intermediate shaft upper Universal Joint mounting bolt (A) connecting
upper and lower intermediate shafts.
• Remove the 12mm connector intermediate shaft from the steering gear.
• Remove the 15mm catalytic converter joint mounting nut and insulator.
• Remove air filter assembly along with vacuum hoses, intake/ dirty side hose and clean hose.
• Remove the fuel filter assembly and its hoses.

• Remove the bonnet lock assembly and cable.
• Remove the electrical fan assembly and remove the body cross panel.
• Remove radiator and condenser assembly.
• Remove front grill add on and grill assembly.
• Remove the mounting bolts on clutch housing to engine.
Remove the hydro mount stud top nut on RH and

LH side.
Unlock the engine wiring harness clips mounted

on the engine room body and place it aside.
Tie-up the rope chain with the hook of the engine

lifting jack and the lift the engine carefully out of
the vehicle.
Make sure that all the engine wiring harness

sockets and other connections on engine are
removed and kept aside.
Lift the vehicle slowly to pull out the engine

carefully along with the accessory and rest it on
suitable stand.
Improper tie-up of the lifting rope chain will cause damage to the vehicle and the persons involved.
Position the engine lifting jack properly and lock it securely.
• Lift the engine carefully and rest it on suitable stand.

• Remove the 18mm engine mounting bracket bolts and nuts. For additional information refer to
Engine mounting removal and installation section.
• For additional information refer to Transmission removal and installation section.
Installation
• Tighten all bolts and nuts to the specified torque.
• Refill the power steering fluid. For additional information refer to Steering Oil Replace Section.
• Refill the engine coolant. For additional information refer to Engine Coolant Replacement/
Filling and Bleeding Procedure: Section.
• Recharge the A/C Freon gas to the HVAC system. For additional information refer to
Refrigerant Recovery Recycling and Recharging Section.
• Check all the electrical functions.
While Engine installation, align LH & RH Hydro

mount top stud to the engine mounting bracket on
block.
Top Stud should not rotate while tightening as this

will twist the rubber inside.
Timing Chain and Sprockets

Removal
Pre removal and Post installation –

Remove and refit -
• Engine Encapsulation and NVH cover.
Drain and refill –
• Engine coolant from Radiator &
Engine block.
• Purge and refill AC gas.
Torque Sequence - Sealant application pattern -
RemovalSteps
Removal Steps– –
1. Chain
1. Hydraulic
Hydraulic Tensioner.
Tensioner.
2. Tensioner
2. Arm.
Tensioner Arm.
3. 3. Fixed
Fixed guide.
guide.
4. 4.
CamChain
gearassembly.
- exhaust
5. 5Chain
Camshaft Gear
assembly.
Removal
Pre-Removal:
• It is recommended to remove the engine from the vehicle and place it on work stand before
doing the chain assembly removal and installation.
• Timing Chain assembly can also be removed without removing engine out of the vehicle.
Remove the engine bottom encapsulation and NVH cover.

Drain the engine oil. For additional information refer to Engine Oil Draining Procedure Section.
Remove the starter motor assembly.
Remove the accessory drive belts.
Remove the alternator assembly.
Remove the power steering pump assembly.
Remove the A/C compressor assembly.
Remove damper pulley.
Remove the auto tensioner on Alternator and

Steering pump drive belt.
Remove the auto tensioner on AC compressor and

Water pump drive belt.
Ensure to lock the auto tensioner with the lock pin

before removal of its mounting bolt.
Remove the AC compressor mounting bracket.
Remove the Steering pump mounting bracket.
Remove the water pump drive pulley.
Remove other 03 nos. small brackets fitted on

timing cover.
Remove the twenty one nos. timing cover

mounting bolts as per recommended sequence
and detach the timing cover case.
Install the crankshaft lock pin.
Ensure that 1st piston is at 90 dg. ATDC and

Crankshaft key should be at 3 O’ Clock position.
Remove the chain hydraulic tensioner assembly.
Use hydraulic tensioner pin to lock tensioner

before removal of its mounting bolts.
Remove the lock clips from fixed guide and

tensioner arm.
Remove the cam gear mounting bolts. First

remove exhaust cam gear and then intake cam
shaft gear.
Use gear holding tool and hold the intake

camshaft gear before loosening both gear
mounting bolts.
Remove the chain assembly.
Inlet and exhaust Camshaft sprocket should not be interchanged during removal and installation.
Failure to follow the instruction may lead to engine malfunctioning.
Installation:
Clean the outer and inner surface of the timing chain area of the engine and timing chain cover.
Check for any damages or cracks in timing chain, sprockets, tensioner and timing chain cover
post installation. If found replace the affected components.
Check and confirm the TDC Position of the piston for cylinder-1 before installation, in case the
same was not followed while removing the timing chain.
Do not remove the camshaft locking tool/ the Crankshaft TDC locater pin from its location, else
the engine timing could get disturbed. For additional information refer to Timing Procedure.
Assembly is in reverse to the removal sequence.
• Install the damper pulley

• Install the A/C compressor mounting bracket and assembly.
• Install the power steering pump mounting bracket and assembly.
• Install the alternator assembly.
• Install the accessory drive belts.
• Install the starter motor assembly.
• Install the engine bottom encapsulation and NVH cover.
• Refill the engine oil. For additional information refer to Engine Oil filling Procedure Section.
Camshafts
Removal
Pre removal and Post installation –

Remove and refit -
• Engine NVH cover, HPP and
• Timing cover assembly.
• Engine coolant from Radiator
& Engine block.
Removal Steps –
1. Oil filler cap and bracket.
2. Oil filler neck/ hose.
3. Heat shield – Oil separator.
4. Oil Separator.
5. Cam phase sensor.
6. Vacuum Pump assembly.
7. High Pressure Fuel pump
assembly.
Sealant application pattern - Torque Sequence –
Description
A. Exhaust Camshaft
B. Intake Camshaft
C. Exhaust Camshaft Gear
D. Intake Camshaft Gear and Sprocket
E. Gear mounting Bolts
The camshaft controls the valve opening and closing events. It is driven by the crankshaft through a
chain connection. The intake camshaft has sprocket and it is directly driven by chain from crankshaft
and the exhaust camshaft is driven by gear. The camshaft rotates at half the speed of the crankshaft to
maintain proper timing of the four cycle of combustion. The opening and closing of the valves are done
by lobes on the camshaft. The engine has two camshafts one for operating intake valves and the other
for exhaust. The exhaust camshaft is identified by the presence of a ring for the purpose of operating a
cam phase sensor.
The timing of the valve depends on the position of the camshaft and shape of the lobes on it.
The valve lift is the distance the valve is lifted off its seat when fully opened. This is determined by the
height of the cam lobe. The valve need enough lift to allow air to flow freely into the cylinder and for
exhaust gases to flow out of the cylinder, without interfering with piston or binding the spring.
The duration is the length of time the cam lobe keeps the valve open. it is measured in degrees of
camshaft rotation and is determined by the shape of the cam lobe.
Removal
Disconnect the engine wiring harness electrical

connectors from the engine.
Remove the fuel suction and return hose to HPP.
Remove the fuel injectors from the cylinder head

assembly.
Remove the oil filler adaptor from cam cover

assembly.
Remove the intake manifold and intake pipe

assembly.
Remove the intake manifold gasket carefully.
Remove the two 10mm mounting bolts on heat

shield from oil separator assembly.
Remove the six 12mm the oil separator mounting

bolts and oil filling neck mounting bolt and cam
phase sensor.
Remove the fuel rail unit from the cylinder head

assembly.
Remove the cam phase sensor.
Handle the cam phase sensor carefully such that

it is not damaged during the removal and
installation.
Remove vacuum pump assembly.
Remove the HP Pump assembly.
Remove the timing cover, timing chain and

sprocket from the engine assembly.
Remove the twenty six 10mm cam cover

mounting bolts as per the recommended
sequence and remove the cam cover.
Remove both the inlet and exhaust cam shafts

from the cylinder head assembly.
Cam shafts should not be interchanged during

the removal. Exhaust camshaft has the trigger
wheel for the cam phase sensor mounted on it.
Inspection
Check the inlet camshaft and the exhaust

camshaft for any damage and replace it if
necessary.
Check the camshaft cover bearing for any

scoring mark, crack or scratches.
Installation
Check and confirm the TDC Position of the piston for cylinder-1 before installation, in case the same
was not followed while removing the timing chain.
Cam shafts should not be interchanged during the installation. Exhaust camshaft has the trigger
wheel for the cam phase sensor mounted on it.
Check and ensure proper fitment of all HLA

assemblies.
Install both the cam shafts on the cylinder head

assembly.
Ensure that lobs are facing in upward direction.
Apply sealant (Locktite 5900) on the cylinder

head. (Refer sealant application pattern in RM)
Align and fit the camshaft lock tool on the rear

side.
Fix the tool on cylinder head using two

mounting bolts.
Assemble cam cover over camshafts.
Tight the mounting bolts to the recommended

torque values following tightening sequence.
Refer below schematic for Camshafts and Chain assembly -
Insert TDC position lock pin in crankshaft.
NOTE:
Rotate the engine in such a way that the 1st

piston should be at 90 dg. ATDC and Crankshaft
key comes at 3 O’ Clock position.
Assemble the cam sprocket and chain assembly

along with hydraulic tensioner.
Assemble the inlet cam sprocket and gear; and

exhaust cam gear along with mounting bolts.
Ensure to assemble diamond washers.
Friction washer can be used multiple times provided that the set of parts is same.
Inlet camshaft has sprocket and gear

assembled on front.
Exhaust camshaft has gear fitted on front

which is driven by inlet camshaft gear.
Refer illustration for cross section of Inlet

camshaft sprocket and Gear.
Diamond washer to be assembled along with

sprocket and gear.
Assemble the crankshaft locking tool;
Assemble the crankshaft lock tool with the help

of mounting bolt on cylinder block.
Tighten the camshaft gear mounting bolts.
Turn and hold the intake camshaft gear against

the tightening direction with the help of the
tool as shown in the illustration and tighten the
bolt of intake camshaft gear to the specified
torque.
TITLE: ENGINE CHAIN TIMING
Remove –
 Camshaft holding tool.
 The camshaft locking tool mounted on cylinder head back.
 Crankshaft locking tool.
• Assemble the front cover and assemble the bolts. Tighten the front cover bolts to the specified
torque with following the specified sequence.
• Assemble the flywheel. Torques tightens the flywheel bolts following the specified sequence.
• Remove the crankshaft TDC locating pin from the block.
• Fit the damper pulley and tighten the bolt to the specified torque.
Refer illustration for High Pressure Fuel pump and Vacuum Pump installation –
Install the vacuum pump assembly.
Install the HP Pump assembly.
Install the fuel injector assemblies.
Install the fuel rail unit with the cylinder head

assembly.
Install fuel HP pipes between Injector & Common

Rail and CR to HPP.
Install the Oil separator assembly.
Install the Intake manifold assembly.
Install oil filler hose adaptor
Install the Intake manifold, intake pipe assembly.
Install the Turbocharger assembly.
Install Oil filler neck and bracket.
Install the six 12mm the oil separator mounting

bolts and oil filling neck mounting bolt and cam
phase sensor.
Use only the recommended sealant, failure to follow the instruction may lead to leakages. While
tightening the oil separator mounting bolts follow torque sequence as shown in the illustration.
Apply loctite 5900 to the timing cover.

Hydraulic Lash Adjuster (HLA)

Removal
Remove the camshafts from the engine. For additional information refer to Camshaft removal and
Carefully lift the hydraulic lash adjuster from the
cylinder head assembly and place them safely in a
oil filled container.
Hydraulic lash adjuster should be kept in straight

upward position in an engine oil filled container
only.
Inspection
Check the HLA for any damage, and replace it if

necessary.
Do not disassemble the HLA, as it is not a

serviceable component. In case of a failure of a
HLA, replace the complete assembly.
Installation
Install the hydraulic lash adjuster into the cylinder

head assembly and properly align them.
Hydraulic lash adjuster should be kept in straight upward position in the cylinder head.
Install the camshafts to the engine. For additional information refer to Camshaft removal and
Cylinder Head and Gasket

Removal
Pre removal and Post

Installation –
Remove and refit -
• Engine NVH cover, HPP
and bottom
encapsulation.
• Timing cover assembly.
• Engine coolant from
Radiator & Engine block.
Removal Steps –
1. Oil filler cap and bracket.
2. Oil filler neck/ hose.
3. Heat shield – Oil
separator.
4. Oil Separator.
5. Cam phase sensor.
6. Vacuum Pump assembly.
7. High Pressure Fuel pump
assembly.
8. Cam cover assembly
9. Coolant outlet elbow
10. Cylinder head assembly
11. Cylinder head gasket
(Refer Timing cover and
chain assembly removal
section separately)
Sealant appln. pattern (Cy. Head to Cam cover)- Torque Sequence –
Description
The cylinder head is bolted on top of the cylinder block with the help of cylinder head gasket.
The cylinder head:
• Seals the top of the cylinder block.

• Holds the fuel common rail and injectors.
• Provides seats, guides and ports for the intake and exhaust valves.
• Holds the valve train.
• Provides mountings for the intake and exhaust manifold.
The intake and exhaust manifolds are mounted to the cylinder head against the valve ports. The top
part of the cylinder head is designed such that the rocker arm and other parts of the valve train can be
mounted on it. The aluminum alloy gives the head superior heat dissipating capability to that of the cast
iron head. The coolant and oil passages are incorporated in the head for cooling and lubrication
purposes.
The cylinder head gasket forms the gas and watertight junction between the cylinder head and block. It
also offsets
Removal
Remove the HLAs from the engine. For additional information refer to Hydraulic Lash Adjuster (HLA)
removal and installation section.
Loosen the Eight 15mm cylinder head mounting
bolts as per the sequence and remove them.
Firmly hold the cylinder head assembly and

carefully remove the cylinder head assembly.
Remove the cylinder head gasket from the engine

block.
Inspection
Clean the cylinder head assemblies thoroughly, if any cracks or damages are found replace the
cylinder head.
Check the Cylinder Head for external damages.
Check the cylinder head height and if not meeting

the specified value, replace the cylinder head
assembly.
Check the cylinder head flatness, if any

misalignment or bend found replace the cylinder
head assembly.
Check the Cylinder Head bottom face for

distortion.
Check the cylinder head for war page.
Check the length of the Cylinder Head bolts.
Replace bolts if it is out of service limit.
Check the valve seat area for leakages.
Installation
Clean the cylinder head assemblies thoroughly, if any cracks or damages are found replace the
cylinder head.
Replace the cylinder head gasket to the engine
block.
Replace the cylinder head gasket with a new one. Failure to follow this will lead to compression
failure.
The cylinder head mounting bolts cannot be reused.
Hold the cylinder head assembly and carefully
place it on the engine block.
Tighten the Eight 15mm cylinder head mounting

bolts as per the recommended sequence.
Install the HLA. For additional information refer to Hydraulic Lash Adjuster (HLA) removal and
Intake Manifold
Removal

• NVH Cover and engine top encapsulation.
• Intercooler assembly.
• Remove battery terminals and Battery.
• Drain radiator coolant and refill.
• Coolant hoses.
• EGR Valve, vacuum hose, and EGR pipe.
Removal Steps – Torque Sequence -

1. Coolant temp sensor and
WH connector.
2. Coolant elbow pipe.
3. Coolant elbow pipe seal.
4. Intake pipe assy.
5. Intake pipe gasket.
6. Intake manifold assembly.
7. Intake manifold gasket.
Removal
Remove the engine from the vehicle and place it on work bench. For additional information refer to
Engine removal and installation section.
Remove the High Pressure Pump (HPP). For additional information refer to High Pressure Pump (HPP)
Remove a 12mm mounting bolt and a 17mm
mounting nut from the oil dipstick pipe.
Using a 6mm allen key, remove the two EGR

cooler inlet pipe mounting bolts from the inlet
manifold and detach the EGR cooler inlet pipe.
Remove four 12mm mounting bolts from the inlet

manifold top pipe.
NOTE:
Intake pipe can also be removed along with intake
manifold.
Press the lock and pull out the thermostat hose

from the coolant outlet pipe.
Press the lock and pull out the electrical connector

from the engine coolant temperature sensor.
Remove the 12mm coolant outlet pipe top

mounting bolt and using a 6mm allen key remove
two coolant outlet pipe bottom mounting bolts,
and detach the coolant outlet pipe.
Press the lock and disconnect the inlet and outlet

oil cooler hoses from the oil cooler.
Using a suitable oil filter wrench, remove the oil

filter, and remove the three oil cooler mounting
bolts from the crankcase.
Remove seven 12mm inlet manifold mounting

bolts from the cylinder head.
Detach the inlet manifold from the cylinder head.
Inspection
Check for any physical damages to the intake manifold.
Installation
1. To install, reverse the removal procedure.
Replace the gaskets to the intake manifold whenever removed from the engine.
2. Tighten all bolts to the specified torque. For additional information refer to Torque Sequence
Section.
3. Refill the coolant. For additional information refer to Engine Coolant Replacement/Filling and
Bleeding Procedure: Section.
Oil Sump
Removal

• NVH Cover and engine top
encapsulation.
• Engine Bottom encapsulation.
• Engine Oil drain and refill.
• Transmission assembly.
• Clutch plate assembly.
• Flywheel assembly.
• Oil sump Sealant application.
Removal Steps –
1. Remove Oil refill cap.
2. Place oil collecting tray and
remove Oil drain plug.
3. Dip stick and dip stick guide.
4. Oil sump assembly.
Torque Sequence - Sealant Application Pattern -
Removal
Disconnect the negative terminal of the battery. For additional information refer to Battery removal
and installation section.
Lift the vehicle. For additional information refer to Jacking and Lifting Section.
Remove the oil dipstick from the engine and place it aside.
Drain the engine oil. For additional information refer to Engine Oil Draining Procedure Section.
Remove the dipstick and the 12mm two nos. dip

stick guide bracket mounting bolts.
Remove the 17mm mounting lock nut of the oil

dipstick pipe and keep the oil dipstick pipe aside.
Oil sump can be removed when engine is on vehicle. In that case it is necessary to remove
Transmission assembly before removal of oil sump.
Below procedure given when engine is installed on mounting stand.
Remove the 14mm and 13mm mounting bolts on

the oil sump.
Detach the oil sump along with the strainer.
Carefully pull out the oil pan and make sure that oil
pan seating area is not disturbed. If any damage
occurs to oil pan seating area, it will lead to oil
leakage.
Inspection
Visually inspect oil pan for crack or damage.
Installation
• Clean the oil pan mounting edge and cylinder block edge before applying the loctite.
• Replace with new drain plug washer to avoid oil leakages.
• Apply the loctite to the oil pan. For additional information refer to Sealant Application Pattern
Section.
• Tighten the engine oil drain plug bolt to the specified torque.
• Tighten all the bolts to the specified torque. For additional information refer to Torque
Sequence Section.
• Refill the engine oil. For additional information refer to Engine oil filling procedure Section.
Oil Strainer
Removal
Remove the oil pan. For additional information refer to Oil Pan/Oil Sump removal and installation
section.
Remove the two 12mm oil sump strainer
mounting bolts to the oil pan.
Pull out the oil sump strainer from the oil sump.
Pull out the oil sump strainer ‘O’ rings.
Inspection
Check the oil sump strainer filter for blockages.
Installation
Replace with new strainer pipe O-ring.
To install, reverse the removal procedure.

Tighten the oil sump strainer mounting bolts to the specified torque.
Vacuum Pump
Removal
Remove the intercooler. For additional information refer to Intercooler removal and installation
section.
Remove the EGR inlet and outlet pipe. For additional information refer to EGR Short Pipe removal and
installation section. For additional information refer to EGR Long pipe removal and installation
section.
Don’t disconnect the EGR coolant inlet and outlet hoses, it will lead to coolant loss.
Disconnect the vacuum hose from the vacuum

pump.
Remove the two 12mm vacuum pump mounting

bolts and detach the vacuum pump.
Inspection
• Visually check the vacuum pump for any cracks or damage.
• Check the vacuum pump teeth for any worn out or damage.
Installation
Match the vacuum pump teeth with the camshaft

groove.
To install, reverse the removal procedure.
Replace with the new vacuum pump O-ring.
Apply the loctite to the vacuum pump. For additional information refer to Sealant Application Pattern
Section.
Tighten all the bolts to the specified torque.
Exhaust manifold and Turbocharger

Removal

• Air filter & Intercooler assembly.
• Engine Oil level and leak check and
top up if required.
Torque Sequence -
Removal Steps –
1. Low pressure TC oil inlet banjo on
TC and block.
2. High Pressure TC oil inlet banjo on
TC and block.
3. Low pressure TC oil outlet pipe.
4. High Pressure TC oil outlet pipe.
5. TC Mounting bracket on block.
6. Exhaust manifold mounting nuts.
Remove TC compressor inlet hose.
Remove Vacuum hose connected on

Turbocharger.
Remove TC compressor outlet hose.
Remove Turbocharger mounting bracket bolts

on block.
Remove both Oil inlet pipe with all four banjo

bolts on TC and block.
Remove both Oil outlet banjos on block.
Remove both oil outlet pipes from Turbocharger.
Remove the TC mounting bracket bolts on block.
Remove the exhaust pipe connected on

Turbocharger.
Remove Exhaust manifold mounting nuts.
Use anti rust liquid spray in case exhaust

manifold mounting nuts are too jams. Stud may
get brake if tight nuts removal attempt without
using anti-rust spray.
Installation
Assembly is in reverse to the dismantling.
Do not use liquid gasket/ sealant to the TC oil outlet pipes.

Replace oil inlet banjo and outlet pipe gaskets during every time while installation.
Start the engine and check for oil leakages,

arrest it if observed any leakage.
Check exhaust gas and air leakages if any.
Check rubber hoses for crack, leak if any.
TITLE: TWIN TURBO
Disassembly and Assembly - Engine

Disassembly
Remove the engine assembly from the vehicle. For additional information refer to Engine removal and
Install the engine to the mounting stand.
Disconnect all engine wiring harness electrical
connectors and detach the wiring harness.
Open the engine oil refilling cap.
Place oil collecting tray below and remove the

22mm engine oil drain plug bolt from the oil
sump and drain the engine oil.
Remove the drive belt from the engine. For additional information refer to Accessory Drive Belt
Remove the drive belt tensioner from the engine. For additional information refer to Drive Belt /Pulley
Auto Tensioner removal and installation section.
Remove the first and second drive belt and auto tensioner from the engine. For additional information
refer to removal and installation section.
Remove the two 12mm alternator mounting bolts
and nuts and detach the alternator assembly.
Remove the two 12mm power steering pump

mounting bolts and nuts and detach the power
steering pump.
Loosen 12mm bolt and remove TDC sensor from

cylinder block.
NOTE:
Sensor to be handled carefully, do not drop it can

get damaged.
Remove the alternator steering pump mounting

bracket from block.
Remove the four 12mm AC compressor mounting

bolts and carefully place the AC compressor in
secured place.
Remove the fuel inlet and outlet couplers from

the HPP.
Remove the fuel return hose.
Remove the 12mm top mounting bolt and 17mm

bottom oil dipstick pipe mounting locknut from
the oil dipstick fuel pipe, and detach the oil
dipstick pipe.
Press the lock and remove the oil cooler inlet and
outlet hoses from the oil cooler and crankcase.
Using a suitable oil filter wrench, remove the oil

filter and remove the three oil cooler mounting
Remove coolant temperature sensor from coolant

elbow on block.
NOTE:
All sensors to be handled carefully, do not drop

the sensor it can get damage.
Remove the two 6mm mounting bolts from the

coolant outlet pipe, and detach the coolant outlet
pipe.
Remove the two allen key EGR pipe mounting bolt

from the inlet manifold, and detach the EGR pipe.
Remove the two bolts from EGR cooler and one

bolt from intake manifold for removing the EGR
pipe.
Remove the two 12mm coolant bypass mounting

Remove the 14mm fuel outlet pipe locknut and

10mm pipe bracket mounting bolt and remove
the 17mm fuel rail pipe mounting locknut.
Remove the four 12mm top air intake pipe

mounting bolt from the inlet manifold.
Remove the seven 12mm inlet manifold mounting

bolts and detach the inlet manifold from the
cylinder head.
Remove the four 14mm front AC compressor

bracket mounting bolts from the crankcase.
Remove the 17mm fuel rail outlet pipe locknuts

14mm injector inlet pipe locknuts and two 12mm
fuel rail mounting bolts and detach the fuel rail
and pipes.
Remove the three 14mm injector bracket locknuts

and detach the injector brackets.
Using injector removal tool, remove the three

injectors from the cylinder head, carefully detach
the injectors.
Remove the 13mm catalytic converter mounting

bolt from the catalytic converter bracket, and
detach the catalytic converter.
Remove the 14mm turbocharger oil inlet pipe

banjo bolt.
Remove the 14mm turbocharger oil inlet pipe

mounting banjo bolt and 12mm turbocharger oil
inlet pipe bracket mounting bolt and detach the
inlet pipe.
Remove the 12mm mounting bolt and two 12mm

mounting nuts from the turbocharger.
Remove the timing chain and sprocket. For additional information refer to Timing Chain and Sprockets
Remove the camshaft. For additional information refer to Camshaft removal and installation section.
Remove the hydraulic lasher adjuster. For additional information refer to Hydraulic Lash Adjuster
(HLA) removal and installation section.
Remove the cylinder head assembly. For additional information refer to Cylinder Head removal and
Remove the flywheel to the crankshaft. For additional information refer to Flywheel removal and
Remove the oil pan mounting bolt and detach the

oil pan from the crankcase.
Remove the eight 10mm connecting rod cap

mounting bolts from the crankcase.
Using a mallet hammer, carefully tap the

connecting rod, and remove the connecting rod
with piston.

• Engine coolant drain and refill;
• Engine oil drain and refill.
• AC gas purging and refill.
Follow given procedure for all
types of fluid & lubricants refill.
encapsulation.
• Cooling fan and shroud assembly.
• Engine WH connectors all.
• Front grill and body cross
member.
• Engine assembly.
Removal Steps –
1. Connecting rod big end bearing
mounting bolts.
2. Con rod big cap – crankshaft end.
3. Con rod big end cap – con rod end.
4. Piston ring - first.
5. Piston ring – second.
6. Oil scraper ring.
7. Piston pin circlip.
8. Piston pin.
9. Connecting rod small end bush.
10. Piston.
11. Connecting rod.
Remove the rear oil seal retainer seven nos.

12mm mounting bolts.
Remove the eight 15mmcrankshaft mounting bolt

and detach the crankshaft from block.
Mark the shell bearing.
Remove the shell bearing and thrust washer from

the crankshaft.
Lift and remove the crankshaft assembly.
Remove the four 10mm oil spray jet mounting

Mark the shell bearing.
Remove the shell bearings from the cylinder block.
Mark the thrust washer inner and outer and

detach the thrust washers from the crankcase.
Remove engine mounting brackets LH and RH side

from block by removing 16mm four mounting
bolts from each bracket.
Remove the oil cooler mounting body by

removing three 12mm mounting bolts.
Using 5mm allen key, remove the three crankshaft

TDC sprocket mounting bolts and detach the TDC
sprocket.
Engine Component Inspection
Clean the mating faces of the cylinder head and cylinder block with the suitable metal surface cleaner
except cylinder bore and piston.
All the components should be inspected for wear. Any components, which are beyond the wear limits,
have to be replaced Over and above the wear limits: The following points also need to be ensured.
Bearing Inspection
Inspect Bearing for the following defects
A. Cratering - fatigue failure
B. Spot polishing - incorrect seating
C. Imbedded dirt engine oil
D. Scratching - dirty engine oil
E. Based exposed - poor lubrication
F. Both edges worn - journal damaged
G. One edge worn - journal tapered or bearing
not seated
H. Tin coating - bearing excessive wear
Main bearing and connecting rod bearing —

If the scoring is nominal and oil clearance is not affected, then it can be reused. However if flaking
/peeling of the bimetal in any particular zone only is present then use new shell. Look for foreign
particle embedded, deep scratches.
Bearing shells:
The bearing shells are marked with Red and Yellow paint mark according to the clearances. The
bearing shells need a selective assembly for optimum performance of the engine. While dismantling
when the shells are removed from the Cylinder Block as well as the Bed Plate; please note the colour
and while assembly the bearing shells marked with same colors are to be fitted at the respective
position.
Before fitting the bearing shell ensure that the parent bore of the block/connecting rod are clean.
Wipe with a clean cloth the back end of shells before assembling on to the block or connecting rod.
Ensure that the bearing shells are located properly in the notches.
Camshaft Bearing Journal Diameter

• Using a micrometer measure the diameter
at 90 degrees intervals to determine if the
journals are out-of-round.
• Measure at two different points on the
journal to determine if there is any
tapering.
• If the measurements are out of the
specified range, install a new camshaft.
Crankshaft End Play Inspection
• Place the dial indicator and bracket.
• Determine the end float by raising the

crankshaft with the aid of a screw driver.
Cylinder Bore Taper Check

1. Measure the cylinder bore with an internal micrometer.
• Carry out the measurements in different directions and at different heights to determine if
there is any out-of-roundness or tapering
• If the measurement is out of the specified range, install a new block or hone out the cylinder
block.
• Any scoring on the parent bore is not acceptable.
Piston Diameter
• Using a Micrometer measure the piston

Diameter.
Piston Inspection
• Clean the piston skirt, pin bush, ring
grooves and crown and check for wear or
cracks.
• If there are signs of wear on the piston skirt,

check whether the connecting rod is
twisted or bent.
Do not use any aggressive cleaning fluid or a wire brush to clean the piston.
Piston: Check for scuffing/scoring on the skirt. A hard thick layer of carbon lacquer on top land is
acceptable. (If the thick layer is present on the piston check that the liner does not have scuffing).
However scuffing of the top land and skirt giving indication of overheating which is not acceptable.
Piston Ring End Gap
• Take the piston ring and use a piston

without rings to push the piston ring about
xx mm into the cylinder bore.
Do not mix up the piston rings. Install the piston rings in the same position and location.
Piston and Rings

While fitting the piston rings ensure that the rings end gap are staggered in 120 dg.
The first ring end gap should not be on the thrust axis but the minor axis i.e. on the gudgeon pin axis.
Note that the first ring is keystone shaped hence the top mark has to face up. The 2nd ring is taper
faced, the face which should be on the top, has to be facing up. The 3rd 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.
Piston Ring-to-Groove Clearance
The piston ring must protrude from the piston

groove. To determine the piston ring clearance,
insert the feeler gauge right to the back of the
groove, behind the wear ridge.
• Using feeler gauge, measure the piston ring

clearance.
Valve Seat Inspection
• Measure the valve seat width using the

valve seat width scale.
• If the values are not to specification rework
the valve seat.
Valve Stem Diameter
• Using a micrometer measures the diameter

of the valve stems.
• If the measurements are not to

specification, install a new valve.
Valve: If valve tip is worn out/ ridged then not

acceptable.
Crankshaft
Check for scoring on the main as well as

connecting rod journal. If scoring is nominal and
will not the increase the oil clearance then the
crankshaft can be used in, as it is condition.
However if it is unacceptable then the journal has to be ground up to service limits only. Any deep
groove in the rear end oil seal seating area is unacceptable. It will result in oil leaks.
Dampener pulley rubber bonding – Inspect for any gap between the rubber ring and the outer/inner
ring, Cracks on ring. Any deep groove in the front oil seal seating area is unacceptable. It will lead to
leakages.
If any deterioration of rubber or gap noticed between the ring and the rubber replace the dampener
pulley.
• While measuring the inner diameter of the connecting rod big end and main journal please take
the measurements after torque tightening only. For measurement purpose the torque should be
35±3 Nm +60 dg. Do not reuse this bolt.
• If line boring of the crankshafts journal in the block is done to rectify any ovality. Then please
ensure that the material from block half is not removed. In absence of taking this precaution the
piston will move up. It will change the compression, influencing the performance. In the worst
case the valves can hit the piston.
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.
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 torques. The angular torques
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 - 08 nos. - Length 138mm

Main Bearing Bolts - 08 nos. - Length 103mm
Connecting Rod Bolts - 06 nos. - Replace Every Time
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.
Oil Seals
Ensure that
• All the oil seals are fitted using the dolly MST.
• Always ensure that the lip is coated with grease before fitment.
• Apply engine oil on the outside diameter of seal. The receiving bore should be free of burrs,
dent.
Inspection Point
1. Clean the carbon deposits on the piston, cylinder block, crankshaft, connecting rods, connecting
rod bearing shell, crankshaft bearing shell and bedplate.
2. Blow the air to all cleaned components of the engine and wipe it with a clean rag.
3. Check the engine cylinder block thoroughly for any sign of crack and bend. Repair or replace, if
it is beyond the permissible limit.
4. Check and clean lubrication oil galley holes on the cylinder block.
5. Check the engine cylinder bore thoroughly for any sign of scores and scratches.
Inner diameter of cylinder bore should be verified carefully by using the inside vernier caliper or
micrometer caliper.
6. Check the crankshaft thoroughly for bend or crack, and then replace it if necessary.
7. Check the connecting rod thoroughly for any bend, and replace it if necessary.
8. Check the connecting rod bearing shells and crankshaft bearing shells for scratches, wear and
tear, and replace it if necessary.
9. Check the piston for any scratches, scores and damage, and replace it if necessary.
10. Check the piston rings thoroughly for any damage, and replace it if necessary.
11. Check the thrust washers for bend, damage, wear and tear, and replace it if necessary.
12. Check the engine block bedplate for any scratches, score, dent, bend or damage. Remove the
restriction in the oil strainer, and replace it if necessary.
13. Check the oil strainer for any restriction during oil flow, and remove the restriction in the oil
strainer and replace it if necessary.
ENGINE
Assembly
Attach the crankcase to the engine mounting stand.
Clean the mating faces of the cylinder head and cylinder block with suitable metal surface cleaner
except cylinder bore and piston.
Install the four 10mm oil spray jet mounting bolts
from the crankcase.
Place the inner and outer thrust washer into the

crankcase.
Install the inner crankshaft bearings shells into the

crankcase in correct order.
Clean the engine block thoroughly before assembling the bearing shells, wipe the front and back ends
of the shells with a clean cloth. Ensure that the bearing shells are located properly in the notches.
Install the TDC sprocket to the crankshaft and by
using a 6mm allen key, tighten the TDC sprocket
allen bolts.
Carefully place the Crankshaft TDC sprocket without any damage to the sprocket teeth which may
cause engine starting problems.
Coat the crankshaft main bearing journal and the
crankshaft bearing shells with the recommended
engine oil.
Install the crankshaft assembly to the crankcase.
Keep the crankshaft and crankshaft bearing shells in its notches according to the installation.
Install the piston rings on the piston and adjust

the ring end gap. Insert the piston in the piston
ring compressor and close the piston rings.
While fitting the piston rings ensure that the rings end gap is spread out at an angle of 120 dg. The
top mark of the first ring should face upwards. The tapered face of the second ring should be on the
top. The third ring or oil ring can be fitted in either way.
Before assembling, adequately lubricate the

piston, cylinder walls and connecting rod bearing
shells with clean oil.
Post Installation –
• Engine coolant drain and refill;
• Engine oil drain and refill.
• AC gas purging and refill.
Follow given procedure for all
types of fluid & lubricants refill.
encapsulation.
• Cooling fan and shroud assembly.
• Engine WH connectors all.
• Front grill and body cross
member.
• Engine assembly.
Assembly Steps –
1. Connecting rod.
2. Piston.
3. Connecting rod small end bush.
4. Piston pin.
5. Piston pin circlip.
6. Oil scraper ring.
7. Piston ring – second.
8. Piston ring - first.
9. Con rod big end cap – con rod
end.
10. Con rod big cap – crankshaft
end.
11. Connecting rod big end bearing
mounting bolts.
Using the piston ring compressor, tighten piston
rings to ensure easy entry of the piston into the
cylinder block.
Using a mallet hammer, carefully tap the

connecting rod and push the piston inside the
cylinder and observe the correct position, marking
and direction to the crankshaft.
Place the pistons to their respective cylinders. To avoid crankshaft damage do not interchange the
connecting rod shell bearing and connecting rod cap.
While removing and installing the connecting rod along with piston, carry out necessary actions to
avoid the damage to the oil spray nozzle of the cylinder block.
Before assembling, adequately lubricate the piston, cylinder walls and connecting rod bearing shells
with clean oil.
Assemble the crankshaft main bearing shell and

thrust washers on block.

bearing shells and thrust washer.
Assemble the crankshaft on the cylinder block.
Assemble the main bearings, cap end.

bearing shells and thrust washer.
Assemble the crankshaft main bearing and caps.
Check for free rotation of assembled crankshaft

shaft by hand.
Position the connecting rod in the crankshaft and

install the connecting rod caps. Using a 10mm star
socket and wrench, tighten the connecting rod
cap mounting bolts to specified torque.
Lubricate the connecting rod caps before tightening the caps.

Assemble the rear oil seal retainer plate.
Follow torque sequence while tightening

mounting bolts.
Install the strainer in the oil pan. By using a 15mm

socket and wrench set, tighten the mounting bolts
of the strainer to specified torque.
Apply Loctite 574 to the oil sump and install the

oil pan on the engine block. Using a 12mm socket
and wrench set, tighten the oil sump mounting
bolts to specified torque.
Refer sealant application pattern for more details.
Use only recommended sealant to avoid leakages. While tightening the bed plate mounting bolts
follow torque sequence as shown in the illustration.
Install the engine oil drain plug in oil sump and

tighten to the specified torque.
Install the new oil seal on the crankshaft rear oil
seal installer tool and fix the oil seal installer on the
crankshaft rear end.
Using the rear oil seal pressing dolly (Special Tool
No: 0301BM007ST) install the oil seal till the oil
seal is completely seated.
Replace the cylinder head gasket to the engine

block.
Place the cylinder head gasket to the provided markings.
Install the cylinder head to the cylinder block. For additional information refer to Cylinder Head
Section.
Install the hydraulic lasher adjuster. For additional information refer to Hydraulic Lash Adjuster (HLA)
Install the camshaft, gears and do timing setting using engine chain timing special tool kit. For
additional information refer to Camshaft removal and installation section.
Install the timing chain and sprocket. For additional information refer to Timing Chain and Sprockets
Install timing cover assembly. For additional information refer to Timing Cover installation section.
Install the flywheel. For additional information refer to Flywheel removal and installation section.
Install the 12mm mounting bolt and two 12mm

mounting nuts to the turbocharger.
Install the 14mm turbocharger oil inlet pipe

banjo bolt.
Install the 14mm turbocharger oil inlet pipe

mounting banjo bolt and 12mm turbocharger oil
inlet pipe bracket mounting bolt, and detach the
inlet pipe.
Install all the three injectors to the cylinder head

carefully.
Install the four 14mm injector bracket locknuts

and torque tightens the injector brackets nuts.
Install the 17mm fuel rail outlet pipe locknuts,

14mm injector inlet pipe locknuts and two 12mm
fuel rail mounting bolts and install the fuel rail
and pipes.
Install the 10mm crankshaft position sensor

mounting bolts and install the crankshaft position
sensor.
Install the four 14mm front AC compressor

bracket mounting bolts to the crankcase.
Install the four mounting bolts on the steering

pump mounting bracket to the engine block.
Install the crankshaft TDC position sensor to the

block.
Install the nine 12mm inlet manifold mounting

bolts and install the inlet manifold to the cylinder
head.
Install the 14mm fuel outlet pipe locknut and

10mm pipe bracket mounting bolt and install the
17mm fuel rail pipe mounting locknut.
Install the two 12mm coolant bypass mounting

Install the two bolts from EGR cooler and one

bolt from intake manifold for removing the EGR
pipe.
Install the two allen key EGR pipe mounting bolt

from the inlet manifold, and detach the EGR pipe
Using allen key, install the 12mm top mounting

bolt and two 6mm mounting bolts to the coolant
outlet pipe, and install the coolant outlet pipe..
Using a suitable oil filter wrench, install the oil

filter and install the three oil cooler mounting
bolts to the crankcase.
Press the lock and install the oil cooler inlet and
outlet hoses to the oil cooler and crankcase.
Install the 12mm top mounting bolt and 17mm

bottom oil dipstick pipe mounting locknut to the
oil dipstick fuel pipe, and install the oil dipstick
pipe.
Install the fuel inlet and outlet couplers to the

HPP.
Install the four 12mm AC compressor mounting

bolts and carefully install the AC compressor.
Install the two 12mm power steering pump

mounting bolts and nuts and install the power
steering pump.
Install the two 12mm alternator mounting bolts

and nuts and install the alternator assembly.
Remove the 13mm catalytic converter mounting

bolt from the catalytic converter bracket, and
detach the catalytic converter.
Install the front cover oil seal with the help of

dolly.
Refer to the Front Oil seal installation section.
Assembled the damper pulley to the crankshaft.
Lock the crankshaft with the help of locking tool

and applying specified torque.
Assemble the Oil separator to the cam cover.
Apply sealant to the oil separator, refer sealant

application profile.
Assemble the heat shield to the oil separator.
Install the drive belt tensioner to the engine. For additional information refer to Drive Belt /Pulley
Auto Tensioner removal and installation section.
Install the first and second drive belts to the engine. For additional information refer to removal and
Assemble the clutch housing bolts to the engine.
Connect all wiring harness electrical connectors

on engine and install the wiring harness.
Cylinder Head
Disassembly
Remove the cylinder head from the engine. For additional information refer to Cylinder Head removal
and installation section.
Using a suitable tool, remove the valve spring
locks.
Remove the retainer and upper valve spring.
Remove the valve spring along with its seating

washer.
Remove the inlet and exhaust valves and place

them in the respective cylinder.
Using a suitable tool, remove the valve stem seal.
Extreme care should be taken while removing Valve stem. Failure to follow may lead to cylinder head
damage.
Using a suitable tool, remove the valve stem from
the cylinder head.
Inspection
Check the valve spring height.
Check the valve stem height.
• Check the valve spring lock for any internal and external damage.
• Check the valve and valve stem for any damages.
Assembly
Using the suitable tool, install the valve stem.
Extreme care should be taken while installing Valve stem. Failure to follow may lead to cylinder head
damage.
Using the suitable tool, install the valve stem seal.
Install the inlet and exhaust valves in the

respective cylinder valve stem.
In case of reusing the same valves again, make

necessary marking according to the respective
cylinder.
Install the valve spring bottom retainer to the

cylinder head.
Install the upper valve spring with retaine.
Using a suitable tool, compress the valve spring

and lock it properly in its position.
Sealant Application Pattern

1. Sealant Application Pattern on Oil Sump
2. Sealant Application Pattern on Cam Cover to Cylinder Head
3. Sealant Application Pattern on Front Cover
4. Sealant Application Pattern on Cylinder Head to Camshaft
5. Sealant Application Pattern on Vacuum pump
6. Sealant Application Pattern on Oil Separator
7. Sealant Application Pattern on Rear Oil Seal Retainer Plate
8. Sealant Application Pattern on HP Fuel Pump
Torque Specification
Description Torque Value (Nm)

CYLINDER HEAD
CYLINDER HEAD BOLTS 65 ± 3Nm + 2x90°
TAPER PLUG M10 11±1
HLA OIL GALLERY PLUG 25 ± 3
BOLT REAR LIFTING HOOK 25 ± 3
JET OLDHAM COUPLING 11±1
BOLT PIPE HEATER INLET 11±1
HEAT SHIELD MTG 11±1
TAPER PLUG M20 19±1
INTERCOOLER BRACKET MTG 25±3
CAMSHAFT AND CAM COVER
CAM SPROCKET MTG BOLTS 45 ± 3 N-m + 2x60°
LH- BOLT CAM GEAR EXHAUST 45 ± 3 N-m + 2x60°
CAM COVER MTG BOLT 11±1
BOLT PHASE SENSOR MTG 11±1
BOLT ADAPTER OIL FILLING 11±1
BREATHER SYSTEM
ASSEMBLY LABYRINTH SEPARATOR 11±1
EXHAUST MANIFOLD
STUD EXHAUST MANIFOLD 25 ±3
CLINTCH NUT EXHAUST MANIFOLD 25 ±3
STUD BOTH END - CATCON 25±3
BOLT EGR COOLER INLET PIPE 25±3
BOLT EGR COOLER 25±3
BOLT EGR COOLER OUTLET PIPE 25±3
BOLT EGR VALVE TO INLET MANIFOLD PIPE 25±3
BOLT TC SUPPORT BRACKET ON BLOCK 25±3
BOLT TC SUPPORT BRACKET TURBO 25±3
BOLT LIFTING HOOK BKT ON TC 11±1
BANJO BOLT AT TURBO OIL INLET 17.5±2
BOLT HOLDER CLIP 11±1
BANJO BOLT TURBO OUTLET 25±3
BOLT OIL LINE TURBO OUTLET LP&HP 11±1
BOLT EGR PIPE SUPPORT BKT 25±3
BOLTS – MTG INTAKE MANIFOLD 25 ± 3
BOLT PIPE CYLINDER WATER OUTLET 25 ± 3
TEMPERATURE WATER SENSOR 25 ± 3
BOLT PIPE INTAKE MANIFOLD 25 ± 3
HIGH PRESSURE FUEL PUMP
BOLTS CP1H PUMP MOUNTING 25 ± 3
BOLTS COMMON RAIL MOUNTING 25 ± 3
HIGH PRESSURE PIPE NUT ON RAIL 22.5±2.5
HIGH PRESSURE PIPE NUT ON INJECTOR 22.5±2.5
HIGH PRESSURE PIPE NUT ON PUMP 20 ±3
INJECTOR CLAMP NUT 32 ±3
INJECTOR CLAMP STUD 25 ±3
CYLINDER BLOCK
MAIN BEARING CAP BOLTS 65 N-m + 2x45°
Bolt piston cooling jet 11±1

PLUG TPR SK MC18X1.5 ST ZN 22.5±2.5
PLUG M16 17.5±2.5
BOLT SPEED SENSOR MTG 11±1
DRAIN PLUG (WATER) 32.5±2.5
BOLT ENGINE MTG. BRACKET 48±3
BOLT REAR OIL SEAL RETAINER 11±1
OIL PRESSURE SWITCH 22.5±2.5
OIL FILTER BRACKET BOLT 25±3
OIL FILTER STUD 35
OIL FILTER CATRIDGE 11±1
FRONT COVER
BOLT FRONT COVER 25±3
BOLT FRONT COVER (M6X1X12) 11±1
PIPE WATER INLET 25±3
WATER PUMP PULLEY 25±3
VACCUM PUMP
SCREW HEX ON COVER AND HEAD 25±3
TIMING SYSTEM
SHOULDER BOLT 25±3
HYDRAULIC TENSIONER BOLT 11±1
POWER TRAIN
BOLT DAMPER PULLEY 150+65°
BOLTS FLYWHEEL 50+60°
BOLT CONNECTING ROD 35±3+60°
OIL SUMP
OIL SUMP MOUNTING BOLTS 25±3
OIL DRAIN PLUG 22.5±2.5
BOLT OIL STRAINER BRACKET 17.5±2.5
ADAPTOR DIPSTICK GUIDE 20±3
DIPSTICK GUIDE NUT 17±2
BOLT DIP STICK GUIDE BRACKET 20±3
FEAD
BOLT ALTERNATOR BRACKET 25±3
BOLT AC COMPRESSOR BRACKET 25±3
BRACE ALTERNATOR BOLT 25±3
ALLEN BOLT FOR TENSIONER 32.5±2.5
BOLT FOR PSP 25±3
BOLT ALLEN TENSIONER ASSY UP SIDE 32.5±2.5
BOLT ALLEN TENSIONER ASSY DOWN SIDE 25±3
BOLT ALTERNATOR 25±3
NUT FO PSP BRACKET 25±3
NUT FOR ALTERNATOR 25±3
Torque Sequence
1. Cam Cover mounting Bolts
2. Front Cover mounting Bolts
3. Oil Sump mounting Bolts
4. Cylinder Head mounting Bolts
5. Intake Manifold mounting Bolts
6. Exhaust Manifold
7. AC Compressor mounting Bolt
8. Oil Separator mounting Bolts
9. Rear Oil Seal Retainer Plate mounting Bolts
Special Tools (MST)
Description / Part No. Sketch
CAM SHAFT LOCK TOOL
CRANKSHAFT LOCKING TOOL
TDC POSITION LOCK PIN
Cam Chain Tensioning Tool
Injector Removal Tool

Mahindra QUANTO Repair Manual Part 1 of 4 MAN 00209 Rev 1 PDF

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Mahindra QUANTO Repair Manual Part 1 of 4 MAN 00209 Rev 1 PDF

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REPAIR MANUAL

TECHNICAL PUBLICATION CELL

Rev1 – SEPTEMBER 2012

• How to use this manual…………………………………………………………………………………………

Engine Chain Timing Procedure (2D Animation)……………………………………………………

Twin Turbocharger Working Principle (2D Animation)………………………………………….

• How to use this manual…………………………………………………………………………………………

Engine Chain Timing Procedure….…………………….........

Working Principle of Twin Turbo Charger…............………

Clutch System Air Bleeding………………….…………………

Wheel Alignment Procedure ……….................................…

Brake System Air Bleeding………….……….…………………

Parking Brake Check and Adjustment…………….………….

DAB and Clock Spring Removal……………………...……..

Head Lamp Alignment..………..……………………………..

• Description section gives an overview of the functioning of the system.

It is suggested to play these Animations in Adobe 9 reader and above version.

Animation SOP Title

2D Animation Play Screen Area Standard Procedure Step Display Area

Air Conditioning Refrigerant

Adhesives and Sealers

Corrosion Protection Materials

Fuel Handling Precautions

Fuel Tank Repair

To avoid severe burns:

Guidance to safe working

Preparation before dismantling the vehicle parts

• Clean components and surrounding area prior to removal.

Dismantling of the vehicle parts

Environmental protection precaution

Accessories and Conversions

Workshop Tools and Equipment

Hose Removal and Installation

Inspection during Removal/ Disassembly

1. Oil seals 4. Lock washers

• Specified oil/lubricant should be applied to the moving components of parts.

Use recommended/appropriate gauges and testers while making adjustments.

Rubber Parts and Tubing

Prevent fuel or oil from spilling on rubber parts or tubing.

• Legend of the Standard Operating Procedure Symbols

• Legend of the Safety Symbols

Term/ Symbol Denotation

WARNING indicates a potentially hazardous

CAUTION indicates a potentially hazardous

CAUTION used without the safety alert

Indicates important information relevant to

If you see this symbol, it indicates “no”, “do

Refer following chart for QUANTO mCR100 vehicle general specifications –

Long member size, mm 75.0 X 75.0 X 2.8 - minimum,

ABS Fitted (Yes / No / Optional ) No

Secondary brake Parking Brake

Maximum gradeability in 1st gear 10.3°

Refer following chart for QUANTO mCR100 vehicle maintenance schedule –

Refer below chart for QUANTO mCR100 vehicle lubrications recommendations –

Refer below illustrations for Engine accessory & component location -

Engine Accessory and Components Location – Isometric View A

A. Intake Manifold and Pipe F. Power Steering Pump

Refer below illustrations for engine accessory & component location -

Engine Accessory and Components Location – Isometric View B

K. EGR Valve O. Flywheel

Engine Accessory and Components Location – Engine Front View Schematic

Engine Accessory and Components Location – Engine Side View Schematic

Cylinder compression pressure Test