AL BS 2 Engine

ALMDV
Service Manual
AL BS2 Engines
13.02 AL BS2 ENGINES
AL BS2 ENGINES 13.03
CONTENTS
GROUP - 13
AL BS2 ENGINES (L62D-MK II & L62N-MK II)
Section Subject Page No.
Contents ...................................................................................................................................................... 13.03
13.0 General .......................................................................................................................... 13.07

13.0.0 Engine Type and Number ........................................................................................................... 13.07
13.0.1 Design and Operation .................................................................................................................. 13.08
13.0.2 Engine General Data ..................................................................................................................... 13.09
13.0.3 Specifications ..................................................................................................................................... 13.10
13.0.4 Description of Leading Engine Components ....................................................................... 13.13
13.0.5 Special Tools ..................................................................................................................................... 13.14
13.0.6 Engine Preliminary Checks .......................................................................................................... 13.15
13.0.7 To Test Engine Compression .................................................................................................... 13.19
13.1 To Remove and Refit Engine from Vehicle ......................................................... 13.20

13.1.0 To Remove Engine ......................................................................................................................... 13.20
13.1.1 To Refit Engine ................................................................................................................................ 13.20
13.2 Crankcase ...................................................................................................................... 13.21

13.2.0 To Remove and Refit Cylinder Liners ................................................................................... 13.21
13.2.0.1 To Pressure Test Crankcase ........................................................................................................................ 13.21
13.2.0.2 To Prepare Crankcase ....................................................................................................................................... 13.22
13.2.0.3 To Remove and Refit Camshaft Bushes ............................................................................................. 13.22
13.2.1 To Remove and Refit Timing Back Plate .............................................................................. 13.23
13.2.2 To Remove and Refit Flywheel Housing ............................................................................... 13.23
13.3 To Remove And Refit Crankshaft, Piston Connecting Rod Assembly ........ 13.24
13.3.1 To Remove and Refit Viscous Damper and Double Groove Pulley ........................ 13.24
13.3.2 To Remove and Refit Flywheel ................................................................................................. 13.24
13.3.3 Piston and Connecting Rods ..................................................................................................... 13.25
13.3.3.0 To Remove and Refit Piston with Connecting Rod .................................................................. 13.25
13.3.3.1 To Renew Piston Rings ..................................................................................................................................... 13.26
13.3.3.2 To Remove and Refit Gudgeon Pin ....................................................................................................... 13.27
13.3.3.3 Connecting Rods .................................................................................................................................................... 13.28
13.3.3.4 To Remove Gudgeon Pin Bushing and Con Rod Alignments .......................................... 13.28
13.3.3.5 To Assemble Connecting Rod Bushing ................................................................................................ 13.28
13.3.3.6 To Renew Connecting Rod Bearing and Check Connecting Rod
Main Bearing Crush. ............................................................................................................................................. 13.28
13.3.3.7 To Check Piston Projection ........................................................................................................................... 13.29
13.3.4 Crankshaft General ......................................................................................................................... 13.30
13.3.4.0 To Renew Front Crankshaft Sealing ....................................................................................................... 13.30
13.3.4.1 To Renew Rear Crankshaft Sealing / Renew Oil Seal Sleeve ........................................... 13.30
13.3.4.2 To Remove and Refit Crankshaft ............................................................................................................ 13.31
13.3.4.3 To Check and Grind Crankshaft ............................................................................................................... 13.32
13.3.4.4 To Renew Crankshaft Gear ........................................................................................................................... 13.35
13.3.4.5 To Renew Crankshaft Main Bearing and Check Main Bearing Crush ........................ 13.35
CONTENTS
GROUP - 13
13.4 Cylinder Head and Valves ........................................................................................ 13.36

13.4.0 To Remove and Refit Cylinder Head Sub-assembly ........................................................ 13.36
13.4.0.0 Cylinder Head Pressure Testing ................................................................................................................. 13.36
13.4.0.1 Cylinder Head Surface Regrinding ............................................................................................................. 13.36
13.4.0.2 To Remove and Refit Valve ......................................................................................................................... 13.37
13.4.1 To Remove Valve Springs ........................................................................................................... 13.37
13.4.2 To Hand-lap Valve and Valve Seat ......................................................................................... 13.38
13.4.3 To Grind Valves and Valve Seats ............................................................................................ 13.38
13.4.4 To Refit Valve Seat and To Check and Reface Valve Seat ......................................... 13.38
13.4.5 To Refit Valve Guide. ................................................................................................................... 13.38
13.4.5.0 To Renew Valve Guide .................................................................................................................................... 13.39
13.4.6 To Refit Valve Stem Seal ............................................................................................................. 13.39
13.4.7 To Check Valve Springs ............................................................................................................... 13.39
13.5 Timing .......................................................................................................................... 13.40

13.5.0 To Remove and Refit Rocker Levers ..................................................................................... 13.40
13.5.0.1 To Remove and Refit Rocker Lever Bush. ....................................................................................... 13.40
13.5.1 To Remove and Refit Push Rod and Tappets. .................................................................. 13.41
13.5.2 To Remove and Refit Camshaft. ............................................................................................... 13.41
13.5.3 To Remove, Refit Idler Gear and Valve Timing ................................................................ 13.42
13.5.4 To Position Timing Gears for Valve Timing ....................................................................... 13.42
13.5.5 Timing Gear Backlash Checking ............................................................................................... 13.43
13.5.6 To Adjust the Valve Clearance ................................................................................................ 13.43
13.5.7 To Refit the Fuel Injection Pump and adjusting the Fuel Injection Timing .......... 13.44
13.5.8 To Assemble FIP Drive Coupling ............................................................................................ 13.46
13.5.9 To Fit Injector High Pressure Pipes ....................................................................................... 13.46
13.5.10 Fuel Filters .......................................................................................................................................... 13.47
13.5.11 Water Separator .............................................................................................................................. 13.48
13.5.12 To Remove and Refit Injector Nozzle ................................................................................... 13.48
13.5.12.0 Cleaning ......................................................................................................................................................................... 13.48
13.5.12.1 Test the nozzle sinking ...................................................................................................................................... 13.49
13.5.12.2 Test the spray profile ......................................................................................................................................... 13.49
13.5.12.3 Test the fuel leakage (Dribbling) .............................................................................................................. 13.49
13.5.12.4 Install the nozzle holder assembly. .......................................................................................................... 13.49
13.6 Engine Lubrication ..................................................................................................... 13.50

13.6.0 Design and Operation .................................................................................................................. 13.50
13.6.1 Piston Cooling System .................................................................................................................. 13.51
13.6.2 To Remove and Refit Oil Pump .............................................................................................. 13.51
13.6.3 To Overhaul Oil Pump ................................................................................................................ 13.51
13.6.4 To Remove and Refit Oil Filter Assembly ........................................................................... 13.52
13.6.4.0 To Remove and Refit Oil Pressure Relief Valve (PRV) ......................................................... 13.52
13.6.5 To Remove and Refit Oil Cooler Assembly ....................................................................... 13.53
CONTENTS
GROUP - 13
13.7 Cooling System ............................................................................................................ 13.54

13.7.0 General ................................................................................................................................................ 13.54
13.7.0.1 Conventional Cooling System ....................................................................................................................... 13.54
13.7.0.2 De-aeration Tank (DAT) Cooling System ......................................................................................... 13.55
13.7.1 To Flush Cooling System ............................................................................................................. 13.55
13.7.2 To Remove and Refit Radiator ................................................................................................. 13.56
13.7.3 To Test Thermostat ....................................................................................................................... 13.56
13.7.4 To Remove and Refit Water Pump ........................................................................................ 13.57
13.7.5 To Overhaul Water Pump .......................................................................................................... 13.57
13.7.6 To Remove and Refit V Belt. To Adjust V Belt Tension for Alternator. ............ 13.60
13.7.7 To Remove and Refit V Belt To Adjust Belt Tensioner. ............................................... 13.60
13.8 Exhaust and Intake Manifold ................................................................................... 13.61

13.8.0 To Remove and Refit Exhaust Manifold ............................................................................... 13.61
13.8.1 To Remove and Refit Intake Manifold ................................................................................... 13.61
13.9 Maintenance and Servicing of Dry Type Air cleaner ....................................... 13.62
13.10 Aluminium Radiators and charge air cooler ...................................................... 13.63

13.10.0 Service Instruction .......................................................................................................................... 13.63
13.10.0.0 Introduction ................................................................................................................................................................. 13.63
13.10.0.1 Details of Radiator ............................................................................................................................................... 13.63
13.10.0.2 Servicing Kit ................................................................................................................................................................ 13.63
13.10.0.3 Procedure for Servicing ..................................................................................................................................... 13.64
13.10.0.4 Radiator Installation .............................................................................................................................................. 13.66
13.10.0.5 Do's and Don'ts ................................................................................................................................................... 13.66
13.11 Turbocharger ................................................................................................................ 13.67

13.11.0 General ................................................................................................................................................ 13.67
13.11.0.0 Design and Operation ......................................................................................................... 13.67
13.11.0.1 Benefits of Turbocharging .................................................................................................. 13.68
13.11.0.2 For Enhancing Turbocharger Life ................................................................................... 13.68
13.11.0.3 Preliminary Checks ................................................................................................................ 13.69
13.11.1 Precautions to be taken for Turbocharger Installation .................................................. 13.70
13.11.2 Do's and Don'ts .............................................................................................................................. 13.70
13.12 Tightening Torques .................................................................................................... 13.72
13.13 Recommended coolant .............................................................................................. 13.73
13.14 Recommended Lubricants ......................................................................................... 13.73
13.15 Filling Capacity ............................................................................................................ 13.73
13.16 Maintenance Programme .......................................................................................... 13.74

13.0 GENERAL
13.0.0 Engine Type and Number
The Engine Sl. No is stamped onto the

crankcase on the left side near dipstick.
Fig - 1
Fig. 1
The engine Sl. No. is stamped on RH rear

end of cylinder head.
Fig - 2
Fig. 2
The crankshaft has a individual Sl. No.

punched on machined face on its counter
weight web thickness.
Fig - 3
Fig. 3
13.0.1 Design and Operation

Water cooled 4 stroke Diesel Engine with direct fuel injection into re-entrant bowl combustion chamber
in the piston crown.
Fig - 4 Representative Diagram - Intake Side
Fig - 5 Representative Diagram - Exhaust Side

13.0.2 Engine General Data
Models L62D-MK II L62N-MK II
Aspiration Turbo with inter cooler
Capacity 6540 cc
No of cylinders 6
Bore 107.28 mm
Stroke 120.65 mm
Max. output 100 Kw ± 2% @ 2400 rpm 117 Kw ± 2% @ 2400 rpm
Max. torque kgm at rpm (Gross) 460 Nm @ 1080 - 1400 rpm 580 Nm @ 1080 - 1400rpm
Weight of the Engine (Dry) 580 kg
Compression ratio 17.5 : 1
Compression pressure (psi) 390 - 410 (limit - 300)
Idling speed 575 ± 50 rpm
Firing order 1-5-3-6-2-4
Valve clearance - Inlet/Exhaust 0.45 mm
Lubrication system - Oil cooler Water Cooled Plate Type
Fuel Injection Equipment Distributor type (VE) with manifold pressure compensator (LDA)
Injection timing BTDC plunger travel 1.23 - 1.26 mm 1.30 - 1.33 mm
Injector pipe (OD x ID x LT) 6.35 x 1.8 x 750 mm
Nozzle opening pressure 260 - 268 bar
Valve Timing
Inlet opens at 6° BTDC
Inlet closes at 15° ABDC
Exhaust opens at 52° BBDC
Exhaust closes at 6° ATDC
Valve Lift (inlet) 10.4 mm
Valve Lift (Exhaust) 12.0 mm

13.0.3 Specifications
Crankcase
Air Pressure test engine block water ways & oil ways With 2.0 Bar pressure using
Cosmo air pressure tester
Leak rate permissiable 6 cc / min. for 30 seconds.
Crank case bore axis to block top face 365.735 - 365.811 mm
Max. permissible unevenness of cylinder block top surface 0.076 mm
Cylinder bore size (without liner) 111.259 - 111.277 mm
Parent bore dia of main bearing 93.040 - 93.066 mm
Permissible ovality/taper of parent bore 0.051 mm
Cylinder Liner
Liner Soft, INSITU machined
Initial bore of liner before fitting to block 107.30 - 107.33 mm
Renew the liner when the wear measured at 1" below the
top of liner exceeds 0.254 mm
Liner outside diameter 111.285 - 111.31
Interference fit between engine block and liner 0.005 - 0.041 mm
Height of liner above the block surface 0.69 - 0.90 mm
Max. permissible taper or ovality of a finished bore 0.025 mm
Piston Projection 0.40 - 0.65 mm
Piston Ring
Piston Top Compression Ring
1. Type Molyinlaid Keystone
2. Nominal Width 3.19 mm
3. Ring closed gap - New 0.30 - 0.55 mm
4. Nominal Side clearance - New 0.07 mm
5. Service Limit - Ring closed gap 2.032 mm
6. Service Limit - Side clearance 0.2032 mm
Piston Second Compression Ring
1. Type Tapered Faced Internally Bevelled
2. Width 2.368 - 2.380 mm
4. Side clearance - New 0.065 - 0.097 mm
Piston Conformable Oil Ring
1. Type Steel ring - Nitrided
2. Width 3.99 - 3.97 mm
4. Side clearance - New 0.05 - 0.07 mm
Piston
1. Top Ring Groove Nominal Width 3.26 mm
2. Second Ring Groove Width 2.445 - 2.465 mm
3. Third COR Groove Width 4.02 - 4.04 mm
Connecting Rod
Bush outer diameter (std) 45.193 - 45.154 mm
Interference of small end bush in connecting rod 0.050 - 0.114 mm
Connecting rod small end inner dia with bush 41.312 - 41.319
Gudgeon pin type Fully floating retained by circlips
Gudgeon pin outside dia 41.275 - 41.306 mm
Diametral clearance of pin in small end bush 0.031 - 0.045 mm
Renew the small end bush when clearance exceeds 0.05 mm
CYLINDER HEAD
Nozzle tip protrusion 1.7 ± 0.3 mm
Permissible uneveness 0.076 mm
Original height 96.469 - 96.571 mm
Minimum height after facing 96.01 mm
Valve Seat Inserts
Valve face angle Inlet / Exhaust 30° / 45°
Valve seat angle Inlet / Exhaust 30° / 45°
Outside dia of service valve inserts Proposed Current
Inlet 48.354 - 48.338 mm 48.374 - 48.361 mm
Exhaust 45.794 - 45.778 mm 45.756 - 45.809 mm
Interference of valve seat in cylinder head
Inlet 0.055 mm - 0.091 mm
Exhaust 0.048 - 0.083 mm
Valve sink
Inlet 1.15 - 0.83 mm
Exhaust 1.16 - 1.04 mm
Valve Guide
Interference fit of valve guide in cylinder head 0.030 - 0.51 mm
Height of valve guide top above cylinder head top face 15.48 mm
Length of valve guide 62.00 mm
Inner dia. of valve guide 8.720 - 8.700 mm
Stem clearance in valve guide
Inlet 0.04 - 0.075 mm
Exhaust 0.065 - 0.100 mm
Replace guides when clearance exceeds 0.185 mm
Valve Spring
No. of valve springs Single Even Coil
Direction of helix RH
Free length of spring 60.6 mm
Solid length of spring not to exceed 32.5 mm
Rocker Lever Bush
Outer dia of rocker bush 24.766 - 24.790 mm
Diametral clearance between rocker shaft and bushing 0.013 - 0.044 mm
Renew rocker shaft bush when diametral clearance exceeds 0.089 mm
Camshaft
No. of cam shaft journals 4
Bearing type Renewable Bush type
End thrust taken on Front bearing only
Max. permissible runout of camshaft centre journal when
supported on end journals 0.076 mm
Max. permissible runout of journal position where camshaft
gear sits. 0.025 mm
Initial diametral clearance 0.127 - 0.165 mm
Renew brg. when diametral clearance exceeds 0.254 mm
Interference of bush in engine block 0.013 - 0.064 mm
End play of camshaft 0.102 - 0.203 mm
Max. permissible end play 0.254 mm to be adjusted by shims
Camshaft journal dia 53.213 - 53.234 mm
Timing Gears
Permissible back lash between each pair of gears 0.102/0.152 mm
Initial diametral clearance between idler gear and bush 0.051 - 0.076 mm
Initial diametral clearance between bush and spindle 0.025 - 0.083 mm
End float between thrust washer and idler gear 0.064 - 0.241 mm
Renew thrust washers when end play exceeds 0.305 mm
Interference fit of timing gears on crank shaft 0.019 - 0.044 mm
Interference of driving gear on camshaft 0.000 - 0.044 mm
Oil Pump
Bore dia. of gears 17.386 - 17.399 mm
Diametral clearance of gear on idler spindle 0.068 - 0.093 mm
Interference of pump gear on driving shaft 0.000 - 0.033 mm
Radial clearance between oil pump housing and gear teeth 0.042 - 0.076 mm
Initial diametral clearance of upper driving shaft in bush 0.056 - 0.087 mm
Interference fit of drive gear on upper drive shaft 0.000 - 0.033 mm
Backlash between drive gear and camshaft gear 0.102 - 0.203 mm
Backlash between oil pump gear 0.559 - 0.660 mm
End float of the gear 0.114 - 0.191 mm
Pressure Relief Valve Spring
Free length of PRV spring 53.34 mm
PRV spring tension 10.9 kg @ 40.64 mm length
No. of coils (PRV) 11½ effective 10
Oil filter bypass Spring tension Compresses to 37.051 mm under
a load of 2.84 kg
No. of coils (Bypass spring) 13
Engine oil pressure
Minimum 1 kg/cm²
Maximum 3.5 - 4.2 kg/cm²
13.0.4 Description of Leading Engine

Components
Cylinder Block - of high grade cast iron.

Cylinders and the crankcase form an integral
casting. The crankcase is enclosed from
below by the oil sump.
Cylinder Liners (dry, INSITU finished/pre

finished, soft type) - made of cast iron.
Cylinder Head - made of high-grade cast

iron, accommodating all cylinders, fitted with
exchangeable. Valve seat and valve guide
INSTIU finished.
Crankshaft - an alloy steel forging,

mounted in seven bearings with
exchangeable shells. The main journals and
crank-journals are nitrated.
Vibration Damper - viscous damper with

double groove pulley is mounted on the
front end of the crankshaft. Care should
be taken while handling the vibration
damper. Use proper special tool while
extracting the damper pulley.
Alfin Pistons (re-entrant bowl type) -

Fig. 6
made of special grade aluminium alloy with
cast iron insert to form the first
compression ring seat.
Fig - 6
Main and Small - End Bearing Shells

- thin-walled, with aluminium and tin or lead
bronze linings for sliding surfaces.
Camshaft - made entirely of steel,

mounted in the cylinder block in four
exchangeable bearing bushes. Drive is
supplied from the engine crankshaft through
a gear train.
Valve Spring - made of spring steel, Fig. 6A

single, even pitched coil type spring.
Fuel Injection Equipment - MICO

distributor type (VE) pump with manifold
pressure compensator.
Push Rod - Tubular Rod 12 mm dia.
Fig - 6A
Rocker Lever - modified to increase

Rocker Ratio.
Fig - 7
Fig. 7
13.0.5 Special Tools
0101001 0101003 0101004 0101005

Extractor Cylinder Extracotr Water Pump Pilot & Drift Valve Pilot & Drift Valve
Liner Hub Seat Inlet Seat Exhaust
0101007 0101008 0101010 0101011

Compressor Piston Extractor Crank Shaft Compressor Valve Wrench Oil Gallery
Ring Gear Spring Plug
0101012 0101013 0101014 0101016

Brush Oil Gallery Extractor Cam Shaft Centraliser Cam Shaft Extractor Crank Shaft
Gear & Damper Pulley Oil Seal Sleeve
0101020 0101021 0101023

Adapter Compression Extractor Injector Spanner Engine
Checking Cranking
13.0.6 Engine Preliminary Checks

It is mandatory to carry out few preliminary checks on engine before dismounting the engine from the
vehicle. The following cause and effects can lead to overhauling decision.
MECHANICAL HIGH ENGINE LOW ENGINE

LOSS OF
NOISE / OIL OIL
POWER.
FAILURES. CONSUMPTION PRESSURE.
ENGINE
OVERHAULING
AFTER LONG NO PREVENTIVE ENGINE ENGINE

STORAGE MAINTENANCE COOLANT SEIZURES
WITHOUT AND ENGINE
PROPER OIL MIXING
STORAGE COMPLAINT
PRECAUTIONS /
REPRESERVATION
Fig - 9 Engine Overhauling
Fig - 10 Low Engine Oil Pressure

Fig - 11 High Oil Consumption
Fig - 12 Loss of Power

Fig - 13 Mechanical Noise / Failures
Fig - 14 Engine Overheating / Seizures

Fig - 15 Bearing Rotation / Bearing Seizures

13.0.7 To Test Engine Compression
Use Special Tool 0101020 - Adaptor

Compression Checking with Special
Tool 0102021 - Gauge Compression
Checking. (Use Adaptor Cylinder
Compression in place of nozzle).
Fig - 16
Warm-up engine to normal operation

temperature (approx 80°C). Disconnect fuel
delivery pipes and remove all six injectors.
Note: Use Special Tool 0101021 - Extractor Fig. 16

Injector with Special Tool 0102003 -
Sliding Hammer, if injector extraction is
difficult.
Check valve clearance, if necessary adjust as

per recommendation.
Set the Adaptor Cylinder Compression with

standard gauge compression on First cylinder.
Fig - 17
Crank the engine approx 8 to 10 revolutions

by actuating the starter motor. The battery
must be in properly charged condition as to
Fig. 17
achieve a cranking speed of atleast 200 rpm.
Keep engine stop cable in pulled in condition.
Repeat this procedure for all 6 cylinders.
Compression pressure (psi)
Minimum - 300
Maximum - 390 - 410
Pressure difference between each cylinders

should be below 45 psi
If compression pressure is found below 300

psi Engine requires reconditioning.
In the last case it will be necessary to check

valve tightness, condition of piston clearance
of the respective cylinder.
Wet Compression Pressure Check
If the particular cylinder compression pressure is

below 300 psi as per above dry check
procedure, to locate fault with valve tightness or
piston clearance repeat the compression
pressure check after pouring few drops of
engine oil thru Injector hole. If low compression
persists, the fault is with valve seats.
13.1 TO REMOVE AND REFIT ENGINE

FROM VEHICLE
13.1.0 To Remove Engine
- Disconnect battery terminals and choke the
wheels.
- Drain engine oil
- Remove air intake system, turbo connection,
charge air cooler, exhaust system and fuel
pipe connections,
- Drain the coolant and remove cooling
system, radiator, pipes, hoses etc.
- Disconnect electrical connection from
alternator and starter motor.
- Disconnect the clutch / gear linkage system.
- Remove gear box and clutch.
- Remove engine control linkages.
- Unscrew engine fixing bolts of the engine
mounting pad.
- Fasten hoisting cable to the lifting eyes on
right front and left rear of engine.
- Use multipurpose jip crane to lift the engine.
Fig - 1
- Lift the engine slightly and move it
outwards.
- Unscrew the bolts securing the first cross
member with chassis long member and Fig. 1
remove the first cross member.
- Place the engine on suitable platform
keeping in mind that the oil sump is not
damaged.
Note: Use Engine stand of proper dimensions to
keep the engine or use Special Maintenance
Equipment. Fig - 2
- Engine should be thoroughly washed with a
suitable cleaning liquid before it is
dismantled.
- Dismantling and assembly should be carried
out by experienced personal and atmost
cleanliness must be observed. Special tools
manufactured for this purpose to be used.
Fig. 2
13.1.1 To Refit Engine
- The above mentioned procedure to be
fitted back in reverse order.
- Ensure the alignment of the engine in the
exact centre of the chassis frame.
- After connecting the engine control linkage
check whether full load stop screw could be
reached by depressing the accelerator pedal.
Readjust if necessary.
- Before initial starting of the engine, check
whether, engine injection pump, governor,
gear box and cooling system have been
filled with lubricants and coolants according
to specifications.
13.2 CRANKCASE
13.2.0 To Remove and Refit Cylinder

Liners
Use Special Tool 0101001 -

Extractor Cylinder Liner for removal
of cylinder liners with suitable bunk as
shown. The liners can also be extracted
without removing the crankshaft. The
same special tool can be used for
installation of cylinder liners using the
locating bunk on top of the liner.
Fig - 1 Fig. 1
Note: Apply a small amount of clean engine oil

on the outer periphery of liner. Liners
should be fitted after deep freezing (-10°C
to -14°C).
The Special Tool 0101001 - Extractor

Cylinder Liner should be used for liner
fitment wherever deep freezing facility is
not available. Care should be taken to
avoid damages as liner is extremely thin
and high interference fit is used.
Measure the liner projection above block

surface 0.69 - 0.90 mm.
Fig. 2
Fig - 2
13.2.0.1 To Pressure Test Crankcase
Remove all cylinder head studs using stud

remover. Remove water jacket front cover
and rear cover. Remove main oil gallery
plugs.
Place the crankcase on dry flat surface.

Fix dummy plates on cylinder head parting
surface as well as front and rear covers
with thick rubber gasket material.
Fig - 3 Fig. 3
Refer data for air pressure testing.

The casting defects of blow holes, sand

inclusion, mechanical cracks, thermal cracks
can be detected by pressure testing the
crankcase.
Attend to defective crankcase for possible

repairs or reject. Failing to perform
pressure testing of crankcase can result in
coolant and lubricant mixing complaint or
low oil pressure complaint.
13.2.0.2 To Prepare Crankcase
Fix all 26 cylinder head M14 studs with

locking compound on to crankcase and
tighten to an even torque of 50 to 60 lb.
ft.
Fig - 4
Fix oil pump top drive shaft pilot bush after

ensuring oil hole position facing camshaft
side.
Fig - 5
Ensure fitment of brass core plugs wherever Fig. 4

necessary.
13.2.0.3 To Remove and Refit Camshaft

Bushes
Using suitable mandrel and press remove

the worn out bushes from crankcase. To
refit deep freeze the bushes and fit into the
crankcase.
Note: The first bush is dowel located and second

bush oil hole alignment.
Remove / Refit main oil gallery plug using Fig. 5

Special Tool 0101011 - Wrench Oil
Gallery Plug.
Clean the main oil gallery and additional

main gallery (for piston cooling jet) using
Special Tool 0101012 - Brush Oil
Gallery.
Fig - 6
Fix flywheel housing dowels to crankcase.
Note: Also check crankcase top surface flatness,

parent bore geometry, oil gallery plugs and
main bearing crush. Fig. 6
13.2.0.4 To Remove and Refit Piston Cooling

Jet
Loosen the banjo bolt and remove the

cooling jet.
Clean and inspect the cooling jet.
Refit the cooling jet, dowel is provided for

proper fitment on to the block.
Tighten the banjo bolt to the recommended Fig. 7

torque.
Fig - 7 & 8
13.2.1 To Remove and Refit Timing Back

Plate
Remove locking wire and unscrew set

screws of the Timing back plate.
Take off the Timing back plate, taking care

of both 3/8" dowel pins. Before refitment,
remove the old gasket material and clean
Fig. 8
front face of the crankcase.
Fix fresh gasket to crank case face of the

Timing Back plate.
Screw down Timing Back plate with set

screws and spring washers.
Securely tighten hex screws and wire lock.
13.2.2 To Remove and Refit Flywheel Housing
Unscrew fixing screws of the flywheel

housing.
Before refitment, remove the old gasket Fig. 9

material and clean rear face of the
crankcase. Fix fresh gasket to inner side of
the flywheel housing.
Fig - 9
Fit flywheel housing and tighten it securely

with hex screw.
Fig - 10
Fig. 10
13.3 TO REMOVE AND REFIT CRANKSHAFT,

PISTON CONNECTING ROD ASSEMBLY
13.3.1 To Remove and Refit Viscous

Damper and Double Groove Pulley
Remove the wire lock from damper
mounting bolt.
Loosen the damper mounting bolts and

remove.
Remove viscous vibration damper carefully.
Note: The vibration damper is a precision unit.

Even a very slight damage might influence its
operation and harm the engine. Fig. 1
Bend down lock washer securing the hex

bolt of the crankshaft pulley.
Unscrew the bolt after removing lock plate

with suitable socket.
Extract the double groove pulley using

Special Tool 0101013 - Extractor
Damper Pulley and Cam Shaft Gear.
Fig - 1
To refit double groove pulley and damper,

reverse the procedure for removal.
Fig. 2
13.3.2 To Remove and Refit Flywheel
Loosen the flywheel fixing flange bolts (6
Nos.
Unscrew flange bolts (6 Nos.) and remove

flywheel.
Fig - 2
Inspect starter gear ring. If tooth edges are
worn, gear ring can be reused by removing
and reversing it with unworn face upwards.
For this purpose press out the gear ring after
unscrewing bolts. Reverse or replace gear ring
after heating it evenly to approx. 95°C.
Use locking wire 18 SWG for ring gear Fig. 3
fasteners locking.
Fig - 3
Before replacing flywheel, thoroughly clean
crankshaft adaptor and mounting face of
flywheel.
The flywheel with starter gear ring is
dynamically balanced.
Fit flywheel, taking care of the differing
circular pitch of mounting Bolt holes tighten
hex screws to a torque of 130 - 145 lb. ft.
14" flywheel - bolted ring gear.
15" flywheel - press type ring gear
Fig - 4 Fig. 4
Install flywheel.
Install the flywheel and tighten the flange
bolts in diametrically opposite sequence.
Fig 4a & 4b
Finally slacken and tighten the flange bolts
one by one to the specified torque.
Note: Check flywheel faceout with dial gauge it
should not exceed 0.20 mm. Fig. 4a
When tightening the bolt, apply engine oil to

the threads and flywheel surface of the
bolts.
Install the spigot bearing housing. Fig. 4b
13.3.3 Piston and Connecting Rods
13.3.3.0 To Remove and Refit Piston with

Connecting Rod
To Remove
Unscrew connecting rod bolts and remove
bearing cap.
Fig - 5
Scrape off carbon deposit from the upper
end of the cylinder bore.
Withdraw piston with con rod from cylinder
bore.
To Refit Fig. 5
Lubricate piston, piston rings, cylinder bore
and con rod bearing with engine oil.
Displace the piston ring gaps relative to
each other by 180°
Revolve crankshaft so that the crankpin of
the respective piston is in Bottom Dead
Centre. position.
Fig - 6
Insert piston into the cylinder bore

compressing the rings by means of
Special Tool 0101007 - Compressor
Piston Ring.
Fig. 6
Fig - 7
Fig. 7
Pull the con rod into the crankcase until the

big end bearing is seated on the crankpin.
Have a second person keep it in this
position. Fit bearing cap with half bearing,
taking care that the bearing halves are
seated properly in the connecting rod and
cap. Tighten con rod bolts alternatively,
commencing with the lower one to a torque
of 80 - 90 lb. ft..
Fig - 8
13.3.3.1 To Renew Piston Rings

Remove compression rings and oil scraper
ring with the aid of piston ring pliers/ring
expanders. Fig. 8
Remove carbon deposits from piston ring

grooves using a broken compression ring as
scraper.
Fig - 9
Before fitting new piston rings check each
ring gap separately by inserting the ring into
the cylinder bore at right angles and
measuring the ring gap with a feeler gauge.
Fig - 10
Install piston rings.

Note: Apply oil over the piston ring. use a piston
ring expander while fitting the rings.
Fig. 9
Install the piston ring in sequence viz; oil
ring, second ring and top ring with the
identification mark at the top of the ring
facing upwards.
Fig - 11
Connect the ends of the coil and then fit
the coil inside the piston ring after ensuring
that the gap of the piston ring is 180°
away from the joint of the coil. Coil and
piston scraper ring are supplied together.
Arrange the piston ring so that their gaps
are equally spaced.
Check axial play of the piston rings.
Fig - 12 Fig. 10
Fig. 12 Fig. 11
13.3.3.2 To Remove and Refit Gudgeon Pin
Removal
Remove gudgeon pin circlip with circlip plier.
Fig - 13
Remove the gudgeon pin by using suitable

drift and copper hammer.
To Reassemble Fig. 13
Heat the piston to approx 120°C. Insert

the gudgeon pin.
Note: If Induction heating facility is not available,

use water as heating medium.
Fig - 14
Caution: Ensure the valve pockets in the piston crown

and notches on the big end parent body of
the connecting rods are on the camshaft side.
Fig. 14
The crown face of piston has a reference
punch mark "Cam shaft side".
Inspect the I - Section of con rod for

scratches and scorings. i.e. - mirror finish
recommended.
Use lead or copper soft jaws when

clamping connecting rods into a vice.
Insert a gudgeon pin circlip in to one piston

eye groove.
Fig. 15
Fig - 15
Insert the lubricated gudgeon pin into the

piston eye.
Insert the second gudgeon pin circlip in its

groove.
Fig - 16
Fig. 16
13.3.3.3 Connecting Rods
General
The connecting rods are alloy steel stamping

of I - Section design.
Note: Con rod caps should not be interchanged,

since they are matched while boring.
To prepare connecting rods
Remove worn out bearing shells from big

end.
Check big end parent bore for taper/ovality. Fig. 17
Check connecting rod bolts for elongation

after torque tightening to 80 - 90 lb. ft. If
elongation exceeds 0.127 to 0.177 mm
replace connecting rod bolt.
Check connecting rod bend and twist in

suitable fixture. The bend should not
exceed 0.025 mm and the twist should not
exceed 0.05 mm.
Fig - 17
13.3.3.4 To Remove Gudgeon Pin Bushing

and Con Rod Alignments
Fig. 18
Using suitable drift press out the worn out
gudgeon pin bush from small end of con rod.
Fig - 18
13.3.3.5 To Assemble Connecting Rod Bushing
Using suitable drift for pressing new

connecting rod bush.
Note: If there's a rifle hole, ensure the bush hole

to match with the con rod rifle hole.
13.3.3.6 To Renew Connecting Rod Bearing

and Check Connecting Rod Main
Bearing Crush.
Note: Bearing failure can lead to low oil pressure.

The bearing conditions could be ascertained
by visual inspection for Scoring /
Overheating marks.
Renew the bearings if diameteral clearance

of bearings exceeds 0.177 mm.
The bearing crush with respective connecting

rod should not exceed 0.101 - 0.152 mm.
End play of connecting rod installed on

respective crankpin should not exceed 0.101
- 0.381 mm.
To Check Bearings Crush
Locate the connecting rod and cap bearing

shells correctly and fit the cap on respective
connecting rod. Ensure that the match
numbers stamped on the sides are same
and the notch in the con rod and con. rod
cap are in the same side.
Fig - 19
Tighten the connecting rod bolts to specified Fig. 19

torque. Check crush of bearing by loosening
bolt opposite to notch side and check gap.
Fig - 20
13.3.3.7 To Check Piston Projection
Note: The measurement of piston projection is

required whenever piston change is combined
with change of crankcase, connecting rod,
crankshaft.
Fig. 20
Mount the dial gauge with magnetic base on
crankcase and set the dial to zero on head
gasket seating surface.
Rotate engine flywheel to bring subject

piston to Top Dead Centre using the same
dial gauge measure piston projection.
Fig - 21
Piston Projection : 0.40 - 0.65 mm
Fig. 21
13.3.4 Crankshaft General

The crankshaft is made of forged steel,
supported by seven main bearings and
thrust is taken up by thrust washers at the
center journal.
The rear end has spring loaded full circle oil

seal housed in a aluminum housing and at
front end an oil seal is housed in the timing
case cover to prevent loss of oil.
At rear end through an adaptor the engine

flywheel is bolted. The bolt holes in
crankshaft adaptor and flywheel are drilled
out of pitch for timing purpose.
Double groove pulley is bolted at front end

after match lapping the conical surfaces.
The Timing gear drive is provided from

crankshaft through a helical gear pressed
before double groove pulley.
13.3.4.0 To Renew Front Crankshaft Sealing

Remove Pulley vibration damper
Remove timing cover & Replace new oil seal.
13.3.4.1 To Renew Rear Crankshaft Sealing /

Renew Oil Seal Sleeve
Remove flywheel.
Unlock the locking plates and Unscrew

adaptor bolts and withdraw the adaptor.
Unscrew rear oil seal housing bolts and

remove oil seal housing. Replace oil seal if
found defective. Inspect oil seal sleeve for
wear / damage. Extract oil seal sleeve from
crankshaft using Special Tool 0101016 -
Extractor Crankshaft Oil Seal Sleeve.
The Special Tool 0101016 - Extractor

Crankshaft Oil Seal Sleeve helps in
Fig. 22
extracting oil seal sleeve without damaging
the crankshaft.
Fig - 22
To refit crankshaft rear oil sleeve, heat the

sleeve to 190ºC to 200ºC and insert on
crankshaft rear end.
Note: Ensure the tapering end of oil seal sleeve

faces the rear end.
Fig - 23
Refit rear oil seal housing & crankshaft

adaptor. Fig. 23
13.3.4.2 To Remove and Refit Crankshaft
Unscrew collared bolts and remove bearing caps.
Remove thrust bearing cap (centre bearing) last.
Fig - 24
The bearing caps are match marked with

the crankcase by A, B, C, D, E, F, G.
commencing on the Timing gear side.
Lift the crankshaft out of the crankcase with

the aid of the lifting device. Utilise 2 old
bearing shells for this purpose as illustrated. Fig. 24
Take care not to damage centre bearing.
Fig - 25
Installation
Clean crankshaft thoroughly, ensure

lubrication holes are without any dust.
Clean the bearing shell and main journal

bore. Fit all the bearings in the respective
places.
Lubricate crankshaft journals and bearing

shells with engine oil. Carefully lower the
Fig. 25
crankshaft into position.
Fit bearing caps in its position as per the

matching marks. First fit 4th bearing cap
and then the first and seventh, then other
bearings.
Fig - 26
Tighten collared bolts uniformly, starting from

4th main bearing to a torque of 145 - 155
lb. ft as shown in the sequence order (4, 1,
7, 2, 6, 3, 5).
Fig - 27
Fig. 26
After torque tightening rotate crankshaft for
freeness.
Fig. 27
Do not attempt to rotate crankshaft

before all bearing caps have been bolted
down and torque tightened. The
crankshaft must turn freely without binding
i.e. a strong push by hand should make it
turn atleast one revolution.
Fig - 28
Check endplay of crankshaft as follows:
Force crankshaft in one axial direction and

measure the gap between thrust bearing
side and crank web face with dial gauge
as shown in Fig - 29. Fig. 28
Subsequently force crankshaft in the other

direction and repeat the measurement.
The initial end clearance with new thrust

and main bearings should amount to 0.05
- 0.25 mm and end clearance should not
exceed 0.35 mm.
Fig - 29
13.3.4.3 To Check and Grind Crankshaft

Clean crankshaft and blow out lubrication
bores with compressed air, check journals
and crankpins for cracks.
Fig. 29
Recommendation for grinding

(Applicable for AL engines)
1. Specification of Grinding Wheel : A 463 L 5 V 10

(As recommended by Bharat Forge)
2. Speed of rotation of Grinding Wheel for : 450 to 500 RPM

journal Grinding
3. Speed of Rotation of crankshaft

for Grinding : 50 to 60 RPM
for Pin Grinding : 90 to 100 RPM
4. Range of Automatic Wheel Feed : 0.0002" to 0.0008"
5. Recommended Coolant : Clearage - AA, Marketed by M/s. Castrol (or its equivalent).
6. Specification of Tool for grinding oil holes : A 12 Mounting wheels having 0.25" dia spindle to be
used on a Dia Grinder, Model CP 3050
manufactured by M/s. CPT, Mumbai - Speed : 21,000
RPM.
Points to be observed while Regrinding:

1. Crack detect the Crankshaft before & after grinding.
2. The Grinding wheel should be brought slowly and should touch the crankshaft gently.
3. During final cut, 30 to 40 sec. Period should be allowed for dwelling.
4. If the run out of the Crankshaft is excess, it should be renitrided irrespective of the undersize.
Regrinding of Crankshafts
(applicable for AL material engines)
While grinding, care should be taken to

ensure an excessive amount of material is
not removed from the fillets.
The fillet radius of the main and con rod

Journals of the crankshaft is 0.14" to 0.16".
The enclosed figure on crankshaft regrinds
indicates the effect of an S1 regrind using
wheel with radius of 0.14" to 0.17". It is
divided up into eight sections each one
indicating a certain condition.
Examples:
At (3) this indicates the effect of a 0.17"

radius wheel used in a crankpin fillet radius
of 0.14". Likewise at (7) this is a 0.17"
radius wheel in a crankpin fillet radius of
0.16" and so on. The important factor is
that the hardened case is not ground
through in the fillet and the case is not
breached. Therefore case No.2 is in order,
but conditions 6 and 8 are not, only
occuring when the radius of the grinding
wheel is less than that of the crank fillet.
When the wheel has a greater radius, a
line may be formed in the fillet as in
conditions 1,3 and 4 but this is not
normally detrimental. Hence, generalising, a
grinding, wheel of radius equal to or 0.010"
above crankshaft fillet radius should be
used.
With regard to the polishing operation, this

is done to remove nitriding bloom and
attain a surface finish. The correct surface
finish should be 10 micro inches and if
attained by grinding, then polishing is not
required.
The hardness of the journals required

should not be less than 75 on the
skeleroscope scale and at on regrind to S1
size, this hardness should be retained.
However, this should be inspected after a
regrind and rectified as necessary.
Line is produced in fillet radii during re-

grind to S1. This occurs when crank was
ground to bottom limit on radii originally.
Line occurs at points A. B. & C. as shown
by arrow.
Fig - 30
Fig. 30
TABLE OF CRANKSHAFT DIMENSIONS
Type Crankpin Crankpin Journal Journal Width

Diameter Width Diameter
Front Centre Rear Others
in mm in mm in mm in mm in mm in mm in mm
Std. 2.3998 60.955 1.700 43.180 3.4998 88.895 1.845 46.863 1.950 49.530 1.947 49.454 1.395 35.433
Service 2.4005 60.973 1.703 43.256 3.5005 88.913 1.855 47.117 1.952 49.581 1.955 49.657 1.405 35.687
lst 2.3898 60.701 1.700 43.180 3.4898 88.641 1.845 46.863 1.950 49.530 1.947 49.454 1.395 35.433
Service 2.3905 60.719 1.703 43.256 3.4905 88.659 1.855 47.117 1.952 49.581 1.955 49.657 1.405 35.687
2nd 2.3798 60.451 1.700 43.180 3.4798 88.387 1.845 46.863 1.950 49.530 1.947 49.454 1.395 35.433
Service 2.3805 60.461 1.703 43.256 3.4605 88.151 1.855 47.117 1.952 49.581 1.955 49.657 1.405 35.687
3rd 2.3698 60.193 1.700 43.180 3.4698 88.133 1.845 46.863 1.950 49.530 1.947 49.454 1.395 35.433
Service 2.3705 60.211 1.703 43.256 3.4705 88.151 1.855 47.117 1.952 49.581 1.955 49.657 1.405 35.687
4th 2.3598 59.939 1.700 43.180 3.4598 87.879 1.845 46.863 1.950 49.530 1.947 49.454 1.395 35.433
Service 2.3605 59.957 1.703 43.256 3.4605 87.897 1.855 47.117 1.952 49.581 1.955 49.657 1.405 35.687
5th 2.3498 59.685 1.700 43.180 3.4498 87.625 1.845 46.863 1.950 49.530 1.947 49.454 1.395 35.433
Service 2.3505 59.703 1.703 43.256 3.4505 87.643 1.855 47.117 1.952 49.581 1.955 49.657 1.405 35.687
Note 1: When grinding crankpin and journals the sides must not be ground unless they have been damaged if
the location faces of the centre main bearing have been damaged, the vvidth should be Increased to
49.784, 49.835 mm otherwise the dimension, should remain unchanged.
Wheel having a radius of 3.810 / 4.318 mm must be used.
Note 2: The crankshaft should be re-nitrided at service sizes S.2 and S.4
Note: The crank shafts with visible cracks at radius

or oil hole area need to be abandoned from
any further usage. The cracks could be
traced using magnetic particle crack
detection.
Defects in crankshafts displayed by
magnetic testing
Regions shown thus ////// indicate one half
of semi-circle at any fillet between crankpins
and webs or journals and Webs. Within
these areas, or within a radius of 0.25" of
the centre of an oil hole, crankshafts shall be
rejected if inspection discloses.
a) Any defect visible to naked eye, or by Fig. 31
the aid of x 10 magnifying glass.
b) Thread like deposits of magnetic
powder exceeding 0.10" in length.
Fig - 31
Surface cracks must be ground out to with

in the 0.010" dia, undersize dimension;
otherwise it will mean that the crankshaft
should be ground further in steps of 0.010"
undersize on diameter until shaft cleans up.
This in turn means that the crankshaft will
have to be re-nitrided before it is reused.
The overheating marks have to be removed
Fig. 32
fully by grinding down to the possible service
size. The depth of material removed will
determine the loss of nitriding case depth
and the decision to subject the crank shaft
for re-nitriding.
13.3.4.4 To Renew Crankshaft Gear

By using Special Tool 0101008 -
Extractor Crank Shaft Gear, remove
crankshaft gear from crankshaft. Eliminate
high spots, nicks and chippings from pulley
key by filing before re using.
Fig - 32
13.3.4.5 To Renew Crankshaft Main Bearing Fig. 33

and Check Main Bearing Crush
Locate the new main bearing shells correctly
on the crankcase and fit the cap on
respective location by matching punch marks
i.e A, B, C, D, E, F, G,. Ensure the notch in
the crankcase and main bearing cap are in
the same side. Tighten the main bearing
cap bolts to specified torque.
To Check crush (0.101 - 0.152 mm) of
bearing loosen the bolt opposite to notch
side and check the gap using feeler gauge.
Fig - 33
13.4 CYLINDER HEAD AND VALVES
13.4.0 To Remove and Refit Cylinder Head

Sub-assembly
Remove cylinder head cover and remove

rocker gear assembly. Unscrew cylinder
head nuts, and lift off the cylinder head.
Place ends of cylinder head onto the
wooden blocks.
Fig - 1
Fig. 1
Cylinder head nut loosening sequence.
Fig - 2
13.4.0.0 Cylinder Head Pressure Testing
Place the cylinder head on dry flat surface.

Fix dummy plates on cylinder head parting
surface as well as front and rear covers
with thick rubber gasket material.
Fig - 3 Fig. 2
Connect pressurised water supply to the

cylinder head water jackets (2.1 kg/cm²).
Inspect water leakage from oil cross hole.
Pressure test oil holes with 5.6 kg/cm² by

closing both the ends and pressurising with
water.
Fig - 4
13.4.0.1 Cylinder Head Surface Regrinding
/ Valve guides, valve seats and studs Fig. 3

removed /
Machining Data
Permissible unevenness 0.076 mm
Original height 96.469 - 96.571 mm
Minimum height after 96.01 mm

refacing
Note: Ensure after grinding the minimum cylinder

head height, valve seat counter bore depth.
Check for surface cracks, blow holes near

core plugs. Fig. 4
Installation
Use only genuine cylinder head gasket.
Fig - 5
Clean contact faces of cylinder head and

crankcase. Place cylinder head gasket
"TOP" mark facing upward.
Mount cylinder head and tighten the nuts in

sequence from centre.
Fig - 6
Fig. 5
Tighten the cylinder head nuts moderately

and then torque tighten to 125 - 130 lb.
ft.
Fig - 7
NOTE: After the initial warming up of the engine,

the cylinder head bolts must be retightened
to the specified torque. The rocker shaft
assemblies need to be removed for this
purpose.
Readjust valve clearance as per

Fig. 6
recommendation.
13.4.0.2 To Remove and Refit Valve
Remove valve spring seats and valve spring

and withdraw the valve from its guide.
13.4.1 To Remove Valve Springs
Note: Valve springs can be replaced without

removing cylinder head by bringing
respective piston to Top Dead Centre.
Remove the valve split cones, and valve Fig. 7

spring from cylinder head.
Special Tool 0101010 - Compressor

Valve Spring.
Fig - 8
Remove the intake and exhaust valves.
Tag valves to identify their cylinder numbers

and to eliminate mixing up of valves.
Caution: Avoid damage to cylinder head surface.
Fig. 8
13.4.2 To Hand-lap Valve and Valve Seat
Lightly apply lapping compound to the valve

face. Install the valve with a Valve Lapping
Tool, tap and rotate valve against the seat.
Fig - 9
13.4.3 To Grind Valves and Valve Seats
Note: Grinding of valves and valve seats should

only be performed when hand lapping does Fig. 9
not result in proper seating. Any
conventional valve grinding machine can be
used.
Fig - 10
13.4.4 To Refit Valve Seat and To Check

and Reface Valve Seat
Cut the circumference of a old valve head

at three places with a grinder and install it
into the seat and weld the valve to the
seat. Then drive the valve and the seat Fig. 10
out with a mallet.
Valve seat installation
Heat the cylinder head to about 80° -

100°C with hot water. On the other hand,
cool the valve seat with dry ice or liquid
nitrogen for about 30 minutes. Hold the
seat with pincers and place it into the
heated cylinder head. Use Special Tool
0101004 - Pilot and Drift Valve Seat
Inlet and Special Tool 0101005 - Pilot
and Drift Valve Seat Exhaust for fixing Fig. 11
valve seats.
Fig - 11
Refer section 13.4.2 and 13.4.3 for valve

seat lapping/grinding.
Check sealing between valve and valve seat.
13.4.5 To Refit Valve Guide.

The Valve guide may require replacement if
stem to valve guide clearance exceeds
13.4.5.0 To Renew Valve Guide

Remove the valve stem seal.
Using a brass rod and hammer, drive out
the valve guide.
Install the new valve guide using Special Tool.
Fig - 12
Height of the valve guide from cylinder head
surface - 15.48 mm.
Fig - 13
Note: Apply engine oil lightly to the valve guide
outer circumference before installation.
Wherever deep-freezing facilities available,
Fig. 12
freeze the valve guides to -10ºC to -14ºC.
13.4.6 To Refit Valve Stem Seal

Remove the valve stem seal.
Fig - 14
Install the valve stem seal using Special
Tool.
First, install the lower spring seat (for
stopper of special tool) and valve. Then
apply engine oil to the lip of the stem seal
and drive the special tool until it hits the
lower spring seat.
Fig - 15
Fig. 13
Note : After installing stem seal, make sure that a
check is made on the condition of the
rubber seal for cracks or any other damage.
Do not use the special tool if its tip
(surface contacting lower spring seat) is
worn or deformed.
13.4.7 To Check Valve Springs

Check valve springs on a valve spring scale
for re-usability
Fig - 16
When pressing valve springs take special
care to avoid damaging stem seals.
Fig. 14
Fig. 16 Fig. 15
13.5 TIMING
13.5.0 To Remove and Refit Rocker Levers
Rocker lever - modified to increase

rocker ratio.
Fig - 1
Remove cylinder head cover.
Remove Injector clamp and fasteners, Fig. 1

remove rocker shaft assembly and remove
the circlips at either ends to dismantle the
rocker arm subassembly.
Fig - 2
Reassemble rocker arm assembly in the

order as follows:-
Washer, Exhaust lever, bracket, inlet lever,

washer, spring - for first three cylinders
Fig. 2
Washer, Inlet lever, bracket, exhaust lever,
washer, spring - for last three cylinders
Fig - 3
Note: Confirm that oil hole of rocker arm

bracket No.3 Support aligns with shaft
oil hole. This is ensured by locking
second rocker bracket with respect to
rocker shaft by means of a pin.
Caution: Improper installation will result in seizure

of the entire valve assembly. Fig. 3
13.5.0.1 To Remove and Refit Rocker Lever

Bush.
Using suitable drift drive out the worn out

bush.
Use suitable mechanical or hydraulic

press for pressing new rocker lever
bush. Drill two nos. holes using 2 mm
drill-bit for lubrication.
Fig - 4
Fig. 4
13.5.1 To Remove and Refit Push Rod and

Tappets.
Remove rocker gear and withdraw push
rods.
Check push rods bend between centres.
Maximum permissible bend = 0.3 mm
Examine both push rod ends for wear.

Replace if necessary and check rocker gear
and tappet lubrication in this case.
Fig - 5
Remove the engine RH side covers. Fig. 5
Check diametral clearance of tappet in

crankcase bore and inspect sliding surface
and push rod seat for wear.
Data
Tappet plunger
clearance in engine 0.057/0.083 mm
block
Max. permissible
diametral 0.127 mm
clearance
Renew worn parts. To refit push rods

and tappets, reverse the procedure for
removal.
13.5.2 To Remove and Refit Camshaft.

Unscrew 4 nos set screws holding
camshaft thrust washer and shims. With
draw camshaft from front end.
Fig - 6
Extract camshaft after removing tappets.
Use special tool Drift and Extractor

camshaft bushes to remove and refit
Fig. 6
camshaft bushes.
To refit camshaft reverse the procedure for
removal.
Note: Use Special Tool 0101014 -

Centraliser Cam Shaft Thrust
Washer for centralising cam shaft thrust
washer before tightening setscrews. Set
end play of camshaft by adjusting shims to
0.101 - 0.203 mm.
Fig - 7
Fig. 7
13.5.3 To Remove, Refit Idler Gear and

Valve Timing
Rotate engine until match marks of

camshaft gear and timing backplate punch
mark to align.
Fig - 8
Unscrew Idler gears nut and remove it

with thrust washer, withdraw intermediate
gear. Fig. 8
Fig - 9
To refit spindle Idler gear, reverse the

procedure for removal. The idler gear
bush is floating type.
Seating faces of spindle must be perfectly

clean. Install intermediate gear taking care
of the match marks, for timing.
Retighten the idler gear castle nut to

Fig. 9
specified torque (65 - 75 lb. ft.), lock the
nut using new split pin.
13.5.4 To Position Timing Gears for Valve

Timing
Align 1/6 mark on engine flywheel with
flywheel pointer by rotating the engine.
Align camshaft gear timing mark with

reference punch mark on timing back plate.
Fix idler gear along with spindle on idler

bolt without changing the position of
Fig. 10
camshaft/crankshaft gear.
Fig - 10
Proposed Valve timing Arrangment
No. 1, 2, 3 punched on gears to align

timing marks as shown in figure.
Fig - 11
Fig. 11
13.5.5 Timing Gear Backlash Checking

Check tooth backlash with feeler gauge.
Permissible backlash between each pair of gears
0.102 to 0.152 mm.
Fig - 12
13.5.6 To Adjust the Valve Clearance

Method for determining if the No. 1
or No.6 piston is at the Top Dead
Center on compression stroke.
* Turning the crankshaft, align the mark
"1-6" on the flywheel pointer on the Fig. 12
flywheel housing.
* In this position either the No. 1 or
No. 6 piston is at the top dead
center on compression stroke.
If both No. 1 intake and exhaust rocker
arms can be moved easily by hand, the No.
1 piston is at top dead center on
compression stroke.
With the No. 1 piston positioned at top
dead center on compression stroke, adjust
the No. 1 valve clearance using a feeler
gauge.
Fig. 13
The feeler gauge should move with a very
slight pull.
To adjust the valve clearance for the other
cylinder valves, by turning the crankshaft
clockwise 120° (viewed from the front side).
Adjust the valve clearance for each cylinder
as per firing order 1-5-3-6-2-4. Fig - 13,
14 & 15.
Quick checking method

To save time the following method can be
practiced.
Step 1: Rotate engine in clockwise direction till flywheel Fig. 14
1/6 mark aligns with flywheel pointer.
Step 2: If 3rd rocker lever from the front end of the
engine on rocker assembly is fully actuated
downward i.e. when the third valve is fully open,
start setting valve clearance for 1st, 2nd, 4th, 5th,
7th, 10th valves from frontend.
If 10th rocker lever of engine on rocker assembly
is fully actuated downward i.e. when 10th valve is
fully open, start setting valve clearance for 12th,
11th, 9th, 8th, 6th, 3rd valves from rear end.
Step 3: Rotate engine clockwise 360° to realign 1/6
mark and repeat step 2 suitably to complete
valve clearance setting for all 12 valves.
Fig. 15
13.5.7 To Refit the Fuel Injection Pump and

adjusting the Fuel Injection Timing
A. Removal of FIP from Engine:

1. Isolate battery.
2. Remove high pressure pipe connections,
remove over flow pipe and boost compen-
sator pipe (black colour nylon hose).
3. Loosen the 3 nuts mounting the FIP onto
the injection pump drive housing, and
remove the FIP. There is no need to
remove the injection pump drive housing.
Caution: After removal ensure that the Over
flow Banjo (marked as ‘OUT’) and
the LDA connection banjo if fitted
back to the respective FIP. These are
not to be interchanged and will be
required for Bench calibration also.
B. Bench Calibration:
1. Remove the splined bush by a suitable tool.
The FIP can now be put on bench for
calibration.
2. After bench calibration, fix the splined bush
and torque tighten to the specified value.
3. Set the specified pre-stroke value by using
dial indicator and cam lock.
4. The FIP is now ready for fitment onto the
engine. Fig. 16
5. Ensure that the inlet adaptor on the FIP fuel

inlet, Overflow (‘OUT’) Banjo and the LDA
Banjos are fitted back onto the FIP after
bench calibration.
Note: For Calibration chart refer MICO dealer.
C. To Refit the Fuel Injection Pump and

adjusting the Fuel Injection Timing
1. Bring the no.1 cylinder at TDC on
compression stroke. Fig - 17 ( Hint: there is
no need to remove the rocker cover. At
the first cylinder compression the double
groove in the Inj. Pump drive coupling, which
can be felt with hand from the open end
rear end of the Inj. Pump drive housing, will Fig. 17
be vertical).
2. Check the FIP mounting Gasket.
3. Fit the FIP onto the engine aligning the
double tooth with the double groove in the
injection pump drive coupling (Hint: at the
correct timing the double tooth on the
splined bush would be vertical) and cam
locked condition.
4. Tighten the 3 FIP mounting nuts, by pushing
the pump towards cylinder block. Fig - 18
5. Loosen the cam-lock, insert the interposing
plate under the camlock screw and tighten
the cam-lock screw again. (To make the
drive shaft free).
Fig. 18
Check and Setting Injection Timing
1. Remove the dummy plug on the distributor

head and fix the special tool. Fig - 19 &
20
2. Rotate the engine in the opposite direction

of rotation. Stop the rotation when the
pointer of the dial indicator stops moving.
3. Set Zero on the dial. Fig - 21
4. Rotate the engine in the direction of rotation

and align the 1/6 mark on the engine
flywheel to the flywheel housing ref. Fig. 19
5. The dial indicator should now read pre-

stroke specified for the engine type.
6. If not, loosen the three nuts holding the FIP

to the housing-inj. Pump drive and turn the
FIP towards or away from the engine so
that the dial reads the required pre-stroke
value.
7. Tighten the three nuts to secure the FIP

firmly.
8. Remove the dial indicator and fit the dummy

plug.
Fig. 20
9. Fit the Over flow pipe, boost compensator

pipe, high pressure pipes and FIP support
bracket.
FIP Timing Setting Tool

FIP rear end dummy plug sizes are M8 and
M10.
Use special tool part no.
Small Tool - M8 - Z00WEO203193
M10 - Z00WEO230528
for checking timing without high pressure
pipes. Fig - 22
Fig. 21
Use special tool part no.
Long Tool - M8 - Z00ZZ0031450
M10 - Z00ZZ0031604
for checking timing with just loosening the
high pressure pipes at injector end. Fig -
23.
Supplier Address:
Productive Tool Engineers,
No. 251 1st Main, 7th Cross,
New 3rd Cross, Prakash Nagar,
Bangalore - 560 021.
Ph : 080-3124606.
Fig. 22 Fig. 23
13.5.8 To Assemble FIP Drive Coupling

(Fig - 24)
Assemble the bushes (2) on to the injection

pump drive housing (1).
Pump drive shaft (3) is assembled alongwith

a thrust washer (4) into the housing (1).
Feeler shim inseration - drive shaft play on

the housing is 0.1 mm.
Fig - 25
Fig. 24
Eccentric (5) is press fit on to the drive
shaft (3) and retainer circlip (6) is fitted.
The IPD coupling (7) is assembled into the

drive shaft (3).
Circlip (12) is fitted into the IPD.
FIP gear (8) is fitted onto the drive shaft

(3) and retained with 8 bolt (9).
The end cover (11) with O ring (10) is

fitted.
Fig. 25
Feed pump is fitted on the drive on the
Identification for FIP Splined Bush
injection pump drive housing.
FIP is assembled with splined bush on to

the FIP drive coupling.
Note: For derated pump, use splined push punched

"6D".
For nominal pump use splined bush punched
Part No. ID Mark Application
"6N"
Fig - 26 X1600315 6D Derated
13.5.9 To Fit Injector High Pressure Pipes X1600415 6N Nominal

The fuel outlet at distributor head of the FIP Fig. 26
would be identified with alphabets A-B-C-D-
E-F as shown in Fig. 27
The fuel outlet on the pump corresponding

to each Engine cylinder is given in the table
below:
Connection Sequence
On Cap nut
at Injector end 1 2 3 4 5 6
On Cap nut
A E C F B D
at pump end
Fig. 27
13.5.10 Fuel Filters

Effective fuel filtration is absolutely essential
for trouble free operation of the fuel
injection equipment. Fuel filters have been
designed to retain even the smallest of the
impurities and protect the extremely sensitive
precision parts of the injection pump and
nozzle from damage.
Note: Do not use star type filter inserts. Always
use coil type fuel filter. Fig - 28
Maintenance
Fig. 28
Filter inserts must be replaced at regular
intervals. Guidelines for replacement period
under normal conditions are given below.
Filter Change Period (Both Paper Coil

Type)
First stage First 16000 km and
element thereafter every 16000 km
Second stage First 24000 km and
element thereafter every 16000 km
Note: Never change both the filters at a same
time.
The filter elements (inserts) should never be
cleaned, at an interval lesser than the
recommended period. Sometimes the filter
inserts get clogged in a very short time due
to asphaltene or waxy compounds present in
fuel. In such cases the filter inserts have to
be replaced.
Renew Fuel Filter Element

- Unscrew centre bolt and withdraw the
bowl and filter, Install new sealing ring
and ensure it is correctly located.
- Clean the bowl free of sediments.
Replace a genuine filter element and
refit the bowl.
Bleed the fuel system

While bleeding the fuel system bleed the fuel
through the high pressure injector pipes upto
the injector end. It is necessary to crank
the engine intermediately.
Note: Do not disturb FIP for bleeding.
While loosening the injector pipe nut at the
injector end for bleeding. Hold the fuel inlet
connection stud of the injector to avoid
loosening/fuel dilution.
13.5.11 Water Separator
Remove and empty the bowl and wash out

with clean fuel. Prefill the bowl with clean
fuel before refitting. Always renew the
sealing ring. Fig - 29
13.5.12 To Remove and Refit Injector Nozzle
Clean the surrounding area of the nozzle

and fuel line connections.
Remove injector pipes, clean and cover both

the ends of the pipes to prevent entry of Fig. 29
the dirt.
Remove nozzle assembly.
Use a special tools 0102015 - Adaptor

Injector Removal and 0102003 - Sliding
Hammer. Fig - 30
13.5.12.0 Cleaning
Important: The ball profile of DSLA nozzle is not

hardened, extreme care to be
exercised in handling the injectors and
nozzles at all levels. Do not use Fig. 30
emery sheet or hard material to clean
the nozzles.
To Clean nozzles
Use ultrasonic cleaning equipment.
Ultrasonic cleaning is a safe and effective

way of cleaning the nozzles.
Ultrasonic cleaning equipment consists of

generator capable of generating electrical
energy at an ultrasonic frequency and a
'transducerized tank' which holds the cleaning
solution and the parts to be cleaned. The
Ultrasonic frequency waves are transmitted
to the cleaning solution contained in the
tank, which dislodges the dirt and soot.
The main objective of using this equipment

is to clean the spray holes of the nozzles
especially the DSLA type in which the ball
profile is soft.
13.5.12.1 Test the nozzle sinking
Wash the nozzle with the diesel then

immerse it in diesel oil.
Slide the needle inside the nozzle and ensure

moves smoothly. The needle should fall
under its own weight when withdraw
vertically about 1/3rd and released. If its
motion is sluggish, replace the nozzle with
new one. Fig - 31
Fig. 31
Adjust the injection pressure.
Connect the nozzle holder with a nozzle

tester and move the lever at the rate of
about 50 - 60 strokes per minute.
Adjust the injection pressure as

recommended. Fig - 32
If the injection pressure is not within

specifications, readjust the injection pressure
with the shims.
Fig. 32
13.5.12.2 Test the spray profile
In case of the new nozzle, operate the lever

at the rate of 30 - 60 strokes per minute
and for a used nozzle, operate the lever at
the rate of 15 - 60 strokes per minute.
Fig - 33
13.5.12.3 Test the fuel leakage (Dribbling)
When checking for fuel leakage from the

nozzle, apply a pressure of about 10 - 20 Fig. 33
kg/cm², to lower than correct injection

pressure to the nozzle. If there is no
leakage, the nozzle is normal. Fig - 34
13.5.12.4 Install the nozzle holder assembly.
Fit the new nozzle washer.
Tight the nozzle holder bolts alternatively

right and left, tightening the bolts gradually
until the specified torque is reached evenly
[Torque 150 kgcm (11 lb.ft.)]. Fig. 34
13.6 ENGINE LUBRICATION oil supply from camshaft second bush rises
via vertical oil way drilled in the crankcase
13.6.0 Design and Operation meeting an angular passage in the cylinder
head. This angular passage meets the third
The Fig - 1 diagram illustrates the rocker shaft bracket. The tubular rocker
arrangement of the equipment, and the shaft has transverse drilling for lubricating
flow of oil through the system. rocker lever bushes. The push rods, tappets
The engine is arranged for forced feed and valve stems are lubricated by rocker
lubrication. The oil pump supplies the lever oscillations.
lubricating oil for engine. The oil pump is The air compressor, Turbo are pressure
located within oil sump and driven by fed through an external pipe connected to
Engine camshaft. main oil gallery and the oil returns to the
engine sump through timing case as well as
The oil pump forces the oil from the sump FIP timer housing. Oil pressure gauge
to the oil filter through pressure relief valve. connection is taken from fifth main bearing
The oil is then filtered through full flow on RH side.
paper type oil filter, the filter by-pass valve
Additional main oil gallery provided to
provided on filter head opens whenever the
supply the oil to piston cooling jet.
filter gets chocked. After filtering oil passes
to the main oil gallery and forced through Crankcase breathing is done by a breather
oil ducts to the crankshaft main journals pipe fitted on right hand side with air and oil
and through idler gear to camshaft first separator. Crankcase ventilation is improved
due to venturi action of breather pipe end.
bush. The camshaft oil supply through its
own gallery lubricates remaining three Note: Incase of Turbo charged engines the
camshaft bushes. The connecting rod connecting rods are provided with riffle
bearing are supplied with lubricant passing hole to lubricate gudgeon pin bush. Also
from the crankshaft bearings, through turbocharged engines are fitted with water
inclined oil ducts in crankshafts. Intermittent cooled oil cooler.
Fig - 1 Engine Lubrication Schematic Diagram

13.6.1 Piston Cooling System
Additional piston cooling gallery gets oil

from filter head. When the engine oil
pressure is 2 bar, the valve opens in the
filter head and the oil supply starts from oil
filter head to additional piston cooling
gallery/ piston cooling nozzle.
Relief valve opening pressure - 1.9 - 2.1

bar.
Fig. 2
To adjust relief valve pressure add or
remove washer no. 4. (Fig - 2)
Piston cooling system oil supply arrangement

shown in the oil filter head.
1. Filter Head
2. Steel Ball
3. Spring
4. Washer
5. Washer
6. Special Plug
Fig. 3
7 Copper washer.
8. Dummy Plug
Fig - 2 & 3
13.6.2 To Remove and Refit Oil Pump
Unscrew oil pump mounting nuts and

withdraw oil pump from engine.
Fig - 4
13.6.3 To Overhaul Oil Pump Fig. 4
Inspect gears and shaft for wear. Replace if

necessary.
Check contact surfaces between housing and

cover. Check radial clearance between
housing and gears. Also check backlash
between oil pump gears using feeler gauge.
Check condition of suction strainer.
Fig - 5
Fig. 5
13.6.4 To Remove and Refit Oil Filter

Assembly
Clean oil filter head and adjoining areas.
Unscrew filter dome nut and withdraw the
filter bowl.
Remove the oil filter element and conical
spring.
Wash the bowl in kerosene or diesel.
Replace new genuine filter element after
fixing conical spring smaller dia facing
downward.
Fig - 6 Fig. 6
Wash the filter head after dismantling in
kerosene or diesel.
Check filter bypass valve spring, plunger
and replace if necessary with fresh sealing
washer.
Fix oil filter bowl on filter head with new
sealing ring.
Refit the filter assembly on crankcase with
new 'O' rings.
Fig - 7
Caution: The opening pressure of bypass valve is
set by factory and should not be
altered. Fig. 7
13.6.4.0 To Remove and Refit Oil Pressure

Relief Valve (PRV)
The oil pressure relief valve located on left
side of crankcase near oil filter assembly.
It consists of spring loaded valve with
reversible five nos. welch washers.
Fig - 8
Whenever low oil pressure is reported
(below 1 kg/cm²) the PRV can be
removed to check plunger seating on
crankcase.
The plunger seating on crankcase can be Fig. 8
re-cut using suitable cutter to achieve
uniform contact.
If the seat is pitted or grooved lap the
PRV plunger on the seat with lapping
compound.
Fig - 9
To increase the spring tension reverse the
welch washer or replace spring.
Fig. 9
13.6.5 To Remove and Refit Oil Cooler

Assembly
Disconnect connecting hoses. Unscrew

mounting bolts. Dismount oil cooler
assembly.
To refit follow the above in reverse order.
Fig - 10
Fig. 10
13.7 COOLING SYSTEM
13.7.0 General
The engine is water cooled, the coolant

being circulated by a pump of impeller type.
13.7.0.1 Conventional Cooling System
The coolant, drawn by the 45 GPM (Gallons

Per Minute) capacity coolant pump from
radiator or thermostat control by-pass
enters the crankcase. It is then passed to
cylinder head. The coolant returns to
radiator via thermostat housing.
During vehicle operation the thermostat

serves to maintain a constant temperature
of 80° to 85°C (176 to 185°F).
The thermostat starts opening at 75°C -

80°C and fully opens at 92°C by 9.5 mm
stroke.
The twin thermostat arrangement prevents

engine overheating in case any one
thermostat fails to open.
The thermostat installed in the cooling water

return employs a pressure spring and a
bottom by pass control disc. It controls
not only the cooling water return to the
radiator but also regulates the by-pass
working alternately. i.e when it allows the
coolant to flow back to the radiator it
closes the by pass and vice versa.
The electrical sensing unit of the cooling

water temperature gauge is fixed in the
thermostat housing.
The cooling system is pressurised by

employing a radiator cap with combined
pressure and vacuum valve. The pressure is
limited by the pressure valve which opens
whenever pressure exceeds 0.5 kg/cm²,
allowing steam or water to escape through
the overflow pipe. When the engine cools
down any depression in the system is
relieved by the vacuum valve which opens
to admit air from the overflow pipe.
Fig - 1
Fig. 1
13.7.0.2 De-aeration Tank (DAT) Cooling

System
In a conventional cooling system the

aeration of coolant due to inadequate
filling, reduction in flow rate results in
overheating of engine. The DAT system
enables expulsion of Air while filling and
ensures 100% coolant fill in the system.
The DAT also gives the advantages of no
loss system. Low level of scaling, low level
of corrosion and forms an anti-surge
system with low strain on radiator.
The schematic layout of DAT system is Fig. 2

shown.
Fig - 2
In addition to conventional set up, the

vent pipes are connected to a header tank
from radiator top and engine thermostat
housing. The filling is done by the make
up line from header tank to the bottom
points of radiator and engine.
13.7.1 To Flush Cooling System

Cleaning of the cooling system might
become necessary because of outer
conditions or because of impurities in the
coolant itself.
Unfavorable outdoor conditions e.g.
excessive accumulation of dust, insects etc
can greatly reduce cooling capacity. The
radiator fins may be cleaned by washing
them with a suitable hot cleaning solutions
such as 0.5ll of HP Radiator cleaner
(supplied by M/s Hindustan Petroleum
corpn.).
A 5% caustic soda solution (sodium
hydroxide) may also be used for this
purpose. In addition, the radiator fins
should be blasted from the inside with a
strong jet of air or water. When doing so
note the fins are made of very thin sheet
metal. Avoid rough and unskilled
treatment i.e. cleaning with hard brushes.
The cooling system may also be clogged
by rust deposits, grease or other impurities
in the coolant. This should be removed
by flushing the system several times with
hot water containing a grease dissolving
agent.
Let the engine run when flushing the
system.
Note: Make sure that solution does not contain
any acid as even the smallest amount of it
in the cleaning fluid is likely to affect the
cooling system unfavourably.
Having drained off the solvents, flush the

system several times whilst the engine is
running.
The use of hard water fosters the formation
of fur which may be removed with aid of
an acid free solvent. The fur removing
agent must not be aggressive to copper
brass and zinc materials used in the cooling
systems.
Also flush the cooling system several times
after application of a fur solvent.
If should lime has deposited too heavily in
the radiator tubes remove radiator as
described in 13.7.2 and have it cleaned
mechanically by a specialised workshop.
13.7.2 To Remove and Refit Radiator
Unscrew the bumper mounting bolts and

remove bumper.
Remove the grill.
Drain off coolant by opening drain cock on

right front bottom of radiator.
Fig - 3
Collect coolant in a clean container if anti- Fig. 3

corrosive or anti-freeze has been added
recently.
Remove upper hose connection from cooling

water return.
Fig - 4
Remove lower hose connection from cooling

water exit.
Unscrew the 4 attaching nuts (from both

sides) from the radiator frame and bottom
bolts, take off radiator to the front.
Fig. 4
To refit radiator, reverse the procedure for
removal. Check the hose connections for
tightness after a short test run.
13.7.3 To Test Thermostat
Remove hose connection and take out

thermostat.
Fig - 5
Fig. 5
Check commencement of opening. This is

the temperature at which the stroke of the
thermostat has risen to 0.1mm in a
gradually heated water bath.
Thermostat starts opening at 75° - 80°C

and fully opens at 92°C.
Measure the stroke with the aid of special

device and dial gauge.
Check full working stroke
Working stroke = 9.5 mm at 92°C

Fig. 6
Fig - 6
13.7.4 To Remove and Refit Water Pump

Drain off coolant collecting it in a clean
container if anti-freeze has been added.
Remove radiator.
Unscrew fan and remove V belt for water

pump fan and alternator.
Remove hose connection from water pump

and unscrew attaching bolts.
Fig. 7
Fig - 7
To refit water pump reverse the procedure

for removal.
13.7.5 To Overhaul Water Pump

Dismantling
Unscrew water pump mounting securing
bolts and nuts. Remove water pump with
thermostat housing.
Remove the twin thermostat water outlet

pipe from the thermostat housing and
remove the thermostats.
Fig. 8
Remove the fan pulley.
Remove the nuts holding the thermostat

housing and impeller housing. Detach both
the housing.
Fig - 8
Extract the water pump hub with Special

Tool 0101003 - Extractor Water
Pump Hub / Impeller.
Fig - 9
Fig. 9
Remove the stainless steel grub screw from

impeller.
Extract the impeller using Special Tool

0101003 - Extractor Water Pump
Hub / Impeller.
Fig - 10
Fig. 10
Remove the woodruff key from hub end

and waterpump seal.
Fig - 11
Fig. 11
Remove the outer oil seal and remove the

circlip securing the waterpump bearing from
the impeller casing.
Fig - 12
Press out the water pump bearing along

with driving shaft from impeller casing.
Fig - 13 Fig. 12
Press out inner oil seal.
Press out the bearings from the driving

shaft together with distance pieces.
Inspection
Clean all parts in kerosene or diesel.
Check for wear, damage or corrosion.
Check bearing seats for cracks.
Check thermostat (Refer section 13.7.3) Fig. 13

Assembly
The water pump assembly procedure is in

reverse order of dismantling. The following
spacer selection procedure can be applied
to achieve proper waterpump shaft end
play of 0.000" - 0.005".
Spacer Selection
Take the impeller casing and clean.
Remove dirt / burrs if any, using

compressed air.
Fig. 14
Press both outer races of the bearings on
impeller casing.
Fig - 14
Place the inner race of rear bearing on

centering mandrel.
Fig - 15
Fig. 15
Mount the impeller casing over the cone.
Fig - 16
Fig. 16
Place the inner race of front bearing on
the Mandrel as shown.
Fig - 17
Fig. 17
Place the dial gauge fixture in position.
Fig - 18
Release the ram on the dial gauge fixture to

apply an axial load of 29.5 kg (65 lb) on
the bearing assembly.
Set the dial reading of zero.
Lift the ram.
Remove the dial gauge fixture without

disturbing the zero setting.
Remove the impeller casing with front Fig. 18

bearing inner race and leave the rear
bearing inner cone on the Mandrel,
Place the "Master spacer' over the inner

cone.
Size of Master spacer : 0.4495" / 0.4505"
Replace the front inner race.
Replace the dial fixture without disturbing

the 'zero' set already.
Apply the same axial load by releasing the

ram.
Fig. 19
13.7.6 To Remove and Refit V Belt. To
Adjust V Belt Tension for Alternator.
Loosen the alternator mounting bolt.
Adjust the nut on the adjusting bolt of the
alternator as per requirement.
To refit V Belt, swing the alternator towards
the crankcase.
To Tension the V belt swing the alternator
outwards.
Tighten mounting bolt on the alternator
bracket. It should be possible to move V
belt laterally 1/2" by thumb pressure on the
longer side of the belt. Fig. 20
Fig - 19
13.7.7 To Remove and Refit V Belt To

Adjust Belt Tensioner.
Loosen the tensioner pulley mouting bracket.
Adjust the belt tensioner as required by
adjusting the nuts on the adjusting bolt on
Fig - 21.
Belt tension - to move V belt laterlly 1/2"
by thumb pressure on the longer side of
the belt.
Tighten the mounting bolts.
Fig - 20 & 21 Fig. 21
13.8 EXHAUST AND INTAKE MANIFOLD
13.8.0 To Remove and Refit Exhaust

Manifold
Disconnect front exhaust pipe from the

exhaust manifold flange.
Unscrew manifold attaching studs from

cylinder heads and remove the exhaust
manifold taking care of the gaskets.
Note: For Turbocharger general maintenance and

precautions Refer section 13.11.1.
Fig. 1
Fig - 1
To refit manifold, reverse the procedure for

removal.
13.8.1 To Remove and Refit Intake Manifold
Remove LDA connection and injector pipes.
Unscrew inlet manifold fixing bolts and

remove inlet manifold.
To refit intake manifold, reverse the Fig. 2

procedure for removal.
While replacing use fresh gasket.
Fig - 2
13.9 MAINTENANCE AND SERVICING OF

DRY TYPE AIR CLEANER
* Remove dust deposit weekly by squeezing the

dust evacuator valve. Fig - 1
* Replace dust evacuator valve immediately if it is

torn, cracked, remains open or missing.
* Never operate the engine, if the restriction

indicator is either broken or missing.
* If red band appear in restriction indicator, clean

the primary element immediately and reset the
restriction indicator by pressing the top button.
Fig. 1
Caution: It is recommended that the primary
filter element should not be cleaned
till the red band appears. Good
cleaning practice can increase the life
of the filter element.
* Check for proper adhesion between end plate

of the element and the sealing ring. Fig - 2
* Always clean the primary element with

pressurised air. Keep a distance between the
nozzle and the element. Use the pressurised air
from inside to outside of the primary element.
* Don't tap on the element and never try to clean

it with compressed air, flowing from outside to
Fig. 2
inside of the primary element. Fig - 3
* Glow an electric bulb inside the primary element.

Check for any holes. If light comes out through
any hole, replace the element. Fig - 4
* Change the air filter primary element only if

- due for cleaning after two consecutive
cleaning
- primary element get punctured (refer

electric bulb test) OR
- red band appears in restriction indicator

with engine stopped condition, even after
cleaning the primary element. Fig. 3
* Replace the safety element after third

replacement of the primary element. Safety
element should never be cleaned but
always replaced.
Note: The wing bolt should be tightened

with hand alone, excessive tightening
would damage the air cleaner.
Caution: Frequent cleaning of the air filter

element leads to drop in the dust
holding capacity, weakening of the air
filter media and ruptures. This, in turn,
could result in serious damage to the
engine because of entry of dust in the
Fig. 4
system.
13.10 ALUMINIUM RADIATORS AND

CHARGE AIR COOLER
13.10.0 Service Instruction
13.10.0.0 Introduction
This manual explains the procedure for
servicing (specifically, the sealing of leakages)
of aluminium radiators fitted with plastic
tanks that may damage in actual usage due
to improper handling before installation on
the vehicle.
The procedure covers the following aspects

of servicing :- Fig. 1 Construction of Aluminium Radiators
* Leakage spot detection
* Sealing Techniques and the tools

required
* Confirmation of proper sealing
13.10.0.1 Details of Radiator
A typical radiator is shown in Fig - 2 for

reference.
CAUTION: Users are requested to get themselves

familiar with all the parts and the
Fig. 2
assembly of radiator before
undertaking the servicing.
13.10.0.2 Servicing Kit
The radiator servicing kit consists of

following items:-
* Screw Driver
* Monkey Plier
* Sealant resin and hardener containers

(Araldite Standard of M/s Ciba Geigy
make or on equivalent Epo x y based
system)
* Alumaseal container
* Araldite applicator
* Brush
NOTE: Araldite rapid may be used in place of

Araldite standard for faster drying and curing
of seal.
13.10.0.3 Procedure for Servicing

Removal of radiator from vehicle -
* Allow the coolant in the radiator to
reach to the room temperature.
* Drain the coolant from radiator
completely by unscrewing the drain
cock.
* Remove all the mounting fasteners,
attachments like shroud, hoses etc.
* Take out the radiator from the vehicle
carefully without damaging the core.
CAUTION: Radiator core and plastic tanks are
susceptible to cracking due to impact
and deformation.
Detection of Leakage Spot –

* Connect the inlet of the radiator to
air supply at the gauge pressure of
1.5 bar.
* Seal all other outlet points.
* Dip the radiator completely in a clean
water tank.
* Tilt the radiator and shake it
vigorously to let the air bubbles
trapped at the clinching area to
escape.
* Observe carefully for one minute and
locate the source of air leakage on
the radiator from the direction of air
bubbles that are coming out of the
radiator.
CAUTION: Do not use the water tank that is
used for copper radiators.
Sealing the leakage spot –

Following procedures shall be adopted for
arresting leakages at different locations of
the radiator.
Replacement of Plastic tank –

Fig. 3
* Take out the member supports using
13 size spanner
* Release the clinch projections of
header plate using screw driver.
Fig - 3
* After making all the clinching
projections up, take out the tank from
its seat in header plate while grasping
the outlet.
* In case, it takes more effort, pat the
tank with rubber or plastic hammer
lightly.
Fig - 4 Fig. 4
* Take off the tank packing.

* Clean the area of the header plate
where the tank sits, thoroughly.
* Insert new tank packing in the place
without twisting.
* Insert new tank (top or bottom) as

applicable.
NOTE: If the source of leakage is at the base

of the tank, i.e. area between header
plate and tank there is no need to
replace the tank.
Fig. 5
CAUTION: Tank packing shall be replaced, every
time, the tank is taken off for
servicing.
* If gap is found between the clinching

projections of header plate and tank,
softly hammer the projections.
Fig - 5
* Clinch the header plate projections

with monkey plier.
* The sequence of clinching should be

followed as illustrated in the figure.
Fig. 6
Fig - 6
* After clinching, confirm the dimension.
Fig - 7
CAUTION: If any of the clinching projections is

broken during the clinching or releasing
process, discontinue the servicing and
replace the entire radiator by a new
one.
* Fix the member supports and tighten

the bolts properly wherever applicable.
Fig. 7
Bottom Type pipe, Drain Cock and
Pressure Cap –
Bottom Type pipe -

* Take out the Bottom Type pipe using
10 size spanner.
* Remove the ‘O’ ring.
* Clean the seat of Bottom Type pipe
and the ‘O’ ring groove.
* Insert a new ‘O’ ring.
* Fit the Bottom Type pipe back,
ensuring proper tightness of the bolts.
Drain Cock * Silver colour paint may be used for

* Unscrew the drain cock. touching up the araldite spots and
impart the aluminium type appearance.
* Remove the ‘O’ ring.
* Clean the ‘O’ ring groove. CAUTION: * Do not damage the fins during
the process.
* Insert a new ‘O’ ring.
* Confirm that fins are set properly,
* Screw the drain cock back.
if disturbed during the process.
Pressure Cap – * As the Araldite is inflammable, do
not dry it by heating.
* Replace the pressure cap with a new
one, if leakage is through if after * Proper cleaning of radiator core
cleaning the filler neck. is must for proper setting of
Araldite or else it will come off.
CAUTION: Always use recommended radiator
pressure cap. Confirmation of Proper Sealing
Radiator Core – * After the sealing work is over,

Different procedure of sealing shall be assemble the radiator properly.
followed for minor and major leaks in the * Subject the assembled radiator to
radiator core. leakage test as shown in point 4.2.
Minor Leaks : Leak spots which are very NOTE: If the problem of leakage persists, it is
minute, are to be sealed in following manner. advisable to replace the radiator with new
* Install the radiator. one.
* Pour the contents of alumaseal in the 13.10.0.4 Radiator Installation

radiator.
* Ensure that all the openings of the
* Fill proper quantity of coolant liquid. radiator are closed properly except
* Run the engine in idling for more than the inlet.
20 minutes to detect leakage, if any. * Install the radiator on the vehicle
Major Leaks: Procedure of sealing major ensuring proper alignment, damping
leaks in the radiator is as follows : etc. as applicable.
* Wash the core with clean water and * Connect the inlet and outlet pipes
brush provided in the kit to remove and clamp them.
dirt, dust etc. * Fit the fan shroud.
* To remove the greasy spot on the Fill the radiator with proper quantity of
core, apply thinner with cotton swab fresh coolant as recommended.
and take off the grease.
* Dry the core using a dryer. 13.10.0.5 Do's and Don'ts
CAUTION: Drying by heating must be avoided. Do's
Always use the clinching tool for removing
* Mix adequate quantity of Araldite
and refitting the radiator tanks.
resin and hardener in the ratio of 1:1
and stir it thoroughly. Always drain the radiator fully before
removing it from vehicle.,
* Apply the mixture immediately at the
leakage spot with the applicator. Always refill the radiator with coolant
recommended by the manufacturer.
* If required, apply the mixture to dry
and harden under the shade at room Always check tank packing before
temperature for 10-12 hour. reassembly of tank to core.
* Allow the mixture to dry and harden Don'ts

under the shade at room temperature
for 10-12 hour. Never open the pressure cap when the
radiator is hot.
NOTE: * Araldite Rapid of M/s Ciba Geigy
Don't use acid for cleaning the tubes and
dries and hardens within one hour and
tanks.
hence users may use it to minimize
the down time. Don't use manual force for cleaning clogged
tubes.
13.11 TURBOCHARGER
1. Air Outlet from Compressor 6. Center Bearing Housing

2. Back Plate 7. Turbine Wheel
3. Compressor Wheel 8. Journals
4. Thrust Bearing 9. Waste Gate Valve
5. Boost Pressure Hose to Actuator 10. Actuator
Fig. 1 Turbocharger with Waste gate
13.11.0 General 4. Compressor housing

In exhaust gas turbocharging, the thermal 5. Journals
energy in the exhaust gas, which would 6. Bearing housing
normally be wasted, is used to drive a 7. Waste gate ( When provided)
turbine.
8. Actuator (moved by the boost
The turbine drives a compressor, which pressure opens or closes the waste
draws in filtered air and feeds this, at a gate valve)
higher pressure, to the engine.
Exhaust gas is used to drive the turbine
This enables more fuel to be burnt with a wheel. Turbine wheel rotates the
greater mass of charge air, increasing engine compressor wheel, which is mounted on the
power output. same shaft. Compressor wheel sucks the
clean air through the air filter. The clean air
Better air availability enhances better
is compressed and sent into the engine.
combustion, thus leading to lower fuel
consumption and less emission. Due to more air in the engine more fuel
can be burnt. Due to more fuel and more
13.11.0.0Design and Operation air, we get more power from the same
Turbocharger is operated on the exhaust engine. When waste gate valve is fitted, at
gas, which is normally wasted. higher engine speeds the waste gate limits
the exhaust gas flow through the turbine
Turbocharger consists of:
by diverting a portion of the exhaust gas
1. Turbine wheel direct to the exhaust pipe.
2. Turbine housing
3. Compressor wheel
1. Air Outlet from Compressor 5. Center Bearing Housing

2. Back Plate 6. Turbine Wheel
3. Compressor Wheel 7. Journals
4. Thrust Bearing
Fig. 2 Turbocharger without Waste gate
13.11.0.1Benefits of Turbocharging 3. Filtered oil at required pressure is essential

to lubricate and cool the journals.
Lower fuel consumption
Lower emission 4. The clearances between the rotating parts
Better torque characteristics are very close(in microns)
Lower weight and a smaller engine package 5. Turbocharger rotor assembly rotates at high
Lower engine noise speeds up to 1,00,000 rpm at the rated
engine power. Therefore turbocharger
Altitude compensating rotating parts are balanced to very high
accuracy for optimum performance.
13.11.0.2For Enhancing Turbocharger Life
Turbocharger needs CLEAN ENGINE OIL 6. Since turbocharger compressor wheel is
& CLEAN AIR (from the air filter.) for it's made of aluminum alloy rotating at very
proper functioning and durability for the high speeds, dust, sand or any foreign
following reasons. particle entering in to the turbocharger
compressor housing will damage the
1. Oil contaminated with dirt or foreign compressor wheel blades, which will lead to
material will wear the journals and journal turbocharger failure.
seating area.
7. Damaged blades will lead to imbalance in
2. Dirt in the oil also blocks the oil holes in the rotor assembly resulting in shaft or
the journals (bearings) and bearing housing bearing failure.
leading to oil starvation to the
turbocharger.
13.11.0.3 Preliminary Checks Overhaul Kit

If your Turbo engine does not run the way Description Qty
it Should, For For
Do not start your Search For Defects Non-Waste Waste
at the Turbocharger. Gated Gated
Turbo Turbo
Check for the following:
Journal 2 2
a. Is the clutch slipping?
Snap Ring 4 4
b. Does the vehicle brake drag?
Thrust Plate 1 1
c. Is the throttle opening fully? Thrust Ring 1 1
d. Is the air filter system blocked? Piston Ring T.S 2 2
e. Is the compression of the engine low? Piston Ring C.S 1 1
f. Is the fuel injection system correct? O’ Ring (Big) 1 1
g. Does the crankcase breather system O’ Ring (Small) 1 1
function? Socket Head Bolt 4 4
h. Is the exhaust pipe blocked/ damaged? Washer 4 4
Shaft Nut 1 1
After the above inspection now you can
Bolt Hex. (C.S) 8 8
look at the turbocharger for cause of
Segment (T.S) 3 3
trouble.
Bolt Hex. (T.S) 6 6
Please do not try to service or repair the Segment (C.S) 4 3
Turbocharger yourself. Sealing Ring - 2
Consult TEL Service centre along with AL Tube Clamp - 2
Service engineer. Boost Pressure Hose - 1
Locking plate - 1
If all parameters outside turbocharger are
satisfactory as per the checklist given earlier,
inspect the turbocharger. Secondary kit
Sl. No. Description Qty
Disconnect compressor inlet and turbine
outlet pipes and visually examine both the 1. Flinger Sleeve
wheels. If no fault is found remove (Single Piece Type) 1
turbocharger from the engine and send it for
detailed inspection by TEL Service Centre. Gasket Kit
(Please refer to serviceable parts while
overhauling.) Sl.No. Description Qty
1 Gasket (Oil Inlet) 1
2 Gasket (Oil Outlet) 1
13.11.0.4 Serviceable Parts* of Turbocharger
3 Gasket (Turbine inlet) 1
1. Core assembly kit
2. Overhaul kit
3. Secondary kit Boost Pressure Hose Kit
4. Gasket kit SL. No Description Qty
5. Actuator Assembly kit (For Waste 1 Boost pressure Hose 1
gated turbocharger) 2 Tube Clamp 2
6. Boost pressure Hose kit (For Waste 3 Sealing Ring 2
gated turbocharger) 4 Connecting Adaptor 1
5 Hollow screw 1
Core Assembly Kit
Description Qty Actuator Assembly kit
For For SL. No Description Qty
Non-Waste Waste
Gated Gated 1 Actuator Assembly
Turbo Turbo + Tube clamp
+ Boost pressure hose 1
Core assy 1 1 2 Tube clamp 1
Segment (CS) 4 3 3 Connecting Adaptor 1
Bolts 8 8 4 Sealing ring 2
Segment (TS) 3 3 5 Hollow screw 1
Bolts 6 6 6 Locking plate 1
* These are serviceable parts recommended for use only by TEL Authorised Service Centres for repair / overhaul of
Turbochargers.
13.11.1 Precautions to be taken for 13.11.2 Do's and Don'ts

Turbocharger Installation Do's
Check air cleaner (filter element) and it's * Regular change of engine oil / oil
connecting pipes for blockage, distortion etc, filter.
and should be cleaned / replaced. * Regular change / cleaning of air filter
Check and clean engine intake and exhaust element.
manifold pipes. The oil feed and drainpipe * Check for oil pressure at engine
to the turbocharger should be examined for idling condition. (Minimum oil
dirt, cracks, distortion, etc. pipes should be pressure to be as per
thoroughly cleaned before fitment. If found recommendation during idling.)
damaged it should be replaced. * Idle the engine for two minutes after
Remove any tape or cover used as starting the engine.
temporary cover to the pipe inlet. * Idle the engine for two minutes
before switching off the engine.
Examine the engine oil and the oil filter
condition. * Periodic cleaning of crankcase
breather is necessary to allow free
Replace the oil and the filter element if flow of oil from turbocharger outlet.
necessary. (Adhere to Ashok Leyland's
* Regularly check all air, oil and exhaust
recommendation for correct grade & change
connections for leaks and abnormal
period).
dust / oil / carbon build up.
Use recommended new gaskets for fitment
of the turbocharger to the engine. Do not Don'ts
apply gasket sealant (Shellac, Anabond, * Don't run the engine with low oil
grease etc.,) at the oil inlet and the oil pressure.
outlet flanges for pasting the gaskets.
* Don't put the engine under full load
Do not use a strainer type gasket . ( This is immediately after starting. (Always
a temporary gasket used only for the initial run the engine/vehicle at moderate
testing in the Factory) speed and load for a few minutes
Ensure correct fitment of the turbocharger to before going to full load and speed.)
the engine (rotate the turbine shaft and * Don't switch off the engine under full
check for its free rotation). load.
Fitment of inlet and outlet pipes (to * Don't run the engine with
turbocharger) under strain may result in DAMAGED
turbocharger failure. - Oil feed and drain pipes
NOTE: - After long storage before starting the - Pipes between air filter and
engine, fill-up the oil feed hole of the turbocharger
turbocharger with clean engine oil to - Exhaust pipes
ensure lubrication during start-up. * Don't run with Leaky connections
- Crank the engine till you notice oil from the air cleaner to the
pressure in the gauge before you start turbocharger and turbocharger to the
the engine. inlet manifold.
- Start the engine and idle for two CAUTION: - Don't open the Turbocharger
minutes before accelerating the engine. yourself.
- Please contact the Ashok Leyland
- Check the engine oil pressure. Authorised Dealers for any
- Do not run the engine if oil pressure turbocharger problems.
is found less than that recommended. - As the turbocharger is
- When the engine in running, check all precision built, assembled and
air, oil and exhaust connections for tested by highly skilled personnel,
leaks. we do not recommend opening
of the Turbocharger for servicing
CAUTION - Do not accelerate the engine by unauthorised persons.
immediately after start.
- However, if need be, please
- Idle the engine for at least two contact Turbo Energy Ltd Service
minutes after start and before the centres for assistance for
engine is stopped. servicing Turbochargers.
13.11.3 Turbo charger trouble shooting
High oil consumption
Oil leak from turbine

Engine Lacks power
Turbocharger noisy
compressor side
Oil leak from
Black smoke
Blue Smoke
Possible Cause
seal
Dirty air cleaner
Restricted compressor intake duct / piping
Restricted air duct from compressor to intake manifold
Air leak in pipe from air cleaner to turbocharger
Air leak in pipe from compressor to inlet manifold
Air leak from inlet manifold
Foreign object in exhaust manifold (from engine)
Restricted exhaust system
Exhaust manifold cracked, gaskets blown or missing
Gas leak at turbine inlet/exhaust manifold joint
Gas leak in exhaust piping
Restricted turbocharger oil drain line
Restricted/blocked/distorted crankcase breather
Turbocharger bearing housing sludged or coked
Fuel Injection System defective / incorrectly adjusted
Engine valve timing incorrect
Worn engine piston / piston rings / liners
Eroded valves and / or pistons
Excessive dirt build up on compressor wheel and housing
Boost pressure control swing valve / poppet valve

doesn’t close/damaged
Boost pressure pipe to actuator leaking / damaged
Piston ring sealing defective
Turbocharger journal (bearing) defective
Foreign body damage on compressor / turbine wheels
Insufficient oil supply to turbocharger

13.12 TIGHTENING TORQUES Kgm lb.ft Nm

Rocker assembly nut 5.5 - 6.2 40 - 45 54 - 60
Injector clamp nut 4.1 30 40
Connecting rod cap bolt 10.4 - 11.1 75 - 80 102 - 109
Main bearing cap bolt 20.1 - 21.5 145 - 155 197 - 211
Idler gear assembly nut 9.7 - 10.4 70 - 75 95 - 102
Cam shaft gear set screw 19.4 - 20.1 140 - 145 190 - 197
Damper puller setscrew 27.7 - 30.5 200 - 220 272 - 299
Flywheel adaptor to crankshaft bolt 22.8 - 24 165 - 174 224 - 235
Flywheel to adaptor flange bolt 11.7 - 13.1 85 - 95 115 - 129
Cylinder head assembly nut 17.3 - 18 125 - 130 170 - 176
Flywheel housing setscrews 5.5 - 6.2 40 - 45 54 - 60
Sump bolts 3.5 25 34
Side cover bolts 2 - 2.7 15 - 20 20 - 26
Water pump hub lock nut 13.9 - 14.5 100 - 105 136 - 142
Engine metacone mounting nut 19.4 - 20.8 140 - 150 190 - 204
Cooling Jet Banjo Bolt 1.4 10 14
Compressor pulley nut 9.2 - 10.2 67 - 74 90 - 100
FIP drive spline lock nut 6.2 - 7.6 45 - 55 60 - 75
13.13 Recommended coolant
Recommended
Change
Name & Address Concentration
Coolant intervals
of the manufacturer For Brass- Copper For Aluminium
in km
Radiator Radiator
Gulf Oil Corporation Limited,
Lubricants Division
Gulf Euro Cool 20% 50% 75,000
IN Centre, 49/50, MIDC, 12th Road,
Andheri (E), Mumbai - 400 093. INDIA
GC 1200 Sunstar-CCI (India) Private Ltd., 30% 50% 60,000
67, Maruthi Industrial Area, Sector 18,
GCL-2000 Gurgaon - 122 015. Haryana. 20% 50% 75,000
Tejon 800 S S Industrial Corporation 20% 50% 75,000
G-10, Udyog Nagar,
Tejon 1200 Delhi - 110 041. 30% 50% 60,000
Bharat Petroleum Corporation Limited,
MAK®
ECE House, 28A Kasturba Gandhi Marg, 20% 50% 75,000
SuperKool
New Delhi - 110 001.
Note: For Sub-zero temperature application use 1 : 1 Ratio.
To Prepare the coolant, it is recommended that only potable drinking water is used.
Caution: Use of any hard water will only increase scale formation in the Engine. Also please note that coolant
does not alter the hardness level of water.
13.14 Recommended Lubricants

Use of correct grades of lubrication is most important to prevent the wear and tear of components.
The chart shows the oil grade recommended by AL.
ASHOK
LEYLAND
GENUINE
LUBRICANTS
Ashok Ambient Sah Valvoline
Gulf Indian Oil Hindustan Bharat Elf
Aggregate Leyland Temp. IBP Chemoleums Petroleums Cummins
Oil India Corporation Petroleum Petroleum Lubricants
Specification °C IPOL Ltd.
Bharat Gulf Elf IPOL MCG VALVOLINE
Servo HP Milcy IBP
Stage II API CG4 + -15 and Superfleet MAK®-CG4 Performance Turbo CG4 Diesel All Fleet
Premium Eurol Turbo CG4
Norm MB 228.3 above Special 15W-40 Trophy DX 15W40 Premium Premium
CG4 15W40 15W40 15W40
Engines # 15W40 15W 40 15W40 15W40
13.15 Filling Capacity
Aggregates Qty (ll ) Change

Minimum Maximum Period (km)
Engine (Without Oil Filter) 10 12.5 10000
Note: The drain limits indicated are only for plains operation. For Ghat operations drain interval to be halved.
13.16 MAINTENANCE PROGRAMME
km x 1000
Lubricant
16000 km
8000 km
Weekly
Remarks
No. of
points
Every
Every
Every
Daily
PDI
A. General
1 Check and tighten, front and rear engine
mounting / other peripherals bolts
2 Check and tighten cylinder head nuts/bolts
for correct torque in correct sequence 96
3 Check and adjust valve clearance on cold engine
4 Check vibration damper and replace if necessary 72
5 Check compression pressure 60
B. Lubrication System
1 Check oil pressure (minimum 1.0 kg/cm² at
idling rpm and 85°C engine temperature)
2 Check and top up oil level in sump O 1
3 Change engine oil and filter element 1 10
4 Remove and clean breather 48
5 Clean and refit engine sump and oil pump strainer 48
C. Cooling System
1 Check and top up coolant level in radiator
2 Check radiator hoses and clamps for leakages
and tightness
3 Check and adjust fan belt tension
4 Check and tighten radiator stay rod and
radiator mounting bolts
5 Lubricate water pump bearing. G 1
6 Check water pump, recondition if necessary 48
7 Drain cooling system and fill recommended Refer
coolant section
5.13
8 Replace cooling system hoses and rubber
pads for radiator mounting and stay rod 72
D. Fuel System
1 Check fuel pipes on suction, pressure and
overflow line, for leakages and tighten if
necessary.
2 Lubricate accelerator linkages G 2
3 Lubricate accelerator link pedal shaft O 1
4 Check and tighten F.I.P. / filter mountings 32
5 Check and adjust F.I.P. timing 32
* Both the fuel filter elements must not be changed at the same time
09.12 MAINTENANCE PROGRAMME
km x 1000
Lubricant
16000 km
8000 km
Weekly
Remarks
No. of
points
Every
Every
Every
Daily
PDI
6 Replace fuel filter element*
a. Primary element
b. Secondary element First

24000kms
&
thereafter
every
16000kms
7 Replace chassis filter (Single) 10
8 Check and drain water separator
9 Clean fuel tank and strainer 48
10 Check injector for correct opening pressure 56 First

and spray characteristics, adjust if necessary 16000km
also
11. Clean and refit feed pump strainer
12. Drain fuel filter bowl, till clear fuel appears

and bleed the system
13 Re-calibrate fuel injection pump and timer 150
14 Replace fuel hoses 150
E. Air Intake and Exhaust

1 Check and clean air cleaner - primary element
(If restriction indicator shows red band)
2 Replace air cleaner primary element
(After 2 consecutive cleaning).
3 Replace air cleaner safety element (At the
time of third replacement of primary element
or once in a year - whichever earlier).
4 Check restriction indicator, if necessary clean
the element
5 Check air inlet hose for any puncture/damage
6 Check for any blockage / breakage at
rainhood assembly
7 Check Turbocharger mounting 24
8 Check charge air cooler for any blockage of
fins and clean the cooler if necessary 32
9 Check charge air cooler hoses for any damage
10 Check exhaust manifold and silencer for leaks
and tightness
11 Check intake and exhaust manifold mounting 32
fasteners fins and clean the cooler if necessary

AL BS 2 Engine

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AL BS2 ENGINES (L62D-MK II & L62N-MK II)

Section Subject Page No.

Contents ...................................................................................................................................................... 13.03

13.0 General .......................................................................................................................... 13.07

13.1 To Remove and Refit Engine from Vehicle ......................................................... 13.20

13.2 Crankcase ...................................................................................................................... 13.21

AL BS2 ENGINES (L62D-MK II & L62N-MK II)

Section Subject Page No.

13.4 Cylinder Head and Valves ........................................................................................ 13.36

13.5 Timing .......................................................................................................................... 13.40

13.6 Engine Lubrication ..................................................................................................... 13.50

AL BS2 ENGINES (L62D-MK II & L62N-MK II)

Section Subject Page No.

13.7 Cooling System ............................................................................................................ 13.54

13.8 Exhaust and Intake Manifold ................................................................................... 13.61

13.10 Aluminium Radiators and charge air cooler ...................................................... 13.63

13.11 Turbocharger ................................................................................................................ 13.67

13.12 Tightening Torques .................................................................................................... 13.72

13.13 Recommended coolant .............................................................................................. 13.73

13.14 Recommended Lubricants ......................................................................................... 13.73

13.15 Filling Capacity ............................................................................................................ 13.73

13.16 Maintenance Programme .......................................................................................... 13.74

13.0.0 Engine Type and Number

The Engine Sl. No is stamped onto the

The engine Sl. No. is stamped on RH rear

The crankshaft has a individual Sl. No.

13.0.1 Design and Operation

Fig - 4 Representative Diagram - Intake Side

Fig - 5 Representative Diagram - Exhaust Side

13.0.2 Engine General Data

Models L62D-MK II L62N-MK II

Aspiration Turbo with inter cooler

Max. output 100 Kw ± 2% @ 2400 rpm 117 Kw ± 2% @ 2400 rpm

Weight of the Engine (Dry) 580 kg

Compression ratio 17.5 : 1

Compression pressure (psi) 390 - 410 (limit - 300)

Idling speed 575 ± 50 rpm

Firing order 1-5-3-6-2-4

Valve clearance - Inlet/Exhaust 0.45 mm

Lubrication system - Oil cooler Water Cooled Plate Type

Injection timing BTDC plunger travel 1.23 - 1.26 mm 1.30 - 1.33 mm

Injector pipe (OD x ID x LT) 6.35 x 1.8 x 750 mm

Nozzle opening pressure 260 - 268 bar

Inlet opens at 6° BTDC

Inlet closes at 15° ABDC

Exhaust opens at 52° BBDC

Exhaust closes at 6° ATDC

Valve Lift (inlet) 10.4 mm

Valve Lift (Exhaust) 12.0 mm

13.0.4 Description of Leading Engine

Cylinder Block - of high grade cast iron.

Cylinder Liners (dry, INSITU finished/pre

Cylinder Head - made of high-grade cast

Crankshaft - an alloy steel forging,

Vibration Damper - viscous damper with

Alfin Pistons (re-entrant bowl type) -

Main and Small - End Bearing Shells

Camshaft - made entirely of steel,

Valve Spring - made of spring steel, Fig. 6A