scorpio refresh m-hawk suv & sc/dc - manual de … · index m hawk 2.2 l air intake system...

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Repair Manual MAN-000XX Scorpio Vlx August 2009/Rev 1

All copyrights reserved by The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of

whole of the present document, are prohibited without the prior written consent of © 2009 Mahindra & Mahindra Ltd.

M Hawk 2.2 L

Contents

Description

Trouble Shooting

Care of the System

In Car Repairs

Working principle of various sub systems of the Engine Dismantling & overhauling of the Engine.

Working Principle, Dismantling & Overhauling of the Turbocharger

Specifications & Wear Data

Lubricants & Sealants Sealant Application Pattern

Tightening Torques

Tightening Sequence

List of the MST




Description The 2.2-liter Turbocharged and intercooled common rail direct injected diesel engine with a bore 85 and stroke of 96 mm develop 88 KW(120 HP) at 4000 RPM and a torque of 290 Nm at 1800 RPM. A variable geometry turbocharger controls the boost to 2.2 bars. The compressed air is cooled by the charged intercooler which is mounted upstream of the turbocharger. The cooled air enters the inlet manifold’s plenum and it enters the Aluminium cylinder head through the inlet valves having an angle. The piston features re-entrant type combustion chamber and having ferrous ring insert in the Top ring groove. A 3-ring pack is used. The top ring is asymmetrical barrel face and with CKS coating and keystone shape. The 2ndring is taper faced. The 3rd is conformable Oil Ring. The forged connecting rod is connected to induction-hardened crankshaft. The small end of the connecting rod is trapezoidal shaped to reduce the mass as well as to ensure higher loading. The crankshaft is induction hardened with the filets hardened & ground. The flywheel has a shrunk fit ring gear and also a ball bearing to act as pilot for the gearbox input shaft. The front end is having a rubber molded dampener pulley The high pressure pump & camshaft are chain driven. There are two overhead camshafts (Inlet and exhaust). The valves are actuated through HFF & RLA (hydraulic tappets). There are four valves per cylinder. This ensures that the charge fill as well as the purging is optimum.




Trouble Shooting Refer to the Service diagnosis chart. Additional tests & diagnostic procedures may be necessary for specific engine complaints that cannot be isolated using only the diagnostic chart. Information concerning the additional checks is provided within the following diagnostic.

Cylinder compression pressure Test The results of the cylinder compression test can be utilized to diagnose several engine malfunctions. Before carrying out the compression test ensures that the battery is in good working condition. Otherwise the indicated pressures may not be valid for diagnostic purpose. � Remove all the injectors. � Fit the dummy injector (MST Tool) and connect it with the compression gauge. � Disconnect the engine RPM sensor or phase sensor connector so that the engine

does not start. � Crank the engine. � Note the compression value should be 30 bars. � Repeat the procedure for the other cylinder. � Refer to the Specification for the value.

Engine cylinder Head Gasket Failure Diagnosis A leaking engine cylinder head gasket usually results in loss of power, loss of coolant and engine misfiring, overheating and poor fuel economy. An engine cylinder head gasket leak can be: A. Between adjacent cylinders Or B. Between a cylinder and adjacent water jacket. Cylinder head gasket failure between cylinders is indicated by Loss of power and /or engine misfiring. Cylinder head gasket leaking between a cylinder and coolant passage results in coolant foaming or overheating and loss of coolant indicate leakage in engine water jackets.




Cylinder to Cylinder Leakage Test Check the cylinder compression pressure as already explained. Leakage between cylinders will be result in drop of compression pressure by nearly 50 to 70% in the affected cylinders.

Cylinder to Water jacket Leakage Test

• Remove the radiator cap.

• Warm up the engine and allow it to warm up until the engine thermostat opens.

• If large combustion /combustion pressure leak exist, bubbles will be visible in coolant.

• If bubbles are not visible, install a radiator pressure tester and pressurize the cooling circuit. If a cylinder is leaking combustion pressure into the water jackets then the tester’s needle will pulsate with every combustion stroke of the cylinder.




Symptom Causes Remedial action Engine will not start & emit black smoke

1. Air intake obstructed 2. Defective injectors 3. Lack of compression. 4. Cylinder head gasket failure 5. Engine timing- Valve 6. CR system

� Replace the element. � Check for free operation

of Turbocharger. � Replace � Check compression

pressure.- if low check for valve seat ,rings & liner wear

� Replace the cylinder head gasket.

� Check timing chain. � Refer diagnostic manual.

Noisy engine & black smoke.

1. Faulty injectors. 2. Loose main bearings 3. Broken parts 4. EGR valve stuck open

mechanically

� Replace injectors � Tighten the main

bearings. � Inspect and replace the

broken parts. � Check the EGR valve &

replace if required

Engine does not give full power.

1. Air intake restricted. 2. Clogged fuel filter. 3. Defective injectors. 4. Air leaks in pressure line

after turbocharger( Turbo to intercooler, intercooler & intercooler to intake manifold)

5. Fuel return pipe to tank

blocked. 6. Valve leak 7. Turbocharger damaged. 8. Gas leaks between exhaust

manifold & cylinder head. 9. Leaking exhaust system.

� Replace air cleaner element if required.

� Replace filter. � Replace � Plug the leaks, replace

hose or clip if required. � Locate the kink/block in

return pipe and rectify. � Check the compression,

re-lap if required. � Get the Turbocharger

repaired at authorized TEL dealer.

� Replace gaskets. � Tighten the TC mounting

bolts. Replace gasket if required.




10. Exhaust gas leak between

turbo & manifold. 11. Gas leak between EGR pipe

joints 12. EGR pipe leak. 13. Fuels supply line kink

creating restriction. 14. Compression leak. 15. Jammed piston rings 16. Viscous fan continuously

engaged. 17. Vacuum leak to the VGT

actuator causing the delayed VGT operation

18. Check CR system

� Correct the leak � Change the gasket or the

hose. � Replace the pipe. � Remove the restriction. � Check compression. � Replace piston rings. � Check the VFD as

outlined in cooling. Replace if required.

� Check the vacuum leak and rectify. Please note that the VGT operation is sensitive to vacuum leak.

� Refer the diagnostic manual

Noisy engine & high smoke ( White/ Grey)

Cylinder head gasket defective.Worn out or damaged valve

seats. Leaking injector holder

� Replace the cylinder head gasket.

� Lap the valve seats or regrind.

� Tighten the injector

holder.

Black smoke. 1. Air intake restricted. 2. Defective injectors 3. Air leaks. 4. EGR valve stuck open 5. Restricted exhaust system.

� Check for hoses, replace air cleaner element.

� Check injectors. � Check for leaks between

Turbocharger to intercooler, intercooler & intercooler to inlet manifold.

� Check the EGR valve � Remove restriction or

replace parts.




6. Gas leak between exhaust manifold & cylinder head.

7. Worn out rings, liners & valves.

8. Improper vacuum

connection for EGR valve

� Replace manifold gasket or parts.

� Overhaul engine. � Check & correct

Excessive oil consumption

1. Cracked vacuum line hoses. 2. Clogged air filter element. 3. Restriction in air intake to

compressor duct. 4. Restrictions in turbocharger

oil drain line. 5. Restriction in crankcase

breather. 6. Damaged oil separator 7. Turbocharger damaged. 8. Worn out rings, liners, and

valves. 9. External oil leaks 10. Leakages through inlet

manifold mounting face allowing dust entry.

11. Bend/kink in any of the oil return pipe’s/vacuum hoses.

12. Defective vacuum pump.

� Check the vacuum line from the alternator to the EGR valve - check for leaks, crack. And vacuum line to the VGT actuator. Replace cracked hoses.

� Replace element. � Locate & remove

restriction. � Remove the restriction in

the drainpipe. � Check the crankcase

ventilation & rectify. � Replace the oil separator � Change oil, filter, service

the Turbocharger & use recommended oils & drain intervals. Follow the recommended procedure while shutting down.

� Repair Turbocharger. � Overhaul engine. � Stop the external oil

leakages. � Change the vacuum

hoses. � Change the manifold

gasket or replace the manifold.




� Remove the bend or

kinks. � Replace the vacuum

pump.

Blue smoke. 1. Clogged air filter element. 2. Restriction in air intake to

compressor duct. 3. Air leak between the

Turbocharger to intake manifold.

4. Excess oil. 5. Wear in valve seal. 6. Wear in piston rings & liner. 7. TC oil seal leaks

� Replace element. � Locate & remove

restriction. � Locate the leaks, change

hose or clamp if required.

� Correct the oil level. � Check the valve stem

seals, replace if required.

� Check the compression

pressure, replace rings & liners.

� Check the Turbocharger

if defective get it attended.

White smoke. 1. Improper timing

2. Defective cylinder head

gasket. 3. Restriction in fuel supply

� Check sprockets & chain

for wear. Rectify � Replace the cylinder

head gasket. � Remove the restrictions.

Starter will not work or only cranks slightly

1. Electrical complaints. 2. Check water level. 3. Hydrostatic lock

� Refer the electrical section.

� If water level reduced

drastically then check for hydrostatic lock.

� Remove the water in the

cylinder and find the cause for water entry.




Starter will not crank the engine.

1. Weak battery. 2. Corroded or loose battery

connection 3. Faulty starter.

4. Improper earthing.

� Check the battery specific gravity.

� Clean & tighten battery connections.

� Repair starter. � Rectify earthing.

Noisy valves 1. Thin or diluted oil. 2. Low oil pressure. 3. Worn HLA 4. Worn valve guides. 5. Excessive run out of valves

seats 6. Oil thickening 7. Aeration in oil

� Change oil. � Check the oil level. � Replace the HLA. � Replace the valve guides. � Grind valve seats and

valves. � Replace oil & find the

reasons of thickening, rectify.

� Follow the de-aeration procedure.

Oil pressure drop

1. Low oil level. 2. Defective oil pressure

sensor. 3. Clogged oil filter. 4. Clogged oil cooler 5. Clogged oil strainer. 6. Pressure relief valve in oil

filter bracket stuck. 7. Oil leaks- internal 8. Worn parts in oil pump. 9. Excessive bearing

clearances 10. Thin or diluted oil. 11. Excessive bearing

clearance.

� Check engine oil level. � Install new sensor. � Replace filter. � Clean the oil cooler. � Clean the strainer. � Clean the valve & bore

and assemble. � Check the gasket

between the block & front cover or any of the MOG plugs

� Replace the worn parts

or pump. � Check bearing

clearances. � Change oil to correct

viscosity. � Replace the bearing � Remove the valve,

inspect, clean & refit.




12. Oil pump relief valve stuck. 13. Oil pump suction tube

loose, bent or cracked. 14. Sealant blocking the suction 15. Oil pump cover warped or

cracked

� Remove sump, inspect the parts & replace.

� Check for sealant at the

face of the suction pipe. � Install new pump.

Oil leaks 1. Worn oil seals 2. Misaligned or deteriorated

gaskets. 3. Loose fastener, broken or

porous metal parts

� Replace seals. � Replace gasket. � Tighten fastener � Repair or replace.




Care of the System The performance of the engine is dependent on ensuring that the following maintenance is carried out as per the schedule without fail. Accessory Belt: The belt system employs an auto tensioner. Hence no tension adjustment is required. The belt for the HVAC is having a manual tensioner. This needs to be checked at every 10,000 KMs & readjusted if required. The manual tensioner bearing needs to be replaced at every 80,000 Km Air cleaner: The element should be replaced at every 40,000 KMs or when red indicator band shows. For the detailed procedure, refer to the Air Intake System. Oil: The oil should conform to CH4 grade and with a viscosity Index of SAE 15W40. It should be kept in mind that in the turbocharger engine the oil has to have do an additional load of lubricating and cooling the Turbocharger shaft If any oil of lower specification is used it can break down under the high thermal load at the turbine end of the shaft especially during the hot shutdown. This oil grade also ensures that the oil consumption is within the desire limits. Use Maximile Supreme Grade of oils. The Oil change intervals are first at 5000 KMs. & then subsequently every 15000 KMs. Cooling system: Ensure that no leakages are present. For details of the coolant and ratio refer the Cooling System. Turbocharger: The engine is having a Variable Geometry Turbocharger. This turbocharger helps in maintaining a good power curve at low speeds also. EGR: The following additional check points have to follow during scheduled maintenance.

• Check for any exhaust gas leakage through sealing faces, EGR pipe. Formation of any black soot indicates leakage.

• Check the vacuum hoses for any leaks, cracks.

• Retighten all nuts and bolts as per the recommend torque. As this engine is equipped with HLA with RFF (Hydraulic tappets); Tappet setting is not required.




In Car Repairs The in car repairs which can be carried out are:

Accessory belt removal & Refitment VFD Assembly with Fan Blade removal High Pressure pump Removal Oil filter changing Turbocharger removal & Refitment Cylinder head gasket Replacement Accessory belt Remove & Refit –

Using the special tool, rotate the auto tensioner in the direction shown in the figure. Lock the auto tensioner in that position using a pin. Remove the auto tensioner mounting bolts & remove the belt tensioner. Note – Check the auto tensioner free arm position. Ensure that end of travel is not reached.




Fan Blade & Viscous Fan Drive Removal & Assembly –

Do not remove the accessory belt before removing the nut.

Loosen the fan nut. Note that the threads are anticlockwise threads. Hence to loosen then the direction of rotation has to be clockwise when viewed from front. Do not tamper or service the center portion of the fan.

Remove the radiator shroud & remove the fan.

The fan blade assembly and the VFD assembly can be removed together.

scorpio refresh m-hawk suv & sc/dc - manual de … · index m hawk 2.2 l air intake system...

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