Developed by: Technical Literature Cell. Release Date : Jan 2019/ First Edition. The information provided in this manual is based on the latest product information available at the time of publication. . C Copyright 2019 TATA MOTORS All rights reserved. The information in this manual shall not be reproduced or copied, in whole or in part, in any form without written permission from TATA MOTORS. Vehicles are subject to modification in design, specification and equipment. Also refer the Service Circulars released by Customer Support about product & procedures.
INTRODUCTION This Service manual provides information pertaining to technical Specifications, repair, maintenance and overhaul of different aggregates fitted on TATA HARRIER. All the data contained in this manual is based on the latest product information available at the time of publication and with the assumption that the person is well aware of general Automobile practices. This manual emphasizes the special features of the vehicle and thus benefits our workman, who is conversant with general Automobile practices. For ease of use, this workshop manual is divided into 3 volumes, comprising several sections. Each aggregate has a separate section. THE BOOK– 1 CONTAINS Engine Transaxle Driveshaft Clutch Release System Steering Suspension Wheels & Tyres Brakes ABS ESP HVAC FATC Body Electrical SRS THE BOOK– 2 CONTAINS Diagnostic Trouble Shooting Codes (DTC) List of All ECU’s THE BOOK– 3 CONTAINS Service Schematics
INDEX SR. NO GROUP 1 ENGINE 2 TRANSAXLE 3 DRIVESHAFT 4 CLUTCH RELEASE SYSTEM 5 STEERING 6 SUSPENSION 7 WHEELS & TYRES 8 BRAKES 9 ABS 10 ESP 11 HVAC 12 FATC 13 BODY 14 ELECTRICAL 15 SRS
ENGINE KRYOTEC ENGINE
KRYOTEC ENGINE INDEX 1. GENERAL INFORMATION ................................................................................................... 1 A ENGINE INTRODUCTION.................................................................................................................... 1 B TECHNICAL SPECIFICATION ............................................................................................................. 2 C SPECIAL TOOLS.................................................................................................................................. 3 D ASSEMBLY CLEARANCES ................................................................................................................. 8 E LEAKAGE RATES ................................................................................................................................ 9 F RECOMMENDED LUBRICANTS AND COOLANTS............................................................................ 9 G SERVICE SCHEDULE........................................................................................................................ 10 2. TROUBLESHOOTING ........................................................................................................ 11 3. CONSTRUCTIONAL AND SERVICE DETAILS.................................................................. 19 4. ENGINE TESTS AND MAINTENANCE............................................................................... 22 A PRELIMINARY INSPECTION............................................................................................................. 22 B ENGINE TESTS.................................................................................................................................. 22 C REGULAR MAINTENANCE ............................................................................................................... 28 i ENGINE OIL AND FILTER CHANGE ............................................................................................ 28 ii ENGINE COOLANT REPLACEMENT ........................................................................................... 29 iii AIR FILTER ELEMENT REPLACEMENT...................................................................................... 30 iv FUEL FILTER REPLACEMENT .................................................................................................... 31 v DRAINING WATER FROM FUEL FILTER .................................................................................... 32 vi AC COMPRESSOR, ALTERNATOR BELT REPLACEMENT....................................................... 32 vii DPF REGENERATION / CLEANING............................................................................................. 33 5. REPAIR AND INSPECTION DETAILS................................................................................ 34 A TIMING BELT...................................................................................................................................... 34 B FUEL TANK ........................................................................................................................................ 35 C CYLINDER HEAD ............................................................................................................................... 35 D VALVES .............................................................................................................................................. 36 E CRANKCASE ...................................................................................................................................... 37
KRYOTEC ENGINE F HYDRAULIC LASH ADJUSTER......................................................................................................... 38 G VALVE GUIDES .................................................................................................................................. 38 H CAMSHAFT ........................................................................................................................................ 39 I PISTON AND PISTON RINGS ........................................................................................................... 40 J CONNECTING ROD ........................................................................................................................... 41 K CRANKSHAFT .................................................................................................................................... 43 L EXHAUST PIPE .................................................................................................................................. 47 6. ENGINE ON VEHICLE SERVICE PROCEDURE ................................................................ 48 A ENGINE REMOVAL............................................................................................................................ 48 B ENGINE INSTALLATION.................................................................................................................... 57 C EXHAUST SYSTEM ........................................................................................................................... 57 D COOLING SYSTEM............................................................................................................................ 65 E FUEL SYSTEM ................................................................................................................................... 68 F TURBOCHARGER REMOVAL AND REFITMENT ............................................................................ 74 G TIMING BELT REMOVAL AND REFITMENT .................................................................................... 74 H STARTER MOTOR REMOVAL AND REFITMENT ............................................................................ 77 I ALTERNATOR MOTOR REMOVAL AND REFITMENT .................................................................... 78 J COMPRESSOR MOTOR REMOVAL AND REFITMENT................................................................... 78 K HIGH PRESSURE PUMP REMOVAL AND REFITMENT.................................................................. 79 7. ENGINE OVEHAULING (ON OVERHAUL STAND) ........................................................... 82 A ENGINE DIS-ASSEMBLY ..................................................................................................... 82 i ON OVERHAUL STAND ................................................................................................................ 82 ii REMOVAL OF FUEL INJECTOR AND PERIPHERAL.................................................................. 85 iii REMOVAL OF EXHAUST MANIFOLD AND OTHER COMPONENTS......................................... 86 iv REMOVAL OF ENGINE PERIPHERALS ...................................................................................... 90 v REMOVAL OF TIMING BELT ........................................................................................................ 92 vi REMOVAL OF INTAKE MANIFOLD .............................................................................................. 96 vii REMOVAL OF CYLINDER HEAD ................................................................................................. 97
KRYOTEC ENGINE
KRYOTEC ENGINE viii REMOVAL OF OIL SUMP ............................................................................................................. 99 ix REMOVAL OF CYLINDER BLOCK SUB-ASSEMBLIES .............................................................. 99 x REMOVAL OF CYLINDER HEAD SUB-ASSEMBLIES............................................................... 101 xi REMOVAL OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES ................................... 102 B ENGINE ASSEMBLY ......................................................................................................... 103 i FITMENT OF CYLINDER HEAD SUB-ASSEMBLIES................................................................. 103 ii FITMENT OF PISTON AND CONNECTING ROD SUB-ASSEMBLIES...................................... 104 iii FITMENT OF CYLINDER BLOCK SUB-ASSEMBLIES .............................................................. 105 iv FITMENT OF OIL SUMP ............................................................................................................. 107 v FITMENT OF CYLINDER HEAD ON CYLINDER BLOCK .......................................................... 108 vi FITMENT OF INTAKE MANIFOLD .............................................................................................. 111 vii FITMENT OF TIMING BELT ........................................................................................................ 112 viii FITMENT OF ENGINE PERIPHERALS ...................................................................................... 116 ix FITMENT OF EXHAUST MANIFOLD AND OTHER COMPONENTS......................................... 118 x FITMENT OF FUEL INJECTOR AND PERIPHERAL.................................................................. 122 xi ON SUPPORT STAND ................................................................................................................ 124
KRYOTEC ENGINE 1 1. GENERAL INFORMATION A. ENGINE INTRODUCTION DESCRIPTION The “2.0L KRYOTEC” is a new generation 4 Cylinder 2.0L Direct injection Common-Rail Turbocharger Intercooled Diesel Engine. This Engine is fitted with common rail system with higher injection pressure (1600 bar) which is controlled by a Electronic Control Unit (ECU).The Engine performance is optimized for various engine speed, load and operating conditions depending upon the various sensor’s inputs. The turbocharger used on this engine is electronically actuated having low inertia of turbine and compressor wheels which reduce the turbo lag at low engine speeds and improves the transient response of the vehicle. This turbocharger incorporates many movable vanes in the turbine housing to control the exhaust flow against the turbine blades which enables higher power, torque, lower fuel consumption and emissions of the engine. The fuel economy and emission has been optimized at source by means of low engine friction, faster engine warm up, fully electronic controlled fuel injection system, EGR (exhaust gas recirculation) and Diesel particulate filter with oxidation catalyst. Hydraulic Lash Adjusters and Roller Finger Followers are used for maintenance free quiet operation and reduced friction. Toothed belt drive with automatic belt tensioner is used for quiet engine operation for longer period. The engine NVH is optimized by means of power train stiffeners and aluminum alloy pan. The engine weight has been optimized by using Aluminum cylinder head, gallery cooled piston.
KRYOTEC ENGINE 2 B. TECHNICAL SPECIFICATION Model KRYOTEC 2.0 Litre Type Direct Injection Common Rail Turbocharged intercooled Diesel engine No. Of Cylinders 4 Inline Bore / Stroke 83 mm x 90.4mm Engine Capacity 1956 cc Compression Ratio 16.5 : 1 Max. Engine Power Output 140 ps @ 4000 rpm Max. Engine Torque Output 350 Nm @ 1750-2500 rpm Firing Order 1-3-4-2 Engine Oil Capacity 5.0 litres Capacity Of Cooling System 7 litres Air Filter Engine Mounted, Dry Paper Cartridge Type Oil Filter Ecological paper cartridge oil filter element Timing Belt Drive Special Items / Features Direct injection, common rail 16 valves, centralized injector. Fully electronic controlled fuel injection system. Higher injection pressure (1600bar) for better performance. Fixed geometry turbo charger with electric actuator EGR cooler with bypass option Single serpentine auxiliary belt drive with automatic tensioner. Emission Norms Bharat Stage IV
KRYOTEC ENGINE 3 C. SPECIAL TOOLS SR NO TOOL DESCRIPTION TOOL PART NO APPLICATION 1 Engine Support Stand 5412 5890 2402 2 Engine Support Stand on Hydraulic Lift 5412 5890 0618 3 Engine mounting bracket for overhauling stand (LH) 5412 5890 2401 4 Engine mounting bracket for overhauling stand (RH) 5412 5890 0602 5 Fixture (Stand) Assembly Aggregate Repair 5425 5890 0605
KRYOTEC ENGINE 4 SR NO TOOL DESCRIPTION TOOL PART NO APPLICATION 6 Adapter - Injector puller 5438 5890 0701 7 Mandrel for aligning clutch disc 5412 5890 2501 8 Adapter for compression testing 5412 5890 0702 9 Tool for Timing gear camshaft locking 5412 5890 0604 10 Flywheel locking tool 1860 8460 01
KRYOTEC ENGINE 5 SR NO TOOL DESCRIPTION TOOL PART NO APPLICATION 11 Flange (for F.I.P. Gear Removal) 8855 TOOL 0001 12 Auxiliary belt auto tensioner locking pin 5412 5890 0605 13 Drift for camshaft oil seal 2704 5890 3316 14 Drift for oil pump oil seal 5412 5890 0616 15 Camshaft Locking tool ( Qty. 2) 1870 8969 00 16 Powertrain e lifter 5412 5890 0614
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KRYOTEC ENGINE 7 SR NO TOOL DESCRIPTION TOOL PART NO APPLICATION 23 On Vehicle Flywheel locking tool 1860 8980 00 24 Clutch alignment locking tool 1871 0031 00 25 Fuel tank unit cap tool 5412 5890 4701
KRYOTEC ENGINE 8 D. ASSEMBLY CLEARANCES CRANKSHAFT Measure Value Crankshaft End Play (mm) 0.049 - 0.211 Journal diameter (mm) 63.705 - 63.718 Journal diameter - Class A (mm) 59.995 - 60.002 Journal diameter - Class B (mm) 59.988 - 59.995 Journal diameter - Class C (mm) 59.981 - 59.988 Connecting rod pin diameter - Class A (mm) 50.800 - 50.807 Connecting rod pin diameter - Class B (mm) 50.793 - 50.800 Connecting rod pin diameter - Class C (mm) 50.786 - 50.793 Journal out of round diameter (mm) 0.127 Diameter connecting rod pins 0.127 MAIN BEARINGS/CRANKSHAFT CONNECTING ROD Measure Value Thickness of bearing shells - Class To (Red) (mm) 1.832 - 1.836 Thickness of bearing shells - Class B (Blue) (mm) 1.835 - 1.839 Thickness of bearing shells - Class C (Yellow) (mm) 1.838 - 1.842 Oversize bearing shells / connecting rod - Class A (Brown) (mm) 0.127 Oversize bearing shells / connecting rod - Class B (Green) (mm) 0.254 Oversize bearing shells / connecting rod - Class C (Black) (mm) 0.508 Thickness of connecting rod bearing - Class A (Red) (mm) 1.528 - 1.532 Thickness of connecting rod bearing - Class B (Blue) (mm) 1.532 - 1.536 Thickness of connecting rod bearing - Class C (Yellow) (mm) 1.535 - 1.539 Clearance of main bearings - crankshaft bearing journals (mm) 0.031 - 0.051 Clearance of rod bearings - crankshaft rod bearings (mm) 0.030 - 0.056 TIMING ANGLES Operation control clearance (mm) Intake ( • ) Exhaust ( • ) Control timing clearance (mm) Intake - Exhaust - Intake Opening (BTDC) 10ᵒ Opening (ATDC) - Closed (after BDC) 2ᵒ Exhaust Opening (before BDC) 40ᵒ Opening (BTDC) - Closed (ATDC) 9ᵒ ( • ) Hydraulic Tappets
KRYOTEC ENGINE 9 CYLINDER BORE Measure Value Internal diameter cylinder Bore - Class A (mm) 83.000 - 83.010 Internal diameter cylinder Bore - Class B (mm) 83.010 - 83.020 Internal diameter cylinder Bore - Class C (mm) 83.020 - 83.030 Cylinder Bore Out of Round (mm) < 0.05 Cylinder Bore Taper < 0.005 Oversize inner diameter cylinder bore (mm) 0.1 CYLINDER HEAD Measure Value Cylinder head gasket thickness with maximum protrusion piston (mm) protrusion -0.110 - + 0.230 thickness (no hole) 0.95 +/- 0.05 Cylinder head gasket thickness with maximum protrusion piston (mm) protrusion -0.231 - + 0.330 thickness (one hole) 0.95 +/- 0.05 Cylinder head gasket thickness with maximum protrusion piston (mm) protrusion + 0.331 - + 0.425 thickness (two holes) 1.15 +/- 0.05 Nominal cylinder head height (mm) 107 +/- 0.05 Flatness Cylinder Head Surface (mm) < 0.1 E. LEAKAGE RATES Region Pressure Leakage (Max.) Air Side 0.125 bar < 200 cc/min Water Side 0.7 bar < 20 cc/min F. RECOMMENDED LUBRICANTS & COOLANTS Item Specification Company and Brand Qty. Engine Oil SAE 5W30 ACEA A5/B5 TATA SS6579 CASTROL - Magnatec Professional T 5W30 PETRONAS TATA MOTORS Genuine Oil – Engine Oil Synth 5W30 EXXON Mobil - Mobil Super 3000 TMGO 5W 30 Tata Motors genuine oil 5.0 Litres Coolant (Pre-mixed) (Antifreeze agent + Soft water) 40 : 60 ratio RAD COOLANT TYPE2 SS7700 179B TS25205P1 SUNSTAR CCI - Golden Cruiser LLC 2200NP IOCL TATA MOTORS GENUINE COOLANT KOOL PLUS 6.5 Litres
KRYOTEC ENGINE 10 G. SERVICE SCHEDULE # Kms Or Months whichever occurs earlier.
KRYOTEC ENGINE 11 2. TROUBLESHOOTING ENGINE DIAGNOSIS MECHANICAL CONDITION POSSIBLE CAUSES CORRECTION LUBRICATING OIL PRESSURE LOW 1. Low oil level. 1. (a) Check and fill with clean engine oil. (b) Check for a severe oil leak, worn rings (burning oil), oil leaking from the turbocharger to the intake, or other root causes for low Oil level. 2. Oil viscosity thin, diluted or wrong specification. 2. (a) Verify the correct engine oil is being used. (b) Look for reduced viscosity from fuel dilution. 3. Improperly operating pressure switch/gauge. 3. Verify the pressure switch is functioning correctly. If not, replace switch/gauge. 4. Relief valve stuck open. 4. Check/replace valve. 5. If cooler was replaced, shipping plugs may have been left in cooler 5. Check/remove shipping plugs. 6.Worn oil pump. 6. Check and replace oil pump. 7. Suction tube loose or seal leaking. 7. Check and replace seal. 8. Loose main bearing cap. 8. Check and install new bearing. Tighten cap to proper torque. 9. Worn bearings or wrong bearings installed. 9. Inspect and replace connecting rod or main bearings. Check and replace directed piston cooling nozzles. 10. Directed piston cooling nozzles under piston, bad fit into main carrier. 10. Check directed piston cooling nozzles position. 11. Loose directed piston cooling nozzle. 11. Tighten directed piston cooling nozzle. LUBRICATING OIL PRESSURE TOO HIGH 1. Pressure switch/gauge not operating properly. 1. Verify pressure switch is functioning correctly. If not, replace switch/gauge. 2. Engine running too cold. 2. Coolant Temperature Below Normal 3. Oil viscosity too thick. 3. Make sure the correct oil is being used. 4. Oil pressure relief valve stuck closed or binding 4. Check and replace valve. LUBRICATING OIL LOSS 1. External leaks. 1. Visually inspect for oil leaks. Repair as required. 2. Crankcase overfilled. 2. Verify that the correct dipstick is being used. 3. Incorrect oil specification or viscosity. 3. (a) Make sure the correct oil is being used (b) Look for reduced viscosity from dilution with fuel. (c) Review / reduce oil change intervals. 4. Oil cooler leak 4. Check and replace the oil cooler. 5. High blow-by forcing oil out the breather. 5. Check the breather tube area for signs of oil loss. Perform the required repairs.
KRYOTEC ENGINE 12 CONDITION POSSIBLE CAUSES CORRECTION 6. Turbocharger leaking oil to the air intake. 6. Inspect the air ducts for evidence of oil transfer. Repair as required (slight oil residue is normal). COMPRESSION KNOCKS 1. Air in the fuel system. 1. Identify location of air leak and repair. Do not bleed high pressure fuel system. 2. Poor quality fuel or water/gasoline contaminated fuel. 2. Verify by operating from a temporary tank with good fuel. Clean and flush the fuel tank. Replace fuel/water separator filter. Replace fuel/water separator filter. 3. Engine overloaded. 3. Verify the engine load rating is not being exceeded. 4. Improperly operating injectors. 4. Check and replace misfiring/inoperative injectors. EXCESSIVE VIBRATION 1. Loose or broken engine mounts. 1. Replace engine mounts. 2. Damaged fan or improperly operating accessories. 2. Check and replace the vibrating components. 3. Improperly operating vibration damper. 3. Inspect/replace vibration damper. 4. Improperly operating balance shaft. 4. Inspect/replace balance shaft. 5. Improperly operating electronically controlled viscous fan drive. 5. Inspect/replace fan drive. 6. Worn or damaged generator bearing. 6. Check/replace generator. 7. Flywheel housing misaligned. 7. Check/correct flywheel alignment. 8. Loose or broken power component. 8. Inspect the crankshaft and rods for damage that causes an unbalance condition. Repair/ replace as required. 9. Worn or unbalanced driveline components. 9. Check/repair driveline components. EXCESSIVE ENGINE NOISES 1. Drive belt squeal, insufficient tension or abnormally high loading 1. Check the automatic tensioner and inspect the drive belt. Make sure water pump, tensioner pulley, fan hub, generator and power steering pump turn freely. 2. Intake air or exhaust leaks. 2. Refer to Excessive Exhaust Smoke (Refer to Engine - Diagnosis and Testing). 3. Excessive valve lash. 3. Adjust valves. Make sure the rocker arms are not bent. Replace bent or severely worn components. 4. Turbocharger noise. 4. Check turbocharger impeller and turbine wheel for housing contact. Repair/replace as required. 5. Gear train noise. 5. Visually inspect and measure gear back- lash. Replace gears as required. 6. Power function knock. 6. Check/replace rod and main bearings.
KRYOTEC ENGINE 13 ENGINE LUBRICATION DIAGNOSTIC TABLE CONDITION POSSIBLE CAUSES CORRECTION OIL LEAKS 1. (a) Gaskets and O-rings. Misaligned or damaged. 1. (a) Replace as necessary. (b) Loose fasteners, broken or porous metal parts. (b) Tighten fasteners, Repair or replace metal parts. 2. Crankshaft rear Oil seal. 2. Replace rear crankshaft Oil seal (Refer to Engine/ Engine Block,' Seal, Crankshaft Oil, Rear/ Removal) 3. Crankshaft seal flange. Scratched, nicked or grooved. 3. Polish or replace crankshaft. 4. Oil pan flange cracked. 4. Replace Oil pan (Refer to Engine/ Lubrication/ Pan, Oil Removal) 5. Damaged or misaligned crank- shaft front oil seal. 5. Replace crankshaft front oil seal (Refer to Engine/ Engine Block/ Seal, Crankshaft Oil, Front/ Removal) 6. Scratched or damaged vibration damper hub. 6. Polish or replace vibration damper. OIL PRESSURE DROP 1. Low oil level 1. Check and correct oil level. 2. Faulty Oil pressure sensor. 2. Replace Oil pressure sensor (Refer to Engine/ lubrication/ Sensor, Oil Pressure - Removal) 3. Low oil pressure. 3. (a) Check main bearing clearance (Refer to Engine/Engine block - Standard Procedure) . (b) Check rod bearing clearance (Refer to Engine/Engine Block/ Bearings, Connecting Rod - Standard Procedure) 4. Clogged oil filter. 4. Replace oil filter (Refer to Engine/Lubrication/ Filter, Engine Oil - Removal) 5. Worn Oil pump. 5. Replace Oil pump (Refer to Engine/ Lubrication/ Pump, Engine Oil - Removal) 6. Thin or diluted oil. 6. Change oil and filter (Refer to Engine/Lubrication/ Oil Standard Procedure) 7. Excessive bearing clearance. 7. (a) Replace crankshaft bearings (Refer to Engine/ Engine Block/ Bearings, Crankshaft - Standard Procedure) . (b) Replace rod bearings (Refer to Engine/Engine Block/Bearing, Connecting Rod - Standard Procedure). 8. Oil pump relief valve stuck - 9. Oil pump pick-up loose, damaged or clogged 9. Replace oil pump pick-up (Refer to Engine/ Lubrication/, Oil pump - Removal).
KRYOTEC ENGINE 14 CONDITION POSSIBLE CAUSES CORRECTION OIL PUMPING AT RINGS 1. Worn or damaged rings. 1. Hone cylinder bores and replace rings (Refer to Engine/ Engine Block/Bearings, Piston- Standard Procedure). 2. Carbon in Oil ring slots. 2. Replace rings (Refer to Engine/ Engine Block/ Rod, Piston and Connecting - Removal). 3. Worn valve guides. 3. Replace cylinder heads (Refer to Engine/ Cylinder Head Removal). 4. Leaking valve guide seals. 4. Replace valve guide seals (Refer to Engine/ Cylinder Head/ Seal, Valve Guide - Removal).
KRYOTEC ENGINE 15 ENGINE PERFORMANCE DIAGNOSTIC TABLE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1. Weak battery. 1. Charge or replace as necessary. 2. Corroded Or loose battery connections. 2. Clean and tighten battery connections. Apply a coat of light mineral grease to the terminals. 3. Faulty starter. 3. (Refer to Electrical/ Engine Systems/ Starting - Diagnosis and Testing). 4. Faulty camshaft position sensor. 4. Replace the camshaft position sensor (Refer to Electrical/ Ignition Control/ Sensor Camshaft Position/ Removal). 5. Faulty crankshaft position sensor. 5. Replace crank position sensor (Refer to Fuel System/ Fuel Injection/Sensor, Crankshaft Position/ Removal). 6. Faulty fuel pump, relay or winding. 6. Repair or replace as necessary. 7. Dirt or water in fuel system. 7. Clean system and replace fuel filter. ENGINE STALLS OR ROUGH IDLE 1. Vacuum leak. 1. Inspect intake manifold and vacuum hoses, repair or replace as necessary. 2. Faulty crank position sensor. 2. Replace crank position sensor (Refer to Fuel System/ Fuel Injection/ Sensor, Crankshaft Position/ Removal) 3. Incorrect camshaft timing. 3. (Refer to Engine/ Valve Timing - Standard Procedure) ENGINE LOSS OF POWER 1. Dirt or water in fuel system. 1. Clean system and replace fuel filter. 2. Faulty fuel pump. 2. Replace the fuel pump 3. Blown cylinder head gasket. 3. Replace the cylinder head gasket. 4. Low compression 4. (Refer to Engine - Diagnosis and Testing) , repair as necessary 5. Burned, warped or pitted valves 5. Replace as necessary 6. Plugged or restricted exhaust system. 6. Inspect and replace as necessary. 7. Incorrect camshaft timing. 7. (Refer to Engine/ Valve Timing - Standard Procedure) ENGINE MISSES ON ACCELERATION 1. Dirt in fuel system. 1. Clean fuel system. 2. Burned, warped or pitted valves. 2. Replace as necessary. ENGINE MISSES AT HIGH SPEED Dirt or water in fuel system. Clean system and replace fuel filter.
KRYOTEC ENGINE 16 SMOKE DIAGNOSIS CHARTS The following charts include possible causes and corrections for excess or abnormal exhaust smoke.Small amounts of exhaust smoke (at certain times) are to be considered normal for a diesel powered engine. EXCESSIVE BLACK SMOKE POSSIBLE CAUSE CORRECTION Air filter dirty or plugged. Check and replace the filter if necessary. Air intake system restricted. Check entire air intake system including all hoses and tubes for restrictions, collapsed parts or damage. Repair/replace as necessary. Air Leak in Intake System. Check entire air intake system including all hoses and tubes for collapse, cracks, loose clamps, or holes in rubber ducts. Also check intake manifold for loose mounting hardware. Diagnostic Trouble Codes (DTC's) active or multiple, intermittent DTC's. (Refer to DTC-Based Diagnostics/ Module, Powertrain Control (PCM) - Diagnosis and Testing) Powertrain Control Module (PCM) has incorrect calibration. (Refer to DTC-Based Diagnostics/ Module, Powertrain Control (PCM) - Diagnosis and Testing) Exhaust system restriction is above specifications. Check exhaust pipes for damage/restrictions. Repair as necessary. Fuel grade is not correct or fuel quality is poor. Temporarily change fuel brands and note condition. Change brand if necessary. Fuel injection pump malfunctioning. A DTC may have been set. If so, (Refer to DTC- Based Diagnostics/Module, Powertrain Control (PCM) - Diagnosis and Testing) Fuel injector malfunctioning. A DTC may have been set. Perform "Injector Classification Programming" using scan tool. Also (Refer to DTC-Based Diagnostics/ Module, Powertrain Control (PCM) - Diagnosis and Testing) and, Return Fuel Quantity Test Fuel injector lower washer doubled or missing. Remove and inspect injector washer. Fuel return system restricted. Check fuel return lines for restriction. Intake manifold restricted. Remove the restriction. Manifold Air Pressure (Boost) Sensor or sensor circuit malfunctioning. A DTC should have been set. (Refer to DTC-Based Diagnostics/ Module, Powertrain Control (PCM) - Diagnosis and Testing). Turbocharger air intake restriction. Remove the restriction. Turbocharger damaged. Replace the turbocharger. Turbocharger has excess build up on compressor wheel or diffuser vanes. Clean or replace the turbocharger. Turbocharger wheel clearance out of specification. Replace the turbocharger.
KRYOTEC ENGINE 17 EXCESSIVE WHITE SMOKE POSSIBLE CAUSE CORRECTION Air in fuel supply: Possible leak in fuel supply side. Inspect fuel system Coolant leaking into combustion chamber. Perform pressure test of cooling system. Diagnostic Trouble Codes (DTC's) active or multiple, intermittent DTC's. (Refer to DTC-Based Diagnostics/Module, powertrain Control (PCM) - Diagnosis and Testing) In very cold ambient temperatures, engine block heater is malfunctioning (if equipped). (Refer to Cooling/Engine/Heater, Engine Block - Diagnosis and Testing) Engine coolant temperature sensor malfunctioning. A DTC should have been set. (Refer to DTC-based Diagnostics/ Module, powertrain Control (PCM) - Diagnosis and Testing). Also check thermostat operation. Powertrain Control Module (PCM) has incorrect calibration. A DTC should have been set. (Refer to DTC-Based Diagnostics/Module, Powertrain Control (PCM) - Diagnosis and Testing). Fuel filter plugged. (Refer to Non-DTC Diagnostics/Drivability - Diesel - Diagnosis and Testing). Fuel grade not correct or fuel quality is poor. Temporarily change fuel brands and note condition. Change brand if necessary. Fuel injector malfunctioning. A DTC should have been set. Perform "Injector Identification Programming" or "Cylinder Cutout Test" using scan tool to isolate individual cylinders. Also (Refer to DTC-Based Diagnostics/ Module, Powertrain Control (PCM) - Diagnosis and Testing) Fuel injector hold-down(s) loose. Replace the copper washer(s) (shim) and tighten to specifications. Fuel injector protrusion not correct. Check washer (shim) at bottom Of fuel injector for correct thickness. Fuel injection pump malfunctioning. A DTC should have been set. (Refer to DTC-Based Diagnostics/ Module, Powertrain Control (PCM) - Diagnosis and Testing). Fuel supply side restriction. (Refer to Non-DTC Diagnostics/Drivability - Diesel - Diagnosis and Testing) for fuel system testing. Intake manifold air temperature sensor malfunctioning A DTC should have been set. (Refer to DTC-Based Diagnostics/ Module, Powertrain Control (PCM) - Diagnosis and Testing). Intake manifold heater circuit not functioning correctly in cold weather. A DTC should have been set. (Refer to DTC-Based Diagnostics/ Module, powertrain Control (PCM) - Diagnosis and Testing). Also check heater elements for correct operation. Intake manifold heater elements not functioning correctly in cold weather. A DTC should have been set if heater elements are malfunctioning. (Refer to DTC-Based Diagnostics/ Module, Powertrain Control (PCM) - Diagnosis and Testing)
KRYOTEC ENGINE 18 EXCESSIVE WHITE SMOKE POSSIBLE CAUSE CORRECTION Internal engine damage (scuffed cylinder). Analyze engine oil and inspect oil filter to locate area of probable damage. Restriction in fuel supply side of fuel system. (Refer to Non-DTC Diagnostics/Drivability - Diesel - Diagnosis and Testing) for fuel system testing. EXCESSIVE BLUE SMOKE POSSIBLE CAUSE CORRECTION Dirty air cleaner or restricted turbocharger intake duct. Check Air Cleaner Housing for debris and replace filter as necessary Air leak in boost system between turbocharger compressor outlet and intake manifold. Service charge air system. Obstruction in exhaust manifold. Remove exhaust manifold and inspect for blockage. Restricted turbocharger drain tube. Remove turbocharger drain tube and remove obstruction. Crankcase ventilation system plugged. Inspect oil separator system for function and clear drain back hole in cylinder head cover/intake manifold Valve seals are worn, brittle, or improperly installed. Replace valve stem Oil seals Valve stems or guides are worn. Remove valves and inspect valves and guides. Broken or Improperly installed piston rings. Tear down engine and Inspect piston rings. Excessive piston ring end gap. Remove pistons and measure piston ring end gap Excessive cylinder liner wear and taper. Remove pistons and measure cylinder liner wear and taper. Cylinder damage. Remove pistons and inspect cylinder liner for cracks or porosity. Repair with new cylinder liner if necessary. Piston damage. Remove pistons and inspect for cracks, holes. Measure piston for out-of-round and taper. Turbocharger failure. Replace the turbocharger.
KRYOTEC ENGINE 19 3. CONSTRUCTIONAL AND SERVICE DETAILS ENGINE MOUNTS DESCRIPTION (TIGHTENING TORQUE (N-m)) NO REUSE Left Mount Bolt 120 Left Mount to Frame Rail Bolts 90 + 45° Left Mount Bracket Bolts 40 + 45° Right Mount to Frame Rail Bolts 60 + 45° Right Mount Bolt 90 + 45° Rear Mount to Bracket Bolt 90 + 45° Rear Mount Bracket to Transmission Bolts 90 + 45° Rear Mount to Crossmember Bolt 90 + 45° CYLINDER HEAD DESCRIPTION TIGHTENING TORQUE (N-m) NO REUSE Upper Head Engine 25 Cylinder Head Bolts 65 + 90° + 90° + 90° Glow Plugs 8 Upper Engine Cylinder Head Caps 14 ENGINE COVERS DESCRIPTION TIGHTENING TORQUE (N-m) NO REUSE Engine Oil Drain Plug 20 Crankcase Bolts 9 Crankcase Bolts 25 Front Cover Oil Seal Bolts 9 Front Cover Oil Seal Bolts 9 Rear Oil Seal Bolts 9 CRANKSHAFT AND FLYWHEEL DESCRIPTION TIGHTENING TORQUE (N-m) NO REUSE Flywheel Bolts 160 Crankshaft Bearing Caps Bolts 25 + 100°
KRYOTEC ENGINE 20 PISTONS AND CONNECTING RODS DESCRIPTION TIGHTENING TORQUE (N-m) NO REUSE Connecting Rod Cap Bolts 25 + 60° TIMING CONTROL DESCRIPTION TIGHTENING TORQUE (N-m) NO REUSE Mobile Tensioner 25 Fixed tensioner Bolts 50 Crankshaft Bolts 340 Camshaft Pulley Bolt 30 + 40° Protection cover of timing control 9 Tensioners Support of Timing Belt Bolt 25 Timing big bracket 50 ENGINE TURBOCHARGER SYSTEM DESCRIPTION TIGHTENING TORQUE (N-m) NO REUSE Turbocharger Nuts 25 Engine Oil Pressure Pipe to the Turbocharger 26 Engine oil pressure pipe to the turbocharged 25 Duct engine oil return from the turbocharger - base side Bolt 50 Oil return tube turbocharger engine turbocharger side Bolt 9 INTAKE AND EXHAUST MANIFOLDS DESCRIPTION TIGHTENING TORQUE (N-m) NO REUSE Intake Manifold Nuts 25 Exhaust Manifold Nuts 20 LUBRICATION SYSTEM DESCRIPTION TIGHTENING TORQUE (N-m) NO REUSE Engine Oil Filter Cover 25 Output Pipe From Turbocharger Engine Oil Bolt 50 Oil Pressure Pipe to Turbocharger Bolt 15 Turbocharger to Cylinder Head Oil Pressure Pipe Bolt 25 Oil Pressure Warning Light Switch 25 Oil Pressure Switch 20 Introducing Engine Oil Nozzle 9 Displacement Control Valve Oil Pump motor 7
KRYOTEC ENGINE 21 FUEL SYSTEM DESCRIPTION TIGHTENING TORQUE (N-m) NO REUSE Fuel Delivery Pipe to Fuel Injection Pump 23 Fuel Filter Housing Bolts/Nuts 8 Fuel Injection Pump Nuts 25 Fuel Injection Pump Pulley Nut 50 Fuel Rail Pressure Sensor 70 Fuel Tube to Fuel Rail 19 Fuel Tank Strap Bolts 35 Fuel Injector lug bolts 25 MISCELLANEOUS ENGINE PARTS DESCRIPTION TIGHTENING TORQUE (N-m) NO REUSE Vibration Damper Bolt 25 Fixed Tensioner Bolt 50 Mobile Tensioner Bolt 50
KRYOTEC ENGINE 22 4. ENGINE TESTS AND MAINTENANCE A. PRELIMINARY INSPECTION NOTE It is always advisable to first use the diagnostic tool and rectify the electrical faults, before commencing with mechanical repairs/ troubleshooting. Refer ENGINE MANAGEMENT SYSTEM section in this group for procedure. General Check for leakage of Oil, fuel, and Coolant. Check for overheating of engine. Check for unusual smoke. If there is any fault in the Engine Management system (EMS) then the MIL indicator in the instrument cluster will come ON. In such a case connect the diagnostic tester. (For procedure refer EMS section). Before proceeding to carry out actual reconditioning of engine, it is desirable to have a preliminary inspection of engine to ascertain whether an engine reconditioning is necessary and if so, to what extent. Most common reasons for which engine is reconditioned are 1. Loss of power. 2. Excessive engine oil consumption. 3. Extremely low engine oil pressure. 4. Mechanical failures. B. ENGINE TESTS CYLINDER COMPRESSION TEST 1. Warm up engine to operating temperature (approximately 80 °C, 176 °F). 2. Shut the engine off. 3. Check that fuse of the electric fuel pump has been removed, before removing the injectors. 4. Remove the fuel injector. 5. Install the dummy injector (5412 5890 0702) complete with the injector claw into fuel injector hole of cylinder to be tested. 6. Install the clamp and tighten the nut 25 N·m (18 ft. lbs.). 7. Connect the compression tester to the fitting 8. Test compression pressure by cranking engine with starter for at least 8 revolutions. Description Specification Difference Between Cylinders Cylinder Compression 21 – 25 bar (304-362 psi) 5 bar (73 psi) 9. Carry out test procedure at the remaining cylinders in the same way. 10. Check that there is not a great difference between the pressure readings for the cylinders. 11. Remove the dummy injector complete with fitting from cylinder head. 12. Install the fuel injector
KRYOTEC ENGINE 23 CYLINDER LEAKAGE TEST The cylinder leakage test provides an accurate means for determining engine condition. Cylinder leakage testing will detect: • Exhaust and intake valve leaks (improper seating). • Leaks between adjacent cylinders or into water jacket. 1. Check the coolant level and fill as required. DO NOT install the radiator cap. 2. Start and operate the engine until it attains normal operating temperature. 3. Turn the engine OFF. 4. Remove the fuel injector. 5. Set the piston of the cylinder to be tested at TDC on the compression stroke. 6. Install the 5412 5890 0702 dummy injector complete with the fitting into fuel injector hole of cylinder to be tested. 7. Install the clamp and tighten the nut 25 Nm (18 ft. lbs.). 8. Calibrate the tester according to the manufacturer's instructions. The shop air source for testing should maintain a regulated air pressure at 552 kPa (80 psi). 9. Connect the leakage tester and perform the leakage test procedure on each cylinder according to the tester manufacturer's instructions. 10. As each cylinder is pressurized, listen for the air escaping through the EGR air flow control valve, tailpipe, and the oil filler cap opening. Check for bubbles in the pressurized coolant bottle. 11. All gauge pressure indications should be equal, with no more than 25% leakage. Refer to CYLINDER LEAKAGE DIAGNOSIS CHART below. CYLINDER LEAKAGE DIAGNOSIS CHART CONDITION POSSIBLE CAUSE CORRECTION AIR ESCAPES THROUGH THROTTLE BODY Intake valve bent, burnt, or not seated properly. Inspect valve and valve seat. Reface Or replace, as necessary. Inspect valve springs. Replace as necessary. AIR ESCAPES THROUGH TAILPIPE Exhaust valve bent, burnt, or not seated properly. Inspect valve and valve seat. Reface or replace, as necessary Inspect valve springs. Replace as necessary. AIR ESCAPES THROUGH RADIATOR Head gasket leaking or cracked cylinder head or block. Remove cylinder head and inspect. Replace the defective part. MORE THAN LEAKAGE FROM ADJACENT CYLINDERS Head gasket leaking or crack in cylinder head or block between adjacent cylinders. Remove cylinder head and inspect. Replace gasket, head, or block as necessary. MORE THAN 25% LEAKAGE AND AIR ESCAPES THROUGH OIL FILLER CAP OPENING ONLY Stuck or broken piston rings; cracked piston; worn rings and/or cylinder wall. Inspect for broken rings or piston. Measure ring gap and cylinder diameter, taper and out-of-round. Replace defective part as necessary.
KRYOTEC ENGINE 24 OIL CONSUMPTION TEST AND DIAGNOSIS The following diagnostic procedures are used to determine the source of excessive internal oil Consumption, these procedures and tests apply to vehicles with 50,000 miles or less. NOTE Engine oil consumption may be greater than normal during engine break-in. Repairs should be delayed until vehicle has been driven at least 7,500 miles. Severe service (high ambient temperature, short trips, heavy loading, trailer towing, off-road, or law enforcement use) may result in greater oil consumption than normal. Sustained high speed driving and high engine RPM operation may result in increased oil consumption. Failure to comply with the recommended oil type and viscosity rating, as outlined in the owner's manual, may impact oil economy as well as fuel economy. Oil consumption may increase with vehicle age and mileage due to normal engine wear. NOTE Because a few drops of external oil leakage per mile can quickly account for the loss of one quart of oil in a few hundred miles, ensure no external engine oil leaks are present. • Oil leakage is not the same as oil consumption and all external leakage must be eliminated before any action can be taken to verify and/or correct oil consumption complaints. • Verify that the engine has the correct oil level dipstick and dipstick tube installed. • Verify that the engine is not being run in an overfilled condition. Check the oil level 15 minutes after a hot shutdown with the vehicle parked on a level surface. In no case should the level be above MAX or the FULL mark on the dipstick. OIL CONSUMPTION TEST 1. Check the oil level at least 15 minutes after a hot shutdown. 2. If the oil level is low, top off with the proper viscosity and API service level engine oil. Add one bottle of MOPAR® 4-In-1 Leak Detection Dye into the engine oil. 3. Tamper proof the oil pan drain plug, oil filter, dipstick and oil fill cap. 4. Record the vehicle mileage. 5. Instruct the customer to drive the vehicle as usual. 6. Ask the customer to return to the servicing dealer after accumulating 800 km., Check the oil level at least 15 minutes after a hot shut down. If the oil level is half way between the "FULL" and "ADD" mark continue with the next step. 7. Using a black light, re-check for any external engine oil leaks, repair as necessary, if no external engine oil leaks are present, continue with oil consumption diagnosis. OIL CONSUMPTION DIAGNOSIS 1. Perform a cylinder compression test and cylinder leak down test using the standard leak down gauge following manufacturers suggested best practices. 2. If one or more cylinders have more than 15% leak down further engine tear down and inspection will be required. 3. If the compression is good it can be assumed the valve guide seals or valve guides are at fault. TOP 18 REASONS THAT MAY LEAD TO ENGINE OIL CONSUMPTION 1. Tapered and Out-of-Round Cylinders The increased piston clearances permit the pistons to rock in the worn cylinders. While tilted momentarily, an abnormally large volume of oil is permitted to enter on one side of the piston. The rings, also tilted in the cylinder, permit oil to enter on one side. Upon reversal of the piston on each stroke, some of this oil is passed into the combustion chamber. 2. Distorted Cylinders This may be caused by unequal heat distribution or unequal tightening of cylinder head bolts. This condition presents a surface which the rings may not be able to follow completely. In this case, there may be areas where the rings will not remove all of the excess oil. When combustion takes place, this oil will be burned and cause high oil consumption. 3. Improper operation of "Closed Crankcase Ventilation (CCV)" system The main purpose of the Closed Crankcase Ventilation (CCV) is to recirculate blow-by gases back from the crankcase area through the engine to consume unburned hydrocarbons. The system uses a filter, tubing, and rubber hoses that route crankcase blow by gases to the intake manifold. Vacuum within the engine intake manifold pulls the blow by gases out of the crankcase into the combustion chamber along with the regular intake air and fuel mixture. The CCV system can become clogged with sludge and varnish deposits and trap blow by
KRYOTEC ENGINE 25 gases in the crankcase. This degrades the oil, promoting additional formation of deposit material. If left uncorrected, the result is plugged oil rings, oil consumption, rapid ring wear due to sludge buildup, ruptured gaskets and seals due to crankcase pressurization. 4. Worn Piston Ring Grooves For piston rings to form a good seal, the sides of the ring grooves must be true and flat - not flared or shouldered. Piston rings in tapered or irregular grooves will not seal properly and, consequently, oil will pass around behind the rings into the combustion chamber. 5. Worn, Broken or Stuck Piston Rings When piston rings are broken, worn or stuck to such an extent that the correct tension and clearances are not maintained, this will allow oil to be drawn into the combustion chamber on the intake stroke and hot gases of combustion to be blown down the cylinder past the piston on the power stroke. All of these conditions will result in burning and carbon buildup of the oil on the cylinders, pistons and rings. 6. Cracked or Broken Ring Lands Cracked or broken ring lands prevent the rings from seating completely on their sides and cause oil pumping. This condition will lead to serious damage to the cylinders as well as complete destruction of the pistons and rings. Cracked or broken ring lands cannot be corrected by any means other than piston replacement. 7. Worn Valve Stems and Guides When wear has taken place on valve stems and valve guides, the vacuum in the intake manifold will draw oil and oil vapor between the intake valve stems and guides into the intake manifold and then into the cylinder where it will be burned. 8. Bent or Misaligned Connecting Rods Bent or misaligned connecting rods will not allow the pistons to ride straight in the cylinders. This will prevent the pistons and rings from forming a proper seal with the cylinder walls and promote oil consumption. In addition, it is possible that a bearing in a bent connect rod will not have uniform clearance on the connecting rod wrist pin. Under these conditions, the bearing will wear rapidly and throw off an excessive amount of oil into the cylinder. 9. Fuel Dilution If raw fuel is allowed to enter the lubrication system, the oil will become thinner and more volatile and will result in higher oil consumption. The following conditions will lead to higher oil consumption; • Excess fuel can enter and mix with the oil via a leaking fuel injector • Restricted air intake • Excessive idling 10. Contaminated Cooling Systems Corrosion, rust, scale, sediment or other formations in the water jacket and radiator will prevent a cooling system from extracting heat efficiently. This is likely to cause cylinder distortion thus leading to higher oil consumption. 11. Oil Viscosity The use of oil with a viscosity that is too light may result in high oil consumption. Refer to the vehicle owner's manual for the proper oil viscosity to be used under specific driving conditions and/or ambient temperatures. 12. Dirty Engine Oil Failure to change the oil and filter at proper intervals may cause the oil to be so dirty that it will promote accumulation of sludge and varnish and restrict oil passages in the piston rings and pistons. This will increase oil consumption; dirty oil by nature is also consumed at a higher rate than clean oil. 13. Crankcase Overfull Due to an error in inserting the oil dip stick so that it does not come to a seat on its shoulder, a low reading may be obtained. Additional oil may be added to make the reading appear normal with the stick in this incorrect position which will actually make the oil level too high. If the oil level is so high that the lower ends of the connecting rods touch the oil in the oil pan excessive quantities of oil will be thrown on the cylinder walls and some of it will work its way up into the combustion chamber. 14. Excessively High Oil Pressure A faulty oil pressure relief valve may cause the oil pressure to be too high. The result will be that the engine will be flooded with an abnormally large amount of oil in a manner similar to that which occurs with worn bearings. This condition may also cause the oil filter to burst. 15. Aftermarket Performance Chips and Modification Increasing performance through the use of performance/power enhancement products to a stock or factory engine will increase the chance of excessive oil consumption.
KRYOTEC ENGINE 26 16. Lugging Engine Lugging is running the engine at a lower RPM in a condition where a higher RPM (more power/torque) should be implemented. Especially susceptible on vehicles equipped with a manual transmission. This driving habit causes more stress loading on the piston and can lead to increases in engine oil consumption. 17. Turbocharged Engines There is a possibility for higher crankcase pressure (as compared to naturally aspirated engines) which is normal for turbocharged engines. This condition causes varying amounts of engine oil to enter the intake manifold, charge air cooler and associated plumbing to and from the charge air cooler, also a leaking turbocharger seal will draw oil into the combustion chamber where it will burn (blue smoke from tail pipe may be present) and form carbon deposits which contribute to further oil consumption as they interfere with proper engine function. 18. Restricted Air Intake Excessive restriction in the air intake system will increase engine vacuum and can increase oil consumption, an extremely dirty air filter would be one example of this situation. Maintenance Instructions for Common Rail Common rail refers to a small fuel accumulation tank called Rail, where the pressure of the fuel remains almost constant and always available to injectors. The high-pressure pump compresses the fuel at a pressure of 1600 bar and transfers it through a connection pipe to the high-pressure accumulation duct or Common Rail. The common rail then softens the pressure oscillations caused by the opening and closing of the injectors and by the continuous discharge of the high pressure pump. The fuel is then transferred from the common rail through pipes to the electronic injectors Due to high pressure developed in the common rail system, care and cleanliness is of utmost importance during removal and installation of the common rail system. Tiny dust particles (0.2 mm) can block injector nozzle in opening position, which will then continuously inject fuel into the cylinder there by increasing the cylinder pressure leading to engine damage. NOTE The ambient conditions to store common rail parts are: -30°C to +60°C, and humidity between 0 to 80%. The nozzle holder should not place in or near a magnetic field source above 400 A/m. All system components must be thermally sealed in plastic bags and clearly labeled. Prior to working on common rail system, the technician must thoroughly wash hands before and during the work as necessary. WARNING Smoking is strictly prohibited while working on common rail system, as the system is under high pressure and may cause serious injury, or component damage. Prior cleaning of engine and injection system Clean the area around the engine and then fuel injection system with clean brush and degreasing agent. Cover electrical unit’s viz., starter, alternator etc., to avoid fuel spray/splash. Clean the joints and external surface of the injection system and each connection that is to be opened, by a vacuum cleaner. The surface of the workstation on which the work on common rail is to be carried, should preferably be stainless steel. The workplace should be a closed room, clean and free from machine tools and welding equipment.
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