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Mile SZ 2498 Service Manual

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SZ 2498 ENGINE
Mahindra institute of learning
excellence, Nasik

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  • Page 1 SZ 2498 ENGINE Mahindra institute of learning excellence, Nasik...
  • Page 2 ABBREVATION USED SZ 2498 Plus : Timing - Chain Drive : Scorpio Zip 2498 : CC of engine : Turbo charged intercool The SZ 2498 TCI engine is a 4-cylinder, in- line, overhead valve, water-cooled, direct injection engine.
  • Page 3 Specification-SZ 2498 No. of cylinders Bore 94mm Stroke 90mm Displacement 2498cc Compression ratio 18.5 : 1 Power 105 HP at 3800 RPM Torque 238 Nm at 1700 to 1900 RPM Type of operation Four stroke , Direct injection Timing mechanism...

  • Page 4: Maintenance Schedule

    Maintenance schedule • Change engine oil & filter [ Maximile Premium oil -10K ] OR Viscosity index 15W 40. If API CG4 grade oil then. 5000km ,10000km & then every 10,000km • Refill fresh coolant [ Maximile Coolant ] Once in a year / After every 40,000 kms •...
  • Page 5 • Clean air filter Every 10000Kms / Service indicator shows red band • Change air cleaner cartridge At every 40,000kms / Service indicator shows red band even after cleaning • Adjust tappet 5000Km[ If required ], 20000 Km & then every 20000Km •...

  • Page 6: Engine Oil

    Engine oil Alternate oil : Oil confirming to API CG4 grade with Viscosity index 15W 40. If API CF4 grade oil used then oil change interval is after Every 5000Kms.

  • Page 7: Engine Coolant

    Engine Coolant Maximile Coolant should be used for SZ 2600/ SZ 2600 Plus engine. Note: No alternate coolant is available in the market. Used of any other coolant may deteriorate liner ‘O’ rings which may lead to coolant & oil mixing. This coolant is premixed with water.
  • Page 8 Sealant RTV silicon sealant-Rhodoseal to be used : Between ladder frame & block. : Between Rear oil seal retainer & block. All other places use Loctite 547 Rust cleaning solution [ For Turbo charger mounting Nut, EGR pipe Nut etc.] : WD 40...
  • Page 9 General construction All engine internal parts remain same as SZ 2600 except crankshaft, connecting rod, FIP & nozzles...
  • Page 10 SZ 2600 ENGINE Mahindra institute of learning excellence, Nasik...
  • Page 11 ABBREVATION USED SZ 2600 Plus : Timing - Chain Drive : Scorpio Zip 2600 : CC of engine : Turbo charged intercool The model SZ 2600 TCI engine is a 4-cylinder, in-line, overhead valve, water-cooled, direct injection engine.
  • Page 12 Specification-SZ 2600/SZ 2600 Plus No. of cylinders Bore 94mm Stroke 94mm Displacement 2609 cc Compression ratio 18.5 : 1 Type of operation Four stroke , Direct injection Power 109bhp @ 3800rpm Max Torque 26.00 Kg-m Timing mechanism Chain drive [ Plus] Cooling System Pressurised Centrifugal water pump...
  • Page 13 Maintenance schedule • Change engine oil & filter [ Maximile Premium oil -10K ] 5000km ,10000km & then every 10,000km • Refill fresh coolant [ Maximile Coolant ] Once in a year / After every 40,000 kms • Change primary fuel filter 10000km, 20000kms &...
  • Page 14 • Clean air filter Every 10000Kms / Service indicator shows red band • Change air cleaner cartridge At every 40,000kms / Service indicator shows red band even after cleaning • Adjust tappet 5000Km[ If required ], 20000 Km & then every 20000Km •...
  • Page 15 Engine oil Maximile premium [10k] oil should be used for SZ 2600/ SZ 2600 Plus engine. Alternate oil : Oil confirming to API CG4 grade with Viscosity index 15W 40. If API CF4 grade oil used then oil change interval is after Every 5000Kms.
  • Page 16 Engine Coolant Maximile Coolant should be used for SZ 2600/ SZ 2600 Plus engine. Note: No alternate coolant is available in the market. Used of any other coolant may deteriorate liner ‘O’ rings which may lead to coolant & oil mixing. This coolant is premixed with water.
  • Page 17 Sealant RTV silicon sealant-Rhodoseal to be used : Between ladder frame & block. : Between Rear oil seal retainer & block. All other places use Loctite 547 Rust cleaning solution [ For Turbo charger mounting Nut, EGR pipe Nut etc.] : WD 40...
  • Page 18 GENERAL CONSTRUCTION...
  • Page 19 Block Replaceable wet type liner , Inline cylinder arrangement Chain Drive [ Orange colour]...

  • Page 20: Cylinder Head

    Cylinder head Height of cylinder head 97.70mm to 98.30mm Min. cylinder head height: 97.40mm 97.70 - 98.30 mm...

  • Page 21: Cylinder Head Gasket

    Cylinder head Gasket Type : Multilayer steel gasket Gives uniform sealing on surface area. Note : Do not use any oil or shellac on the cylinder head gasket or on block surface or on cylinder head surface.Do not reused the gasket even if it appears to be good.
  • Page 22 Head gasket position : Assemble gasket with lettering facing upward.
  • Page 23 Cylinder block warpage Standard limit : 0.07mm Service limit : 0.10mm max. Cylinder head warpage Standard limit : 0.05mm Service limit : 0.10mm max.
  • Page 24 Ladder frame • Support block from bottom side. • Act as a barrier between rotating crankshaft & returning oil to control oil mist formation. • Reduces engine noise & vibration.
  • Page 25 Piston Piston : Re-entrant bowl type Max weight difference allowed : +/- 5 gms...

  • Page 26: Piston Pin

    Diameter grading Weight grading Piston pin Type : Full floating. Surface hardened & ground Diameter : 32.00 mm...

  • Page 27: Piston Rings

    Piston rings Keystoned shaped. [ Top mark ] Middle Oil Scrapper ring - Taper faced [ Top mark ] Bottom Conformable type oil ring...
  • Page 28 Piston rings Ring gap [ Standard ] 0.35 to 0.55mm ( 14 to 22 Thou) Middle 0.80 to 1.05mm ( 32 to 42 Thou) Bottom 0.25 to 0.55mm ( 10 to 22 Thou) Ring gap [ Service limit ] 0.90mm ( 36 Thou ) Middle 1.50mm ( 60 Thou ) Botom...
  • Page 29 Piston ring to piston groove clearance Standard limit Service limit 0.11 to 0.15mm 0.25mm Middle 0.05 to 0.09mm 0.15mm Botom 0.04 to 0.07mm 0.15mm...
  • Page 30 Liner Liner : Replaceable wet type liner. Coolant & oil jacket are separated by ‘O’ rings. Both ‘O’ rings are same . Viton base rubber is used.
  • Page 31 Liner projection from block surface : 0.03mm to 0.09mm Note : Check liner projection without ‘O’ rings.

  • Page 32: Connecting Rod

    Connecting rod Identification No : Punched on connecting rod cap viz. 1,2,3,4 No. 1 start from Fan side. Also help for cap positioning. Identification number...
  • Page 33 Weight grading mark : Punched on connecting rod cap viz. F, G H,I,……T,U. Recommended for service replacement : Grade ‘M’ Weight grading mark...
  • Page 34 Connecting rod side play: 0.10mm to 0.30mm ( 4 to 12 thou)
  • Page 35 Crank pin journal Std size of crank pin journal 52.98 to 53.00mm u/s 0.25 Crank pin journal 52.73 to 52.75mm u/s 0.50 Crank pin journal 52.48 to 52.50mm u/s 0.75 Crank pin journal 52.23 to 52.25mm...
  • Page 36 Crank shaft main journal Std size of main journal 58.98 to 59.00mm u/s 0.25 main journal 58.73 to 58.75mm u/s 0.50 main journal 58.48 to 58.50mm u/s 0.75 main journal 58.23 to 58.25mm...
  • Page 37 Main bearing Cap Identification mark i.e. 1 to 5 is punched on main bearing cap. No 1 cap start from fan side.
  • Page 39 Main bearing cap position : Projection on block & Cap is provided to avoid wrong fitments of Main bearing cap. Projection on block Projection on cap...
  • Page 40 Crank shaft end float Standard 0.10 mm to 0.37 mm ( 4 to 15 thou) Service limit 0.50mm ( 20thou )
  • Page 41 End float is adjusted by using thrust washer. Thrust washer on cap have locating lips. Oil grooves faces outer side...
  • Page 42 Crankshaft bearing removal MST:543 MST:577 Crankshaft bearing pressing MST:544...
  • Page 43 Cam shaft Axial clearance of cam shaft Standard 0.10 to 0.30 mm Service limit : 0.40 mm...
  • Page 44 Cam shaft bush to cam journal clearance Standard 0.02 to 0.075 mm Service limit : 0.10 mm Cam shaft runout : 0.01mm [ max ]...
  • Page 45 Camlobe lift Inlet Exhaust Standard 6.08 mm 6.91 mm Service limit 5.58 mm 6.41 mm...
  • Page 46 Cam shaft thrust plate mounting : While assembling the cam shaft thrust plate ensure that the vertical groove will face towards gear / sprocket. Gear / Sprocket side Cam bush side...
  • Page 47 Cam shaft identification On chain drive cam shaft letter ‘CHAIN DRIVE’ in forged on cam shaft..
  • Page 48 Tappets Inner dia of tappet hole in crankcase 24.48mm Tappet to tappet hole clearance Standard limit 0.075mm to 0.02mm Service limit 0.10mm Oil return hole...
  • Page 49 Flywheel Flat ness Standard limit : 0.05mm[max] Service limit : 0.10mm[max] Run out Standard limit : 0.05mm Service limit : 0.10mm...
  • Page 50 Valve,Guide & spring Valve seat angle 45’ to 45 Valve stem OD [ Inlet & exhaust valve] 6.95mm to 7.10mm Clearance between valve & valve guide. Inlet valve 0.03mm to 0.07mm Exhaust valve 0.05mm to 0.09mm Thickness of valve head Standard limit : 2.00mm Service limit...
  • Page 51 Valve & valve lock Valve spring free length : 53.60mm [ Standard limit ] 50.60 mm[ Service limit ]...
  • Page 52 Valve spring is variable pitch spring. While assembling ensure that the closer pitch should face towards head side.[ Paint marking is given for identification] Closer pitch Paint marking...

  • Page 53: Push Rod

    Push rod Push rod bent Standard limit : 0.25 mm[ max.] Service limit : 0.40 mm...
  • Page 54 Viscous fan drive Uses fluid coupling, which drives the fan blade by means of silicon fluid. The fan drive has to be engaged only periodically,between 5 to 10% of the normal operating conditions. Bi-metal coil senses the air temperature behind the radiator. The VFD assembly should be kept in either vertical plane or in horizontal plane with bimetallic strip facing down.
  • Page 55 Temperature sensor...
  • Page 56 VFD Checking To check if the VFD is operating itself or not. Let the engine temperature go near the red band. Stop the engine. The moment the engine is stopped the fan blade should also stop rotating. If the fan blade is still rotating then the VFD is not engaged.

  • Page 59: Oil Filter

    Oil filter Ensure that the oil retaining seal is present inside the filter. Oil retaining seal retained oil inside the filter even after engine is switch off.

  • Page 60: Oil Cooler

    Oil cooler Control the oil temperature. Uses engine coolant as a cooling media for hot oil.
  • Page 61 Oil cooler made by vacuum brazing process Copper traces on surface...
  • Page 62 Oil cooler stud Torque oil cooler stud with 3.00Kg-m to avoid loosening of stud while removing the filter.

  • Page 63: Oil Pump

    Oil pump Black phosphating on cover plate on chain drive engine. Note : Crank opening pressure of chain drive engine is 4.50bar...
  • Page 64 IMPORTANT ADJUSTMENTS & SETTING...
  • Page 65 Chain timing Chain sprocket sprocket Chain tensioner Crank sprocket...
  • Page 66 Guide- Cam sprocket to FIP Oil jet Guide- FIP sprocket to idler...
  • Page 67 Match center link of two copper coated link with crank sprocket mark. Next copper coated link with cam shaft sprocket mark.Last copper coated link with FIP sprocket mark...
  • Page 68 Match no 1 link with Crank sprocket mark Match no 14 link with Cam sprocket mark Match no 30 link with FIP sprocket mark...
  • Page 69 Chain tensioning Chain tensioning : SZ 2600 Plus engine uses hydraulic chain tensioner hence doesn’t required initial chain tensioning. Note : Lock hydraulic chain tensioner, before removing.
  • Page 70 Guide - Cam sprocket to FIP sprocket must be secured with a class of 10.9 bolt. 10.9 Class bolt [ Part no-0310EC0110N]...
  • Page 71 Wear limits of chain guides Hydraulic chain tensioner 2.00mm Guide - Cam shaft to FIP sprocket 1.50mm Guide - F I P to Idler sprocket 1.00mm...
  • Page 72 Tappet setting It is recommended to do the tappet setting in cold condition Inlet : 0.30mm ( 12 Thou ) Exhaust : 0.45mm ( 18 Thou ) Valve layout – In – In – In – In...
  • Page 73 Procedure for tappet setting Bring no.1 piston at TDC. Ensure no 4 cylinder valve at rockering position. Adjust the tappet clearance of No-1 cylinder valve as per given specifications. Turn the engine further to 180 in the dirction of engine rotation.
  • Page 74 Tappet setting-cold condition Inlet : 0.30mm ( 12 Thou ) Exhaust : 0.45mm ( 18 Thou )
  • Page 75 Rocker lubrication system Holes are drilled to lubricate rocker arms below the rocker support 1 & 2. Oil hole -2 Oil hole -1...
  • Page 76 However to supply uniform oil pressure for all rocker arms, oil is taken from oil hole 2. Oil hole -1 ( From fan side) is blocked by means of flat rocker support . Oil support without slots Note : Ensured that oil hole 1 is blocked by means of rocker support w/o slot.
  • Page 77 Rocker support bolt : Longer bolt are used to secured rocker support above oil holes.
  • Page 78 While assembling the rocker shaft, ensure that lubricating holes will face towards head side.
  • Page 79 Cylinder head torquing Step 1: Tighten each bolt in sequence to 9.00 Kg-m ( 65.00lbsft ) Step 2: Rotate each bolt in the same sequence further by 60 Step 3: Rotate each bolt in the same sequence further by 60 Tightening sequence Note : While removing cylinder head , ensure that the bolts are loosen in reverse of tightening sequence.
  • Page 80 Front end accessories drive-SZ 2600PLUS Check frequency...
  • Page 81 Belt alignments / Belt replacements Loosen the tensioner pulley nut and release the belt tension by loosening tensioning bolt. Remove the old belt. Ensure integral bracket bolts tightness on the front cover (Torque 2.5 Kg-m) It is not necessary to loosen the alternator and brace mounting bolts.
  • Page 82 Loosen tensioner pulley nut & tensioner bolt to release belt tension...
  • Page 83 loosen the top & bottom mouting alternator mtg bolts on cylinder head...
  • Page 84 Push the top portion of alternator with bracket backward & tighten the alternator bracket mtg. bolts on cylinder head...
  • Page 85 Ensure tightness of alternator mounting bolt ( 2.5 Kg-m), Brace mounting bolt on alternator ( 2.5 Kg-m) & brace mounting 2 bolt (m10) on alternator bracket ( 3.5 Kg-m). Hand tighten the tensioner pulley nut so that nut face is resting against bearing face.
  • Page 86 If the belt is new, run the engine for few minutes and confirm the tension 140 - 145 Hz. S.O.P for belt noise (continuously on the engine) Spray some drops of water between tensioner pulley and belt. On running the engine at idling rpm, if the noise disappears and again reoccurs, the alignment is said to be off.
  • Page 87 Belt tensioning [Gate/Clavis gauge] Chain drive New belt tension 170 +/- 2 Stabilised belt tension 140 + 5 Min belt tension While fitting a new belt, set the tension as per new belt value. Drive the vehicle for min 5 Kms, check the belt tension, if it is less than stabilised belt tension, reset it to stabilised belt tension.
  • Page 88 Bolt acceptance criteria It is possible that that bolt may get elongated when torque either by using angular torquing or by using torque wrench. Measure the length, if it is within the limit the bolt can be reused Measure this length...
  • Page 89 Cylinder head bolt : 135.40mm to 136.60mm Flywheel bolt : 29.58mm to 30.42mm...
  • Page 90 Main bearing bolt : 89.40mm to 90.60mm Connecting rod bolt : Replace all the time...
  • Page 91 Idling , Antistalling & FICD setting Engine : SZ 2600 / SZ 2600 Plus Fuel injection pumps BSII : 0 460 414 223 Idling Specification Normal Idling : 825 to 900 rpm Fast Idling on vehicle : 850 to 950 rpm ( With AC load )
  • Page 92 Clamp PLA unit Idling screw Fast idle screw LFG lever...
  • Page 93 Antistalling screw High idle screw [ Do not disturb this screw ]...
  • Page 94 Procedure to adjust the Idling rpm on Vehicle 1] Observe / record idling rpm in as is condition. 2] Ensure LFG lever is resting on idling screw . Gap between lever and clamp on cable to be approx. 1.0 to 1.5 mm. If LFG lever is resting on clamp, release the clamp and check for Idling rpm again.
  • Page 95 Unscrew Fast idle screw to ensure it doesn't stop the movement of LFG lever. 5] Set the idling to 845 - 850 rpm approx. by adjusting idling screw. Screw in : increases rpm , screw out : reduces rpm. 6] Re set the anti-stalling screw to get idling rpm of 855 - 860 approx..
  • Page 96 Gap to be maintained 1.0 ± 0.5 mm...
  • Page 97 B ] Setting Fast Idling rpm on the Vehicle. 1. Ensure Idling is with in the specification 2. Ensure gap is maintained between LFG lever and clamp 3. Switch on the AC. When AC is on vacuum supply will go to PLA unit which activates the LFG lever and pulls in lever so that it butts against fast idle screw .
  • Page 98 Turbo charger...
  • Page 99 Pressurized Oil Compressor Turbine Air Cleaner Exhaust gases turbine Compressed Oil to Turbocharger. air to engine sump Front End Inter cooler...
  • Page 100 Principle of turbocharger In exhaust gas turbo-charging, the exhaust gas energy which would normally be wasted , is used to drive a turbine. The turbine drives a compressor, which draws in combustion air and feeds this at a higher pressure to the engine. Main advantages of the turbocharger are : Lower fuel combustion.
  • Page 101 Precautions for turbocharger 1. Use specified grade of engine oil & oil filter. 2. Regular cleaning / change of air filter element according to engine manufacturer’s recommendations. 3. Check for oil pressure at engine idling condition. 4. Idle the engine for 60 seconds after starting the engine. 5.
  • Page 102 1. Don’t run the engine with low oil pressure. 2. Don’t put the engine under full load immediately after starting. 3. Don’t switch off the engine in full load condition. 4. Don’t run the engine with leaky, restricted oil feed & drain pipes.
  • Page 103 Exhaust gas recirculation...
  • Page 104 Emission control for BS2 diesel engines Normal/Ideal combustion Diesel(C ) + Air(77% N , 23% O ) ---> 0 + N Actual combustion Diesel(C ) + Air(77% N , 23% O ) ---> 0 + N + Co + HC + No + PM...
  • Page 105 Components of diesel exhaust - Colourless, poisonous gas - Colourless , poisonous gas - Brownish ,poisonous gas - particulate matter, commonly called soot or smoke - Non-poisonous - Potential greenhouse gas related to global warming. - Non-poisonous...
  • Page 106 Bharat stage 2 emission norms Chassis Dynamometer Tests ( Cycle : EEC + EUDC - 90 km/h) All in g/km HC+Nox RW >1700 1.50 1.20 0.17 RW [ Reference Weight] = Curb weight + 200 Kgs Tests are on Chassis Dynamometer EUDC Cycle Speed is limited to 90 km/h instead of 120 km/h (in EEC)
  • Page 107 Emission control technologies try to reduce these harmful exhaust gases by the following technologies : 1] In-cylinder combustion improvements In-cylinder improvements aims to attack the problem at the source, i.e improve the quality of combustion inside the cylinder so that less of harmful pollutants are produced inside the cylinder.
  • Page 108 2] Exhaust gas after treatment Exhaust gas after treatment aims to reduce the pollutants after they are generated inside the engine but before it is released to the atmosphere. Some of the options are : • Catalyst in the exhaust...
  • Page 109 Principles of No generation (Oxides of nitrogen) comprises of various types of oxides of nitrogen, clubbed together. These are no, No , No etc. Nitrogen is an inert gas and will not react with oxygen in normal conditions. However, under certain conditions, nitrogen starts to react with oxygen and forms oxides of nitrogen.
  • Page 110 Principles of No control can be controlled either by arresting the formation,at source or by exhaust after treatment. 1] In-cylinder No control Formation of No can be controlled either by reducing the combustion temperatures or by reducing the availability of free oxygen. This is achieved by exhaust gas recirculation - egr, 2] Exhaust after treatment No control...
  • Page 111 Principles of exhaust gas recirculation (EGR) EGR system recirculates part of the burnt exhaust back in to the intake system, to help in reducing the combustion temperatures as well as reducing the quantity of free oxygen. EGR VALVE WHEN TO OPEN ? HOW MUCH TO OPEN ?
  • Page 112 Reduction of combustion temperatures Exhaust gases are inert gases with a very high value of c they do not take part in combustion but absorbs heat without increasing its temperature. This acts as a heat sink and reduces the overall combustion temperatures. (Point 1). Reduction of free oxygen inside cylinder Exhaust gases occupy some space and reduce the equivalent amount of free oxygen (Point 2).
  • Page 113 In order to meet Bharat stage II emission norms, the following modifications are done on the SZ 2600 engine In-cylinder control • Modifications to fuel injection system • Exhaust gas recirculation - Electronically controlled variable EGR.
  • Page 114 Fuel injection system modifications 1. Higher peak injection pressures 2. Injector nozzle - 6 holes 3. Cold running advance 4. FIP timing - 1.25 mm plunger lift at TDC. 5. FIP with throttle potentiometer BS1 Vs BS2 MICO DTVS FIP TIMING 1.25 (Plunger Lift at TDC, mm) NOOZLE OPENING...
  • Page 115 Exhaust gas recirculation - EGR Electronically operated, pneumatically actuated variable EGR Engine load Coolant temperature Vacuum modulator EGR ECU Engine speed Diagnostic outlet EGR valve lift...
  • Page 116 Layout – EGR system[SZ 2600 BS 2] Alt/vac. Pump Vacuum modulator Vac. Reservoir Egr valve potentiometer To FICD Throttle potentiometer EGR valve Air cleaner EGR map Load Thermostat hsg. Coolant temp. Speed Temperature sensor Alternator...
  • Page 117 Vacuum Modulator Throttle Potentiometer...
  • Page 118 EGR valve ( New) Vacuum reservoir Temperature Sensor...
  • Page 119 Vacuum line connection at vacuum modulator From vacuum pump To EGR valve From air cleaner From ECU...
  • Page 120 Controls & strategies Accleration cut-off - The EGR valve will close when the vehicle is suddenly accelerated. Overheating cut-off - The EGR valve will close if the coolant temperature reaches 95 Cold engine - The EGR will not work if the coolant temperature is less than 25 Half EGR - Between 25...
  • Page 121 Diagnostic defect codes reading Connect a 12V, 2W bulb to the diagnostic connector provided in the wiring harness. Switch on the ignition Wait for minimum 3 seconds Start the engine and run at idle speed Look for blink codes in the bulb Observe the blink codes Compare blink codes with decoding chart to identify the defective sensor/actuator.
  • Page 122 Defect code decoding chart Sr No. Parameter Error type Blink code Lamp on EGR ECU No errors continuously No ECU supply / ECU EGR ECU No blink defective No Signal On 2s / Off 2s Throttle Sensor not connected sensor On 1s / Off 5s / Setting error Temperature...
  • Page 123 EGR Valve checking Remove the EGR valve and check it for valve-sticking, deposition of carbon etc. If excess carbon deposits and sticky valve noticed then it should be cleaned with a suitable solvent, so that the correct valve seat is ensured. After cleaning the valve blow air from the bottom side of the valve and check for any leakage.
  • Page 124 FIE Details BS II Static timing 1.25mm Plunger lift at TDC Lock timing bolt FICD Potentiometer Injector Identification Milky white ring Nozzle opening pressure 250 + 8 bar Specification 6 X 0.203 X 150° Nozzle holder F 002 C70 555 Nozzle holder pressure 1200 bar...
  • Page 125 Identification of Nozzles of BSII Milky white colour ring BS II Nozzle...
  • Page 126 Features in F I P LDA : Increases the fuelling according to the boost pressure developed by turbo charger.
  • Page 127 Lock timing bolt [ FBB] : Ease in FIP timing. LFG: Avoids the fuelling to become zero during gear changing.
  • Page 128 Fast idling control device [ PLA] : Controls the idling to the set band when AC is on.
  • Page 129 Potentiometer [ BS II FIP] : Gives input of engine load to the EGR ECU.
  • Page 130 F. I. P. TIMING [ SZ 2600 Plus ]...
  • Page 131 In BSII sprocket, Key ways is offset w.r.t. centre line of weight reducing hole. Offset...
  • Page 132 BS 2 Sprocket : Timing marks is on 8 teeth clockwise from keyway. Timing mark...
  • Page 133 Procedure for FIP removal of SZ 2600 + engine Remove viscous fan drive & shroud Remove FIP inspection window cover...
  • Page 134 Remove R/A cover. Bring no. 1 cylinder to compression stroke.
  • Page 135 Remove all high pressure pipe. Remove first cylinder injector. Put MST No. 0272 & dial gauge.
  • Page 136 Loosen FIP sprocket lock nut & re-torque it to 2.5kg-m. (20 lbs.ft) Bring no 1 piston exactly at TDC...
  • Page 137 remove lock plate. Torque lock screw to 1.5 kg-m Note: At this point FIP shaft is locked. Even slight rotation of engine will damage FIP rotor shaft.
  • Page 138 Remove flange mounting nuts & rear mounting bracket Place sprocket locking pins (three no.) of MST 0270 in sprocket relief holes. Note: If piston not at TDC, threads on blocks will not align with the holes provided for locking pins.
  • Page 139 Torque them to 1.0-1.5 kg-m. Remove sprocket mounting nut & washer...
  • Page 140 Put slotted pins. Ensure that the side with ‘F’ punched will face outside. Letter ‘F’ punched should Face outside Note : Slide pins in the slot such that bottom portion of slot will butt against the back face of sprocket when FIP shaft is pushed away from sprocket...
  • Page 141 Sprocket locking pin Slotted pin...
  • Page 142 Slotted Pin Drawing...
  • Page 143 Slotted pin used for commonised cast block with CRDI...
  • Page 144 Locking Pin - FIP Sprocket...
  • Page 145 Assemble FIP pusher plate of MST 0270 with. Ensure plate butting properly on all the three pins. Push FIP by tightening puller bolt Note : Till the refitment of done, possible to use MST 0270 on another vehicle.
  • Page 146 Procedure for FIP fitment of SZ 2600 Plus engine FIP is removed with following engine condition: No 1 piston is TDC compression. FIP sprocket is hold by locking pin. FIP is locked with required plunger lift. Note: FIP, if return from MICO dealer is also locked when it is injecting fuel in no.
  • Page 147 Key position of FIP when injecting into no 1 cylinder i.e. in-between 9 to 12 O’ clock position.. this should match with key way position of FIP sprocket.
  • Page 148 Put the locked FIP into fip sprocket. Assemble sprocket mounting nut & washer. Torque it to 2.5 kgm. Remove sprocket locking pins & slotted pins Assemble flange mounting nut & torque them to 3.5 kgm.
  • Page 149 Put back the locking plate & tight locking screw. Finally torque sprocket mounting nut to 9.00 kgm. Note: it is advisable to check plunger lift using dial gauge. For BSII - 1.25 mm at TDC Complete the assembly...
  • Page 150 FIP removal & refitment w/o special tools Without MST 270 & 272, if pump has to be removed ,remove timing cover & chain.
  • Page 151 Cooling system...
  • Page 152 Water bypass system- SZ 2600 Plus...
  • Page 153 intake system...
  • Page 154 Positive crankcase ventilation system...
  • Page 155 POSITIVE CRANK CASE VENTILATION Front End Oil Separator Rocker Cover Air Cleaner To Turbocharger Ladder Frame Sump...
  • Page 156 This hose connects the ladder frame assembly to rocker cover. This hose balances the gas pressure in the rocker cover & sump.
  • Page 157 This hose connect rocker cover to the oil separator. It has a coarse mesh, at both ends which trap bigger particle & thus help to improve oil separator efficiency. Wire mesh...
  • Page 158 Oil separator separates oil particle & gas due to centrifugal action. The vacuum after the air cleaner acts on to the top of diaphragm . The balance of the vacuum against the spring & the vapour pressure controls the amount of the oil going to the sump.
  • Page 159 Vacuum connection to EGR & FICD FICD switch FICD at FIP Reservoir Pressure Modulator Vacuum pump Alternator To air cleaner Valve...
  • Page 160 Important clearances & dimension Exhaust cam lobe lift 6.07 Inlet cam lobe lift 6.90 Valve stem & guide 0.03 to 0.07[ inlet ] 0.05 to 0.09 [ Exhaust ] Crank shaft & main bearing 0.02 to 0.07 Crank shaft run out 0.025mm [max] Crank shaft end float 0.10 to 0.37...
  • Page 161 Cylinder head height : 97.70 to 98.30 Transverse deflection of head : 0.05 Tappet setting - inlet : 0.30 Tappet setting - exhaust : 0.45 Nozzle opening pressure- MICO : 250 + 8 bar All dimension in ‘mm’ unless specified...
  • Page 162 Important torque Kg-m lbs-ft Cylinder head : 9.00+ 60 65.00+ 60 Connecting rod bolts : 4.50+90 30.00+ 90 Main bearing caps : 17.00 Crank shaft pulley : 9.00+ 90 65.00+ 90 Flywheel bolts : 9.00+60 65.00+ 90 Cam shaft gear/sprocket bolt : 11.00 Timing cover mounting bolt : 2.50...
  • Page 163 Important MST MST No Piston ring compressor (Common with XD 3P) Spanner for engine mounting nut Extractor - Fly wheel bearing Drift - Flywheel bearing Wrench- Oil filter removal Cylinder head bolt deep socket Tool for removing FIP[ Chain drive] Flywheel lock[ Chain drive] TDC tool Lock pin for chain tensioner...
  • Page 164 THANK YOU...

This manual is also suitable for:

Sz 2600

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