REPAIR MANUAL FRESH M-HAWIK Vv & SC/DC MahindraRepair Manual MAN-ODDKX Scorpio Vix August 2009/Re~ 1 Speci & Wear Data — “Figure Description Value Bore 85 mm t Stroke 96mm Power- Max 88 RWW (120 HP) @ 4000 rpm Torque-Max 290 Nma1800 rpm Firing Order 1-3-4-2 Direction of rotation Clockwise from fan side Compression Rati 185 Standard Service Compression Pressure | Limit bar Re-entrant Bowl Piston Full floating. Surface Piston Pin hardened & ground. Offset Oil grade & Quantity by 0.3mm API grade CHa Viscosity Index 15W40 6 liters Manimile SupremeRepair Manual MAN-OODXX Scorpio Vix August 2000/Rev 1 Figure Description Value Inlet valve BTDC OPENS ABDC __ CLOSES Exhaust Valve OPENS BEDC CLOSES ATDC Oil filter bypass bar opening pressure 1.0+/-0.2 ke/em2 | Relief valve opening bar pressure ( for gear drive engines only) low idle: 1.5 bar, oil Oil pressure at temp 90 degrees € Idle ( 60-80°C) bar high idle: 4.5-5.5 | Max speed( 60-80°C) bar, oil temp 90 degrees © Standard Service Limit Piston ring to groove Diametrically clearance tring 1.22 2 ri 1.2-24 ¥* ring 07-15 eS Piston ring end gaps 1 ring 0.25-0.4 2" ring 0.40.6 ¥* ring 0.25-0.5 Gudgeon pin O.D@ = 31.00-0.006 Connecting rad - Small end bush |.D} in assembled condition Gudgeon pin to connecting rod small end bush clearance. Standard 31.00 (+0.041 / +0.025) Standard Service Limit 0.025 to 0.047Repair Manual MAN-D00XX Scorpio Vix August 200%/Rev 1 Figure, _ Value, Standard Service Limit Gudgeon pin to piston 0.00% to 0.021 pin hole clearance Piston to Bore clearance Piston weights grading A Az 594-599 GMS B 8: 2599-604 GMS c C: 9604-609 GMS o D: 609-614 GMS. E Connecting rod grading FOUR CONNECTING ROO as per weights WEIGHT ASSEMBLIES OF ONE F ENGINE WILL HAVE WEIGHT G DIFFERENCE OF 5 GM H MAXIMUM, 1 J IGHT OF ONE CONROD K ASSEMBLY (CONROD, BOLT, L BEARING, BUSH)- 950 «/- My 12.5 GMS N o Pp R s T u Recommended for Connecting red bend or twist BEND AND TWIST: PARALLELISM OF SMALL END 1D 0.06/ 100 WRT BiG END IDRepair Manual MarL-ODOX Scorpio Vix August 200WRew 1 Figure Value ‘Connecting rod end Standard Service Limit play 0.1-0.3 Crankshaftendplay | Standard Service Limit ; 0.1-0.3 Crankcase top surface distortion Top surface flatness: 0.04 and 0.02/10 (Cylinder head bottom face distortion Bottom face flatness: O.1 and 0.03/ 100x100 L. ‘Height of cylinder head 124 Le. from top to bottom face Rocker lever bush |.D 22.0 {in pressed condition) Rocker shaft 0.0 21.98/21.980 Rocker to shaft Standard Service Limit clearance 0.02/0.08 a2 Standard Service Limit | Push rod bent 20.25 O.4 Valve spring Standard Service Limit Free Length | 47.16 Squareness | 1.5 max Installed Load/Installed | jyaq- 204.0 -/- 40.2 N, Fength | Length: 34.5 Valve seat angle 90.00/+0.15' degrees Valve stem 0.0 Inlet ExhaustRepair Manual MAN-OODX Scorpio Vix August 2009/Rer 1 Valve to Valve guide clearance Inlet O.012-0.142 Exhaust 0.032-0.168 | Thickness of the valve head ‘Chain Crank Sprocket | 20 teeth idler HA Sprocket 21 and 30 HPP Sprocket Difference between Cam height & base circle diameter Inlet 371 Exhaust 4.00777 Camshaft Bush 1.0 ‘Camshaft Journal 0.D 24.0 (-0.04/ -0.053) ‘Camshaft bush to cam journal clearance ‘Standard Service Limit 0.02/0.075 a1 Camshaft bend Crankshaft pin op Roundness/Qwvality Cylindricity ‘Taper Standard Service Limit 50.981-50.996 0.008 0.005Repair Manual MAN-OODXX Scorpio Vix August 2009/Rev 1 Figure Description Value Standard Service Limit Main Bearing oil clearance Dimensions of the crankpin. Undersize of the c's crank pin OD 6.25mm US 6.50 mm US 0.75 mm US Standard Service Limit Crankshaft journal Yellow: 61.986-61.993 oD Red: 61.993-62.000 Roundness/ Ovality 0.005 Cylindricity! Taper 0.008 Dimensions af the journal Undersize of the c/s journal pin OD 0.25mm US 0.50 mm US 6.75 mm US (Crankshaft bend Standard Service Limit FILLETS ARE HARDENED. DO NOT ATTEMPT TO STRAIGTEN Standard Service Limits 3.0 mm typical Crankshaft Hardness Minimum surface hardness: 505 all case areas are effective case depth is at HV450 Connecting rod Bearing oil clearance Standard Service Limit 0.026-0.069Repair Manual MAN-O00% Scorpio Vix August 2009/Rev 1 _ Figure Description Value The Maximum length of bolts after which they cannot be used Cylinder head bolts Can be used 3 times Main Bearing Bolts Can be used 3 times Connecting rod Flywheel bolts length Can be used 3 times Thermostat Starts opening at NA Fully opens at Lift Water pump pulley | 0.74 (WP pulley runs faster ratio than damper pulley) Flywheel BSH-015 Width from Mounting face to clutch face —+! Flywheel Flatness Runout Cykinder Head warpage Limit Standard Service Limit 0.05 0.06 O.1 mm.Repair Manual MAN-OODKX Scorpio Vie August 2009/Btew 1 Lubricants & Sealant - Mahindra Maximile Supreme or any other engine oil conforming to API grade CH4 or above and a viscosity Index of 15W 40. RTV silicone sealant - RHODOSEAL. Part number 0024532 to be used: « Between Rear oil seal retainer & Block Rust cleaning solution (For the Turbocharger mounting nuts): Brand Name: WD-40--- Manufacturer- WO-40 COMPANYSealant Application Pattern - Sealant on Front Cover - Loctite 5900Flepair Manual MAN-DODKX Scorpio Vix August 2008/Rew 1 Sealant between Head & Cam Cover - Loctite 574 "Sealant On Oil Sump - Loctite 5900Tightening Torques - Head Bolts 65.4 3Nm +90 Bed Plate bolts 504 2Nm Main Bearing bolts f23Nm+ 2k eo “Connecting Rod caps 3523-60 Flywheel 50 .Nm + 6! Damper Pulley 750 = 65" HPP Mounting Nut 10-12.Nm Trigger wheel to Crank 15-20 Nm Speed Sensor Mtg. bolt 10-12 Nm Oil Jets mtg. bolts 10-12 Nm HPP sprocket lock nut 72.54 2.5Nm HP pipe nut - Rail End 274 2Nm HP pipe nut - Injector End 274 2m Viscous Fan altace nut 50-60 Nm Injector holdi 25.4 3Mm_ Injector holding aan 22.522.5Nm ‘Common Rail Mounting Bolts 25.4 3Nm HP pipe Pump to Rail - Pump End 10-12 Nm HP pipe Pump to Rail - Rail End i0-12. Nm Front cover Bolts 254 3Nm Water Pump Bolts 2a 3Nm Water Outlet Pipe from Water Pump 10-12 Nm Water Inlet pipe from Head to Radiator 10-12 Nm Alternator Bracket bolts 30.35 Nm Chain Guide Bolts 104 1Nm Chain Tensioner (Primary) Bolts 254 36m Chain Tensioner (Secondary) Bolts 25a 3Nm Cam to Cam Chain Guide TONm Cam Sprocket Bolts 85.295 Nm Oil Filter Cartridge i2inm Dip Stick Guide 18.Nm Oil Filter body 2543Nm ‘Alternator oil supply line - Banjo End 15 2 20Nm “Alternator oil supply line - Block End Te.Nm ‘Power Steering Pump Mtg. Bolts “254 3Nm_ Exha id Mtg. Bolts z im Turbocharger Mtg. studs on exhaust 25a 36m manifold Turbocharger Oil supply pipe - Sanjo End 16-12 Nm Turbocharger Oil supply pipe - Block End 10-12 Nm Turbocharger Oil drain Banjo Bolt 254 3Nm EGR Mtg. nuts 254 3Nm ‘AC compressor Mig. Bracket Bolts 754 3Nm ‘AC compressor Mtg. Bolts 354 3NmRepair Manual MAN-D00KK Scorpio Vix August 2009/Rev 1 Intercooler Mtg. Nuts 17.542.5Nm Intercooler dampers, T5225Nm ‘AC compressor on bracket 252 3Nm Automatic belt tensioner Mtg. nuts 254 34m Bolts - Mtg Inlet Manifold 1a 3Nm