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ENGINEERING

ENGINE (DIESEL)

TECHNICAL SPECIFICATIONS

ENGINE

Model : TATA 475 IDI

Type : Water cooled Indirect Injection Diesel Engine

No. of Cylinders : 4 inline

Bore / Stroke : 75 mm x 79.5 mm

Capacity : 1405 cc

Max. Engine Output : 53.5 PS at 5000 rpm

Max. Torque : 85 N-m at 2500 rpm

Compression Ratio : 22 : 1

Firing Order : 1-3-4-2

Engine oil capacity : 4 Litres

Cooling system capacity : 6 Litres

Weight of engine : 100 kg

Air filter : Dry (Paper) type

Oil Filter : Spin on full flow paper type

Fuel filter : Two stage fine filteration

Fuel injection pump : Rotary type with electric stop solenoid

Governor : Mechanical

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ENGINEERING

ENGINE (DIESEL)

TIGHTENING TORQUES

The fasteners should be tightened to specified torque at recommended intervals (km). If various fasteners are not tightenedto specified torques, that is either over tightened or left loose, it will result in leakage at joints and damage to the parts/threads. It will also adversely affect the performance of the parts/systems because various clearances/bearing plays in theaggregates are governed by the tightening torques of the fasteners.

When choosing the torque wrench, remember that it should not be subjected to torque exceeding three fourths of itscapacity. Before tightening, clean the threads and apply a little oil.

Serial Description Torque in kg-mNo.

1. Main Bearing Cap bolt M10 x 1 5.5 #

2. Cylinder head bolts M10 x 1.1 3, 5, 7.5 (Ref. Note) #

3. Screw plug for oil gallery cylinder head M12 x 1.5 3

4. Injector to cylinder head M12 x 1.5 9#

5. Cylinder head cover bolts M6 0.5 #

6. Oil sump Screw M6 x 1 0.6 to 0.7 #

7. Sealing plug for oil gallery block rear M14 x 1.5 3.5

8. Oil sump drain plug M12 x 1.5 3.5

9. Rear timing cover to block M6 x 1 1.0

10. Rear timing cover to Cylinder head cover M6 x 1 1.0

11. Timing belt cover M6 x 1 1.0

12. Rear cover crank case on cylinder block screw M6 x 1 1.0 #

13. Connecting rod cap Nut M9 x 1 5.25 #

14. Flywheel mounting screw M10 x 1 5.0 #

15. Crankshaft gear to crankshaft bolt M14 x 1 5.0 #

16. Vibration damper / 4 groove A/C pulley to crankshaft gear 2.5

17. Belt tensioner adjuster bolt M10 x 1.5 3.0

18. Timing belt idler to cylinder block bolt M10 x 1.5 4.5

19. Camshaft gear to camshaft screw M12 x 1.25 8.0 #

20. Camshaft bearing cap mounting Nuts M6 1.5 #

21. Flange on F I P gear for locking screw M 8 x 1.25 2.0

22. F I P gear to F I P shaft Nut M 12 x 1.5 5.0 #

23. F I P Bracket to block and head M10 x 1.5 4.0

24. F I P rear Bracket to block M10 x 1.5 2.0

25. F I P to rear bracket M18 x1.25 2.0

26. Exhaust manifold on cylinder head M8 x 1.25 2.0 #

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ENGINEERING

ENGINE (DIESEL)

27. Inlet Manifold on cylinder head M8 x 1.25 2.0 #

28. Starter motor mounting bolt M8 x 1.25 2.4

29. Alternator bracket to cylinder crankcase M8 x 1.25 2.0

30. Alternator to bracket M10 2.0

31. Glow plug in cylinder head M10 x 1 2.0#

32. Glow plug connection M4 x 0.7 0.2

33. Alternator tensioner bracket to block M8 x 1.25 2.0

34. Alternator to tensioner bracket screw M8 x 1.25 1.5

35. Oil pump on cylinder block 1.0 #

36. Assembly Strainer to oil pump M6 x 1 1.0

37. Assembly oil filter to cylinder block M12 x 1.5 Ref Note @ #

38. Oil pressure switch on cylinder block 3.0

39. Oil cooler to cylinder block 2.0

40. Water pump mounting screw M6 x 1 1.0 #

41. Thermostat cover to cylinder block M6 1.0 #

42. Water inlet elbow to cylinder block M8 x 1.25 2.0

43. Temperature Transducer on cylinder head M14 x 1.5 1.5

44. Assembly Tube (water by pass) on cylinder head Nut M6 1.0 #

45. Lifting hooks on cylinder head screw M8 x 1.25 2.5

46. Engine mounting bracket to block M10 x 1.5 4.5

47. Engine mounting bracket to arm 4.0

48. Power steering pump mounting on bracket screw M8 x 1.25 2.5

49. A. C. Compressor bracket to cylinder block screw M8 x 1 2.5

50. A. C. Compressor to A. C. compressor bracket bolt M8 x 1.25 2.5

51. Power steering pulley to power steering pulley Nut M12 x 1.25 8.0

52. Assembly idler to Slider (A. C. compressor belt tensioner) Nut M8 x 1.25 2.5

Tolerance on Torque values + 5% for marked # and + 10% for others

Note @ Apply oil on seal face and screw in until seal touches face. Tighten further by 3/4 turn. Do not over tighten.

Serial Description Torque in mkg.No.

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ENGINEERING

ENGINE (DIESEL)

LIST OF SPECIAL TOOLS

Sr. No. Description Part No.

1. Flange (for F.I.P. Gear removal) 2547 0713 7103

2. Engine repair stand 2573 5890 2401

3. Spanner for holding FIP gear 2654 5890 0501

4. Valve spring compressor 2654 5890 0507

5. Drift for camshaft oil seal 2654 5890 0508

6. Timing rod (For lucas F.I.P.) 2654 5890 0601

7. Extended Socket (10 A/F) for oil sump mounting screws 2702 5890 0603

8. Flywheel locking pin 2702 5890 0605

9. Locking plate for camshaft 2702 5890 0606

10. Lock plate for camshaft gear washer 2702 5890 0607

11. Drift for crank shaft oil seal (rear cover) 2702 5890 0608

12. Pin for locking F.I.P gear 2702 5890 0609

13. Support rail for valve spring compressor 2702 5890 0610

14. Drift for valve guide (Inlet/Exhaust) 2702 5890 0611

15. Spacer for valve guide fitment 2702 5890 0612

16. Socket for injectors 2702 5890 0702

17. Compression gauge adapter for checking compression 2702 5890 0703

18. Drift for oil pump oil seal 2702 5890 1801

19. Spanner for oil filter 2702 5890 1802

20 Support stand for engine 2702 5890 2401

21. Engine mounting bracket (LH) on stand 2702 5890 2402

22. Engine mounting bracket (RH) on stand 2702 5890 2403

23. Mandrel for aligning clutch disc 2702 5890 2501

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ENGINEERING

ENGINE (DIESEL)

PRELIMINARY INSPECTION OF ENGINE

Before proceeding to carry out actual reconditioningof engine, it is desirable to have a preliminaryinspection of engine to ascertain whether an enginerecondition is necessary and if so to what extent.

Most common reasons for which engine isreconditioned are :

1. Loss of power

2. Excessive engine oil consumption.

3. Excessive low engine oil pressure

4. Mechanical failures

To know exact reason and general condition ofengine, proceed as follows :

1. LOSS OF POWER

Loss of engine power may be due to :

a. Clogged air cleaner/loss of charge airpressure / choked exhaust passage

b. Loss of engine compression

c. Defective fuel system

d. Clutch slippage

e. Brake binding

a. CLOGGED AIR CLEANER/LOSS OF CHARGE AIRPRESSURE/CHOKED EXHAUST SILENCER

Loss of power with unusual black smoke fromengine exhaust indicates lack of air or low aircharging pressure to engine cylinders.

Clean air filter. Check all joints for air leakage. Ifpower loss with black smoke is still felt, checkexhaust silencer for choking. Clean and replacesilencer if necessary. Check for nick formation inexhaust piping.

b. CHECKING ENGINE COMPRESSION PRESSUREon Fig. A

l If loss of power is not on account ofdefective fuel system, lack of air, chokedexhaust system, clutch slipping and brakebinding, check engine compression asfollows.

l Warm up engine preferably by road driveto get a temperature of about 80 to 1000 C.

l Remove the air cleaner.

l Remove all injectors.

l Fit adapter (part no. 2702 5890 0703) inplace of one injector.

l Connect compression tester to adapterand tighten vent knob.

l Crank engine with starter motor by 200-350 rpm approximately. Pressure gaugeneedle will start rising. Continue crankingtill gauge needle stops rising any further.Note down reading. Loosen vent knob tomake sure the tester needle returns to zero.Repeat this operation for remainingcylinders.

Minimum compression

pressure in each cylinder 19 bar.

Variation in compression pressure

between cylinders 1.5 bar.

l Low compression pressure may be due toleakage past valves/piston rings /blowncylinder head gasket. To ascertain the pointof leakage, spray small quantity of cleanengine oil in to cylinder showing lowpressure. If it improves, wear in pistonrings/cylinder bore is indicated. If it doesnot, leakage past the valves is indicated. Ifcompression pressure of adjacent cylinderis also on lower side and equal, it may bedue to blown cylinder head gasket.

Fig. A

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ENGINEERING

ENGINE (DIESEL)

c. FUEL SYSTEM

Check condition of fuel filter elements, fuelinjection pump for proper function i.e. pumptiming antistall setting etc. Bleed the fuel systemfor removing air.

d. CLUTCH SLIPPAGE

Clutch slipping can be confirmed by any of thefollowing two methods :

Drive car in 1st and 2nd gear at maximum speedcorresponding to that gear. With acceleratorpedal fully pressed, apply brake gradually withleft foot. If the engine stalls it means that clutchdoes not slip.

OR

Drive the car with normal load in 3rd gear on levelground and let the speed drop down toapproximately 15 kmph.

Now press accelerator pedal fully. With slippingclutch the car speed will not pick up and alsoclutch burning smell will be noticed. If this doesnot occur and car picks up speed, it indicates thatclutch does not slip.

e. BRAKE BINDING

During driving apply brakes number of times andthen shift gear to neutral position and check freerolling of car. Check brake drums/brake discs foroverheating and if necessary jack up the car andcheck wheels for free rotation.

stage and finding oil consumed from the topped upposition taking into consideration dipstick level andoil tank capacity.

PROCEDURE :

1. Once it is doubted that engine oil consumptionis higher, place the car on level ground.

2. Top up oil sump to its capacity of 4 litres.

3. Warm up the engine so that oil temperature is75 - 800 C.

4. Now take a clean vessel, place it below the drainplug of oil tank.

5. Drain the hot oil into the clean vessel. Drain itfully.

6. Screw in oil sump drain plug and tighten it.

7. Weigh the vessel along with oil let this weightbe ‘w1’, gms.

8. Refill the weighed oil into the oil tank. Do notspill any oil. The vessel used for draining shouldnot be used for any other purposes.

9. Drive the vehicle approx. 200 - 300 km. This driveshould include at least 30 - 40 kms. of highwayor similar road, vehicle running at about 60 kmph.Let this drive distance be ‘D’ kms.

10. Immediately after the test drive, place the vehicleat the same spot from where it started.

11. Now place the same previously used vesselbelow the oil tank, unscrew the drain plug anddrain off oil into the vessel. Drain the tank fully.

12. Weigh the vessel along with oil, now for thesecond time. Let this weight be ‘w2’ gms.

13. Find out standard oil consumption as -

Std. oil consumption =

(w1 - w2)(wt. of oil consumed, gms) x 1000‘C’ (litres/1000km) sp. wt. of oil (gm/cm3) x ‘D’ (drive dist. in km.)

‘C’ =w1 - w2

litres/1000km0.88 x D

3. EXTREMELY LOW OIL PRESSURE

Check the following :

a. External leakages.

b. Oil level in sump upto maximum mark ondipstick.

c. Oil pressure indicator for proper functioning.

EXCESSIVE ENGINE OIL CONSUMPTION

High engine oil consumption may also lead tooverhauling of the engine but before proceeding tooverhauling, check following points :

1. Make sure that there is absolutely zero externalleakage of the oil (i. e. from the camshaft oil seal,crankshaft oil seal, oil sump gasket, oil pumpgasket, cylinder head cover gasket etc.

2. Ensure that oil separator in the cylinder headcover is properly mounted.

3. If no external leakage is found, determine theexact engine oil consumption, as per followingprocedure.

DETERMINING EXACT ENGINE OIL CONSUMPTION :

CAUTION :

Do not make a rough estimate of engine oil consumptionby noting the kilometers covered by the car at any random

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ENGINEERING

ENGINE (DIESEL)

d. Functioning of pressure relief valve on oilpump.

e. Oil pump performance using suitablepressure gauges.

If low oil pressure is not on account of above factors,wear of journals/bearings is indicated for whichoverhaul of engine may be considered.

4. MECHANICAL FAILURES

Defective water pump idler, pulley, Engine mounts oralternator can be a source of mechanical noise. Defectcan be located by replacing alternator, water pump,Engine mounts, idler, pulley with a NEW one.

Metallic knocking sound from an engine may be dueto faulty injection, excessive clearance in main and bigend bearings, small end bush, tappets, piston slap,seizing of piston rings, scored cylinder bore orbreakage of any moving parts. Noise due to defectivefuel injection equipment is generally termed as‘DIESEL KNOCK’ and can be eliminated by attendingto fuel injection equipment. By cutting off highpressure line to individual injectors with enginerunning will pin point the cylinder with Diesel Knock.Overhauling of fuel system will set right Diesel Knock.

Dismantling of engine may be considered if still noiseoccurs even after attending all above mentionedproblems.

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ENGINE (DIESEL)

REMOVAL OF 475 IDI ENGINE FROM THE CAR :

Remove Bonnet

Disconnect electrical cable connections for :

l Battery

l Starter motor

l Alternator

l Fuel injection pump solenoid switch Fig. 1

l FICD (Fast idling control device) Solenoid

(If A. C. fitted)

l Glow plugs Fig. 2

l Oil pressure switch

l Water temperature transducer

l Reverse light switch

Disconnect :

l Accelerator cable

l Speedometer drive cable

l Clutch actuating cable Fig. 3

Disconnect pipe lines from :

l Fuel filter to fuel injection pump

Overflow line from injector to fuel return line.

l Fuel return line from fuel injection pump to fueltank Fig. 4

l Vacuum pump to vacuum booster

Fig. 2

Fig. 3

Fig. 4Fig. 1

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ENGINEERING

ENGINE (DIESEL)

Fig. 6

Fig. 7

Fig. 8Fig. 5

Disconnect exhaust pipe from exhaust manifold

Drain coolant from cooling system

Disconnect hoses from and to radiator and heatercoil (if fitted)

Disconnect pipe from radiator to auxiliary tank &cylinder head to radiator.

Remove the AC pipe lines (if AC is fitted)

Remove the following sub assemblies :

l Air filter

l Condenser in case of DLE & DLX models

l Gear shift lever and lever from transaxle to gearshift lever bracket assembly. Fig. 5

l Drain transaxle oil Fig. 6

l Remove drive shafts (For procedure, seesuspension group)

Fix chain to front and rear engine lifting hooks and holdchain in position with crane.

Unscrew and remove engine mounting bolts atlocations ‘A’, ‘B’ and ‘C’. Fig. 7

Place support stand 2702 5890 2401 under the engineFig. 8

Lower the engine on support rail along with transaxleassembly and remove the chain.

Lift the front end of the car till engine is clear. Pull outthe engine (It is recommended to use 2 pole hoist forlifting the car)

Remove starter motor. ‘A’ MOUNT ‘B’ MOUNT

FRONT

‘C’ MOUNT

SUPPORT RAILPART NO. 2702 5890 2401

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ENGINEERING

ENGINE (DIESEL)

Fig. 9

Fig. 10

Fig. 11

Disconnect transaxle assy. from engine (For procedurerefer Transaxle group)

Remove alternator (ref. alternator removal ahead)

Mount the engine on work stand 2573 5890 2401.

Drain engine oil. Fig. 9

INSTALLATION OF ENGINE ON CAR :

l Check engine mounting pads for wear &damage. Replace them if necessary.

l Install the engine in reverse sequence of removal

l Tighten engine mounting bolts to specifiedtorque

l Connect all pipes, hoses and electricalconnections

l Fill specified quantity of recommended oil inengine. (Fig. 10)

l Fill coolant in the cooling system through aux.tank.

l Crank the engine momentarily. Let oil and coolantcirculate through the system. Remove airtrapped in cooling system with the air ventingscrew provided.

l Confirm whether Engine oil pressure indicatorlight is switching off when engine is started

l Check for leakage, rectify if any

l Top up coolant upto FULL mark in auxiliary tank,if necessary

REMOVAL OF RADIATOR FROM CAR

(Front bumper, Splash guard already removed - Forprocedure refer Body group of this manual)

1. Drain the coolant.

2. Remove all the hose connections i. e.

i. From the thermostat

ii. From the auxilliary tank.

iii. To the outlet elbow.

3. Disconnect the electrical connections,

i. To the condenser fan (In case of DLE & DLX)

FILL OILFROMHERE

1. ASSY. RADIATOR COMPLETE

2. CROSS MEMBER RADIATOR MOUNTING

3. RUBBER GROMET

1.

2.

3.

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ENGINEERING

ENGINE (DIESEL)

ii. To the temperature sensor of cooling fan.

4. Unscrew the 2 M8 bolts & remove the radiatorbottom mounting member along with theradiator. Fig 11

SPECIFICATIONS

Leakage testing pressure : 1.5 bar

Auxillary Tank Cap Fig. 12

Pressure valve opening : 1 barVacuum valve opening : 0.05 bar (max)(suction)

INSPECTION

Check radiator for damages / leakages. Straightenbent fins if any.

CLEANING

Clean radiator frontal cores.

Installation :

1. Fit the radiator along with the radiator bottommounting member on to the car & tighten themounting bolts.

2. Fit back the 3 hose connections.

3. Connect the electrical connections fortemperature sensor & condenser fan (In case ofDLE & DLX models)

Fill coolant (clean water blended with anti freeze agentas per recommendation).

Top up coolant through auxiliary tank cap upto ‘Full”mark.

Fit Auxillary tank cap.

Run engine for short duration and top up coolant ifnecessary. Remove the trapped air though ventingscrew.

Bleeding procedure for cooling system :

(For refilling or during reconditioning after completedraining )

a. Fill coolant from the auxilliary tank (50 : 50mixture of soft water and antifreeze agent) afterensuring all the hoses are secured and leak proof.

b. During filling, keep the bleeding screw (on thehose from cylinder head to radiator) loose. (fig.152)

c. During coolant filling, ensure that the air in the

Fig. 12

Fig. 13

system is removed from this bleeding screw andonly then tighten the screw, using a screwdriver.

d. Start the engine & slowly raise the engine speed& wait for the temperature to reach 850 C to 900

C to allow the thermostat to open up. Enginerunning at idling speed, open the bleedingscrew by using a screwdriver to allow anytrapped air in the system to escape. Tighten thebleeding screw & top up with coolant to max.level.

ALTERNATOR / POWER STEERING PUMP BELT

Removal :

l Loosen alternator top mtg. screw and bottommounting bolt Fig. 13

AUXILLIARY TANK CAPAUXILLIARY TANK

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ENGINE (DIESEL)

l Slightly loosen banjo bolt connections on vacuumpump

l Reduce alternator belt tension by loosening oftension adjusting nut (fig 14) or by pushingtowards engine.

l Remove alternator belt

Inspection :

l Inspect alternator belt for wear, cracks and signsof failure. Replace, if necessary.

Fitment :

l Install alternator belt over crank shaft andalternator pulleys

l Pull alternator away from engine for specifiedtension & tighten the nut to specified torque.

l ALTERNATOR BELT TENSION IS CORRECT IF IT CANBE DEPRESSED BY 10-11 mm (for engine withalternator) & 8-9 mm (for engine with A.C.Alternator and Power steering) WITH THUMBPRESSURE (1O KG APPROX.) APPLIED IN THEMIDDLE OF ITS LENGTH Fig. 14 & 15

l Tighten alternator top mounting screw andbottom mounting bolt.

l Tighten banjo bolt connections on vacuum pump

A.C. COMPRESSOR BELT

REMOVAL

1. Loosen belt tension bolt. (Fig. 15) on idler /tensioner.

2. Release tension load on the belt and remove thebelt from the pulleys.

INSPECTION

1. Inspect the A. C. compressor belt for wear cracks,and signs of failures. Replace if necessary.

2. Inspect pulley grooves.

ENGINE WITH PULL TYPE ALTERNATOR BELTTENSIONING ARRANGEMENT

Fig. 14

ENGINE WITH A.C. ALTERNATORAND POWER STEERING PUMP

Fig. 15

ENGINE WITH SCREW & NUT TENSIONINGARRANGEMENT

BELT

ALTERNATOR

TENSIONER BRACKET(ON BLOCK)

TENSIONER

ALTERNATORFLANGE

TOP MOUNTING SCREW

BOTTOM MOUNTING BOLT

LOCK NUT

TENSIONADJUSTINGNUT

A. C. COMPRESSORTENSIONER

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ENGINE (DIESEL)

FITMENT

1. Install the belt over crankshaft and A. C.compressor pulleys.

2. Press the tensioner againsts the belt and tightthe tension bolt to specified torque.

3. Check belt tension.

4. A. C. Compressor belt tension is correcrt if it canbe depressed by 8-9 mm with thumb pressureapplied in the middle of its length betweencompressor and crankshaft pulleys.

TIMING BELT : Fig. 16

Removal :

Fig. 17

Fig. 18

Fig. 19

Fig. 20

Fig. 16

LOCKING PLATE

1. BELT TENSIONER ROLLER2. TIMING BELT3. TIMING BELT IDLER4. BELT TENSIONER ROLLER

MOUNTING BOLT5. BELT TENSIONER BRACKET

1.

2.

3.

4.

5.

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ENGINE (DIESEL)

Disconnect battery negative terminal

Remove alternator and also AC belt. (If fitted)

Unscrew the 4 nos. mounting screws & remove fronttiming gear train cover Fig. 17. Remove bottom cover

Insert flywheel locking pin 2702 5890 0605 incrankcase. Fig. 18 (FIRST PISTON AT TDC /COMPRESSION STROKE)

(If flywheel hole is not matching, keep crank shaftrotating with a spanner Fig. 19 simultaneously pressingtiming pin till it locks flywheel.)

By using locking plate for cam shaft gear washer (27025890 0607), lock the washer. Fig. 20

Loosen mounting bolt of belt tensioner roller assemblyFig. 21 and rotate the belt tensioner to loosen the belttension.

Remove timing belt

Inspection :

Check belt in detail. If following flaws are evident,replace belt with new one.

l Back surface glossy, non elastic and so hard thateven if finger nail is forced into it, no mark isproduced.

l Cracked back surface rubber

l Cracked or exfoliated canvas

l Cracked tooth bottom

l Side of belt cracked

l Side of belt badly worn

l Badly worn teeth

l Missing tooth

l Soaked with oil

NOTE :

Normal belt should have clear cut sides, as if cut witha sharp knife.

In initial stage of wear, load side tooth flank will looklike fluffy canvas fibre, rubber gone and colourchanged to white.

In last stage of wear, canvas on load side tooth flankwill be totally worn out exposing rubber.

Fig. 21

Fig. 22

Fig. 23

Locking plate

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ENGINE (DIESEL)

Timing Belt Fitment :

ENSURE THAT FLYWHEEL LOCKING PIN, IS INFLYWHEEL LOCKING POSITION.(FIRST PISTON AT TDC / COMPRESSION)

Disconnect rubber hose between cylinder head &intake manifold

Remove the cylinder head cover. Fig. 22

Remove rear oil seal cap on cylinder head

By using locking plate-cam shaft (2702 5890 0606) lockcamshaft in TDC. Fig. 23

Loosen the camshaft gear mounting bolt so that thegear is free. This will help in fitting the belt properly.

Lock FIP gear with Locking pin (2702 5890 0609). Fig.24

Fit timing belt on camshaft gear, water pump gear, F. I.P. gear and tensioner. Tension the belt by rotation thetensioner bolt. Tighten the tensioner mounting boltwith allen key.

Remove the camshaft locking plate 2702 5890 0606.

Using camshaft washer lock plate 2702 5890 0607lock the bolt washer in position.

Tighten the bolt to specified torque.

Remove lock plate, timing pins from flywheel and F. I.

Fig. 25

Fig. 26

Fig. 27Fig. 24

1 2 3 4

FLYWHEEL

CRANKPULLEY

FUEL TANK

X

W V

U

FIP

FILTER

Injector Injector

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ENGINE (DIESEL)

Fig. 29

Fig. 30

P.

ENSURE THAT BOTH TIMING PINS ARE REMOVED AFTERTIMING BELT FITMENT.

Install timing gear train cover.

Tighten front timing cover mounting bolts

Install alternator and/or AC belt.

FUEL INJECTION PUMP : Fuel system Fig. 25

Removal :

l Remove the over flow hose from 1st injector tofuel injection pump. Fig. 26

l Remove high pressure injection pipe connectinginjectors to fuel injection pump. Fig. 27

l Remove fuel pipe connection on F. I. P.

l Remove fuel return pipe from fuel injection pumpto fuel tank. Fig. 28

Disconnect from fuel injection pump,

l Accelerator cable

l Engine stop solenoid electrical cable Fig. 29

l FICD Unit (if fitted)

Fig. 28 Fig. 31

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ENGINEERING

ENGINE (DIESEL)

Fig. 33

Fig. 34

Fig. 35

Ensure that 1st cylinder is in compression TDC positionby the fitment of Locking pin in flywheel locating hole.Fig. 30

Remove Timing belt cover after removing thealternator and A. C. belt (If fitted)

Insert the F. I. P. gear locking pin 2702 5890 0609.

Remove timing belt.

Loosen lock plate mounting bolts (if fitted) by 2-3turns (Otherwise mount flange part no. 2547 07137103) on fuel injection pump gear with two M8 x 20screws, do not tighten the screw fully.) Alternatelyused special tool Flange Part No. 2544 0713 7103 forremoving F. I. P. gear, on engines where lock plate isnot provided.

Hold fuel injection pump gear with spanner 2654 58900501 and unscrew mounting nut to remove fuelinjection pump gear. Fig. 31 Remove woodruff key fromshaft.

Remove F. I. P. gear locking pin (2702 5890 0609)Remove fuel injection pump rear mounting bolt. Fig. 32Unscrew and remove fuel injection pump frontmounting nuts. (3 nos.) Fig. 33Remove fuel injection pump.Fitment :Install fuel injection pump in its positionFit fuel injection pump rear mounting bolt.Hand tighten fuel injection pump front mounting nuts(3 nos.)Install wood ruff key in its positionInstall fuel injection pump gearTighten fuel injection pump gear mounting nut tospecified torque. Fit locking pin to lock flywheel.

Fig. 32

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ENGINE (DIESEL)

Fig. 37

Fig. 38

Fig. 39

Adjust fuel injection timing as explained belowFit back the timing belt, timing belt cover, Alternatorand A. C. belt.Connect to fuel injection pump :l Accelerator cablel Engine stop solenoid electrical cablel Over flow hose from 1st injector to fuel injection

pumpl High pressure injection pipe connecting injectors

to fuel injection pumpl Fuel pipe from fuel filter to fuel injection pumpl Fuel return pipe from fuel injection pump to fuel

tank.INJECTION TIMING SETTING :Ensure that timing pin is located in the flywheel holethrough the cylinder block rear wall (CompressionTDC)Disconnect high pressure injection pipes frominjectors to fuel injection pump. Fig. 34Slightly loosen fuel injection pump front mounting nutsand rear mounting bolt.Remove timing sealing plug on fuel injection pump tofit timing rod for timing checking purpose.. Fig. 35

Fit timing rod Pt. no. 2654 5840 0601 (Lucas) in thetiming sealing plug bore. Fig. 36

Tighten dial gauge mounting bracket Fig. 37

Remove timing pin from the fly wheel.

Mount dial gauge in its bracket with some preload.Fig. 38

Rotate the engine crankshaft by approximately 300

anticlockwise till dial gauge needle becomes steady.

Set dial gauge reading to 0.

Fig. 36

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ENGINE (DIESEL)

Fig. 40

Fig. 41

Fig. 42

Rotate the crank shaft clockwise to bring 1st cylinderin TDC position & insert the locking pin in the flywheel.

Slowly rotate fuel injection pump till plunger lifts by0.90 mm + 0.02 mm (Dial Gauge).

Turning fuel injection pump towards crank caseincreases plunger lift and vice versa.

Fully tighten fuel injection pump front mounting nuts,rear mounting bolt and nut in this position. Fig. 39

Remove flywheel locking pin from cylinder block.

Rechecking timing :

Rotate crank shaft by two full rotations. Check injectionpump plunger lift is 0.90 mm + 0.02 mm (dial gauge).In this position it should be possible to insert lockingpin in the fly wheel. Fig. 40

If not, repeat fuel injection timing adjustmentprocedure.

Remove dial gauge and timing bracket & pin (Lucas).

Fit back timing sealing plug on fuel injection pump

Connect high pressure injection pipes from injectorsto fuel injection pump. Fig. 41

Anti-Stall speed setting procedure :SPECIFIED VALUE:1. Antistall speed :

For DL - 1200 rpmFor DLE & DLX - 1800 to 2000 rpm

Failure symptoms :

- Engine idling speed erratic/hunting.

- Engine stalls (stops) while sudden deceleration(while braking)

- Excessive throttle pedal “dead” travel / Lesspower

PROCEDURE :

ANTISTALL SCREW THROTTLE LEVER

SHIM À

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ENGINEERING

ENGINE (DIESEL)

Fig. 43

Fig. 44

Fig. 45

1. Set a) when engine is hot.

b) when “AC”, if fitted, is in ‘Off’ position.

2. Place 3 mm shim À between throttle lever & itsminimum stop Fig.42

3. Adjust antistall screw Á (turn clockwise oranticlockwise) with 3mm shim to set engine rpm,as specified Fig. 43

4. Remove the shim and set idling speed, asspecified in application data sheet (Using idlingscrew  as shown in Fig. 44)

5. Move the shut-off lever à away from the stop by0.5 to 1.0 mm. Check, if idling rpm decreases, ifnot repeat procedure 2, 3, 4. Fig. 44

6. Depress accelerator pedal to run engine at threequarter maximum engine speed. Then releaseaccelerator pedal instantaneously.

7. If the engine speed falls below, the idling speedand engine jerks severely or stalls of if thedeceleration too slow repeat procedure 2 to 6.

8. It the problem persists, adjust the anti-stall screwÀ shown in Fig. 44

If the engine “die-down” time is too long, screwin towards the throttle lever, by quarter turn.

Following this adjustment, the idling speedshould be rechecked and adjusted if necessary,and then repeat the exercise from point 5.

9. Check the accelerator pedal play for “dead travel”of the lever. If required, adjust the acceleratorcable.

IDLING SPEED SETTING

PROCEDURE :

1. Set when engine is hot.

2. Slacken the locknut Å and turn the idling screwÁ Fig. 45, to set the idling screw as specified.

1

4

2

3

2

6

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ENGINEERING

ENGINE (DIESEL)

DO’S DONT’s

1) TlGHTEN FIP MOUNTING NUTS 1) DO NOT OVERTIGHTEN THEEVENLY TO THE SPECIFIED TORQUE TIMING CHIMNEY PLUG

2) WHEN EVER PRESSURISING VALVE IS 2) DO NOT SEPARATE THE RETURNREPLACED THE PUMP MUST BE LINE BANJO BOLT (CAM BOXRE-CALIBRATED. PRESSURISING VALVE) FROM

THE PUMP

3) TIGHTEN THE SOLENOIDTERMINAL NUT TO THE SPECIFIEDTORQUE

4) VENT AIR IN THE SYSTEM PRIOR TOSTARTING

5) CARRY OUT PUMP SETTINGS ON AWARM ENGINE TO THE SPECIFICATIONSAS PER APPLICATION DATA SHEET.

Fig. 46

3. Tighten back the locknut Å Fig. 46

4. The fast idle speed as specified can be adjustedby setting the stroke length of fast idle controldevice (if fitted)

SPECIFIED VALUE:

1. Idling speed -

Nominal value - 850 rpm (with A/C off )

Tolerance - + 25 rpm

Fast idle - 950 rpm (with A/C on)

Tolerance - + 25 rpm

6

22

ENGINEERING

ENGINE (DIESEL)

AIR CLEANER Fig. 47

For regular cleaning as per maintenance schedule :

l Unclip and remove housing cover, and removeelement. Fig. 48

l Clean it gently by tapping on clean table

l Do not use compressed air for cleaning theelement

l Check the condition of rubber sealing

l Check element for major rupture or puncture ofpaper pleats

l Replace element if any rupture or puncture isobserved

l Always use GENUINE air filter element to ensurelong engine life

l Install paper filter element

l Fit housing cover and clamp it firmly with the clips

l Check condition of air hose

l Check condition of air filter mounting rubberpads and replace if necessary.

CYLINDER HEAD :

Removal (Engine on stand) :

Remove

l Intake manifold Fig. 49

l Exhaust manifold Fig.50

l Thermostat cover

l Upper cooling line

Fig. 47

1. Air filter housing cover2. Air filter element3. Rear Bracket for air filter

mounting4. front bracket for air filter

mountiing and lifting hook

5. Spring clip6. Snorkel7. Hose from snorkel to air

filter8. Air intake manifold

Fig. 48

Fig. 49

Fig. 50

1

257

36

4

8

Air filter elementpaper with pleats

clips

Housingcover

23

ENGINEERING

ENGINE (DIESEL)

Fig. 51

Fig. 52

l Water temperature sensor for glow plug timing.Fig. 51

l Water temperature transducer.

l By pass line Fig. 52

l Cylinder head cover

l Over flow line from fuel injection pump to 1stinjector Fig. 53

l High pressure fuel lines from injector to fuelinjection pump

l Timing belt

l FIP mounting bracket from cylinder blockFig. 54 & 55

Fig. 53

Fig. 54

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ENGINEERING

ENGINE (DIESEL)

Fig. 55

Fig. 56

l Timing belt rear cover mtg. bolts (2 nos.)

l Hose connection from oil cooler to cylinder head

l Remove lifting hook at front. Fig. 56

l Remove elbow for bypass line Fig. 57

Unscrew and remove cylinder head mounting screwsin reverse order of tightening. Fig. 58

Slightly lift cylinder head to clear locating hollowdowel in crank case and remove it.

Fig. 57

Fig. 58

25

ENGINEERING

ENGINE (DIESEL)

Dismantling of Cylinder head :

Fig. 59 & 60

Fig. 59

INJECTOR

GLOW PLUG

PRE-COMBUSTIONCHAMBER

CYLINDER HEAD

Fig. 60

1.

2.

3.

4.

5.

6.7.

8.

9.

10.

11.

12. 13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

24.

1. CAMSHAFT BEARING CAP

2. SHIFT

3. LOCK HALF

4. VALVE SPRING RETAINER

5. VALVE SPRING

6. SPRING SEAT

7. VALVE GUIDE SEAL

8. VALVE GUIDE (INLET VALVE)

9. VALVE SEAT INSERT (INLET VALVE)

10. VALVE GUIDE (EXHAUST VALVE)

11. VALVE SEAT INSERT (EXHAUST VALVE)

12. INTAKE VALVE

13. EXHAUST VALVE

14. CORE PLUG

15. HOLLOW DOWEL

16. PRE-COMBUSTION CHAMBER

17. GASKET FOR CYLINDER HEAD COVER

18. ADAPTOR FOR VENT ON CYLINDER HEAD

19. CYLINDER HEAD COVER

20. OIL FILLER CAP

21. RUBBER WASHER FOR CYLINDER HEAD COVER

22. SPACER TUBE FOR CYLINDER HEAD COVER

23. STUD FOR CYLINDER HEAD COVER

24. CYLINDER HEAD MOUNTING BOLTS (10 NOS.)

23.

26

ENGINEERING

ENGINE (DIESEL)

Fig. 61

REMOVE :

l Injector over flow hoses

l Injectors and sealing washer, by using socket(2702 5890 0702). Fig. 61

l Glow plugs by using socket spanner. Fig. 62

Unscrew cam shaft bearing cap mounting nuts (first3rd and 1st caps and lastly 2nd, 4th cap). Fig. 63

l Cam shaft bearing caps.

l Cam shaft with oil seal. Fig. 64

l Tappets and shims and place them carefully incorrect sequence Fig. 65

Fig. 62

Fig. 63

Fig. 64

Fig. 65

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ENGINEERING

ENGINE (DIESEL)

Fit support rail, (2702 5890 0610) to cylinder head Fig.66

With spring compressor 2654 5890 0507, compressvalve springs and remove valve lock halves Fig. 67

Remove valve lock retainers, valve springs, valve springseats and valves. Place them in correct sequence.

Valve Springs Dimensions :

Inner diameter - 21.4 mmWire diameter - 3.75 mmFree length - 53.28 mm

Fully compressed length - 27 mm

Spring load when compressed to,

1. 40.3 mm - 273N + 15N1. 31.1 mm - 522N + 20N

Checking cyl. head Mating Surface :

Using a straight edge and feeler gauge, checkevenness of cylinder head parting surface with crankcase, Fig. 68 & 69

If, unevenness exceeds specified values (withoutconsidering PC chamber protrusion), replace cylinderhead.

Fig. 67

Fig. 68

Fig. 69Fig. 66

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ENGINEERING

ENGINE (DIESEL)

CYLINDER HEAD TOP AND BOTTOM SURFACEREMACHINING IN SERVICE IS NOT PERMITTED

Length wise Cross wise

Permissible 0.030 mm 0,015 mmunevennessof cyl. headmating surface

The PC Chamber protrusion should be in the range0.010-0.040 mm as shown in Fig. 70

Valves :

Check valve leakages by pouring gasoline on valvehead. Gasoline must not seep past valve seat.

Valves with burnt heads, excessive scoring and wearon stem should be replaced.

Check valve seat run out with respect to valve stem.Fig. 71. If it exceeds specified limit replace valve. Noattempt should be made to straighten bent valves. Ifvalve is free from any other defects except worn outseat, then only it can be rematched on valve grindingmachine as follows :

l Clamp valve on grinding machine jaws as closeas possible to valve head

l Adjust grinding angle on graduated scale toachieve correct valve seat angle

l Feed valve slowly towards grinding wheel untilwheel just touches valve head.

l Grind at low feed until valve seat is just clean allaround.

NOTE :

After grinding, valve head thickness should not be lessthan 0.85 mm.

Cylinder head cover:

Remove the baffle plate in the cylinder head cover byremoving the screws. Fig. 71A.

Check the baffle plate gasket if it is torn/damage,replace if necessary otherwise it might result in highengine oil consumption.

Fig. 70

Fig. 71

Fig. 71A

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ENGINEERING

ENGINE (DIESEL)

Valve dimensions Fig. 72 & 73

INLET EXHAUST

Valve head dia ‘A’ m m 35.9/36.1 30.4/30.6

Valve seat angle 45deg.+15' 45deg.+15'

Valve stem dia ‘B’ m m 6.97-0.015 6.96-0.015

Maximum run out of valve

face with respect to valve

stem m m 0.2 0.2.

Valve seat dia ‘C’ m m 33.0 28.0

Valve seat distance from

valve face ‘D’ m m 5.02 +0.1

3.85 +0.1

Maximum run out of valve

seat with respect to valve

stem. m m 0.030 0.030

Distance of valve head

from cylinder head mating

surface with crank case ’E’ m m 0.75/1.05 0.95/1.25

VALVE GUIDES :

In case of valve stem sticking in valve guide bore orexcessive clearance between them, remove valveguide from cylinder head using drift 2702 5890 0611.Fig. 74

Remove valve guide seal. Check condition.

Check valve guide bore diameter in cylinder head andif necessary, ream valve guide bore in cylinder head.

Fig. 72

Fig. 73

Fig. 74

INLET VALVE

A450

D

B

EXHAUST VALVE

Ý

Ý

C

B

AD

E

C

30

ENGINEERING

ENGINE (DIESEL)

to next over size.

Install matching size valve guide in cylinder head usingdrift 2702 5890 0611 and spacer, 2702 5890 0612. Fig.75

Ream valve guide inside diameter to specified sizeFig. 76

Fit valve guide oil seals.

Fig. 75

Fig. 76

Valve Guide Dimensions :

Size Valve guide Valve guide Valve guide Valve guide

bore in cyl. head OD,mm ID,mm length, mm

Normal 12.99 + 0.008 / - 0.01 13.0 6.992 + 0.015 / + 0.000 39.5 (inlet)

43.5 (exhaust)

Normal 1 13.09 + 0.008 / -0.01 13.1 -- do -

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ENGINEERING

ENGINE (DIESEL)

VALVE SEATS

Check valve seat height with respect to cylinder headmating surface. Replace valve seat inserts if they areworn out beyond specified limit.

Cut exhaust and inlet valve seats with a 45 deg. cutter.Fig. 77 & 78

VALVE SEAT MUST BE ABSOLUTELY FAULTLESS ANDWITHOUT ANY CHATTER MARKS

If necessary lap valve seats to a smooth and even finishby using suitable hand pump grinder or a lappingpaste and valve itself.

Smear valve seat with carbon blue. Install valve in guideand turn it slowly under axial pressure.

CONTACT LINE ON VALVE SEAT MUST BE AROUNDENTIRE CIRCUMFERENCE AT EQUAL WIDTH

Distance between narrow diameter of valve face tocontact line should be minimum 0.5 mm Fig. 79

Check for leakages through valve seat by pouringgasoline on valve head. Gasoline must not seep pastvalve seat.

VALVE SEAT INSERTS :

For removing valve seat inserts from cylinder head usesuitable boring machine. Bore old insert thin (about0.5 mm thickness) and then pry it out.

Alternatively use a suitable turning tool to cut anannular groove into valve seat insert and then pull itout with a suitable puller. In order to avoid damagingmachined cylinder head mating surface with crankcase, place any soft protective sheet metal undersupports of puller.

Measure valve seat insert bore in cylinder head.

If boring and prying is done carefully withoutdamaging valve seat insert bore in cylinder head,fitment of an over size valve seat insert will not benecessary.

Re-machined valve seat insert bore in cylinder headmust be exactly at right angle to cylinder head matingsurface with crank case. All specified dimensionsshould be strictly maintained to ensure properinterference of valve seat insert in its bore.

Clean valve seat insert and its bore in cylinder headthoroughly.

Fig. 78

Fig. 79

Fig. 77

0.5mm

Ý

Ý

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ENGINEERING

ENGINE (DIESEL)

Fig. 80

Valve seat dimensions Fig. 80

INLET EXHAUST

Valve seat angle ‘H’ 45 deg.-10'/-20' 45 deg.-10'/-20'

Valve seat dia ‘F’ in 33.0 28.0cylinder head mm

Distance ‘G’ between cylinderhead mating surface with crank 3.35+0.1 3.35+0.1case to valve seat in cylinder head mm

Maximum run out of valve seat in cylinderhead with respect to valve guide axis mm 0.035 0.035

INLET

F

F

G

G

EXHAUST

H