Mahindra Jivo 365 DI Service Manual Download Page 29

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Manifold & Cylinder Head

Manifolds

Intake & Exhaust Manifold Removal:

Remove Hose between Intake manifold and Air cleaner

Remove High Pressure, Low Pressure pipes, Fuel Filter and Bracket assy.

Remove 02 nos M8 bolts and remove Pull to Stop Mounting Bracket.

Remove 06 nos, M10 bolts and pull Intake Manifold & gasket.

Summary of Contents for Jivo 365 DI

Page 1: ...1 Mahindra Jivo 365 DI SERVICE MANUAL...

Page 2: ...5 Greasing Points Locations 10 6 Consumable Details 11 7 Primary Check up 12 8 Tyre Maintenance 13 15 Engine 9 Engine Specifications 17 22 10 Torque Chart 23 25 11 Manifolds Cylinder Head 27 40 12 Ti...

Page 3: ...ed Engine Speed 590 845 2600 erpm Brakes Mechanical Dry Disc Type Oil Immersed Brake OIB HYDRAULICS Type Fully Live Hydraulic with Position Draft Controls Lifting Capacity Kgs 900 Hitch TRACTOR Steeri...

Page 4: ...IONS mm Vineyard Overall Height 1305 20 Overall Length 3050 20 Ground Clearance 196 20 Overall Width Front 1200 20 Rear 1245 20 Wheel Base 1650 Front Track Width 1040 20 Rear Track Width 1010 20 PRODU...

Page 5: ...SIONS mm Paddy Overall Height 1405 20 Overall Length 3050 20 Ground Clearance 306 20 Overall Width Front 1305 20 Rear 1410 20 Wheel Base 1650 Front Track Width 1115 20 Rear Track Width 1095 20 PRODUCT...

Page 6: ...4 PRODUCT SPECIFICATION...

Page 7: ...5 MAINTENANCE...

Page 8: ...M Star Premium Change Oil Filter Change Valve Clearance Tappet Setting Check Low Hi Idle Engine R P M Check Power Response Exhaust Smoke Check Belt Tension Check Set Air Cleaner Primary Element Clean...

Page 9: ...System Thrash Guard Clean Radiator Fins Clean Coolant Water Check Top Up Fan Belt Fan Belt Tension Check Correct Hydraulics Suction Filter Change Electrical System Battery Electrolyte Level Check Batt...

Page 10: ...by Operator To be done by Dealer Technician 10 Hrs Periodic 100 Hrs 350 Hrs 600 Hrs 850 Hrs Tyre Air Pressure Check Front Axle Front Wheel Bearing free play Check Front Axle 4WD Oil Level Check Toe in...

Page 11: ...mmy Injector Engine 6 MST 9A01 EN 106 Crankshaft Rear Oil Seal Retainer Engine 7 MST 9A01 TN 107 Shaft Transmission MST 9A01 TN 107 1 Washer MST 9A01 TN 107 2 Nut MST 9A01 TN 107 3 Shaft MST 9A01 TN 1...

Page 12: ...10 GREASING POINTS LOCATIONS...

Page 13: ...ission Oil 31 Mahindra M Star Genuine OIB Oil Servo M Trac 30 Every 850 Hours Front Axle 4WD 3 7 Vineyard 4 0 Paddy Servo M Trac 30 1st at 100 then at every 850 hours Cooling System 5 7 Mahindra M Sta...

Page 14: ...recovery bottle Top up if required Use redimix coolant for top up Warning Do not open the coolant cap when the engine is hot Do not remove the radiator cap when the engine is hot 2 Checking Radiator F...

Page 15: ...s At Rear To increase drawbar pull of the tractor reduce wheel slip Increase tyre life Cast Iron weights can be attached to the rear driving wheels In case the slip continues it may be necessary to li...

Page 16: ...entres of both front wheels from front of tractor Let that distance be Y Now adjust track rod ball joints such that distance will remain same in front side of front wheels and at rear side of front wh...

Page 17: ...entres of both front wheels from front of tractor Let that distance be Y Now adjust track rod ball joints such that distance will remain same in front side of front wheels and at rear side of front wh...

Page 18: ...16 ENGINE...

Page 19: ...re 250 8 bar Manifold Cylinder Head Inlet Valve Specifications 14 Numbers of Valve Per Cylinder 1 15 Stem diameter mm 8 695 8 707 16 Head diameter mm 38 25 38 50 17 Clearance in guide mm 0 051 0 025 1...

Page 20: ...Spring rate at 30 70 of final load N mm 20 1 0 8 Valve Tappets 37 Diameter mm 14 224 13 97 38 Running clearance mm 0 013 0 076 Valve Push Rods 39 Diameter mm 7 94 Thick solid Push rod 40 Length mm 248...

Page 21: ...r of rings per piston 3 53 Type Cam Ground Oval 54 Top KS Semi Inlaid Half Keystone 55 Middle Reverse Torsion Ring 56 Bottom Coil Spring Loaded Bevel edged oil ring Width Axial 57 Top Top 2 5 58 Middl...

Page 22: ...ove 2 06 0 01 73 Bottom groove 2 53 0 01 Clearance In grooves 74 Middle groove 0 075 0 014 75 Bottom groove 0 065 0 080 Piston Pins 76 Diameter mm 29 0 005 77 Clearance in piston mm 0 014 0 004 78 Len...

Page 23: ...ng pressure PSI 30 35 94 Valve clearance in bore mm 0 127 0 0889 Oil Pump Clearances 95 Gears to housing mm 0 135 0 211 96 Gears to end plate mm 0 05 0 1 97 Drive shaft to body mm 0 038 0 089 98 Drive...

Page 24: ...115 Idler gear end clearance mm 0 1 to 0 3 116 Idler gear end float mm 0 1 to 0 3 Crankshaft 117 Material EN19 B 118 Main journal diameter mm 53 980 to 53 998 119 Running clearance main journal mm 0 2...

Page 25: ...57 54 61 13 Camshaft Assy Bolt Camshaft Thrust Plate 27 33 14 FIP Fitment FIP Flange Bolt M10 x 1 5 x 35 5 34 41 15 Nut FIP Shaft M14 X 1 5 80 90 16 Front Plate To FIP Adapter M8 x 1 25 x 20 24 30 17...

Page 26: ...Sensor Fitment Sensor Temperature Gauge 24 30 40 Intake Manifold Fitment Bolt M8 x 1 x 40 x 8 8 24 30 41 Thermostat Assembly Thermostat Housing Bolt Huh_ M8 x 1 25 x 55 5 24 30 42 Bolt M8 x 1 25 x 22...

Page 27: ...ounting Bolt M12 x 1 5 x 40 Pre 40 45 Final 90 95 59 Fuel Filter Fitment Bolt Hex FL M10X1 5X25 5X8 8 25 30 60 Bolt Hex FL M8 x 1 25 x 17 5 x8 8 25 30 61 Low Pressure Pipe Fitment Low Pressure Pipes B...

Page 28: ...26 Manifolds Cylinder Head...

Page 29: ...d Removal 1 Remove Hose between Intake manifold and Air cleaner 2 Remove High Pressure Low Pressure pipes Fuel Filter and Bracket assy 3 Remove 02 nos M8 bolts and remove Pull to Stop Mounting Bracket...

Page 30: ...torque to avoid leakage of gases Cleaning Inspection Repair Clean the manifold and inspect for cracks and distortion Replace the manifold with new one whenever distortion is more than 0 4 mm 016 in pe...

Page 31: ...29 Manifold Cylinder Head 2 Loosen 06 nos Nut Valve adjusting 06 nos grub screw 3 Remove M12 bolt Washer and lift Rocker Arm assembly Valve Lever Shaft 4 Lift out all six Push Rods...

Page 32: ...30 Manifold Cylinder Head Rocker Arm Shaft Assembly Dismantling 1 Remove Circlip and washer 2 Remove 1st rocker arm Bracket 2nd rocker arm 3 Remove roll pin with punch and pull bracket...

Page 33: ...anifold Cylinder Head 5 Remove 3rd rocker arm Valve Lever spacer and Washer 6 Remove 4th rocker arm Spring Valve Lever 5th rocker arm 7 Remove Washer lever shaft bracket 6th rocker arm Washer and circ...

Page 34: ...terial to give an even face on the end of the valve lever and take care that the rounding is maintained lengthwise to ensure perfect grinding action on valve stem Note Replace worn screw nut with new...

Page 35: ...hould not be more tight or loose 6 Tighten the nut by keeping filler gauge in insert position 7 Insert filler gauge of 0 40 mm for Inlet valve 8 Loose nut tighten grub screw insert filler gauge Note F...

Page 36: ...heel anti clockwise 20 Press 3rd cylinder exhaust valve 21 Do tappet setting of 2nd cylinder 22 Insert filler gauge of 0 40 mm for Inlet valve 23 Loose nut tighten grub screw insert filler gauge Note...

Page 37: ...head bolts progressively in the reverse order to the tightening sequence 7 Remove Cylinder head and gasket Note 1 Clean the Engine externally Mark dismantled parts such as valves Valve stem guides an...

Page 38: ...nd blow dry with compressed air 2 Remove any old gasket material from the faces of the cylinder head 3 Blow through all oil passages to ensure that they are clear 4 Remove all carbon deposits from the...

Page 39: ...ions 14 If the valve seat inserts are to be replaced take a fine cut if necessary from the bottom of the counter bore to ensure a square seat for the replacement insert 15 Thoroughly chill the new val...

Page 40: ...move valves compress valve springs with compressor tool and take out spring retainer locks 5 Clean the cylinder head thoroughly 6 Remove carbon deposits from the bottom of the cylinder head and out of...

Page 41: ...Head Assembly 3 Insert Valve Stem Seals Now insert valve from bottom side 4 Insert Washer spring Cup Valve Retainer Press the spring by using special tool 5 Insert Collet Similarly complete assembly...

Page 42: ...em indicates engine oil consumption due to excessive clearance between stem and valve guide 3 Discard valve springs if they have lost tension or are broken 4 Always replace valve collects whenever val...

Page 43: ...41 Timing Gears Camshaft Front Plate...

Page 44: ...ng Gears Camshaft Front Plate Timing Gears Camshaft Front Plate Dismantling 1 Remove FIP gear and 4 nos M8 bolts and washers 2 Remove FIP Adapter Plate and Gasket 3 Remove G12 7 bolt and Idler Gear as...

Page 45: ...43 Timing Gears Camshaft Front Plate Timing Gears Camshaft Front Plate Dismantling 4 Use puller to remove Crank shaft gear 5 Remove Hydraulic Gear and bearing 6 Keep tappets in vertical position...

Page 46: ...Front Plate Timing Gears Camshaft Front Plate Dismantling 7 Remove 2 nos M8 bolts of thrust plate and pull Camshaft assembly 8 Remove Cam Gear Camshaft Key Thrust Plate 9 Remove M6 screw 2 no M8 Bolt...

Page 47: ...Gears Camshaft Front Plate Timing Gears Camshaft Front Plate Dismantling 10 Take out Front Plate washer and gasket Assembly Cam shaft gear Sub Assembly 1 Insert thrust plate and press woodruff key wi...

Page 48: ...46 Timing Gears Camshaft Front Plate Sub Assembly 2 Place 2 nos M8 bolts on thrust plate Insert Cam shaft gear Crankshaft Gear Sub Assembly 1 Press woodruff key with mallet and insert gear...

Page 49: ...Plate Assembly 1 Insert Gasket 2 no s screw and Front plate 2 Tighten G7 93 M6 bolt with Tap Washer and apply 27 Nm torque 3 Tighten G6 35 bolt with 13 Nm torque Insert screw and tighten it with Scre...

Page 50: ...48 Timing Gears Camshaft Front Plate Tappets Camshaft Assembly 1 Insert tappets and Cam shaft assembly 2 Tighten 2 no s G 9 5 bolts with 30 Nm torque...

Page 51: ...49 Connecting Rods Pistons Cylinder Liners...

Page 52: ...pan Refer Oil Sump section for detail 3 Remove the gasket from the crankcase and discard it 4 Remove 2 no s nut and bolts from Connecting Rod Cap Now Remove Connecting Rod Cap Bearing shell 5 Similar...

Page 53: ...cting Rods Pistons Cylinder Liners 8 Remove Main Bearing Cap Bearing shell bottom Take out Crank shaft 9 Remove Bearing shell top Valves Tappets 10 Use Yuvo Special tool MST H1 EN 1 to remove Cylinder...

Page 54: ...52 Connecting Rods Pistons Cylinder Liners 11 Remove Cylinder Sleeve O rings from Crankcase 12 Remove Retainer Piston Pin Retainer Piston bush 13 Remove Piston rings with Special plier...

Page 55: ...s shown 2 The Big end and Small end bores must be square and parallel with each other in all the planes 3 Measure 127 mm on each side of connecting rod Note If alignment is not ok then please replace...

Page 56: ...nd Ring by ensuring Top mark on should be on Top side 4 Measure the End Gap It should be 0 4 mm to 0 6 mm 5 Similarly put 3rd Ring by ensuring Top mark on should be on Top side and measure the End Gap...

Page 57: ...by using new rings and feeler gauge 2 Land Clearance for 1st Ring should be 0 075 mm to 0 014 mm 3 For 2nd Ring Land Clearance should be 0 075 mm to 0 014 mm 4 For 3rd Ring Land Clearance should be 0...

Page 58: ...eft Side Crankshaft Direction X Axis Direction Perpendicular Y axis 1 Take Dial Bore Gauge and measure Sleeve bore diameter first in a direction along the Crankshaft axis i e X axis 2 Measure at the d...

Page 59: ...xis at the distance of 15 mm i e A Caption Y Y 50 mm i e B Caption Y Y1 and 75 mm i e C Caption Y Y2 5 Maximum Sleeve Taper is the maximum difference between X X1 and X2 or Y Y1 or Y2 6 Maximum Sleeve...

Page 60: ...ing Rod Assembly 1 Insert Piston Rings with special plier 2 Insert Connecting rod Piston pin and retainers 3 Please ensure during sub assembly arrow mark on piston top should be on front side of engin...

Page 61: ...l gauge base on plane surface put needle under some tension ensure zero 2 Put needle on liner collar Measure readings at two opposite position Liner protrusion should be 0 051 above face to 0 025 belo...

Page 62: ...60 Connecting Rods Pistons Cylinder Liners Assembly 5 Remove Liners and insert O rings and insert Liner 6 Press Liner with dolly 7 Similarly insert O rings for remaining Liners...

Page 63: ...61 Connecting Rods Pistons Cylinder Liners Assembly 8 Remove Liners and insert O rings and insert Liner 9 Press Liner with dolly 10 Similarly insert O rings for remaining Liners...

Page 64: ...ng shell notch should be match with crankcase notch Ensure thrust bearing should be fitted on flywheel side 2 Insert crankshaft assembly Ensure timing marks should match with reference to mark availab...

Page 65: ...apply 122 to 128 Nm torque 5 Similarly tighten remaining bolts from inside out 6 Cam shaft End Float measurement 7 Fix dial gauge base on plane surface Put dial gauge needle on can shaft under tensio...

Page 66: ...needle on Crankshaft and ensure zero Move crank shaft axially 10 Measure the reading End float should be between 0 1mm to 0 4 mm If readings are not ok then replace Crankshaft assembly 9 Insert Rear...

Page 67: ...tecting sleeve rear oil seal retainer Tighten 10 nos M8 bolts with 22 to 28 Nm torque 2 Take Piston assembly Ensure arrow mark on piston should be on front side big end notches are on FIP side 3 Remov...

Page 68: ...crankcase surface and push the piston into liner with pusher 5 Locate connecting rod in to proper position Put Cap tighten 2 no s M10 bolts with 60 Nm torque 6 Similarly insert remaining piston assemb...

Page 69: ...y on crankcase surface and push the piston into liner with pusher 8 Locate connecting rod in to proper position Put Cap tighten 2 no s M10 bolts with 60 Nm torque 9 Similarly insert remaining piston a...

Page 70: ...ssembly 1 Insert oil pump assembly Tighten Hex bolt G9 525 with 40 nm torque 2 Insert 2 no s Flywheel dowels on Crankshaft Assemble Flywheel correctly with respect to dowel pin 3 Tighten 6 no M12 bolt...

Page 71: ...FIP Adapter on Crankcase and tighten 4 nos M8 bolts with 27 Nm torque 5 Insert Hex bolt G7 937 with Washer Assemble FIP tighten 4no M10 bolts with 40 Nm torque 6 Put wood ruff key carefully Insert ge...

Page 72: ...haft by properly locating roll pin in to the crankcase Tighten Hex Bolt G12 7 with 90 Nm torque 8 Ensure timing marks provided should match with reference to marks available on all gears 9 Insert 2 no...

Page 73: ...ssembly 1 Insert gasket front cover Tighten Screw on Front Cover with screw driver and Nut G 7 93 2 Tighten 05 no s Hex Bolt G 7 93 and with 25 Nm torque 3 Put O ring on Adapter Hydraulic Pump and pla...

Page 74: ...ghten 2 no s M10 bolts with 25 Nm torque 5 Insert Phase Sensor on Front Cover and tighten M10 bolt with 10 Nm torque 6 Place L bracket and washer on Front Cover and tighten M10 bolt with 25 Nm torque...

Page 75: ...t Cover and tighten M8 bolts with 10 Nm torque Insert 3nos Hex Bolt G7 93 with washer and tighten nut with 25 Nm torque 8 Locate cylinder head gasket correctly with respect to dowel pin Locate cylinde...

Page 76: ...es 11 Tighten all bolts sequentially as shown with 35 Nm torque then apply 90 degree angular torque 12 For angular torque Mark the bolt with chalk at one position Then apply torque till mark rotate by...

Page 77: ...ssembly 14 Insert push rods rocker arm assembly 15 Tighten M11 Long bolt with 60 Nm torque and then apply 90 degree angular torque 16 Insert gasket Valve housing cover Tighten 2 nos washer M 10 Cap Nu...

Page 78: ...gasket Thermostat housing Tighten 3no M8 bolts with 30 nm torque 18 Insert gasket exhaust manifold Tighten 4 no M10 bolts with 40 Nm torque 19 Insert gasket intake manifold pull to stop bracket Tighte...

Page 79: ...Assembly 20 Place Pull To Stop Bracket and tighten 2 no s M8 bolts with 30 nm torque 21 Tighten Temperature Sensor and washer with 27 Nm torque 22 Lock the fly wheel with tappet and insert woodruff ke...

Page 80: ...78 Engine Assembly Assembly 23 Insert Crankshaft Pulley washer and tighten M14 bolt with 190 Nm torque 24 Remove tappet 25 Apply Loctite 5900 and insert 2 nos Pin Dowels...

Page 81: ...r Frame on Crankcase and tighten 10 nos M10 bolts with 28 Nm torque 27 Apply Loctite 5900 on Ladder Frame and place oil sump 23 Tighten 16 nos M10 bolts with tighten with 28 NM torque Tighten M26 drai...

Page 82: ...80 Engine Assembly Assembly 24 Tighten Oil Pressure switch with apply 20 Nm torque 25 Fit Oil Filter 26 Fit Dip Stick Guide assembly...

Page 83: ...Cap with O Rings 28 Insert starter motor and tighten 2 no M10 bolts with 40 Nm torque 29 Place Bracket Fuel Filter Mounting and tighten 2 no s M8 bolts with 10 Nm torque 30 Fit Fuel Filter on bracket...

Page 84: ...ssembly Assembly 31 Fit Fuel Filter on bracket and tighten 2 no s M10 bolts with 10 Nm torque 32 Fit Return Line on FIP and Injector 3 no s Banjo and Washer 33 Fit FIP Lubrication Pipe with M10 Banjo...

Page 85: ...Pipe Feed Pump to Filter with M14 Banjo and washer Fit Pipe Filter to FIP with M14 Banjo and washer 35 Fit High pressure pipes tighten with 30 Nm torque 36 Place Water Pump on Cylinder Head assembly...

Page 86: ...by pipe tighten hose clip with screw driver 38 Insert thermostat by pass tube tighten hose clip with screw driver Insert Radiator Lower Hose tighten hose clip with screw driver 39 Fit Hydraulic Pump...

Page 87: ...nator Bracket Rear on Front Cover Rear side Hold Alternator in between Bracket Rear and Brace and place Bracket Front on alternator Now tighten 3 nos Hex Bolts with 20 Nm torque 42 Insert Belt on Alte...

Page 88: ...86 Engine Assembly Assembly 43 Fit Spacer and Fan on Water Pump and tighten 4 nos M8 bolts with 20 Nm torque Assemble fan tighten 4no M8 bolts with 25 Nm torque...

Page 89: ...87 Trouble Shooting...

Page 90: ...defective air being drawn into fuel Fuel filter gaskets defective d Moisture in fuel tank Drain entire system and fuel filter Refill with clean fuel and vent the air from the system 2 Poor fuel Use a...

Page 91: ...2 Insufficient coolant in cooling system Check level and add if necessary Check hose connections for leaks 3 Dirt trash on outside of Radiator Clean between the tube fins with air or water pressure 4...

Page 92: ...tion 1 Piston rings worn or broken Install new rings 2 Oil level in crankcase too high Maintain proper oil level 3 Crankcase oil pan gasket leaking Install new gasket 4 Worn valve guides Install new v...

Page 93: ...cylinder 2 Loose connecting rod Tighten connecting rod 3 Poor grade of fuel or water in fuel Use good grade of fuel and check for water in fuel 4 Incorrect engine temperature Keep temperature in work...

Page 94: ...cating oil Use grade of oil specified in operator s manual 6 Foreign materials entering engine Use clean oil containers when filling engine with oil and see that there no leaks in the air cleaner or i...

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Mahindra Jivo 365 DI, Service Manual

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