Repair Manual MAN-00
190
THAR
CRDe
BS-IV
MAY
2012
/Rev 1
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2012 Mahindra & Mahindra Ltd.
Care of the System
To meet the emission norms it is essential that the Fuel system, Air intake system & cooling system be
maintained as per the schedule .For details refer to the particular sections.
Generally it is not appreciated that if the engine is running below the optimum temperature (happens
when thermostat is removed then tailpipe emissions in particular the particulate increases (up to
30%). Similarly a wrong grade or poor quality of fuel increases the emissions. A blocked air cleaner or
restriction in intake system increases the emissions.
Oil separator system:
Check the hose connection at every 10,000 Kms for cracks, aging and leaks.
EGR:
On vehicles fitted with EGR system the following additional points check have to done during
scheduled maintenance.
•
Check for any exhaust gas leakage through sealing faces, EGR pipe. Formation of any black
soot indicates leakage.
•
Check the vacuum hoses for any leaks, cracks.
•
Retighten all nuts and bolts as per the recommend torque.
If the pipes are removed then it is essential that while fitting back new gaskets is used. Do not open
the pipe from one end only; it will cause the pipe to twist. If the EGR pipe has to be removed, then
open from both the ends.
The EGR operation is controlling by Engine ECU. Hence it is prone to get damaged if spikes are
generated in the system. It is advised that the following precautions be taken.
♦
If any welding work is being carried out on the vehicle then the battery terminals needs to be
removed.
♦
Similarly, the practices of shorting the battery to check the battery have to be avoided. (It can
cause a spike.).
♦
The practice of changing battery with a running engine is also not acceptable. Again, the resultant
spike can damage the ECU beyond repairs.
EGR Valve
Remove the EGR valve and check it 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 leakages.
To check for the functioning of the EGR valve apply vacuum on the vacuum connection of the EGR
valve. The lift of the valve at the required vacuum should be achieved.
EGR Pipe
Remove the EGR pipe and check for gas leakage, damages etc. Clean the gasket seating area from any
carbon deposits burrs etc. Spray ‘WD-40’ rust cleaning spray on the nut. To check the pipe for any
leakages, close one end of flange and from other end blow air at two bars. Dip the pipe in water and
observe if any leakage is observed. If any leaks are observed then the pipe has to be replaced. Do not
attempt to weld/ seal the leakage joint.
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