Technician Level 2 – Module 1 Engine Systems LCV

Technician Level 2 – Module 1
Engine Systems LCV
497 SPTC, 497 TCIC, 483 DL TCIC

Introduction
 Participant Name
 Dealership Name
 Location
 Experience in Tata Motors (In years & months)
 Specialization in which Models / Aggregates
 Hobbies
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Program Objectives
At the end of this module the participants will be able to:
 Understand the entire range of LCV models manufactured by Tata
 Identify the different types of Engines used in LCV range of Vehicles
 State the Technical Specification of each type of Engines
 Disassemble, Inspect & Overhaul the different types of Engines of LCV range of vehicles
 Perform different important settings on the LCV Engines
 Perform timing belt installation procedures of all the Engines of LCV
3

Program Agenda
 Product Familiarization of LCV range of vehicles
– Product Familiarization of Tata 407/410, 709/712, 909/1109, 207 DI & RX, Xenon DI & RX, Winger
 Engine Systems of 497 SPNA/SPTC/ TCIC and 483 DL TCIC Engines
– General Information
– Engine Sub systems
 Engine Overhauling of 497 SPTC /TCIC and 483 DL, Engines
– Removal of Engine from Vehicle
– Engine Dismantling
– Inspection and checking of components
– Reassembling the Engine
– Refitting of the Engine on to the Vehicle
 Important Settings & adjustments
– Important Adjustments & Settings of 4SP/497/483DL & Dicor-2.2
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407/410, 709/712, 909/1109, 207 DI & RX, Xenon DI & RX, Winger
Product Familiarization – LCV
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LCV Products Line
 Winger
 207 DI
 207 DI BS III EX
 Xenon BS3 & BS4
 LP/LPT/SFC 407 Turbo / EX -Twin tyre
 LP/LPT/SFC 410 Turbo / EX BS III
 LP/LPT/SFC 709 E Turbo
 LP/LPT/SFC 709 EX Turbo
 LP/LPT/SFC 712 EX Turbo
 LPT909 Turbo EX
 LPT912 Turbo EX
 LPT/LP 1109 Turbo EX
 LPT/LP 1112 Turbo EX
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Model Nomenclature & Usage
No. Model Types Usage
1 407 HT SFC Used in hilly area with twin tyre and 709 type Rear Axle
2 407 Ex All With Manual Steering
3 407 Ex2 All With Power Steering
4 709 Ex2 All With Power Steering
5 909 HEx2 LPT With Power Steering
6 909 HD LPT With Manual Steering
7 1109 Ex LPT With Manual Steering
8 1109 HEx2 LPT With Power Steering
9 1112 LP With Power steering Bus application
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Chassis Numbering System
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Chassis Number is punched on the LHS side rear
Near the stepney
MAT 457 056 D 7 K 29261
Indicates Country
and manufacture
name
MAT: MA-India, T-
Tata Motors
Chassis Model
457: 1109 Chassis
Chassis Serial No.
09116
Chassis Type
056: LPT, 4200 WB
Year of production
D: 2013
Month of
Manufacture
K: October
Manufacturing Plant
Code
7: D Block Pune

Winger
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Winger
Engine 483 DL TCIC
Engine Capacity 1948 cc
H.P. of the Engine 90 HP @ 4300 RPM
Max engine output 68 kW @ 4300 rpm
Max torque 190 N-m @ 2000 - 3000 rpm
Transmission Transaxle TA 70
Clutch 215 mm, Push Type

Winger - Variants
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TATA Winger
2800 WB 3200 WB
Flat Roof
4 DL NA Engine,
BSIII
Flat Roof
4 DL TCIC
Engine,BSIII
Non AC Non AC With AC With AC
Non AC
Standard bench
type
Capacity : 9 + D &
13 + D
Luxurious seats
Seating capacity :
9 + D
Semi luxurious seats
Seating capacity :
9 + D & 13 + D
High Roof
4 DL TCIC
Engine,BS III
Wheel base
options
Body & Engine
options
HVAC options
Seating
options

207 DI BS III EX ( Extra)
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207 DI BS III EX
Engine 4SPTC (497)
H.P. of the Engine 110 HP @ 3000 rpm
Max engine output 83.2kW at 3000 rpm
Max torque 300 Nm at 1600-2200 rpm
Transmission G-76 - 5/4.1 with overdrive
Clutch 240 mm, Push type

XENON BSIII Crew Cab & Xenon Pickup (Single Cab) -
RX
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XENON BSIII Crew Cab
Engine 4SPTC IC-TATA 3.0L DICOR BS-III
H.P. of the Engine 110 HP @ 3000 rpm and 100 HP for RX with Mechanical FIP
Max engine output 83.2kW at 3000 rpm and 70 Kw for RX with Mechanical FIP
Max torque 300 Nm at 1600-2200 rpm and 223 Nm for RX with Mechanical FIP
Transmission TATA G-76 with overdrive

XENON BS IV
Xenon (Crew Cab) - EX
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XENON BS IV
Engine TATA 4SPTC-CR10
Max engine output 64 kW at 3000 rpm as per MOST/CMVR/TAP- 115/116
Max torque 250 Nm at 1000-2000 rpm as per MOST/CMVR/TAP - 115/116
Transmission GBS-76-5/4.1 with overdrive
Clutch 240 mm, Single plate dry friction diaphragm type

LP/LPT/SFC 407 Turbo / EX –TT with Mechanical FIP
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LP / LPT / SFC 407 Turbo / EX - TT
Engine 497 SP TCIC
Max engine output 75 kW (100 PS) @ 2800 rpm
Max torque 300 Nm @ 1400-1500 rpm
Transmission GBS-27 (7.36) Ratio

LP/LPT/SFC 709 E Turbo - BSIII
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LP/LPT/SFC 709 E Turbo
Engine 497 TCIC ( max.stroke length)
Bore & Stroke Length 97 mm and 128 Stroke length
Max engine output 92 kW @ 2400 rpm
Transmission GBS- 40

LPT 909 Turbo EX- BSIII
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LPT 909 Turbo EX
Max engine output 92 kW @ 2400 rpm ,
Clutch 310 MM

LPT 912 Turbo EX- BSIII
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LPT 912 Turbo EX
Clutch 310 MM

LPT/LP 1109 Turbo EX- BSIII/1112 BS4
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LPT/LP 1109 Turbo EX
Engine 497 CRDI
Clutch 330 MM

Technical Specification - 4SPTC
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Engine model Tata 4SPTC (BS II) Tata 4SP TC (BS III)
Type :
Water cooled direct injection Diesel
engine
Water cooled direct injection Diesel
engine
No. of cylinders : 4 in line 4 in line
Bore/stroke : 97 mm x 100 mm 97 mm x 100 mm
Capacity : 2956 cc 2956 cc
Horse Power: 75 100
Max. Engine output : 55.2 kW (75 ps) at 2800 rpm 75 kW (100 ps) at 2800 rpm
Max. Torque : 225 Nm at approx. 1500-1800 rpm 300 Nm at approx. 1400-1500 rpm
Compression ratio : 17.5:1 17.5:1
Firing order : 1-3-4-2 1-3-4-2

Technical Specification - 497 TCIC
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Engine model Tata 497 TCIC
Type : Water cooled direct injection Diesel Engine
No. of cylinders : 4 In line
Bore/stroke : 97 mm X 128mm
Capacity : 3783 cc
Horse Power: 90/110/130 ( As per the models)
Max. Engine output : 67.5 Kw (90 ps) at 2800 rpm (to be changed as per the HP)
Max. Torque : 370 Nm at 1800-2200 rpm
Compression ratio : 18:1
Firing order : 1-3-4-2

Vehicle Model Matrix
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Models fitted with 497 & 4SPTC Engines
497 SPNA Engine
 Tata 207 DI/EX
 Tata 407 NA
4SPTC Engine
 Tata 407 LPT & SFC
 Tata 410 SFC & Xenon
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497 TC & TCIC Engines
 Tata 709 EX SFC
 Tata 712 Ex
 Tata 909 Ex
 Tata 912 EX
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497 TC & TCIC /CRDI Engines
 Tata 1109 LPT  Tata 1112 LP
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407/410, 709/712, 909/1109, 207 DI & RX, Xenon DI & RX, Winger
Vehicle Walk around
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 Take the participants to the vehicle models of LCV
and using the Worksheet, Identify the
Components
 Vehicle Walk around of
– 407/410
– 709/712
– 909/1109
– 207 DI & RX
– Xenon DI & RX,
– Winger
Vehicle Walk around
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Physical Walk around of
all the LCV range of
vehicle
Duration: 2 Hours

4SPTC/497 TCIC & 483 DL
Engine Familiarization
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4SPTC Engine General Information
 4SPTC Engine
 Max. Power 75 Kw@ 2800 rpm
 Max. Torque 300 Nm@1500 rpm
 4SPTC Engine is a four cylinder Naturally
Aspirated or Turbo Charged Diesel Engine.
This has got different configuration as
follows:
– 497 SPNA DI
– 497 SP ( 100 mm Stroke)
 SPNA – Square Pattern Naturally Aspirated
 DI – Direct Injection
 SPTC – Square Pattern Turbo Charged
 Engine Capacity of 2956 CC and maximum
power of 75 KW at 2800 rpm (varies as per
the configuration)
 Maximum Torque out put of 300 Nm at 1500
rpm (again varies as per the configuration)
 Has BSII & BSIII variants & BS4 variant also
which is known as 3.0 Ltr. Engine (Xenon)
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497 TCIC Engine General Information
 497 TCIC Engine 497 is the family of Engines in which we will
find different configurations as below:
 497 TC (128 mm Stroke)
 497 TCIC
The power and the torque specifications
differs from each other but the basic Engine
constructions remain same
 TC – Turbo Charged
 TCIC – Turbo Charged Inter Cooler
 Has BSIII & BS4 variant (also which is
known as CRDI Engine)
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Engine Number Location & Engine Number Decoding
497TC 41 B YY 8 11531
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Engine Model
Variation in basic
model
41: SFC 497 SP
engine - CMVR
2000
Serial No.
11531
Plant location
8: H Block Pune
Month of
manufacturing
B: February
Year of production
YY: 2000
Engine number plate is punched
on the rear side of the engine

Engine Sub-components - 497 TCIC
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Cylinder head cover
Timing Gear Housing Alternator
Water pump

Engine sub components - 497 TCIC CRDI
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Alternator
Cylinder head cover
Timing Gear Housing
Turbocharger

Engine sub components - 497 TCIC CRDI..
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Water pump
High pressure pump
Common rail
EGR

General Information
Engine Systems - 483 DL TC
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483 DL TC General Information
 483 DL NA/TC IC Engine  4 Cylinder inline water cooled, Water
cooled, indirect injection, turbo charged,
and intercooler Diesel engine with
Crankcase breather / oil separator &
Exhaust gas recirculation system.
 Has a capacity of 1948 CC, producing 64
Kw of power a@ 4300 rpm
 Max. Horse Power: 90 HP(TC Engines) , 68
HP( NA Engines)
 Maximum Engine torque of 190 Nm@3000
rpm
 Compression ratio of 21:1
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Max. Power – 64 Kw @ 4300 rpm
Max. Torque – 190 Nm @ 3000 rpm

483 DL TC General Information
 483 DL NA/TC IC Engine
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Engine number location & Information
J WY 7 09116
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FIP side
Month of
Manufacture
J: September
Year of
production
WY:
Serial No.
09116
Plant location
7: D Block Pune

Models in which the Engine is used
 Tata Winger
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Standard (NA engine) Luxury (TCIC engine)
Non- A/C A/C

Technical Specification - 483DL
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Engine model 4DL TCIC 4DL NA
Type :
Water cooled, indirect injection, turbo
charged, and intercooled Diesel engine
with crank case breather
Water cooled, indirect injection,
naturally aspirated with crank case
breather
No. of cylinders : 4 in line 4 in line
Bore/stroke : 83 mm x 90 mm 83 mm x 90 mm
Capacity : 1948 cc 1948 cc
Horse Power: 90 HP 68 HP
Max. Engine output : 68kW (90 ps) at 4300 rpm 48kW (68 ps) at 4500 rpm
Max. Torque : 190 Nm at approx. 2000-3000 rpm 120 Nm at 2500 rpm
Compression ratio : 21:01 22.5:01
Firing order : 1-3-4-2 1-3-4-2

Technical Specification - 483DL..
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Engine model 4DL TCIC 4DL NA
Air filter : Dry (paper) type Dry (paper) type
Oil filter : Spin-on full flow paper type Spin-on full flow paper type
Fuel filter : Two stage, fine filtration Two stage, fine filtration
Fuel injection pump : Rotary type with electric stop solenoid Rotary type with electric stop solenoid
Governor : Mechanical Mechanical
Engine oil capacity : Max. 7.7 liters / Min. 5.7 liters Max. 7.7 liters / Min. 5.7 liters
Weight of engine : 220 kg (dry) 200 kg (dry)
Radiator frontal area: 2340 sq. cm. 2940 sq. cm.
Exhaust System : With Catalytic Convertor With Catalytic Convertor

4SPTC/497TCIC/483DL/2.2 Lt. DICOR
Engine Systems
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General Air Intake System Layout
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Clean air
from air filter

Air Intake System Components - 497 TCIC
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Air Intake System
Snorkel
Hose
Pre-cleaner
Dust Cap
Hose
Clamps
Hump Hose
Air Cleaner Assembly
Vacuum Indicator
Hump Hose
Clean
Side Pipes

Air Filter Components
General: Air filter serves to filter dust from intake air for the engine. Air filter used on TATA LCVs
are of dry type. They also serve to dampen intake air noise. In addition to good dust separation,
these filters have high dust accumulation capacity.
Operation: In dry type air filter, air flows into air chamber through cyclonic pre cleaner. A part of
dust separates from air and settles down, which is collected in dust bowl. The remaining dust
particles carried by air stream are filtered by filter cartridge.
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Dust bowl
Primary Cartridge
Secondary Cartridge
Atmospheric air from
intake duct
Air to turbocharger
Evacuator valve
Plastic cover
Service Indicator Air Filter
Air Intake Pipe

Air Filter Components..
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Air Filters: Air filters are made up of paper and are covered by
perforated metallic sheet for protection.
There are two filters namely: Primary and secondary
Primary filter is main filter which cleans the air, while secondary
filter is fitted inside primary filter to protect the filtration in case
of failure of primary filter.
Primary Filter Axial type sealing: This sealing is on top surface and
the sealing rubber will prevent mixing of air.
Primary Filter Radial type sealing: The sealing is on top surface as
well as on diameter. This is used in Prima and Ultra models.
The primary filter is to be changed after red signal at indicator.
After changing 3 times primary filter, secondary filter is to be
changed.
Sealing – Radial
Sealing - Axial
Assy Primary
& Secondary
Pre Filter

Air Filter Assembly Components
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Air Filter Assembly Evacuator valve
Service Indicator Air Filter Assembly Bowl Type Pre filter in snorkel
Secondary filter
Primary
Filter
Bowl

Air Filter - Maintenance
 Service indicator provided for checking of condition of air filter.
 If Air filter is choked, RED indication appears on indicator.
 As a result of chocked air filter, loss of power and increased fuel consumption may be
observed, further wear of pistons & cylinder bores also may happen.
 Never clean air filters, always replace if red indicator appears.
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Turbocharger
General: If it is intended to increase the engine horse power, more air for combustion and more
fuel have to be delivered. The turbocharger is one of the efficient supercharging device which is
used in our engine.
Advantages:
 Increased power & power to weight ratio.
 Lower specific fuel consumption, improving fuel efficiency.
 Reduces black smoke in exhaust.
 Less power loss at high altitude.
 Reducing engine noise considerably.
Driving instruction
 Run the engine in idle speed one minute after starting & before switching off.
 Ensure cleanliness of engine oil & adhere maintenance schedule.
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Turbocharger
Components of Turbocharger:
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Air Intake
Compression
housing
Exhaust Outlet
Turbine housing

Working System of Turbocharger
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Type of Turbochargers
Fixed Geometry Turbocharger:
 The amount of air pressure rise and air
volume delivered to the engine from the
compressor outlet is regulated by a waste
gate valve in the exhaust housing.
 .The engine control module (ECM) controls
the waste gate valve solenoid to open or to
close the vacuum line to the waste gate
actuator.
 The diaphragm on the inside of the waste
gate actuator is pressure sensitive, and
controls the position of the waste gate
valve inside the turbocharger. The position
of the valve will increase or decrease the
amount of boost to the turbocharger.
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Variable Geometry Turbochargers:
 The ECM uses pulse width modulation on
to an electric actuator, which in turn moves
the crank.
 The Turbocharger Nozzles (also known as
vanes) are controlled to vary the amount of
boost pressure.
 The ECM utilizes a turbocharger nozzle
control solenoid valve and a boost pressure
sensor to control the turbocharger nozzles.
 When the engine is not under load, the
turbocharger nozzles are in an open
position, or no boost condition, this allows
free (unrestricted) flow of the gas across
the turbine blades, and into the exhaust.
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Variable Geometry Turbochargers:
 When the engine is under load, the ECM commands the control solenoid valve to close the
turbocharger nozzles, which then causes, the Turbine to increase speed thus increasing the
boost pressure.
 The ECM will vary the boost dependent upon the load requirements of the engine. The ECM
uses a pulse width modulation (PWM) on the control circuit to open and control the solenoid
valve.
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Nozzles in Open position Nozzles in Close position

Turbocharger - Maintenance
No adjustments or repairs to be carried out on the turbocharger. In case of doubtful
performance from the engine because of mal-functioning of the turbocharger, following
precautionary measures should be taken to obtain trouble free performance:
 Look carefully for any oil leakage at the oil inlet banjo connection on the turbocharger bearing
housing. (do not run engine unless leakage at this point is rectified)
 Do not stop the engine suddenly as it may damage turbocharger rotor bearings.
 Since the speed of the turbocharger rotor assembly is tremendously high, it requires finest
filtered oil which comes from the engine lubrication system.
 As the unfiltered dust particles coming into the turbocharger compressor may prove
dangerous, make sure that there is no leakage in the air intake system and that the air filter
element is in good condition, and sealing perfectly.
 Use of only the recommended brands of engine oil as well as the use of genuine engine oil
filter and air filter cartridges.
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Intercooler
 An intercooler, is a heat exchanger.
 The temperature of compressed air drawn by turbocharger may increase unto 200 0C.
 In order to increase the volumetric efficiency, the compressed air is cooled by Intercooler.
 The air flow is parallel to ground in the Inter cooler.
 Silicon hoses connect the Inter cooler to turbocharger and the Inlet manifold.
Servicing of Intercooler:
 If the Intercooler is removed for any repairs/diagnosis, it should be cleaned with
Trichloroethylene. Tap it gently with a mallet on sides to remove the debris & shake well.
 Flush the Trichloroethylene & dry it with compressed air.
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Intercooler Location
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Exhaust Gas Recirculation Actuator (EGR)
 General EGR Flow Diagram
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Exhaust Gas Recirculation Actuator (EGR)
 The Exhaust Gas Recirculation (EGR) System is used to reduce the amount of nitrogen oxide
(NOx) emission levels caused by high combustion temperatures.
 At temperatures above 1,371°C (2,500°F), oxygen and nitrogen combine to form oxides of
nitrogen (NOx).
 Introducing small amounts of exhaust gas back into the combustion chamber displaces the
amount of oxygen entering the engine.
 With less oxygen in the air/fuel mixture, the combustion pressures are reduced, and as a
result, combustion temperatures are decreased, restricting the formation of NOx.
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Exhaust Gas Recirculation (Cooled EGR 497 BS IV)
 An EGR (Exhaust Gas Recirculation) Cooler
is a heat exchanger installed in the EGR
circuit.
 The cooler simply cools the exhaust gas
prior to gas being reintroduced into the
engine.
 By cooling the gas the combustion
temperature is reduced and NOX also as
NOX is formed at higher temperatures.
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ECU Operated EGR valve
 Operated by PWM(differential type) signal
from ECU
 Position feedback sensor available
 Water cooled
 Suitable for 12 V rating only
 Motor drives the valve through gear trains
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Motor

Exhaust System – Cat Con System
 Cat Con System – Winger/Xenon
 This is fitted in the exhaust piping which controls outgoing exhaust emissions to the minimum
levels.
Catalytic action :
 This unit consist of ceramic substrate of Honey-comb structure. This is coated with catalyst
material consisting of precious material as Valedium and Rhodium. It enhances the rate of
chemical reactions.
 By using the catalytic converter, the exhaust emissions like CO, Nox is getting reacted with the
coated material and oxidation takes place which reduces the Nox and CO values.
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CAT-CON
EX Brake
Silencer
Tail Pipe

Exhaust Brakes
Exhaust Brake :
 Exhaust brake is attached before silencer
and immediate to the pipe from
turbocharger. The brake is controlled by
switch on instrument panel.
 Exhaust brake consist butterfly valve
operated pneumatically or vacuum (for
407). The valve cylinder is operated by
solenoid controlled by brake switch.
 It is a butterfly valve which operate when
the brake pedal is pushed. It stops the
exhaust gases and hence reduces the
speed of engine.
 Exhaust brake is to be operated when the
vehicle is at down gradient.
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Exhaust System –DOC & POC
 Layout of Exhaust System 497 BSIV CRDI:
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Diesel Oxidation Catalyst (DOC):
 It is made from ceramic substrate which is
loaded with coat of precious metals like
platinum or vanadium up to 40 gm/cu. Ft
 Removes 95 % of CO and HC.
 Oxidation Reaction with exhaust pollutants
is as below.
– 4HC + 3O2 -> 2CO2 + 2H2O
– 2CO + O2 -> 2CO2
– 2NO + O2 -> 2NO2
 The formation of the NO2 is very important
for soot regeneration. Therefore it is
recommended to use correct grade of
diesel which has Sulphur content up to 50
PPM
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Particulate Oxidation Catalyst (POC):
 POC which is also called as PM trap has an open
filter construction, consisting of corrugated
stainless steel fine screens that form a
cylindrical substrate.
 Exhaust gas has a free route to flow through the
construction, but part of particulate is trapped
inside the screen “eyes”. This unit is always
after an oxidation catalyst.
 POC collects soot and regenerates itself with
help of NO2 during strong accelerations and
highway driving.
 Reaction that happens for suit regeneration is
as follows:
– C + 2NO2 = CO2 + 2 NO
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 Cut Section of DOC POC  Failure Modes of DOC POC
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Maintenance of Exhaust System – DOC & POC
The exhaust after treatment system will function efficiently and regenerate itself under normal
highway driving conditions, high speeds. However, in some vehicles operating under continuous
very slow moving and dense traffic, city running, tippers, garbage compactors etc. may choke the
exhaust after treatment system. Only for such cases. It is recommended to perform the below
procedure by the customer on monthly basis or once in every 5000 kms to avoid choking of
catalytic converter.
 Warm the engine to 80 0C coolant temperature.
 Run the vehicle at higher speeds (more than 60 kmph) in 5th or 6th gear for 15 mins. In case
if the road conditions are not conductive of higher speeds then the vehicle may be driven at
40 kmph in 4th gear for 15 mins. This will help to self-clean the after treatment system.
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Fuel System
 The fuel system consists of a fuel tank, fuel filters, a fuel injection pump and the injectors.
 The fuel is drawn into the fuel injection pump by the transfer pump through filter assembly.
 A hand primer fitted between the tank and the filter facilitate in filling and venting
operations.
 A return line from the pump and the injectors is connected to the tank thus forming a closed
loop system.
 The transfer pump sucks the fuel from the tank, through filter assembly and increase the feed
pressure and regulates it.
 The transferred pressure fuel is metered by a metering valve and passes through the various
drillings of the head & rotor between the pumping plungers in the rotor.
 The pumping plungers when depressed by the action of the opposed cam lobes, rise the
pressure to much greater level and the fuel at high pressure flows to the injectors.
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Mechanical Rotary FIP (VE) Layout BS-III
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Mechanical Rotary FIP- Internal parts
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Mechanical Fuel Injection Pump (MFIP)
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Layout of MFIP System
 To meet BS-III emission norms with mechanical system (non electronic) fuel system, EGR has
been introduced on 4SP TCIC Engine. The desired flow rate of exhaust gas can be met at any
operating conditions based on the Engine RPM, coolant temperature, throttle position etc.
The EGR valve open & close conditions / maps are embedded inside the EGR controller.
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Components & Working of MFIP System
 The EGR valve is a diaphragm type valve,
mounted on intake elbow. This valve is actuated
progressively by vacuum from the Vacuum
Pump driven by the Alternator through
Electronic Vacuum Regulating Valve.
 The exhaust gas starts flowing into the inlet
manifold once the vacuum is fed into the EGR
valve. The valve lift sensor is provided on the
top of the EGR valve, which gives feed back
signal to the EGR controller.
 The EGR controller compares the valve lift
position feedback to its command position and
determines if the valve is at the correct position. If
the valve is not at the correct position then a
“Blink Code” is set / triggered.
 The Electronic Vacuum Regulating Valve is an
electro pneumatic solenoid switch, which
controls the input vacuum from alternator
mounted vacuum pump, based on the
command from the EGR controller.
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Electronic Vacuum Regulating Valve

Fuel System Layout – VP 37 Rotary Pump
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Fuel Tank
Fuel supply
line
fuel filter
Injector
FIP
Fuel return
line
HP lines
Tank cap
with
breather
Legends
Red: Pressurised fuel
Dark Blue: Non filtered fuel
Blue: Low pressure filtered fuel
Light Blue: Fuel return
Fuel Feed Pump

Fuel Feed Pump – VP 37 & Mechanical FIP
 Driven by eccentric on FIP cam shaft
 Plunger and return spring mechanism
 Feed pump strainer should be cleaned periodically
 Feed pump housing O ring should be in good condition
 Feed pump plunger O ring should be in good condition to prevent diesel dilution
7/26/2022 TML 75

Fuel System Layout - CRDI
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Fuel System – CRDI( Bosch)
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Fuel System Components – CRDI (Bosch)
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Fuel Tank
Fuel Filter with Water
Separator
High Pressure Pump
Protect filter Injector
Common rail

Fuel Injector (Bosch)
 Injector works by solenoid which operates by ECU.
 The spring keeps the ball in LOCK condition and there is only one pressure in injector.
 As solenoid operates, moves the ball up and join two different pressures which moves the
needle and injection takes place.
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Fuel Injector (Bosch)
Identification of Injector
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Shift / Line / Clamping station
Production plant code
IQA - Alpha Numeric Code (for
field use)
Serial number
Manufacturing date
IQA - Data Matrix Code (for
EOL use)
Bosch part number

Handling the Fuel Injectors
Use Protective Caps After Removal Removal & Fitment:
 Push the clip and remove pipe
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✔ ✘
Do not Hold Here
Clip Pushed Condition
Clip Original Condition
Push the Clip & Fit the Pipe

Fuel Injection Pump (Bosch-CB-18)
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Metering Unit (Bosch)
 Located at back of high pressure pump.
 Controls Fuel Intake volume to the pump.
 Receives battery voltage supply through protection fuse.
 Energized by EMS ECU via negatively triggered PWM.
 Operating frequency : approximately 180Hz.
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High Pressure Pump
Metering Unit

Handling of HP Pumps Bosch
Use Protective Caps
Do not Hold in the Marked Place
Removal & Re-fitment – Electrical Connector
Loosening or tightening of HP Pipes
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✔ ✘
• For removal press the knob & pull the connector
• For re-fitment just push the connector
Use two spanners
for loosening or
tightening of HP Pipes

Fuel Filter with Water Separator- BS4 - Bosch
 To remove the water contamination from Fuel.
 Water to be drained weekly basis or whenever WIF indicator comes on
 If water do not drained the damage caused by the water to FIP and Injector is much more
serious than on vehicle without water separator
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Fuel Filter – Auto drain System
 Automatically drains water from fuel filter
 It saves FIP from water ingress.
 No external fault reset mechanism is
required. Faults are self reset when the
faults cause is removed.
 Indicator in front of driver & hence lamp is
visible
 Auto drain System Schematic
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How It Works:
 The water in fuel in fuel indicator ON for 3 sec. when ignition key inserted ON.
 As water in fuel filter increases the indicator glows continuously.
 Driver should stop the vehicle away from road.
 Switch OFF ignition, wait for 3 min.
 After 3 min, water will get drain automatically for 15 sec.
 Switch ON ignition. If indicator remains ON repeat above cycle.
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Water present it will remain ON continuously
No water The indicator will be OFF if there is no water in the system
Sensor fault it will blink for 1 times in 0.5 seconds and remains OFF for 9 seconds
Fuse fault it will blink for 3 times in 0.5 seconds and remains OFF for 7 seconds
Actuator fault it will blink for 2 times in 0.5 seconds and remains OFF for 8 seconds
SDC fault it will blink for 4 times in 0.5seconds and remains OFF for 6 seconds
BLINK CODE DETAILS

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Common Rail- Bosch
 The Common Rail Assembly is used to maintain the high fuel pressure provided by high
pressure pump, allows the fuel injector to be regulated and injected separately for each
cylinder by using the management strategy of ECM.
 The Common Rail Assembly consists of common rail body, rail pressure sensor.
 The fuel pressure in the rail is monitored by rail pressure sensor and regulated constant
pressure by IMV and Injector back leak.
 In this way, the Common Rail Assembly controls the fuel pressure to desired point.
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Handling of Common Rail- Bosch
 Use Protective Caps
 Do not Hold in the Marked Place
General Guidelines:
 Ensure the cleanliness in work area.
 Do not damage Data matrix code (DMC) & IQA
code.
 Ensure no damage to copper washer. Use new
copper washer while reassembling injector.
 Use the special tool for removal of remove the
injector from engine.
 Do not tamper any hardware on HP pump, injector
or rail.
 Use correct torque specification for tightening
interfaces for all hydraulic components.
 Do not pour externally diesel from old filter into
the new filter during assembling. This will lead to
contaminated fuel entry into the clean side. Prime
the vehicle to start after filter change.
 Do not leave any loose connections, see that all
interfaces are connected.
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✔ ✘

Diesel Tank
 Pressure cap is in tact to prevent leakage.
 Do not take out rubber seal from cap.
 Capacity: 60L
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Fuel System – CRDI(Delphi)
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Fuel System Components – CRDI (Delphi)
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Fuel Filter
Injector
Fuel Tank Sedimentor
Common rail
High Pressure Pump

Cooling System
Necessity of Cooling system:
 To bring the engine to the operating temperature as quickly as possible
 To maintain the engine temperature at optimum range
 Main Parts:
– Water pump
– Auxiliary/ Recovery Tank
– Radiator and radiator cap
– Thermostat
– Radiator fan / Shroud
– Hoses
– Antifreeze Coolant (1:1 ratio with water)
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Engine Cooling System General Layout
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Legends
Blue: Cool coolant
Red: Hot coolant
Arrow: Direction of coolant flow
Air flow
Cylinder block
Cylinder head
Recovery tank
Radiator fan
Radiator cap
Pump
Thermostat
For SFC models
System with recovery tank

Cooling System Types
Auxiliary Tank System
 Regular checking and Topping to be done on
Auxiliary tank
 The coolant flows from auxiliary tank to the
bottom of radiator and hot coolant is collected in
the tank
 Condition of radiator cap with twin seal and hose
are essential for proper function of this system
 The auxiliary tank is having two different caps
subjected to different pressure. The cap that is on
top of the tank is of 0.5 bar and another is at the
filling side is at 0.9 bar. THESE CAPS SHOULD NOT
BE INTERCHANGED
Recovery Tank system or No Loss Coolant Tank
 Regular checking and Topping to be done on
Recovery tank
 Water expands and flow from radiator to recovery
tank when engine is started.
 When engine is switched off the coolant in
radiator condenses and the volume is
compensated by coolant flowing back from
recovery tank
 Condition of radiator cap with twin seal and hose
are essential for proper function of this system.
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Cooling System Components
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Water pump
Auxiliary/ Recovery
Tank
Radiator
Thermostat Radiator fan / Shroud Radiator Cap

Aluminium Radiator
Aluminium Radiator has following advantages
 High durability against mechanical and thermal shocks
 Higher heat transfer rate
 Higher corrosion resistance leading to longer life.
 Less coolant capacity of Radiator.
 Less clogging, longer trouble-free performance.
 Environment friendly product (No lead)
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Care of Aluminium radiator
 Do not open radiator cap for checking the coolant level in radiator
 Use only recommended Non Amine coolant in 50:50 ratio
 Brand :
– CASTROL: CASTROL Long Life Coolant
– BPCL: TELCO SUPER COOLANT
 Protect Radiator and auxiliary tank from weld spatters and mechanical damage. Use proper
cover to protect radiator and auxiliary tank during welding in the vicinity of radiator.
 Do not open radiator system pressure cap for checking the coolant level in radiator.
 Always check and fill thro’ recovery tank or check level in translucent Auxiliary tank and top
up thro’ filler cap.
 Dust accumulated in the fins should be cleaned by blowing compressed air at low pressure
from inner side of radiator. Please do not clean with pressurized water jet as it will deform the
fins
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Thermostat
 Function: The function of thermostat to bring the engine operating temperature as soon as
possible.
 Operation: There is a valve which operates based on the coolant temperature.
 It restricts the water flow from engine to radiator during cold condition, and allows hot water
going into radiator for cool down when in normal operation
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Bypass to Engine
From Engine
To Radiator
Valve lift in fully
open condition
Start opening Temperature (SOT): 83 0C
Fully open temperature (FOT): 97 0C
Check lift of by-pass valve: 8 mm after fully
opened condition.

Water Pump
 To feed the water from radiator to engine
 Water flow varies as per the engine speed
 Flow Rate at 2700 rpm and at 0.5 bar pressure : 130 lit / min
Water pump Bearing Types:
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Radiator Fan
 Purpose: To cool the radiator coolant and
hence to control engine operating temp.
 Sizes: 330 mm
 No. of blades: 7 /8
 Types:
– Mechanically Driven
– Electrically Driven
 Care: Do not use the fan rotation during
fuel timing and tappet setting.
 Mechanically Driven Fan
 Electrically Driven Fan
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Viscous Coupling
 A mechanical device to engage and
disengage the cooling fan to optimise
engine cooling.
 Is fitted to the engine with no external
controls to run the fan drive.
 Only use the fan in the engaged condition
when it is needed.
 Allows the engine to work at it’s designed
operating temperature
 Saves fan power about 6%
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Components of Viscous Coupling
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Working System of Viscous Coupling
 Does not need any outside controls.
 The Bi-Metal coil on the front of the
viscous fan drive measures the air
temperature coming off the radiator.
 This air temperature relates to the radiator
water temperature
 At a pre-set point the fan drive will open a
fill port inside the drive, allowing silicone
fluid to enter the drive area and the fan
speed will increase
 Fan Drive Engaged
 Fan Drive Disengaged
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Engine Cooling System with Cabin Heating
 Hot air to cab
 Water Pump
 Thermostat
 Heating Coil
 Blower
 Hot water flow control valve
 Operating cable
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Lubrication System
Purpose of lubrication
 To minimize the friction, thus reducing power losses.
 To reduce wear, so that reducing possibility of seizure.
 To act as an oil-seal- preventing blow-by.
 To act as a coolant.
 To act as a cleaning agent.
 Cushions the sudden thrust on bearings.
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Properties of Good Lubricant
1. Viscosity, viscosity index, viscosity number
2. Chemical Stability
3. Corrosion Resistance
4. Foaming Resistance
5. Detergent-dispersants
6. Pressure Resistance
7. Specific Gravity
8. High Flash Point & Fire Point
9. High Pour Point
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Oil to be used & change period
 Oil conforming to APICF4+ and MB228.1 specification
 The 497SPTC Engine uses 15W40 oil which is a multi-grade oil.
 The recommended brand is CASTROL.
 Oil Quantity: In sump- Max. 7 lit and Min. 5 lit.
 Change interval: Every 10000 KMS
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Engine Oil Grade Ambient Temp(0
C)
15W40 -10 & Above
10W30 -20 to 0
5W20 -10 & Below
Engines Interval
497 SP 20000 kms
497 TCIC 40000 kms
483 DL 10000

General Lubrication System Circuit
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Lubrication System Layout – 497 TCIC
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Oil pump – 497 Engine
1. Positive displacement GEAR pump
2. Driven by cam shaft gear.
3. System pressure of 5.2 bar is controlled
by relief valve
4. Flow rate : 43 lit/ min @ 1400 rpm
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Oil cooler- 497 Engine
1. Hot oil is passed through it.
2. Oil is cooled by the convection by circulating coolant around it.
3. The oil cooler is of plate type.
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Plate oil cooler
Oil cooler cover
Gasket

Valves and their functions
Oil pump pressure relief valve
 Opens when the system pressure exceeds 5.2 bar and oil drains back into the oil sump.
 Maintains the system max. pressure.
 Spring and plunger type valve.
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Valves and their functions
Oil filter bypass valve
 Opens when the oil filter gets choked.
 Opens when the oil filter gets choked.
 Set to open at a pressure difference of 1.8 to 2.6 bar.
 Placed between the inlet and outlet of the oil filter.
Oil cooler bypass valve
 At the initial starting of engine, it opens and supplies oil to the main gallery, also opens when
oil cooler gets choked.
 Present between the inlet and outlet of the oil cooler.
 Spring loaded valve.
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Checking of settings of oil pump
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Gap between gear and
housing: 0.030 – 0.105 mm
Backlash between gears:
0.15 – 0.25 mm
Axial clearance between housing
cover and gears: 0.04 -0.099 mm

Lubrication System Layout – 2. 2Lt. DICOR
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Oil Pump – 2.2 L Engine
Oil Pump Crank Driven:
 These oil pumps are run by crank shaft.
 Oil pump is having two lobes which creates
the required pressure.
 Pressure is controlled by relief valve (spring
loaded)
 These are used in 2.2 L engines.
Oil Filter and Cooler:
 Oil filter is attached outside to the engine
with oil cooler.
 Oil from the engine first gets cooled in
cooler and then gets filtered.
 Oil cooler is having 2 coolant pipes from
where the coolant circulates.
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Oil Pump- 483 DL
Oil Pump Chain Driven:
 These oil pumps are run by crank shaft
with chain.
 Oil pump is having two lobes which creates
the required pressure.
 Pressure is controlled by relief valve (spring
loaded)
 These are used in 483DL & 4PL engines.
Plate Type Oil cooler:
 Fixed in the water jacket.
 The coolant from radiator flows over the
plate which cools the oil inside.
 For better movement of oil inside the
plate, the plate is having perforated sheets
inside.
Spin on Oil Filter
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Oil filter
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Bypass valve
opens at 1.6 to 2.2 bar

Oil filter
Filter in the system
1. Oil filter cartridge should be changed at the time of changing the oil.
2. Oil filter capacity 1 lit. to be filled along with the new filling of oil.
3. A by-pass valve is provided in the oil filter bracket which will cut off the oil supply from filter
if filter gets chocked, then supply will be started to engine and engine can be saved from oil
starvation.
4. Use always genuine filter cartridge.
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Positive Crankcase Ventilation System (PCV)
Oil Separator for Air Breather
 A step towards developing environment
friendly products, to eliminate the engine
blow by being emitted to atmosphere, the
engine breather / oil separator has been
fitted.
 The oil separator, separates oil from the
blow by of the engine and sends it back to
engine oil sump.
 The remaining air, carbon particles and
other gases are sent to the inlet manifold.
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Intercooler
Air
Filter
Inlet Manifold
Cylinder head cover
Turbocharger
Gases
Oil separator
Oil return to
crank case
Blow by
Blow by
gases

Positive Crankcase Ventilation System (PCV)
Oil Separator for Air Breather
 There is also a spring loaded diaphragm valve
provided on the oil separator outlet to the inlet
manifold.
 This prevents the flow of blow-by from the oil
separator to inlet manifold in case the air filter is
choked and high suction starts acting on outlet port
of oil separator.
 No leakage past diaphragm top cover of oil
separator is permitted. Replace the assembly if
there is any leakage.
Oil separator is used only in 483 DL & 2.2 L Engines
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PCV System Layout – 483 DL & 2.2 L
7/26/2022 TML 124

Electronic Diesel Control (EDC)
 The Electronic Diesel Control includes ECU, Sensors, Actuators, and electronically controlled
VP 37 FIP (BS3)
 The Micro-controller inside the ECU continuously evaluates the signal from sensors.
 Electronic Control Unit performs certain calculation based on algorithms and function groups
to control Vehicle operations like fuel injection, timing, governing, emission control, error
identification, self test and safety checks with the help of actuators in the engine/vehicle
system based on closed loop feedback received from sensors.
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Electronic Diesel Control – BSIII ( VP – 37)
7/26/2022 TML 126
EDC system block diagram
Sensors
Coolant Temperature
Air Temperature
Boost Pressure
Engine Speed
Vehicle Speed
Needle Lift Sensor
Accelerator Pedal Sensor
ECU
Fuel Quantity
Engine Shut Off
Injection begin
Starting Control
MAPS (Data Base)
Actuators
Fuel Injection Pump with
Timer & Fuel shut off
Valve
Diagnostic
Diagnostic Display
Micro
Processor

Differences between BSIII & BSIV
No. Parameters BS-III System BS-IV System
1 Fuel Injection Electronically controlled VP 37 FIP
(BOSCH)
CB 18 - 2 Lobes high pressure pump
(BOSCH)
2 Injector VCO Nozzle 6 holes CRI 2.2 Nozzle with ECU operating
solenoid
3 Operating fuel pressure 1200 Bars 1600 Bars
4 EGR Not Applicable Cooled EGR (Output temp of gases is
1200 C)
5 Piston Modified Modified to suit high pressure
combustion
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Differences between BSIII & BSIV
No. Parameters BS-III System BS-IV System
6 Turbocharger Waste Gate Waste Gate
7 Sensors Fuel temp, Boost pressure and temp,
vehicle speed, Engine speed, needle
lift, engine temp, Acc. Pedal Module,
brake and
clutch switch.
Addition to BS-III
1. Air Mass Flow sensor
3. Phase sensor (Cam shaft Sensor)
4. Common Rail pressure sensor
5. Differential Pressure sensor
8 Fuel Filter Single filter with built in fuel water
separator and water in fuel sensor.
Single filter with built in fuel water
separator and water in fuel sensor & fuel
temperature sensor are on filter head.
9 Oil Filter Spin on type Spin on type
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Sensors –BS3
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Boost Pressure Sensor Accelerator pedal module
Brake pedal switch Clutch pedal switch Engine speed sensor

Sensors –BS3
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Coolant temperature sensor Vehicle speed sensor
Atmospheric pressure sensor Needle lift sensor (NBF)

Boost Pressure Sensor
 The sensors serves to measure the absolute intake manifold pressure up to 2.50 bar and inlet
air temperature.
 The signal is sent to ECU for evaluation and execution. The piezo-resistive pressure sensor
element and a suitable circuitry for signal amplification and temperature compensation are
integrated on a silicon chip.
 The temperature sensor element is an NTC-resistor. (NTC - Negative Temperature Coefficient)
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Accelerator Pedal Module
The Sensor serves to measure the position of the
accelerator pedal. It has two potentiometer for
measuring the position of accelerator pedal from
0% travel position to 100% travel position . The
accelerator pedal module is part of accelerator
pedal. Tightening torque of the retaining screws:
9 Nm
Specifications:
Operating voltage : 5 V DC
Short circuit protection : 60 min. at 16 V
Double-potentiometer
Potentiometer resistance
Potentiometer 1 : 1.2 kW ± 0.4 kW (pin no. 342)
Potentiometer 2 : 1.7 kW ± 0.8 kW (pin no. 541)
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Brake pedal switch (brake light switch)
 Brake pedal switch is a double push button switch mounted on the brake pedal bracket.
 It indicates to ECU when ever brake pedal is pressed.
 The plunger should move at least 3mm when brake pedal is applied.
 This can be adjusted with the help of two check nuts ‘a’ and ‘b’.
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Clutch pedal switch
 It is mounted on the clutch pedal. It sends a signal to the ECU. When ever clutch pedal is
depressed.
 The switch plunger is 8 mm in length and shall always be in depressed condition. The switch is
to be tightened to ensure correct contact when clutch pedal is depressed. The plunger
releases when clutch pedal is depressed.
 Tightening torque : 8 Nm
7/26/2022 TML 134

Engine Speed Sensor
 ESS measures the speed of the engine and continuously sends signal to the ECU for further
evaluation and control. It is mounted on the fly wheel housing. Engine position sensor is an
inductive type proximity sensor. Electric pulse are generated when the ring gear teeth pass by
in proximity of the sensor transducer.
 The sensor is to be mounted perpendicular to the surface and correct gap is automatically
maintained. Gasket is to replaced before installation. Sensor should be fitted by light taping
with mallet and not be hammered.
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Engine Speed Sensor Operation
7/26/2022 TML 136
B
WB
CKP SENSOR
1 2 3
Signal Low REF. Shield Ground
A27 A12 A7
Gr
G
ON
Start

Coolant Temperature Sensor
 It is mounted on coolant return line from cylinder head. It measures the temperature of
coolant and sends signals to the ECU for further evaluation. Wiring harness is connected with
pigtail connectors to the main engine wiring harness.
Specifications:
 Temperature range: -40/1300C
 Rated voltage: Operation by series resistance 1 kW at 5V in the control unit
 Nominal resistance at 20 0C : 2.5 kW ± 5%
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Vehicle Speed Sensor
 Vehicle speed sensor is mounted on the gearbox at speedo cable mounting location. The
sensor is connected to ECU wiring harness through a pigtail connector. Its measures the
speed of the vehicle.
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Atmospheric Pressure Sensor
 Atmospheric pressure sensor is part of ECU. It measures the atmospheric pressure at varying
altitude to compensate for lesser boost pressure and emission control.
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ocation Photo CONNECTIVITY ( contin
he Cab on
r side
EDC 15 ( VP 37 FIP) BS-III vehicles
Atmospheric
Pressure
Sensor

Needle Lift sensor (NBF)
 Needle position sensor is located on the injector of first cylinder. It sends a signal to the ECU
when fuel is injected in the 1st cylinder, i.e. 1st cylinder injection timing.
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Electronic Fuel Injection Pump ( FIP VP 37)
 VP37 fuel injection pump is axial piston pump with distributor head & plunger
 It has inbuilt vane type feed pump.
 In this FIP the governor is controlled electronically ( also called HDK Unit)
 Fuel shut off valve also known as ELAB
 Timer solenoid valve
7/26/2022 TML 141
HDK Unit
ELAB –Fuel shut off
Timer solenoid
valve

Electronic Fuel Injection Pump ( FIP VP 37)
Fuel shut off solenoid
It is also known as ELAB which is operated by ECU. It is solenoid switch located on the distributor
head of the fuel injection pump. When the solenoid is active, the fuel delivery valve is open,
there by ensuring fuel supply to FIP.
Timer advance device
It is a solenoid actuator mounted in the FIP to advance or retard timing on any engine speed
based on instruction given by the ECU. It has a solenoid valve which is actuated about a duty
cycle for desired timer advance or retard.
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HDK unit
HDK unit is an actuator with eddy current sensor mounted on FIP. HDK controls the fuel delivery
by positioning the control sleeve on delivery port of the plunger. HDK also senses the
temperature of diesel for fuel quantity correction. HDK sends a closed loop feedback on the
quantity of fuel delivered.
Actuators..
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Actuators..
Diagnostic Lamp
 Diagnostic lamp is provided on the instrument cluster. In the event of any errors reported by
the ECU in course of operation of the vehicle, the diagnostic lamp glows ‘CHECK ENGINE’,
indicating that there are errors reported by the ECU. However only selected errors which can
have a direct effect on the vehicle performance or engine life are reported to the diagnostic
lamp. Depending on the criticality of the error reported, the ECU can either switch off the
engine or change to Limp home mode.
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Electronic Control Unit (ECU)
 A micro processor inside the ECU
continuously evaluates the feedbacks from
various sensors. Based on this feedback, it
performs certain calculations according to
the algorithms and function groups.
 With this ECU is able to control:
– Fuel injection timing,
– Metering of fuel quantity according to
demand
– Error identification & capturing,
– Emission control,
– Self tests & safety checks.
7/26/2022 TML 145
on / Working principle Location Photo
microprocessor/ brain of
C system
e suggests it Senses
heric pressure
Inside the Cab on
co-driver side
EDC 15 ( VP 37 FIP) BS-III vehic

Electronic Control Unit (ECU)
ECU (Electronic Control Unit)
 Care for ECU
– ECU shouldn’t be disconnected while ignition
is on or Engine is running.
– Do not remove ECU connection unnecessarily
and ensure proper/firm fitment on vehicle.
– Direct spray of pressurized water (Water
wash) on ECU must not be done. Also water
shouldn’t be sprayed in engine compartment
in engine hot condition.
– Do not remove any sensor connection while
ignition is on or engine is running.
– Do not perform welding job on vehicle with
battery & ECU connected.
– ECU shouldn’t be dropped on ground or
water.
– Do not cut & join the wiring harness for extra
connections/vehicle accessories.
Location:
 ECU (Electronic Control Unit) is mounted
inside the cabin, not prone to water and mud
7/26/2022 TML 146
microprocessor/ brain of
C system
e suggests it Senses
heric pressure
Inside the Cab on
co-driver side

Electronic Control Unit (ECU)..
Functions:
 Internal diagnostics and safety checks: by use of diagnostic kit.
 Fuel quantity governing: variable fuel quantity delivery fro various load conditions at specific
engine speed.
 Injection timing control at various engine speed.
 Boost pressure monitoring.
 Limp home functions: The ECU will switch over to limp home mode so that the vehicle can be
taken to nearest service station. This switch over happens in occurrence of certain selected
failure/errors reported in EDC system by ECU.
7/26/2022 TML 147

Electronic Diesel Control – BSIV – General Layout
7/26/2022 TML 148
Sensors
• CKP Sensor
• CMP Sensor
• Rail Pressure Sensor
• MAF /IAT Sensor
• Oil Pressure Sensor
• ECT Sensor
• Fuel Temperature Sensor
• DPF Sensor
• Exhaust Gas Temperature
• Vehicle Speed Sensor
• Brake Switch
ECU Actuators
Signal Inputs Sensor
Evaluation
Functions
• Idle speed Control
• Intermediatespeed regulation
• Smooth running control
• Active surgedamper
• External torque Intervention
• Vehicle Immobilizer
• Fuel Delivery Control & Limitation
• Vehicle Speed Controller
• Vehicle speed limitation
• Cylinder shut off
• Rail pressure Control
• Start of Injection control
• Multiple Injection
• Additional special adaptation
Diagnostic Functions
• On Board Diagnosis
• Substitute Functions
• Engine Diagnosis
• Solenoid Valve output stages
• Power output stages
• Signal outputs
• Diagnosis Communication
Power Supply
• Injectors
• Metering Unit & HP Pump
• EGR Actuator
• Boost pressure actuator-VGT
• Cold start system
• Fuel Heater
• Radiator Fan Control
• Radiator Fan Coupling
• Additional output stage
Communication
• ISO Interface (Diagnostic)
• Glow plug Control Unit
• Engine Speed Signal
• Diagnosis Lamp
• CAN Communication
Main Relay

Electronic Diesel Control Layout – BSIV (Bosch)
7/26/2022 TML 149

Electronic Diesel Control (EDC of BSIV) - Bosch
EMS Functions of BSIV
 Precise Control of:
– Injection Timing
– Duration of Injection
– Quantity of Injection
– Pressure at which the Injection should
happen
 Receiving & processing information from
all the Engine & Vehicle Sensors
 Controlling all the Actuators
 Computing exact behaviour of Engine ,
environment & vehicle conditions
 ECU of BSIV - Bosch
7/26/2022 TML 150

EDC Components BSIV- Sensors
7/26/2022 TML 151
Engine Speed Sensor Cam Phase Sensor
Water Temperature Sensor Hot Air Mass Sensor
On Timing Gear Cover
On Flywheel Housing
On Coolant Return Line
HFM or Hot Air
Mass Flow Sensor
It contains heated sensor film element
The amount of current required to
maintain the film’s temperature is
directly proportional to the mass of air
flowing past the film. The integrated
electronic circuit converts the
measurement of current into a voltage
signal which is sent to the ECU
It is mounted on
air inlet pipe just
after the air filter.
Rail Pressure
Sensor
It senses the pressure in the common
rail and helps to maintain the desired
rail pressure
The feedback is given to ECU which in
turn communicates with inlet metering
unit on FIP
Mounted on the
Common Rail
SENSORS
On Air Inlet Pipe

EDC Components BSIV- Sensors
7/26/2022 TML 152
Rail Pressure Sensor Water in Fuel Sensor
Vehicle Speed Sensor
of air
ed
tage
mon
red
ch in
ering
Mounted on the
Common Rail
edal
he
ction
On accelerator
pedal bracket
On Common Rail
On Rear Side of Gear Box
On Fuel Filter/Water Separator
Fuel Temperature Sensor
On Fuel Filter Head

EDC Components - Actuators
7/26/2022 TML 153
Injectors Metering Unit
Service Vehicle Soon (SVS)
On Cylinder Head
On FIP
EGR valve
On Cylinder Block
On Instrument Panel

High Pressure Pump
 Bosch
7/26/2022 TML 154

Electronic Diesel Control Layout – BSIV (Delphi)
DICOR Engine
7/26/2022 TML 155

7/26/2022 TML 156
DICOR Engine

7/26/2022 TML 157
DICOR Engine

Diagnostic Kit
The Diagnostic tester communicates with the ECU (Electronic Control Unit) on a serial K-line
interface. This tester comprises of a Vehicle interface unit, custom built application software
installed in a Laptop/Desktop.
7/26/2022 TML 158
Laptop Hardware interface
12V
K-Line
ECU
Diagnostic Connector
• As per ISI5031-3, Type A
• Wiring harness : Female connector
• Tester cable : Male connector

 Take the participants to the workshop and make
them identify the following systems of 497 SP
TCIC/ CRDI Engine:
 Engine No. Location
 Air Induction System
 Exhaust System
 Fuel system
 Cooling System
 Lubrication system
 Engine Management System
 Sensors & Actuators Location
Engine Systems Identification
7/26/2022 TML 159
Engine Systems 497
SPTCIC CRDI
Identification

 Take the participants to the workshop and make
them identify the following systems of 483 DL TCIC
Engine:
 Engine No. Location
 Air Induction System
 Exhaust System
 Fuel system
 Cooling System
 Lubrication system
 Engine Management System
Engine Systems Identification
7/26/2022 TML 160
Engine Systems 483 DL
TCIC Identification

497/4SP/3.0L
Engine Removal & Dismantling/Overhauling
7/26/2022 TML 161

 Special Tools Required for Engine Dismantling
 Tightening Torque Specifications
 Engine Removal Steps & Procedures from the
Vehicle
Removal of Engine from the Vehicle
7/26/2022 TML 162
Engine Removal from
the Vehicle

Safety Procedures & Cautions
 When it is necessary to run engine indoors, make sure that the exhaust gas is forced
outdoor.
 Do not perform service work in the areas where combustible materials can come in
contact with a hot exhaust system.
 Engine oil can be hazardous so keep it away from children and pets.
 To minimize your exposure to engine oil, wear a long sleeve shirt and moisture proof
gloves when changing engine oil. If engine oil contacts your skin, wash thoroughly with
running water and soap.
 Recycle or properly dispose of used engine oil and filters.
 When performing service to electrical parts that does not require use of battery power,
disconnect the negative cable of the battery.
 When removing parts that are to be reused, be sure to keep them arranged in an orderly
manner so that they may be reinstalled in the proper order and position.
7/26/2022 TML 163

 Whenever you use oil seals, gaskets, packing, O-rings, locking washers, split pins, self -
locking nuts, and certain other parts as specified, be sure to use new ones. Also before
installing new gaskets, packing, etc…..be sure to remove any residual material from the
mating surfaces.
 Make sure that all parts used in reassembly are perfectly clean and inspected for given
specifications. And use oil or grease on parts wherever specified during reassembly.
 When use of a certain type of lubricant, bond or sealant is specified, be sure to use the
specified one.
 Be sure to use special tools when instructed.
 When disconnecting fuel pipes, oil pipes or hoses mark correct installation positions on it, so
that those can be reinstalled correctly.
 After servicing fuel, oil, coolant, exhaust system; check all lines related to the system for
leaks.
7/26/2022 TML 164

497/4SP/3.0L
Engine Dismantling
7/26/2022 TML 165

Engine Dismantling
7/26/2022 TML 166
Remove Upper water cooling line Remove Thermostat
Remove starter Motor Remove alternator Power steering pump

Engine Dismantling
7/26/2022 TML 167
Radiator fan lock plates Radiator fan Radiator fan pulley
Water pump Turbocharger

Engine Dismantling
7/26/2022 TML 168
Turbocharger elbow & TC Exhaust heat shield Exhaust Manifold
Cylinder head cover bolts In BS-3 engines Cylinder head cover to be removed by tilting
In BS-IV remove HP Lines & injectors before head cover
High Pressure Lines

Engine Dismantling
7/26/2022 TML 169
Removal of oil cooler Rocker arms with shaft
Rocker arms with shaft Remove circlips at end & grub screws to separate Rocker arms, supports & R A shaft

Engine Dismantling
7/26/2022 TML 170
Removal of push rods Removal of injector claw bolt
Removal of injectors. Use puller if needed Loosen & remove cylinder head mounting bolt

Engine Dismantling
7/26/2022 TML 171
Fit the special lifting hooks for cylinder head
Cylinder head removed
Cylinder head gasket removed

Engine Dismantling
7/26/2022 TML 172
Lock the flywheel & removal of FIP lock plate mounting bolt Remove mounting bracket
Remove FIP mounting bolts to TGH Take out FIP

Engine Dismantling
7/26/2022 TML 173
Removal of Push Rod cover Removal of tappets
Removal of air compressor head piston & connecting rod

Engine Dismantling
7/26/2022 TML 174
Removal of oil sump Removal of oil pump
Removal of crank pulley bolt Removal of crank pulley with puller

Engine Dismantling
7/26/2022 TML 175
Removal of clutch release bearing Removal of clutch fork

Engine Dismantling
7/26/2022 TML 176
Removal of clutch plate

Engine Dismantling
7/26/2022 TML 177
Removal of timing gear cover Removal of timing gear cover

Engine Dismantling
7/26/2022 TML 178
Removal of cam gear mounting bolt with spl tool Removal of cam gear /thrust plate & mounting screws

Engine Dismantling
7/26/2022 TML 179
Carefully rotate the engine stand by 180 Deg
to make engine vertical & lock the stand in
this position
Loosen & remove the
connecting rod bolts.

Engine Dismantling
7/26/2022 TML 180
Remove the connecting rod caps.

Engine Dismantling
7/26/2022 TML 181
Tap the connecting rods with mallet & wooden piece Remove the piston.

Engine Dismantling
7/26/2022 TML 182
Remove the engine speed sensor Remove the flywheel
Remove TGH Bottom cover.

Engine Dismantling
7/26/2022 TML 183
Loosen & remove Main Bearing Cap bolts & caps

Engine Dismantling
7/26/2022 TML 184
Support the crankshaft with suitable tackle & take it out
Note: This completes dismantling of engine. Follow reverse process for assembly

497/4SP/3.0L
Engine Overhauling
7/26/2022 TML 185

Ring Gear Inspection
1. Check starter ring gear for wear and
damage. Replace if necessary.
2. Clean flywheel and check for cracks,
scoring, burns and unevenness.
3. If necessary, grind friction face just to
clear defect after removing dowels meant
for pressure plate. Grinding should be
done over entire friction face. In any case,
thickness of flywheel should not be
reduced beyond specified limit. Fix new
dowels
7/26/2022 TML 186

Cylinder Head Inspection
 Valve spring arrangement in the cylinder
head
 Checking of Valve Depth at Cylinder Head :
0.8 mm.
7/26/2022 TML 187

Cylinder Head Inspection
Cylinder Head height 92 mm
 Maximum permissible height: 91 mm
 Permissible unevenness:
 Crosswise: 0.015mm
 Lengthwise: 0.05mm
7/26/2022 TML 188

Inspection and Repair of Connecting Rod..
 Fit new pair of connecting rod bearing shell according to size of crank pin, making sure that
securing lugs of bearing shells are properly seated in grooves of parent bore of connecting
rod and cap.
 Place bearing cap with bearing shell on connecting rod tighten and torque fastening bolts.
7/26/2022 TML 189

Cylinder Block leakage testing
 Leakage Testing Pressure : 5 bar at the
temperature of 70 0C to 80 0C
7/26/2022 TML 190

Engine Component Inspection Cylinder Block
 Unevenness at matching surface
 Value:
 0.00mm (Transverse)
 0.03 mm (Longitudinal)
7/26/2022 TML 191

Checking the Cylinder Block & Bore
 Basic Size : 97.00 mm
 Repair Sizes :
 Standard 1 97.075 +/- 0.01
 Standard 2 97.125 +/- 0.01
 Ovality : Check at 6 places on each cylinder,
value should be within 0.010 mm
 Taper : Check at 6 places on each cylinder,
value should be within 0.010 mm
 If value is more, replace liner
7/26/2022 TML 192

Crankshaft Bearing and Parent Bore
 Crankshaft Bearing (With Bearing Shells)
 Parent Bore (Without Bearing Shells)
 Ovality: within 0.01mm
 Basic Size: 88.07 mm
 Shell Size: 2.477 mm
 Repair sizes (mm):
 Bore Size
Shell size
 Std I: 87.97 2.527
 Repair 1: 87.82 2.602
 Repair 2: 87.57 2.729
 Repair 3: 87.32 2.852
 Repair 4: 87.07 2.977
7/26/2022 TML 193

Connecting Rod Bearing, Parent Bore and Bush
Connecting Rod Big End Parent Bore
Bore Shell
 Size: (mm) 60.085 2.462
 Repair sizes (mm)
 Repair 1 59.835 2.587
 Repair 2 59.585 2.712
 Repair 3 59.335 2.837
 Repair 4 59.085 2.962
 Con Rod Bush OD: 39.075 mm
 Con Rod Parent bore size: 39.00
Bore Bush (OD)
 Repair 1 39.200 39.275
 Repair 2 39.500 39.575
7/26/2022 TML 194

Checking the pistons
 Piston Ring
 Butt Clearance
Check it at bottom side of block by placing the
rings.
 Butt Clearance
 Check it at unworn portion of block by
placing the rings.
Lateral Clearance, Value should be within
specification, if not, replace liner or rings.
7/26/2022 TML 195
Ring Butt Clearance Lateral Clearance
1st 0.20 - 0.35 mm 0.062 - 0.117 mm
2nd 0.20 - 0.35 mm 0.050 - 0.095 mm
3rd 0.25 - 0.40 mm 0.030 - 0.065 mm

Connecting Rod Bend and Twist Checking
 Checking of Connecting rod bend
 Max permissible limit : 0.025 mm
 Checking of Connecting rod Twist
 Max permissible limit : 0.1 mm
7/26/2022 TML 196

Crankshaft Main Bearing Journal and Crank pin
Main Journal
 Repair 1: 87.75
 Repair 2 : 87.50
 Repair 3 : 87.25
 Repair 4 : 87.00
 Crank pin Size : 60.00 mm
Crank pin Repair sizes:
 Repair sizes
 Repair 1: 59.75
 Repair 2 : 59.50
 Repair 3 : 59.25
 Repair 4 : 59.00
 Ovality & Taper : 0.01mm
 Run Out : 0.2mm
 Fillet Radius : 3.5 to 4 mm
 Fillet Radius on 2nd Journal : 4 – 4.5 mm
*Data given are of 497 Engine
7/26/2022 TML 197

Engine Component Inspection
Crankshaft Main Bearing Journal and Crank pin
Main Journal
 Repair 1: 72.75
 Repair 2 : 72.50
 Repair 3 : 72.25
 Repair 4 : 72.00
 Crank pin Size : 60.00 mm
Crank pin Repair sizes:
 Repair sizes
 Repair 1: 59.75
 Repair 2 : 59.50
 Repair 3 : 59.25
 Repair 4 : 59.00
 Ovality & Taper : 0.01mm
 Run Out : 0.2mm
 Fillet Radius : 3.5 to 4 mm
 Fillet Radius on 2nd Journal : 4 – 4.5 mm
7/26/2022 TML 198

Engine Component Inspection
Crank shaft and fly wheel
 Set the fly wheel to crank shaft in its
dowel position
 Checking crank shaft run out at main
bearing and flywheel runout. : 0.1 mm
7/26/2022 TML 199

Installation of Crankshaft
 Install new crankshaft gear together with
new key using new drift, 2574 5890 35 03.
(clean crankcase and crankshaft using
kerosene. Blow dry with moist free
compressed air).
 Install 5th main bearing oil seal in crankcase
and 5th main bearing cap with moist free
compressed air.
 Install bearing shells in crankcase and main
bearing caps. Make sure that locating lugs
of bearing shells are properly seated in
slots of crankcase and main bearing cap. In
case old bearings are being used, install
shells in their respective positions
7/26/2022 TML 200

483DL
Engine Removal & Dismantling/Overhauling
7/26/2022 TML 201

 Tightening Torque Specifications
 Engine Removal Steps & Procedures from the
Vehicle
Removal of Engine from the Vehicle-483DL
7/26/2022 TML 202
Removal of Engine from
the Vehicle-483DL

 Dismantling the Engine -483 DL
 Overhauling the Engine
 Inspection of Components
 Reassembling the Engine
Engine Dismantling & Overhauling- 483DL
7/26/2022 TML 203
Engine Dismantling &
Overhauling- 483DL

 When it is necessary to run engine indoors, make sure that the exhaust gas is forced
outdoor.
 Do not perform service work in the areas where combustible materials can come in
contact with a hot exhaust system.
 Engine oil can be hazardous so keep it away from children and pets.
 To minimize your exposure to engine oil, wear a long sleeve shirt and moisture proof
gloves when changing engine oil. If engine oil contacts your skin, wash thoroughly with
running water and soap.
 Recycle or properly dispose of used engine oil and filters.
 When performing service to electrical parts that does not require use of battery power,
disconnect the negative cable of the battery.
 When removing parts that are to be reused, be sure to keep them arranged in an orderly
manner so that they may be reinstalled in the proper order and position.
7/26/2022 TML 204

 Whenever you use oil seals, gaskets, packing, O-rings, locking washers, split pins, self -
locking nuts, and certain other parts as specified, be sure to use new ones. Also before
installing new gaskets, packing, etc…..be sure to remove any residual material from the
mating surfaces.
 Make sure that all parts used in reassembly are perfectly clean and inspected for given
specifications. And use oil or grease on parts wherever specified during reassembly.
 When use of a certain type of lubricant, bond or sealant is specified, be sure to use the
specified one.
 Be sure to use special tools when instructed.
 When disconnecting fuel pipes, oil pipes or hoses mark correct installation positions on it, so
that those can be reinstalled correctly.
 After servicing fuel, oil, coolant, exhaust system; check all lines related to the system for
leaks.
7/26/2022 TML 205

497/4SPTC/483DLNATC
Important Setting & Adjustments
7/26/2022 TML 206

FIP Timing setting 497/4SPTC/483DLNA/TC
7/26/2022 TML 207
Match FIP mounting gear red + punch make
with inspection hole
Insert flywheel locking pin Insert dial gauge & adapter part no.
F002H31103
Remove flywheel locking pin & rotate
anticlock wise dir. No response on dial gauge.
Hear set zero on dial.
Rotate flywheel clockwise dir. Till locking
pin get inserted . Check reading on dial
gauge.
FIP timing is advance OR retard that time
loosen three pump mounting bolts & pump
push or pull & set time
1 2 3
4 5 6

Tappet cover removal procedure
7/26/2022 TML 208
VP 37 Engine CRDI engine
• Remove Tappet cover bolts
• Tilt tappet cover as shown & take it out
Remove high pressure lines Remove injector clamping bolts with special
tool
Set tappet 1st TDC-1,2,3,5 & 2nd TDC-4,6,7,8 Remove injector with special tool Remove tappet cover

Bleeding Procedure
7/26/2022 TML 209
VP 37 Engine CRDI engine
1. Ensure the sufficient fuel in
fuel tank , fuel pipes are not
leaking and check joints for
looseness / leakages.
2. Do Hand priming by loosening
bleeding screw on the filter
3. After Removal of air bubbles
tighten the bolt.
1. Ensure the sufficient fuel in
fuel tank , fuel pipe are not
leakages and check joints for
looseness / leakages.
2. Do Hand pumping continuous
till vehicle not start.
1. Ensure the sufficient fuel in fuel
tank , fuel pipe are not leakages
and check joints for looseness /
leakages.
2. Do Hand priming by loosening
bleeding screw on the filter &
then loosen bleeding screw on
FIP till air bubbles get removed
and then tighten the bolt.
Bleeding
screw
Priming pump
Bleeding
screw

Specifications
7/26/2022 TML 210
Engine Type Variant Horse Power Plunger Lift
Tappet
clearance
FIP Part No.
Tata 497 TC BS II 90 HP 0.8 ± 0.02
Inlet Valve-
0.20mm
460 424 232
Tata 497 TCIC BS II 90 HP 1.00 ± 0.02
Exhaust valve-
0.30mm
460 424 364
Tata 497 TCIC BS III 125 HP 0.25 ± 0.02 460 424 996

483DL
Important Settings & Adjustments
7/26/2022 TML 211

Cylinder Head Tightening
Three stage cylinder head tightening:
 Tighten all the cylinder head bolts in the sequence given below to 5 m-kg
 Tighten in the same sequence to 7 m-kg
 Tighten in the same sequence to 10.5 m-kg
7/26/2022 TML 212

Timing Belt Removal and Fitment
7/26/2022 TML 213
Camshaft gear
Crankshaft gear
FIP gear
Water pump
gear
Idler
Tensioner
Timing Screws

Timing Belt Fitment Procedure
 Insert locking pins through
– Flywheel & cylinder block
– Camshaft gear
– FIP gear
 Loosen bolt at adjustment slot of tensioner
 Move tensioner away from timing belt and
remove belt
 Ensure that the above 3 pins are in locked
position
7/26/2022 TML 214
Locking flywheel Locking camshaft gear

Timing Belt Fitment Procedure
 Fit timing belt on the following pats in
sequence, ensuring no slackness
– Crank gear
– Idler
– FIP gear
– Cam shaft gear
– Tensioner
– Water pump
 Rock FIP gear anticlockwise for ease of
putting belt on camshaft gear
 Loosen tensioner bolt to allow it to tension
the belt and tighten the bolt
 Remove the 3 pins, rotate clockwise by 2
turns and check if all 3 pins can be inserted
back again
7/26/2022 TML 215
Locking FIP gear Loosening tensioner bolt

FIP Timing
7/26/2022 TML 216
Engine type
FIP Timing in mm
BOSCH LUCAS
483 DL NA BS II 0.90+/- 0.02 NA
483 DL NA BS III 0.80+/- 0.02 NA
483 DL TC BS II 0.71+/- 0.02 NA
483 DL TC BS III NA 0.90+/- 0.02

Valve Clearance Adjustment
 Bring the camshaft to 1st cylinder TDC compression stroke
 Measure clearance between camshafts and tappets
 Install shims = E and re-check
7/26/2022 TML 217
Inlet (mm) Exhaust (mm)
Measured Clearance A 0.25 0.2
Required Clearance B 0.15 +/- 0.04 0.3 +/- 0.04
A – B C 0.1 -0.1
Existing shim thickness D 2.8 3.05
Shim thickness required = C + D E 2.9 2.95

Adjustments in Engine - Head Gasket Selection - 483
DL
Lock Flywheel
 Insert locking pins through Flywheel &
cylinder block.
 Measure the piston protrusion with the
dial gauge as shown. on cylinder block
7/26/2022 TML 218
Description Piston Projection in mm
1 Notch 0.45-0.55,
2 Notches 0.56-0.65,
3 Notches 0.66-0.75
Piston diameter STD 82.92
Cylinder bore diameter 83.020 - 83.000
Clearance between cylinder bore and piston 0.095 - 0.065

Adjustments in Engine- Timing belt adjustment- 2.2L
DICOR
7/26/2022 TML 233
Timing Belt
Alternator &
PS Pump belt
AC Compressor
Belt
Auto Tensioner
Idler
Camshaft
Alternator
AC Compressor
Water pump
Crankshaft
Power Stg. pump

DICOR
7/26/2022 TML 234
Step 1:
Rotate crankshaft to bring the
piston in cylinder no.1 to TDC
position & lock flywheel in this
position using locking pin.
Step 2:
Rotate HP pump gear to align
hole on the HP pump mounting
bracket & lock with the help of
locking pin.
Step 3:
Mount Exhaust and Intake
Camshaft in proper order by
Matching the Dots provided on
the Internal Surface of the
camshaft gear as shown in the
diagram.
Step 4:
Remove the cam phase sensor &
insert The camshaft locking pin
into the hole provided on the
camshaft.

DICOR
7/26/2022 TML 235
Step 5:
Loose fit the auto tensioner finger tight or
0.3-0.6 kgm torque through the fixing bore
hole.
Keep the camshaft bolt loose so that the gear
is free to rotate.
Position the timing belt first on the camshaft
gear & last on the auto tensioner as per the
routing shown.
Step 6:
Remove the Vacuum pump & insert The
Exhaust camshaft Locking Special Tool as
shown in the Diagram.
Step 7:
Move the auto tensioner with allen key
clockwise to align tensioner locator with
cylindrical pin. Tighten the auto tensioner nut
as shown.

All The Best!
7/26/2022 TML 236

Technician Level 2 – Module 1 Engine Systems LCV

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