Copyright 2012 Mahindra & Mahindra Ltd. All rights reserved.

Over-Heating Checksheet Maxximo

July 2013
Rev: 13.7.1

Copyright 2012 Mahindra & Mahindra Ltd. All rights reserved.

Overheating Check Points

Please check the following point for analysing Overheating Symptoms to Find the root cause for Overheating

1. Customer Verbatim 2. Coolant Level 3. Engine Oil Level 4. DTC codes obtained 5. Vehicle Rework history 6. Thermostat valve 7. Thermostat Valve Assembly 8. Temperature Sensor 9. Radiator 10.Fuse Box

11.Wiring Harness (All) 12.Radiator Fan 13.Fan Relay 14.Fan relay Fuse Box 15.Coolant Hoses 16.Cylinder Head blockage 17.Degassing Tank 18.ECU 19.Water Pump 20.Bleeding of Engine
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Other than Overheating Check Points

Please check the following point for analysing Other than Overheating Symptoms to Find the root cause for Engine Failure

1. Vaccum System 2. Oil Pump

3. Over-Race
4. Oil-Consumption

1. Customer verbatim
Get in touch with Customer to identify the Failure mode

Talk to customer about the failure mode Since when is he facing problem? How much did he run the vehicle after Overheating? What were the primary symptoms shows by vehicle? Checklamp shown or not? Was problem eliminated on previous re-works?

Any Obnormal Observation?

2. Coolant Level
Check the quantity of Coolant & condition of Coolant in the Cooling system

1. Check quantity of Coolant level in

the Degassing Tank

2. Check quality of Coolant

recovered (Company coolant / Green Coolant / Water )

Coolant quantity is as Follows: BS III : 4.1 Litres BS IV : 4.2 litres MPV VX : 5.2 litres

3. Engine Oil Level

Check the Quantity of Engine Oil & condition of Engine Oil

1. Check quantity of oil recovered

from Engine

2. Check Quality of Oil recovered.

(Thick or normal, Metal particles present or not)

3. Is it smelling like Burnt?

Engine oil Quantity in Engine is 3 litres.

4. DTC codes in Diagnostic Tester

Check for any DTC codes observed in Diagnostic Manual

1. Check which DTC codes displayed on Diagnostic tester. 2. Describe the DTC codes 3. Check for Live data temperature & Fan ON-OFF cycle

5. Vehicle Rework History

Recover History card from DMS system to check for past work history

1. Download History card from DMS.

2. Read the history of the Vehicle for
Service history, rework history in kms & date of reporting.

3. Find whether there is any relation

between past re-work & current breakdown.

4. Check wether the vehicle is

serviced at other branch but not reported in history.

6. Thermostat Valve
Check whether the Thermosat valve is working as per SOP

1. Check Thermostat valve Opening

temperature in hot coolant bath.

2. Thermostat starts opening at

82 +/- 2 Deg C.

3. Thermostat Opens completely at

96 Deg C.

4. Total Opening/ Closing Travel of

Thermostat valve is 8 mm

5. Reply with at which temperature it

starts opening and fully open temp.

6. Check Thermostat Opening in Hot

Water in Vessel
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7. Thermostat Valve Assembly

Check whether the Thermosat housing is not leaking

1. Check leakage from Thermostat

Housing for any leakages from joint area (marked with circle in fig.)

2. Check whether there is leakage from

Thermostat & hose assembly

3. Check whether thermostat is of Rating

82C

4. Blue Marking on Housing & 82 written

in green marking

5. In case of Doubt, Please replace this

Thermostat on OK vehicle & check for similar Observations.

6. Or Put Thermostat of OK vehicle on

reported Vehicle & check for Observations
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8. Temperature Sensor
Check whether the temperature sensor is working Properly

1. Check Whether Blue Seal is present in wiring

harness connector.

2. Check for any dust or mud near Connector

area of Sensor

3. Remove temperature sensor from Engine,

check for any impurities on sensor area. Clean sensor, refit & verify sensor is working or not.

4. Remove existing temperature sensor &

Replace with new temperature sensor & check.

5. Or fit defective temperature sensor on good

vehicle & check fan operation. Whether fan starting normally or not.
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9. Radiator
Check whether the Raditor is clean & leak free

1. Radiator fins - Is it choked by mud or

foreign material?

2. Check coolant leakage from radiator

Assembly (upper tank & lower Tank joint)

3. Are Radiator Fins damaged by any

external hit like stone?

4. Are Radiator Fins damaged by Shroud

Fouling

5. In case of Doubt, Please replace this

Radiator Coolant Capacity : 700 ml 7. IF Doubt is Radiator is chocked, 6. Or Put Radiator of OK vehicle on reported please verifying by filling water & then Vehicle & check for Observations recover how much Water received
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radiator on OK vehicle & check for similar Observations.

10. Fuse Box

Check whether the Fuse is OK

1. Check fan fuse?

Fuse should be 15 Amps: Before June Vehicles 80 Watt Fan 20 Amps: June 2012 Onwards 25 Amps: LTV 1950 & CNG (130 Watt Fan)

2. If 15 Amps fuse is present, urgently replace

with 20 Amps for 80 Watt Radiator Fans (Do-not replace with 20 Amps Fuse in LTV 1950 & CNG : 130 Watt Radiator Fans)

3. Whether it is blown or ok? Check by

Wire Fuse Blown
removing Fuse, as sometimes customer uses wire on Fuse as shown in picture.

4. Or fuse is with different rating/amp.?

5. Ask customer if he has found fuse blown
and replaced?
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11. Wiring Harness

Check whether the Wiring Harness is OK

1. Is there any CUT or BURNT wiring Harness 2. Check for any loose connection (Especially
Radiator connector & temperature Sensor connector)

3. Refit & Retry for Normal Operation 4. Check for continuity in any doubtful wiring
harness

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11. Wiring Harness (CCB & Engine)

Verify whether Wiring harness is cut or mal-functioning

1. Check for Any cuts in Wiring Harness (CCB, Engine wiring Harness)
2. Replace Wiring Harness One by one to verify Root cause of overheating
vehicle.

3. Replace cluster to verify the Overheating root cause

4. Re-tighten the alternator Screw to verify the root cause 5. Remove & refit ECU connector & other important sockets which may lead to
failure of Cooling system

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12. Radiator Fan

Check whether Radiator Fan is able to cool the Radiator & Cooling system

1. Check whether Fan is working 2. Check for Radiator Fan connector on

3.
If motor found burnt burn mark comes on near to holes. Open the fan blade to see burnt motor

4. 5.

6. 7.

shroud is tight or Loose Check whether it is rotating in anti clockwise Direction as shown in figure besides Check whether Radiator wire is cut near Connecting socket Check whether Radiator Fan Shroud is broken or OK Check whether Motor brackets are OK Check whether Radiator Shroud is making Noise. Check whether Rubber Grommet is present in Shroud Mounting place
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13. Fan Relay

Check whether the Fan Relay is working Properly or not

1. Check Fan Relay operation by starting

the vehicle & accelerating until Fan Starts

2. Is fan replay working properly? 3. Is Fan relay wiring harness intact or

there is any tampering.

4. Check for any Loose connection in

Relay (as shown in picture besides

5. Refit & Retry for Normal Operation

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14. Fan Relay- Fuse Box

Check whether the Fan Relay fuse are as per Given Rating

1. Check Fan Relay operation by starting the vehicle & accelerating until Fan Starts 2. Is fan replay working properly? 3. Open the Fan Relay Fuse box. Check whether Fan Fuse is are per Given Rating
20 Amps : All Vehicles 80 Watt Fan 25 Amps: LTV 1950 & CNG 130 Watt Fan

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15. Coolant Hoses

Check whether Coolant hose is Leaking/Blocked

1. Check Leakages from Hose joints 2. Check for any blockage in any hose. 3. Check for any fouling around hoses
which may lead to hose cutting

4. Check for Leakage in Hose due to Cut

Blocked Radiator Hose T-Joint

Open Radiator Hose T-Joint

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16. Cylinder head, Crankcase

Check whether Head is circulating coolant properly

1. Is there any porosity in crankcase or cylinder water jacket? 2. Check all coolant jacket (passages) for free flow of coolant. 3. Check for any blockage that may obstruct Coolant circulation (Banjo Assembly)

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17. Degassing tank

Check whether Degassing tank is Leaking/Swollen

1. Check joint for leakages.( As shown in pictures

on Left hand side)

2. Check for tank inlet nipple melt/clog/chocked.(As

shown in pictures below)

3. Check whether Degassing tank cap is working

properly. (Cross-verify by using it on OK vehicle)

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18. ECU
Check whetehr ECU is working Normal

1. Check whether ECU isworking

properly or not

2. Check for any rusting or Loose

Connection in ECU pins or Connector Pins

3. In doubtful case take ECU from OK

vehicle & fit in reported vehicle, for Trial & error method (Swapping method)

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19. Water Pump

Check whether Water Pump is working Freely or Not

1. Check whether Water pump is Rotating freely. 2. Check for Any leakages. 3. If it is rotating hard, then open it & check for scoring marks.

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20. Bleeding of Engine

Carry out the proper Bleeding procedure of the Engine

1. After rework of the Engine, Ensure all the bolts are properly torque as per SOP 2. Open the Bleeding Screw & remove air from the system (also known as Bleeding
of cooling circuit)

3. Check whether Bleeding of Engine is done properly or not.

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Other Than Overheating Checksheet

Checkpoints to Conclude other than Overheating

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1. Vacuum System
Check whether Vacuum System is Working Properly

1. Check whether there is any leakage or any puncture in vacuum Hoses 2. Check Whether Vacuum pump tight or loose. & is rotating freely or not

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3. Oil Pump & Oil Sump

Check whether Oil Pump is working Freely or Not

1. Check whether Oil pump is Rotating freely. 2. Check for Any leakages. 3. If it is rotating hard, then open it & check for scoring marks. 4. Check for any blockages in sump 5. Check for any Emery found Oil Sump

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4. Over- Race & Oil- Consumption

Check whether Engine is Over-raced or Oil Consumption

1. Check whether Engine is Over-raced 2. Check whether Engine is having high Oil Consumption 3. Check for oil traces in Head, Intake Manifold, Exhaust Manifold

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Copyright 2012 Mahindra & Mahindra Ltd. All rights reserved.

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