Mahindra MM540: Engine overheating issue on inclined roads

The vehicle's engine temperature goes beyond 100 quickly & when it's hot, I'm also losing power.

BHPian sijuko recently shared this with other enthusiasts.

Hi Experts,

I am using a 96 model MM540 and it's always overheating during the climbs. Temp goes beyond 100 quickly and keeps on increasing and if you return to flat roads or stop and idle the engine, it gradually comes back to 80 or less. When the engine is hot, I am losing power as well.

Below items are already taken care of

• Brand new copper radiator and a tight cap
• Brand new water pump and water hoses
• Brand new drive belt and it is tight enough
• Engine is completely overhauled
• Using coolant + water

I have been using this vehicle for the last 15 years and recently started participating in off-road events and now I am in this situation.

Yet to try out

• Adding a condenser fan in front of the radiator
• Upgrading to DI/MDI engine.

Here's what GTO had to say about the matter:

Common problem with that Mahindra 2.1L. How I solved the overheating issues in my Jeep:

• Good shroud / cowl for the fan.
• Big radiator from Lawrence Radiators. Bought the biggest that would fit.
• Electric fan was lined up in case all that didn't work, but we didn't need it.

Here's what BHPian Jaggu had to say about the matter:

Have you checked the ratings on the cap, if it matches for XDP engine?

You seem to have taken care of most of the usual suspects on the cooling side. First, if you have the fan shroud around the radiator? That makes a difference and next is like you wanted to try, adding an additional electric fan outside and making sure it is pushing the air inside and not turning the other way around.

Other thing that you can check is the fuel pump, how the pump is tuned since the engine is newly done, if it is not set too lean?

How much has the engine run after the rebuild?

Here's what BHPian Ashley Nair had to say about the matter:

Please check if the engine thermostat valve is properly opening.

Here's what BHPian Emvi had to say about the matter:

I suspect it might be a case of a cracked/blown cylinder head gasket. I suggest you get it checked and if it indeed is what I am suspecting, chances are high that the cylinder head might be distorted or damaged as well.

We had a couple of Peugeot powered Mahindras before and have experienced similar issues like the one you are currently dealing with. If for some reason the engine overheats, the aluminium cylinder head (correct me if I am wrong) has the tendency to distort rather easily. Once distorted, the engine overheats quite frequently accompanied by loss of power when heavily loaded or climbing inclines.

Here's what BHPian MB4DI had to say about the matter:

Just wanted to share one mod done by someone I know. He has used the Tata Xenon radiator which has got dual electric fans with sealed shrouds along with its degassing tank unit. It has helped him tremendously in keeping the coolant temperature under control even during the inclines with AC ON in summers.

Check out BHPian comments for more insights and information.