Mahindra 3535, Service Manual

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C-99 35 Series 4WD, Model - 3535, 4035, 4535 and 5035 SM June’08
Fig. 4
Cross-Sectional View of Engine
1. Injector
2. Clamp
3. Cylinder Head
4. Valve Seat Insert
5. Valve Seal
6. Valve
7. Valve Guide
8. Cylinder Block 9. Piston
10. Liner
11. Keystone Ring
12. Bevelled Ring
13. Oil Control Ring
14. Connecting Rod
15. Piston Pin
16. Gasket
The needle seat of the nozzle body, which is
exposed to exceedingly high pressures and
temperatures, must not develop noticeable wear
under the constant hammering action of the
nozzle needle.
Although the nozzles have been designed to bear
these severe working conditions, the nozzle needle
and body seats affected over a prolong period
of operation. Dribbling, incorrect opening
pressures, improper spray patterns and leaky
nozzles affect the engines performance. The clearly
visible symptoms are :
1. Smoky exhaust i.e black or in some cases
white.
2. Increased fuel consumption.
3. Overheating.
4. Loss of power.
5. Engine knocking, misfiring and uneven
running However, complaints of the above
nature may not be solely due to
malfunctioning of the nozzles. Other
contributory factors such as poor
compression, injection timing cooling
problems, exhaust / intake restriction,
Lubrication systems problems, operating
conditions, etc. should also be investigated.
6. Fuel filtration.
7. Quality of high pressure pipes.
8. Careless installation of injectors on the
engine.
2. Injector Nozzle Removal
a. Disconnect the high pressure pipes connecting the
nozzles and injection pump.
b. Disconnect the fuel leak off pipe assembly from
the nozzle.
c. Remove the injector retaining nuts and conical
washers securing the injector clamps.
d. Remove the injectors carefully and the sealing
copper washer from the cylinder head.
NOTE: Cover the cylinder head openings and plug the
inlet and leak - off openings of injectors with
protection caps.
Wipe off dirt and loose carbon from each
injector with a cloth and clean the tip with a
brass wire brush.
Fuel System