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Maintenance Manual

                                                                                   

MAN-00

167

 

 

XYLO 

mHawk

                                                                                     February 2012/ Rev1

 

The repair methods given by the manufacturer in this document are based on the technical specifications

,

 current at the time of release. The methods may be modified as a result of changes introduced by the 

manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of 

or

 whole of the present document, 

are prohibited without the prior written consent of Mahindra & Mahindra Ltd.  The use of  this document  by any person other than the trained personnel, at  the Authorized Service Centre of Mahindra & Mahindra 
Ltd., will amount  to unauthorized use and shall be liable for penalty/prosecution

 

© 2012 Mahindra & Mahindra Ltd.

 

XYLO mHawk

 (712 - MAT-xxxx) 

Sr. No. 

Maintenance item 

Operation Code  Page No. 

1 

Engine oil - Replace 

712 - MAT - 0001 

08 

2 

Engine oil - Level Check 

712 - MAT - 0002 

09 

3 

Engine oil filter - Replace 

712 - MAT - 0003 

10 

4 

Auto tensioner - Inspect 

712 - MAT - 0004 

11 

5 

Auto tensioner – Replace (AC-Water pump drive 

belt) 

712 - MAT - 0005 

12 

6 

Auto tensioner – Replace (Alternator-Stg. Pump) 

712 - MAT - 0006 

12 

7 

Accessory drive belts – Inspect  

712 - MAT - 0007 

13 

8 

Accessory drive belts – Replace (AC-Water pump) 

712 - MAT - 0008 

15 

9 

Accessory drive belts – Replace (Alternator-Stg. 

Pump)  

712 - MAT - 0009 

16 

10 

Coolant - Check 

712 - MAT - 0010 

17 

11 

Coolant - Replace 

712 - MAT - 0011 

18 

12 

Air filter element - Replace 

712 - MAT - 0012 

19 

13 

Fuel filter element - Replace 

712- MAT - 0013 

20 

14 

Fuel tank - Clean 

712 - MAT - 0014 

21 

15 

Water sediments drain – Fuel filter 

712 - MAT - 0015 

22 

16 

Transmission oil – Check & Replace 

712 - MAT - 0016 

23 

17 

Differential oil (Rear) – Check & Replace 

712 - MAT - 0017 

25 

18 

Tyre rotation 

712 - MAT - 0018 

26 

19 

Brake+ Clutch  fluid - level & leak Check 

712 - MAT - 0020 

27 

20 

Brake+ Clutch  fluid - Replace 

712 - MAT - 0021 

28 

21 

Brake pads/ Calipers - Check 

712 - MAT - 0022 

32 

22 

Brake drum and lining - Check 

712 - MAT - 0023 

33 

23 

Parking brake operation - Check & Adjust 

712 - MAT - 0024 

34 

24 

Front Suspension bolts torque - Check 

712 - MAT - 0025 

36 

25 

Rear Suspension bolts torque - Check 

712 - MAT - 0026 

36 

26 

Front suspension bushes- Inspect 

712 - MAT - 0027 

37 

27 

Rear Suspension Link bushes- Inspect 

712 - MAT - 0028 

39 

28 

Power steering fluid - level & leak Check 

712 - MAT - 0029 

41 

29 

Wheel alignment * 

712 - MAT - 0031 

42 

30 

Battery electrolyte level - Check  

712 - MAT - 0032 

45 

31 

Battery specific gravity - Check 

712 - MAT - 0033 

46 

32 

All Lights, Horns, Wipers & Washers - Check 

712 - MAT - 0034 

48 

33 

Head light aiming - Check & Adjust 

712 - MAT - 0035 

56 

34 

HVAC Filter / Clean mesh  

712 - MAT - 0036 

61 

35 

Door setting 

712 - MAT - 0037 

62 

36 

Tyre pressure - Check & Adjust 

712 - MAT - 0038 

63 

37 

Body mounting bolts for tightness-Check & Adjust 

712 - MAT - 0039 

64 

38 

Exhaust pipe mtgs. & damage/leakage - Check  

     712 - MAT - 0040 

65 

39 

Road Test- if any complaints reported 

     712 - MAT - 0041

 

40 

MAINTENANCE CHECK SHEET (FOR ALL SERVICE INTERVALS) 

67 

*

on chargeable basis.

Summary of Contents for MAN-00167

Page 1: ... MAN 00167 www teknetmahindra com ALL INFORMATION CONTAINED IN THIS MANUAL IS MOST UP TO DATE AT THE TIME OF PUBLICATION HOWEVER SPECIFICATIONS AND PROCEDURES ARE SUBJECT TO CHANGE WITHOUT NOTICE THIS MANUAL IS STRICTLY MEANT FOR RESTRICTED INTERNAL CIRCULATION WITHIN M M AUTHORIZED DEALER SERVICE CENTERS RELEASED BY TECHNICAL PUBLICATION CELL MAHINDRA MAHINDRA LTD Rev1 FEBRUARY 2012 ...

Page 2: ...k existing on top left side of each page Maintenance Schedule The maintenance schedules outlines the operations to be carried out a specified interval These operations are Adjust A Inspect Correct I Replace R Clean C The maintenance periods are specified in Kilometers Kms Standard Operating Procedures SOP Each maintenance operation is coded by a operation code 712 MAT xxxx Here 712 stands for the ...

Page 3: ...umes in the workshop If working on high temperature high pressure rotating moving or vibrating parts you should wear appropriate safety gear and take extra care not to injure yourself or others When jacking up the vehicle be sure to support the specified location with a safety stand When lifting up the vehicle use appropriate safety equipment Parts and tools Before starting operation prepare tool ...

Page 4: ...y CAUTION indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury CAUTION used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage Indicates important information relevant to the vehicle the vehicle s use or to sections of this manual to which particular attention must be paid...

Page 5: ... sediments drain Fuel filter or when indicator glows C C C C C C C Transmission Transmission oil 2 R I R Axles wheels tyres Differential oil Rear 2 R I R I Tyre rotation A A A A A A A A A A A A Brakes Brake Clutch fluid level leak check B I I I R I I I R I I I R Brake pads Callipers I I I I I I I I I I I Brake drum and lining I I I I I I Parking brake operation A A A A A A A Suspension Front Suspe...

Page 6: ...nent units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall ...

Page 7: ...oolant Check 712 MAT 0010 17 11 Coolant Replace 712 MAT 0011 18 12 Air filter element Replace 712 MAT 0012 19 13 Fuel filter element Replace 712 MAT 0013 20 14 Fuel tank Clean 712 MAT 0014 21 15 Water sediments drain Fuel filter 712 MAT 0015 22 16 Transmission oil Check Replace 712 MAT 0016 23 17 Differential oil Rear Check Replace 712 MAT 0017 25 18 Tyre rotation 712 MAT 0018 26 19 Brake Clutch f...

Page 8: ...indra Ltd 712 MAT 0001 0 30 hrs ENGINE OIL REPLACE Engine oil MAXIMILE Feo Capacity 6 0 Lit Nut Bolt description Quantity Nos Spanner Size Torque Value Nm Oil Sump drain plug 01 22 mm 27 5 2 5 Park the vehicle on level ground 2 post lift 4 post lift Engine should be hot while draining the oil For other than Maximile brand the oil change interval has to be reduced to 10000kms if the oil meets minim...

Page 9: ...e of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0002 0 05 hrs ENGINE OIL LEVEL LEAK CHECK Ensure that the vehicle is parked on level ground 2 post lift 4 post lift Ensure that the engine is not running Oil Level Check Refer illustrations shown 1 Pull out the dip stick gauge and wipe it clean with a cloth pape...

Page 10: ...secution 2012 Mahindra Mahindra Ltd 712 MAT 0003 0 20 hrs ENGINE OIL FILTER REPLACE Never use a wrench spanner to tighten the oil filter Oil filters need to be replaced during engine Oil change Recommended replacement intervals are at 5000 20000kms then at every 20000kms Use Maximile Universe oil filter Oil filter Removal Refer illustrations 1 Remove the oil filter by unscrewing it in anti clockwi...

Page 11: ...NSIONER CHECK on AC Water pump and Alternator Steering Pump drive belt Auto tensioner to be check at 60000 80000kms and it is recommended to replace it at every 100000kms Auto Tensioner Inspection Refer illustrations shown Inspect automatic tensioner carefully for symptoms such as cracked arms excessive vibration during idle speeds looseness noise clatter or rattling and sticking or seized operati...

Page 12: ...oner mtg bolt Alt PSP Auto tensioner AC Comp mtg bolts 01 01 01 12 mm 8mm Allen 12 mm 25 3 32 5 2 5 25 3 AUTOTENSIONER REPLACE A Alternator Power Steering Pump Drive Belt B AC Compressor Water Pump Drive Belt Refer illustrations 1 Using the special tool rotate the Auto Tensioner in the direction shown in the figure Lock the Auto Tensioner in that position using a pin 2 Remove the belt 3 Take the l...

Page 13: ...ty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0007 0 50 hrs ACCESSORY DRIVE BELT INSPECT AC Water pump and Alternator Steering Pump drive belt ACCESSORY DRIVE BELT LAYOUT ACCESSORY DRIVE BELT TO BE CHECK FOR Refer illustrations below 1 Abrasion 2 Cracking 3 Improper Install 4 Uneven Rib Wear 5 Misalignment 6 Chunk out 7 Gravel penetration 8 Pilling NOTE It is recommended to remove check the dr...

Page 14: ... Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 5 Misalignment Sidewalls of the belt may appear glazed or the edge cord may become frayed and ribs removed A noise may result In severe cases the belt can jump off the pulley 6 Chunk Out Pieces or chunks of rubber material have broken off from the belt When chunk out has oc...

Page 15: ...d Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0008 0 50 hrs ACCESSORY DRIVE BELT REPLACE AC Water Pump Drive Belt Removal Steps Refer illustrations 1 Remove NVH cover 2 Remove Fan shroud 3 Remove Alternator Power steering drive belt 712 MAT 0120 4 Turn Auto tensioner in clockwise direction to...

Page 16: ...e Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0009 0 40 hrs ACCESSORY DRIVE BELT REPLACE Alternator Steering Pump Drive Belt Removal Steps Refer illustration shown 1 Remove NVH cover 2 Remove Fan shroud 3 Turn Auto tensioner in clockwise direction as shown in sketch to loosen drive belt 4 Remove acce...

Page 17: ... Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0010 0 05 hrs COOLANT LEVEL CHECK Coolant MAXIMILE ULTRA COOL Pre mixed COOLANT LEVEL INSPECT Check the coolant level when the engine is cold 1 Check the coolant level in the degassing tank 1 it should be between MAX and MIN marks If below MIN Open...

Page 18: ...mixed Capacity 08 Lit COOLANT REPLACE Refer illustration shown A B 1 Open the degassing tank cap 2 Place coolant collection tray below and remove the drain plug on the Radiator bottom A and Engine block B 3 Let coolant get complete drain in coolant drain tray 4 Refit the drain plugs fill new coolant in degassing tank 5 Check all the coolant hoses clips for proper fitting and no leakage correct if ...

Page 19: ... Nos Spanner Size Torque Value Nm Air filter top cover allen bolt Hose clamps air cleaner to manifold 07 02 02 6 mm 11 mm 11 mm 4 5 0 5 2 5 0 5 4 5 0 5 Never try to clean and reuse the Air filter cartridge It is recommended to replace the air filter cartridge at every 60000kms In case vehicle runs in very dusty condition replace air filter cartridge at 30000kms or red band in chock indicator appea...

Page 20: ...ized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0013 0 50 hrs FUEL FILTER REPLACE Engine Compartment Remove the Water in Fuel Sensor connector and remove the sensor by rotating it in anti clockwise direction NOTE Water in Fuel Sensor is fitted at the bottom of the Fuel Filter element and it can be accessed from front right side wheel housing Remove the Fuel ...

Page 21: ...ain plug if applicable and ensure for complete fuel drain and Refit the drain plug 27 5 2 5 Nm Check the fuel quantity before removing tank from the vehicle if the drain plug is not provided More care to be taken while removing fuel filled tank from vehicle Use proper support and additional manpower to avoid personal injury and other damages Xylo mHawk Fuel Tank Bottom Side View Disconnect the fue...

Page 22: ...a Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0015 0 20 hrs WATER SEDIMENTS DRAIN FUEL FILTER Water in Fuel Sensor is fitted at the bottom of the Fuel Filter element and it can be accessed from front right side wheel housing Remove the Water in Fuel Sensor connector and remove the sensor by rotating it in anti clockwis...

Page 23: ...tre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0016 0 30 hrs TRANSMISSION OIL REPLACE Transmission Oil MAXIMILE Syntec F2 Capacity 1 75 Lit 5MT320 TRANSMISSION SCHEMATIC Ensure that vehicle is lifted on certified hoist If activity is being done out of workshop ensure that vehicle is parked on leveled surfa...

Page 24: ...t by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Breather Cleaning Remove the breather from the transmission use screw driver Clean it externally blow compressed air from bottom Fit back the clean breather Recommended oil brand is Maximile...

Page 25: ...12 MAT 0017 0 20 hrs DIFFERENTIAL OIL CHECK REPLACE Differential Oil MAXIMILE Elite Capacity 1 8 Lit Recommended oil brand is Maximile Elite The oil change interval has to be first at 10000kms then 100000kms Level and leak to be checked at 50000kms 120000 kms For other than Maximile brand the oil change interval has to be reduced to 20000 km if the oil meets minimum of API GL 5 SAE 80W 90 specific...

Page 26: ...n other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0018 0 60 hrs TYRE ROTATION Tyre pressure value Refer below chart COLD TYRE INFLATION PRESSURE TYRE SIZE 215 75 R15 100S Vehicle Load Condition NORMAL PARTIAL FRONT REAR Psi 35 35 Kg cm sq 2 4 2 4...

Page 27: ...itted with common Fluid reservoir for Brake and Clutch System There are three different compartments 2 compartments for brake front and rear circuits and another for clutch circuit In case anyone circuit fails other circuits will not be affected Always use recommended fluid and do not mix different brand fluids In case brake fluid reservoir replaced bleeding required for Brake as well as Clutch sy...

Page 28: ...LACE Clutch Brake Fluid DOT4 Standard Capacity 0 9 Lit Brake Fluid Replacement Brake Bleeding Procedure Use brake fluid DOT 4 standards only Use fresh clean fluid from a sealed container at all times Anti lock Brake system requires conventional bleeding methods plus use of the diagnostic tool Under the normal conditions the diagnostic tool is not required to do the bleeding The complete brake blee...

Page 29: ...nalty prosecution 2012 Mahindra Mahindra Ltd This is Sample illustration 3 Depress the brake foot pedal and hold it down 4 Open the bleed screw The fluid will flow into the transparent container 5 Tighten the bleed screw and release the pedal 6 After the pedal returns allow an interval of 3 to 4 seconds before making the next stroke Steps 4 to 6 should be repeated until there are no more air bubbl...

Page 30: ...UTCH BLEEDING 1 Remove the dust cap of the bleeder screw 2 Connect bleeding tube to bleeding screw on slave cylinder Ensure that the other end of the tube is fully immersed in the bottle having clean clutch brake fluid 3 Fill the Reservoir up to the top level with recommended fluid 4 Operate clutch pedal 3 or 4 times slowly to the full stroke Holding the clutch in depressed condition loosen the bl...

Page 31: ...ttle Entire bleeding operation should be done with ENGINE ON running The reservoir on the master cylinder must be at the Max upper level mark at the start of bleeding procedure and should be checked after bleeding each brake caliper and brake fluid to be topped up as required If the brake system is opened i e all the wheel cylinders are opened and fluid has drained off Even then since inside the E...

Page 32: ... outboard wear indicates either bent or seized sliding pin Please check the complete hydraulic system besides the calipers Always replace the front pads and shims together as a set Install inner pad with its wear indicator upward Inspect at every 10000kms from 20000kms onwards Front Brake Check Refer illustration shown 1 Check the disc for abnormal wear grooves Minimum usable thickness of the disc...

Page 33: ...ake shoes are replaced replace both RH LH assemblies as a set to prevent car from pulling to one side when braking If there is significant difference in the thickness of the liner on the left and right sides check parking brake operation wheel cylinders piston for free movement Rear Brake drum liners to be inspected at every 20000kms from 20000kms onwards Brake Drum Liners Check Refer illustration...

Page 34: ...ent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0024 0 30 hrs PARKING BRAKE CHECK TYPE Mechanical Hand operated acting o...

Page 35: ...person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Rear parking brake cable on LH side to be adjusted through the Clamp provided Refer illustration Rear parking cable can be adjusted with the help of the setting clamp and screw given on RH side cable...

Page 36: ...ION Lower Control Arm Front Mounting 200 Nm Lower control Arm Rear mounting 200 Nm Shock absorber Top on body 40 10 Nm Shock absorber Bottom on LCA 120 10 Nm REAR SUSPENSION Upper Link 150 10 Nm Lower Link 150 10 Nm Pan hard Rod 150 10 Nm A B FRONT REAR SUSPENSION BOLT TORQUE CHECK Refer suspension bolt torque chart 1 Check front suspension bolt torque at Camber bolt production level marking cross...

Page 37: ...shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0027 0 20 hrs FRONT SUSPENSION BUSH CHECK Front Suspension Bush Check Refer illustrations shown 1 Check lower control arm front and rear bush condition both LH RH for wear tear cracks shift Replace if necessary 2 Check upper control arm front and rear bush condition both LH RH for wear tear cracks shift Replace if necessary...

Page 38: ...ument by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Correct fitment identification of Front Suspension Bushes Wrong fitment of voided bush VOIDED BUSH CORRECT POSITION ON LOWER ARM The washer has to be crimped to ensure bush performance R...

Page 39: ...uthorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0028 0 20 hrs REAR SUSPENSION BUSH CHECK 2 2 2 2 1 1 1 1 2 1 1 Rear Suspension Bush Check Refer illustration shown above 1 Check all the suspension link Rubber Bushes for Wear Ageing Cracks Metal sleeve separation 2 Check the Upper Lower L...

Page 40: ... by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Correct fitment identification of Rear Suspension Bushes Lower Link Bush Axle Side Lower Link Bush Frame Side Upper Link Bush Axle Frame Side Wrong fitment of voided bush Pan hard Rod Bush Ax...

Page 41: ...el at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0029 0 10 hrs POWER STEERING FLUID LEVEL LEAK CHECK Power Steering Fluid SHELL SPIRAX S3 ATF MD3 CALTEX TEXAMATIC 1888 Capacity 0 8 Lit Leak Check Points POWER STEERING FLUID LEVEL LEAK CHECK Refer illustration shown above 1 Che...

Page 42: ...mission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0031 0 40 hrs WHEEL ALIGNMENT Cam...

Page 43: ... Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Pre Work for Wheel Alignment Process Tyre pressure Should be as per recommendations in all the tyres Position of bolts Observe the intial positon of the camber castor bolts Sequence It is very important to torque all the camber castor bolts to 200 Nm Shock Absorber Projecti...

Page 44: ...ahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Ride height Is the verticle distance between front camber bolt nut side end center to the ground plane The ride height should be 269 5 mm If ride height is not within limits then please check for the coil spring damage or any issue is the rubber or mounting bolt area or weak shock abs...

Page 45: ...horized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0032 0 10 hrs BATTERY ELECTROLYTE LEVEL CHECK Refer above illustration 1 Ensure the electrolyte level between MIN and MAX marks if the electrolyte level is less than the MIN mark then top up the electrolyte to the recommended level with distilled water 2 Check the terminals clamps for clean and tightness if ...

Page 46: ...ge a Specific gravity b Open circuit voltage Visual Inspection Battery service should begin with thorough visual inspection This inspection may reveal simple and easily correctable problems 1 Check for cracks in the battery case and broken terminals which allows electrolyte leakage Replace the battery if necessary 2 Check for corrosion on terminals and dirt acid on the battery case top Clean the t...

Page 47: ... specific gravity of 1 230 or higher to proceed with the load test 1 Wear suitable eye protectors goggles Remove the vent caps or covers from the battery 2 Squeeze the hydrometer bulb and insert the pickup tube into the cell close to the battery positive terminal 3 Slowly release the bulb to draw in only enough electrolytes to cause the float to rise Do not remove the tube from the battery 4 Read ...

Page 48: ...ke Low Brake Oil Warning Lamp K High Engine Coolant Temperature Warning Lamp B Turn Lamp Left L Turn Lamp Right C Check Engine Lamp M Low Engine Oil Pressure Warning Lamp D Water in Fuel Warning Lamp N Low Fuel Warning Lamp E Fog Lamp Rear O Head Lamp High Beam Lamp F Anti Brake System ABS Warning Lamp P Seat Belt Warning Lamp G Vehicle Armed Status Lamp Q Door Ajar Warning Lamp H OBD Check Lamp B...

Page 49: ...horized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Digital Drive Assist System DDAS It displays the information of current vehicle performance and environmental conditions Intellipark Reverse Assist System IRAS if equipped Intellipark Reverse Assist System is a system which aids the driver while reversing the vehicle at a speed less than 5 kmph Hazard Flasher The ha...

Page 50: ...ng lamps head lamps head lamp beam selection high beam flashing and turn signals when the ignition switch is ON Push the lighting control stalk backward direction to indicate a right turn and push the stalk to forward direction to stop the position B again push it further forward direction to indicate a left turn The instrument cluster arrow lamp pointing towards the right flashes If the turn sign...

Page 51: ...l be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Head Lamp ON Rotate the outer rotary switch on the lighting control stalk aligning the dot on the switch to the 2nd detente position on the stalk to switch ON the head lamps Head Lamp Low Beam With the head lamp high beam ON pull the lighting control stalk up A towards the steering wheel to switch ON the head lamp low beam Pull the lig...

Page 52: ...ra Mahindra Ltd Front Rear Fog Lamp To switch ON the front and rear fog lamps switch ON the parking lamps turn the inner rotary switch on the lighting control stalk to align with the inner fixed stalk as shown Windshield Wipers Wiper Control Stalk The wipe wash function can be activated only when the ignition is in IGN position Wiper Off The wipe function is off when the wipe control stalk is in n...

Page 53: ...per will start wiping Turn the wiper stalk to OFF position before wiper starts second wipe Turn the wiper stalk to position C again after the required delay and the same delay will be programmed On keeping wiper ON position C the wiper will wipe again with the programmed delay Low Speed Wiping Push the wipe control stalk down to the position D to operate the wiper at a fixed low speed High Speed W...

Page 54: ...o nozzles with twin adjustable washer jets in the front on the hood Using a pin the eye ball jets can be adjusted precisely for direction Always direct the washer jet to hit middle of the windshield This will enable the wiper blade to wipe the complete width of the windshield Windshield Washer Rear A single nozzle with twin adjustable washer jets is provided for the rear windshield wash Adjust to ...

Page 55: ...the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0035 0 30 hrs HEADLAMP AIMING ALIGNMENT CHECK AND ADJUST Headlamp alignment by visual Method Refer below illustration Ensure that a Vehicle screen board both are placed on the same Level surface b Check and ensure all four tyre pressu...

Page 56: ... the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Head Lamp Alignment Procedure STEP 1 Setting the Low Beam STEP 2 Checking High Beam STEP 1 Low Beam Setting Procedure Refer below illustration for the headlamp low beam cut off pattern Xylo Head Lamp alignment Dimensions are X 869mm h X 130 7...

Page 57: ...vice Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd LH side head lamp assembled condition Rear View Rotation of the Screw driver Down Clockwise Loose Up anti clockwise Tight LH side head lamp assembled condition Top View Check the horizontal setting of RH LH head lamp Refer above illustration for low beam cut o...

Page 58: ...er than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Check the function of system by operating the switch from 0 to 3 and observe the cut off pattern movement in downward direction accordingly At zero position of switch the cut off should come at 1 3 heights on ...

Page 59: ...cessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for pen...

Page 60: ...ument by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0036 0 20 hrs HVAC FILTER CLEAN Open the Glove box assembly Remove the Glove box stay supports Remove the HVAC filter tray by opening the snap clips on both sides Clean the Filte...

Page 61: ...at the centre of latch striker will foul with top or bottom portion of latch Loosen the bolts of striker and move the striker up or down to remove the fouling 2 Check whether door is over flush or under flush If it is over flush move the striker towards vehicle centre and check flushness If it is under flush move the striker away from vehicle centre and check flushness 3 After above corrections ar...

Page 62: ...l amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0038 0 30 hrs TYRE PRESSURE CHECK AND ADJUST Proper tyre inflation pressure is essential to the safe and satisfactory operation of the vehicle Three primary areas are affected by improper tyre pressure a Safety b Economy c Ride Comfort and Vehicle Stability Tyre pressure value Refer below ch...

Page 63: ...ahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0039 0 40 hrs BODY MOUNTING BOLTS TIGHTEN Nut Bolt description Spanner Size Quantity Nos Torque Value Nm Body mtg bolts 13 mm 08 nos 65 05 Nm NOTE ...

Page 64: ...e reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 712 MAT 0...

Page 65: ...indra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Park the vehicle in inspection pit 2 post lift 4 post lift Exhaust system to be checked and torque tighten first at 5000 kms then 20000 kms and then at every...

Page 66: ...ious component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and...

Page 67: ...for penalty prosecution 2011 Mahindra Mahindra Ltd WORK NATURE ACTION WORK STATUS Time Allotted Man hours Complete Incomplete Engine oil 1 REPLACE 0 30 Engine oil filter REPLACE 0 20 Coolant 3 I 0 05 Water sediments drain Fuel filter or when indicator glows C 0 20 Parking brake operation A 0 30 Front Suspension bolts torque I 0 25 Rear Suspension bolts torque I 0 20 Battery electrolyte level I 0 1...

Page 68: ...cution 2011 Mahindra Mahindra Ltd WORK NATURE ACTION WORK STATUS Time Allotted Man hours Complete Incomplete Engine oil 1 I 0 05 Coolant 3 I 0 05 Water sediments drain Fuel filter or when indicator glows C 0 20 Transmission oil 2 REPLACE 0 30 Differential oil Rear 2 REPLACE 0 20 Tyre rotation A 0 60 Brake Clutch fluid level leak check B I 0 15 Front Suspension bolts torque I 0 25 Rear Suspension b...

Page 69: ... STATUS Time Allotted Man hours Complete Incomplete Engine oil 1 REPLACE 0 30 Engine oil filter REPLACE 0 20 Coolant 3 I 0 05 Fuel filter element REPLACE 0 50 Tyre rotation A 0 60 Brake Clutch fluid level leak check B I 0 15 Brake pads Callipers I 0 60 Brake drum and lining I 0 80 Parking brake operation A 0 30 Front Suspension bolts torque I 0 25 Rear Suspension bolts torque I 0 20 Power steering...

Page 70: ... unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd WORK NATURE ACTION WORK STATUS Time Allotted Man hours Complete Incomplete Engine oil 1 I 0 05 Coolant 3 I 0 05 Water sediments drain Fuel filter or when indicator glows C 0 20 Tyre rotation A 0 60 Brake Clutch fluid level leak check B I 0 15 Brake pads Callipers I 0 60 Power steering fluid level leak check I ...

Page 71: ...mplete Incomplete Engine oil 1 REPLACE 0 30 Engine oil filter REPLACE 0 20 Coolant 3 I 0 05 Fuel filter element REPLACE 0 50 Tyre rotation A 0 60 Brake Clutch fluid level leak check B REPLACE 0 15 Brake pads Callipers I 0 60 Brake drum and lining I 0 80 Parking brake operation A 0 30 Front Suspension bolts torque I 0 25 Rear Suspension bolts torque I 0 20 Front suspension bushes inspect I 0 20 Lin...

Page 72: ...l be liable for penalty prosecution 2011 Mahindra Mahindra Ltd WORK NATURE ACTION WORK STATUS Time Allotted Man hours Complete Incomplete Engine oil 1 I 0 05 Coolant 3 I 0 05 Water sediments drain Fuel filter or when indicator glows C 0 20 Transmission oil 2 I 0 05 Differential oil Rear 2 I 0 05 Tyre rotation A 0 60 Brake Clutch fluid level leak check B I 0 15 Brake pads Callipers I 0 60 Power ste...

Page 73: ... Engine oil filter REPLACE 0 20 Auto tensioner I 0 10 Accessory drive belts I 0 20 Coolant 3 REPLACE 0 60 Air filter element In dusty conditions replace at 30 000 Kms REPLACE 0 25 Fuel filter element REPLACE 0 50 Tyre rotation A 0 60 Brake Clutch fluid level leak check B I 0 15 Brake pads Callipers I 0 60 Brake drum and lining I 0 80 Parking brake operation A 0 30 Front Suspension bolts torque I 0...

Page 74: ...to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd WORK NATURE ACTION WORK STATUS Time Allotted Man hours Complete Incomplete Engine oil 1 I 0 05 Coolant 3 I 0 05 Water sediments drain Fuel filter or when indicator glows C 0 20 Tyre rotation A 0 60 Brake Clutch fluid level leak check B I 0 15 Brake pads Callipers I 0 60 Power steering fluid level leak check ...

Page 75: ...ter REPLACE 0 20 Auto tensioner I 0 10 Accessory drive belts I 0 20 Coolant 3 I 0 05 Fuel filter element REPLACE 0 50 Fuel tank stainer CLEAN 1 00 Differential oil Rear 2 REPLACE 0 20 Tyre rotation A 0 60 Brake Clutch fluid level leak check B REPLACE 0 70 Brake pads Callipers I 0 60 Brake drum and lining I 0 80 Parking brake operation A 0 30 Front Suspension bolts torque I 0 25 Rear Suspension bol...

Page 76: ...to unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd WORK NATURE ACTION WORK STATUS Time Allotted Man hours Complete Incomplete Engine oil 1 I 0 05 Coolant 3 I 0 05 Water sediments drain Fuel filter or when indicator glows C 0 20 Tyre rotation A 0 60 Brake Clutch fluid level leak check B I 0 15 Brake pads Callipers I 0 60 Power steering fluid level leak check ...

Page 77: ...e oil 1 REPLACE 0 30 Engine oil filter REPLACE 0 20 Auto tensioner REPLACE 1 20 Accessory drive belts REPLACE Coolant 3 I 0 05 Fuel filter element REPLACE 0 50 Transmission oil 2 REPLACE 0 30 Tyre rotation A 0 60 Brake Clutch fluid level leak check B I 0 15 Brake pads Callipers I 0 60 Brake drum and lining I 0 80 Parking brake operation A 0 30 Front Suspension bolts torque I 0 25 Rear Suspension b...

Page 78: ...o unauthorized use and shall be liable for penalty prosecution 2011 Mahindra Mahindra Ltd WORK NATURE ACTION WORK STATUS Time Allotted Man hours Complete Incomplete Engine oil 1 I 0 05 Coolant 3 I 0 05 Water sediments drain Fuel filter or when indicator glows C 0 20 Tyre rotation A 0 60 Brake Clutch fluid level leak check B I 0 15 Brake pads Callipers I 0 60 Power steering fluid level leak check I...

Page 79: ...l filter REPLACE 0 20 Coolant 3 I 0 05 Air filter element In dusty conditions replace at 30 000 Kms REPLACE 0 25 Fuel filter element REPLACE 0 50 Differential oil Rear 2 I 0 20 Tyre rotation A 0 60 Brake Clutch fluid level leak check B REPLACE 0 70 Brake pads Callipers I 0 60 Brake drum and lining I 0 80 Parking brake operation A 0 30 Front Suspension bolts torque I 0 25 Rear Suspension bolts torq...

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