2011-2016 Mahindra Genio Service & Repair Manual

© 2011 Mahindra & Mahindra Ltd. All rights reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of Mahindra & Mahindra Ltd. MAINTENANCE MANUAL (BS-III/BS-IV) 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 – JULY 2011 MAN-00135

© 2011 Mahindra & Mahindra Ltd. All rights reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of Mahindra & Mahindra Ltd. About the Maintenance Manual The maintenance manual outlines the correct standard operating procedures (SOPs) for carrying out maintenance operations in a Mahindra GENIO DC vehicle. Carrying out the periodic maintenance operations, as specified, is crucial for safe and trouble-free operation of the vehicle. The recommended maintenance schedule /operations are published in the owner’s handbook. This manual covers the correct method of carrying out the maintenance operations, using the correct process/procedures, tools, parts and lubricants. The manual consists of – 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 – 705-MAT-xxxx. Here 705 stands for the model family code, MAT indicating it is a maintenance operation and xxxx the operation number. Each maintenance operation is explained step-by-step, in the SOP section of the manual. The man-hours required to complete the operation is also mentioned along with the operation code. The correct grade of lubricants /coolants to be used, torque values, special tools are also mentioned wherever applicable. Check Sheets – Check sheets for each service list outs the operation which need to be carried out by the technician, when the vehicles report for scheduled maintenance service. These check sheets need to be attached to the Repair order. Repair Code Repair Time {Manhours} Job Description Lubricant Quantity Lubricant Recommended Tool Specified Torque Specified This chart is only a sample. Crown 705

© 2011 Mahindra & Mahindra Ltd. All rights reserved. This book may not be reproduced or copied, in whole or in part, without the written permission of Mahindra & Mahindra Ltd. Good Workshop Practices Attire/Dress  Always wear clean uniform  Wear safety shoes  Wear gloves, when required  Wear belt cover Vehicle Protection  Put seat cover, fender cover, steering wheel cover, before starting the operations. Safety  When working with 2 or more persons, be sure to check safety for one another  When working with engine running, make sure to provide ventilation for exhaust fumes in the workshop  If working on high temperature, high pressure, rotating, moving, or vibrating parts, 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 stand, MST, Gauges, oils and parts for replacement. Removed Parts  Place removed parts in a separate box to avoid mixing them up with new parts or contaminating new parts.  For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them with new ones as instructed in the manual  Retain the removed parts for customer inspection, if requested. IMPORTANT Mahindra Xylo mEagle is fitted with LSPV (Load Sensing Pressure Regulating Valve) in the brake circuit. Hence it is imperative that the LSPV spring is disconnected before lifting the vehicle on a 2‐post lift. Failure to do so can lead to elongation of the spring, disturbing the LSPV settings, leading to different braking characteristics. Ensure to re‐connect the LSPV spring and measure the fitted length after lowering the vehicle from the 2‐post lift.

Maintenance Manual MAN-00135 GENIO DC (BS-III & BS-IV) JULY 2011/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 © 2011 Mahindra & Mahindra Ltd. 1  Refer below Maintenance Schedule chart for GENIO DC (BS-III & BS-IV) models :-

Maintenance Manual MAN-00135 GENIO DC (BS-III & BS-IV) JULY 2011/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 © 2011 Mahindra & Mahindra Ltd. 2 * on chargeable basis. 705 - MAT-xxxx Maintenance item Operation Code Page No Engine oil - Replace 705 - MAT - 0001 03 Engine oil - Level Check 705 - MAT - 0002 04 Engine oil filter - Replace 705 - MAT - 0003 05 Auto tensioner - Inspect 705 - MAT - 0004 06 Auto tensioner - Replace 705 - MAT - 0005 07 Accessory drive belts - Inspect 705 - MAT - 0006 08 Accessory drive belts - Replace 705 - MAT - 0007 10 Coolant - Check 705 - MAT - 0008 11 Coolant - Replace 705 - MAT - 0009 12 Air filter element - Replace 705 - MAT - 0010 13 Fuel filter element - Replace 705 - MAT - 0011 14 Fuel tank - Clean 705 - MAT - 0012 15 Water sediments drain – Fuel filter 705- MAT - 0013 16 Transmission oil - Replace 705 - MAT - 0014 17 Differential oil (Rear) - Replace 705 - MAT - 0015 18 Tyre rotation 705 - MAT - 0016 19 Rear Wheel Greasing 705 - MAT - 0260 20 Propeller Shaft Greasing 705 - MAT - 0221 24 LSPV setting 705 - MAT - 0017 25 Brake + Clutch fluid - level & leak Check 705 - MAT - 0018 26 Brake + Clutch fluid - Replace 705 - MAT - 0019 27 Brake pads/ Calipers - Check 705 - MAT - 0020 29 Brake drum and lining - Check 705 - MAT - 0021 30 Parking brake operation - Check & Adjust 705 - MAT - 0022 31 Front Suspension bolts torque - Check 705 - MAT - 0023 32 Front suspension bushes- Inspect 705 - MAT - 0025 33 Rear Suspension bolts torque - Check 705 - MAT - 0024 32 Rear Suspension bushes - Check 705 - MAT - 0026 35 Power steering fluid - level & leak 705 - MAT - 0027 36 Power steering belt - Check 705 - MAT - 0028 37 Power steering belt - Replace 705 - MAT - 0029 39 Wheel alignment * 705 - MAT - 0030 40 Battery electrolyte level - Check 705 - MAT - 0031 43 Battery specific gravity - Check 705 - MAT - 0032 44 All Lights, Horns, Wipers & Washers - Check 705 - MAT - 0033 45 Head light aiming - Check & Adjust 705 - MAT - 0034 47 HVAC – Clean mesh 705 – MAT - 0035 49 Door setting 705 - MAT - 0036 50 Tyre pressure - Check & Adjust 705 - MAT - 0037 51 Body & Cargo mounting bolts for tightness-Check & Adjust 705 - MAT - 0038 52 Exhaust pipe mtgs. & damage/leakage - Check 705 - MAT - 0039 53 Road Test- if any complaints reported 705 - MAT - 0040

Maintenance Manual MAN-00135 GENIO DC (BS-III & BS-IV) JULY 2011/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 © 2011 Mahindra & Mahindra Ltd. 3 705-MAT-0001 : 0.30 hrs. ENGINE OIL – REPLACE Engine oil – MAXIMILE CROWN (SAE 15W-40) API CH4 Capacity – 6.0 Lit.  Park the vehicle on level ground/2 post lift* /4 post lift  If the activity is done on a 2 post lift, ensure that the LSPV spring is disconnected before lifting the vehicle. After lowering, re-connect the LSPV spring and ensure that the setting height is correct.  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 minimum of API CH-4 SAE 15W-40 specification.  Recommended intervals for Maximile CROWN engine Oil change are at 5000, 20000kms & then at every 20000kms. Nut/ Bolt description Quantity Nos. Spanner Size Torque Value – Nm.  Oil Sump drain plug 01 22 mm 27.5 ± 2.5 Oil Drain & Refill – 1. Open the oil filler cap. 2. Put the oil collecting tray below the sump, loosen & remove the oil sump drain plug. Allow the oil to drain for 15 min. 3. Fit the drain plug with a new gasket/ washer. Torque tightens the Drain Plug –Torque - 27.5 ± 2.5 Nm. 4. Fill fresh oil as per the recommended quantity and specification. 5. Refit the oil filer cap & check the oil level as per procedure 910-MAT-0002. Oil Filler Cap

Maintenance Manual MAN-00135 GENIO DC (BS-III & BS-IV) JULY 2011/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 © 2011 Mahindra & Mahindra Ltd. 4 705-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.  If the activity is done on a 2 post lift, ensure that the LSPV spring is disconnected before lifting the vehicle. After lowering, re-connect the LSPV spring and ensure that the setting height is correct.  Ensure that the engine is not running when oil level check is being done.  If the engine was running before, wait for 10-12 minutes to accumulate oil in the sump and then do oil level check. Oil Level Check – Refer illustrations shown. 1. Pull out the dip stick gauge and wipe it clean with a cloth/paper. 2. Insert the dip stick gauge into the dip stick guide fully till the end. 3. Pull out the dip stick slowly and check for the oil level between Maximum and Minimum level - if found below, top up with recommended oil. 4. Start the engine and check for oil leakage/ seepage at – Refer illustration [C] checkpoints are shown with arrows.  Oil sump & crankcase joint.  Oil sump drain plug.  Oil filter joint. DIPSTICK DIPSTICK DIPSTICK GUIDE MAX MIN A B C

Maintenance Manual MAN-00135 GENIO DC (BS-III & BS-IV) JULY 2011/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 © 2011 Mahindra & Mahindra Ltd. 5 705-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 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-clockwise direction, using an oil filter wrench. 2. Check the oil cooler stud for tightness – Torque 27.5 ± 2.5 Nm. 3. Smear a layer of fresh engine oil on the oil filter “O” ring 4. Fit the oil filter and turn it clockwise till the “O” ring touches the oil cooler face. 5. Turn the filter another 3/4th turn by hand. 6. Check for Oil leakage/ seepage at – Refer illustration [A] checkpoints are shown with arrows.  Oil pan & crankcase joint  Oil pan Drain Plug.  Oil filter joint.  Oil cooler joint Oil Filter & Cooler disassembly B Oil Leak - Check Points near Oil Filter A

Maintenance Manual MAN-00135 GENIO DC (BS-III & BS-IV) JULY 2011/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 © 2011 Mahindra & Mahindra Ltd. 6 705-MAT-0004 : 0.05 hrs. AUTO TENSIONER - CHECK  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 operation. These can all be signs that a tensioner needs replacing. Refer slots shown by arrow marks on Auto tensioner in sketch [C] & [D]. Two slots marked on Auto tensioner arm, and one slot marked on its coil hub. The slot marked on coil hub should always match in between two slots marked on Tensioner Arm when the belt is in its position. If there is mismatch, either the belt needs to be check and replaced or Auto tensioner needs to be replaced. D Marking on Auto Tensioner Marking on Auto Tensioner C DRIVE BELTS - LAYOUT B Auto Tensioner mounting on Engine A

Maintenance Manual MAN-00135 GENIO DC (BS-III & BS-IV) JULY 2011/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 © 2011 Mahindra & Mahindra Ltd. 7 705-MAT-0005 : 0.60 hrs. AUTO TENSIONER - REPLACE  Auto tensioner to be check at 60000, 80000kms and it is recommended to replace it at every 100000kms. Nut/ Bolt description Quantity Nos. Spanner Size Torque Value – Nm.  Auto tensioner mtg. bolt 01 12 mm. 35 ± 05 Removal Steps – 1. Remove NVH cover. 2. Remove fan & shroud 3. Remove power steering belt (705- MAT-0029) & Accessory drive belt (705-MAT-0007) 4. Remove Auto tensioner assy. Assembly Procedure – 1. Refit Auto tensioner assy. 2. Refit Accessory drive belt (705- MAT-0007) & power steering belt (705-MAT-0029) 3. Refit fan & shroud. 4. Refit NVH cover. NOTE: Auto tensioner is provided with dowel-pin on its mounting face for correct fitment; while assembling the dowel should match & fixed carefully. Refer sketch [D] Dowel Pin location shown by arrow mark. DRIVE BELTS - LAYOUT B A C Auto Tensioner D Auto Tensioner dowel Pin mounting hole

2011-2016 Mahindra Genio Service & Repair Manual

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