Mahindra XYLO mHawk, MAN-00167 Maintenance Manual

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MAINTENANCE MANUAL

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

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About the Maintenance Manual

The maintenance manual outlines the correct standard operating procedures (SOPs) for carrying out maintenance operations in a

Mahindra XYLO mHawk vehicle. Carrying out the periodic

maintenance operations, as specified, is crucial for safe and trouble-fre e 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 –

Soft Copy - The Maintenance Manual

pdf

copy is presented with

bookmarks.

Each

Maintenance activity/ SOP is just at

one click access

through the items listed in Content. To go

back to the Index page from any page of the manual, just click on word

Xylo mHawk

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 period s 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 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 com plete the operation is also mentioned along with the operation cod e. The correct grade of lubricants /coolants to be used, torque values, special tools are also mentioned wherever applicab le.

Check Sheets – Check sheets for each service list outs the operation which need to be carried

out by the technician, w hen the vehicles report f or scheduled maintenance servi ce. These check sheets need to be attached to the R epair order.

Repair Code

Repair Time {Manhours}

Job Description

Lubricant Quantity

Lubricant Recommended

Tool Specified

Torque Specified

This chart is only a sample.

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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, befo r e 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, 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 locat ion 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.

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• Legend of the Safety Symbols

To emphasize information and procedures regarding safety, use, maintenance, etc., the following symbols are used throughout the manual.

Term/ Symbol

Denotation

DANGER indicates an imminently

hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a potentially

hazardous situation which, if not avoided, could result in death or serious injury.

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 for optimum use of the vehicle.

If you see this symbol, it indicates “no”, “do not,” “do not do this,” or “never”.

• Legend of the Procedure/ Action Symbols

To emphasize illustrations and standard operation procedures, the following symbols are used throughout the manual.

Symbol

Denotation

Set / Place / Check here

Locate / Show

Move forward / Fit

Rotate / Turn Clockwise

Rotate / Turn anti-clockwise

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Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods given by the manufacturer in thi s document are based on the technical specifications, current at the tim e of release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component uni ts and accessories from which the v ehicles are manufact ured. The reproducti on, translation, transmission, in part of or whole of the present document, are prohi bited 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 Lt d., will am ount to unauthorized use and shall be liable for penalty/pr osecut ion © 2012 Mahindra & Mahindra Ltd.

Refer below Maintenance Schedule for XYLO mHawk:

Maintenance item

5000 /

4 Months

10000 /

8 Months

20000 /

12 Months

30000

40000

50000

60000

70000

80000

90000

100000

110000

120000

Engine

Engine oil

R I R I R I R I R I R I R

Engine oil filter R R R R R R R

Auto tensioner I I R

Accessory drive belts I I R

Coolant

I I I I I I R I I I I I I

Air,Fuel & Exhaust

Air filter element (In dusty conditions replace at 30,000 Kms)

R R

Fuel filter element R R R R R R Fuel tank & stainer C

Water sediments drain-Fuel filter (or when indicator glows)

C C C C C C C

Transmission

Transmission oil

R I R

Axles,wheels & tyres

Differential oil (Rear)

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

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 Suspension bolts torque I I I I I I I I

Rear Suspension bolts torque I I I I I I I I

Front suspension bushes- inspect I I I

Link bushes- inspect I I I I I

Steering

Power steering fluid - level & leak check

I I I I I I I I I I I I

Wheel alignment * Inspect if abnormal conditions are noticed or 40000kms ,whichever is earlier

Electricals

Battery electrolyte level I I I I I I I I I I I I I

Battery specific gravity I I I I I I I I I I I I

All Lights, Horns, Wipers & Washers I I I I I I I I I I I I I Head light aiming I

Air Conditioner

Clean mesh C C C C C C C C C C C C

Check the system for leaks and recharge if required

Once in every 2 years

Body

Door setting A

Final inspection

Tyre pressure A A A A A A A A A A A A A

Body mounting bolts for tightness I I I I I I I

Exhaust pipe mountings & damage / leakage

I I I I I I I

Road Test- if any complaints reported I I I I I I I I I I I I I

Legends * On chargeable basis I = Inspect and correct

R- Replace A-Adjust C-Clean

XYLO E9

MAINTENANCE SCHEDULE

Distance Covered (in Kms) / Months in service

whichever is earlier for free service

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Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods given by the manufacturer in this document are based on the technical specific ations, current at the time of release. The methods may be modified as a result of changes i ntroduced by the manufacturer in the produc tion of the various component units and accessories fr om which the vehicles are manufactured. The reproduction, translati on, transmission, in part of or whole of the present document, are prohibited without the prior writ ten consent of M ahindra & Mahindr a Ltd. The use of this document by any person other than the t rained personnel, at the Authori zed Service Cent re of Mahindra & Mahi ndra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution © 2012 Mahindra & Mahindra Ltd.

Refer below Recommended Lubricants Chart for XYLO mHawk -

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Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra Ltd.

XYLO mHawk (712 - MAT-xxxx)

Sr. No.

Maintenance item

Operation Code

Page No.

Engine oil - Replace 712 - MAT - 0001 08

Engine oil - Level Check 712 - MAT - 0002 09

Engine oil filter - Replace 712 - MAT - 0003 10

Auto tensioner - Inspect 712 - MAT - 0004 11

5 Auto tensioner – Replace (AC-Water pum p driv e

belt)

712 - MAT - 0005 12

Auto tensioner – Replace (Alternator-Stg. Pump) 712 - MAT - 0006 12

Accessory drive belts – Inspect 712 - MAT - 0007 13

Accessory drive belts – Replace (A C -Water pump) 712 - MAT - 0008 15

9 Accessory drive belts – R ep la c e (A lt ernator-Stg.

Pump)

712 - MAT - 0009 16

Coolant - Check 712 - MAT - 0010 17

Coolant - Replace 712 - MAT - 0011 18

Air filter element - Replace 712 - MAT - 0012 19

Fuel filter element - Replace 712- MAT - 0013 20

Fuel tank - Clean 712 - MAT - 0014 21

Water sediments drain – Fuel filter 712 - MAT - 0015 22

Transmission oil – Check & Replace 712 - MAT - 0016 23

Differential oil (Rear) – Check & Replace 712 - MAT - 0017 25

Tyre rotation 712 - MAT - 0018 26

Brake+ Clutch fluid - level & leak Check 712 - MAT - 0020 27

Brake+ Clutch fluid - Replace 712 - MAT - 0021 28

Brake pads/ Calipers - Check 712 - MAT - 0022 32

Brake drum and lining - Check 712 - MAT - 0023 33

Parking brake operation - Check & Adjust 712 - MAT - 0024 34

Front Suspension bolts torque - Check 712 - MAT - 0025 36

Rear Suspension bolts torque - Check 712 - MAT - 0026 36

Front suspension bushes- Inspect 712 - MAT - 0027 37

Rear Suspension Link bushes- Inspect 712 - MAT - 0028 39

Power steering fluid - level & leak Check 712 - MAT - 0029 41

Wheel alignment * 712 - MAT - 0031 42

Battery electrolyte lev el - Check 712 - MAT - 0032 45

Battery specific gravity - Check 712 - MAT - 0033 46

All Lights, Horns, Wipers & Washers - Check 712 - MAT - 0034 48

Head light aiming - Check & Adjust 712 - MAT - 0035 56

HVAC Filter / Clean mesh 712 - MAT - 0036 61

Door setting 712 - MAT - 0037 62

Tyre pressure - Check & Adjust 712 - MAT - 0038 63

Body mounting bolts for tightness-Check & Adjust 712 - MAT - 0039 64

Exhaust pipe mtgs. & damage/leakage - Check 712 - MAT - 0040 65

Road Test- if any complaints reported 712 - MAT - 0041

MAINTENANCE CHECK SHEET (FOR ALL SERVICE INTERVALS) 67

*on chargeable basis.

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Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra 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

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 minimum of API CH-4 SAE 15W-40 specification.

 Recommended intervals for Maximile Feo engine Oil change are at 5000, 20000kms & then

at every 20000kms.

Oil Drain & Refill –

1. Open the oil filler cap.

2. Place 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 712-MAT-0002.

Oil Filling Point

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Page 9

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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/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 mounting point.

DIPSTICK

GUIDE

DIPSTICK

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Page 10

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 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-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

Oil Leak - Check Points near Oil Filter

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Page 11

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra Ltd.

712-MAT-0004 : 0.10 hrs. AUTO TENSIONER – 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 operation. These can all be signs that a tensioner needs replacing.

Refer slots/ marking shown by arrow marks on Auto tensioner in sketch [C] & [D]. Two or three 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.

Marking on Autotensioner 1

Marking on

Autotensioner 2

Auto Tensioner mounting on Engine

Auto Tensioner [1] & [2]

And Drive Belts [A] & [B] Layout

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Page 12

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra Ltd.

712-MAT-0005 : 0.70 hrs. & 712-MAT-0006 : 0.50 hrs. AUTO TENSIONER – REPLACE (AC-Water pump and Alternator-Steering Pump drive belt)

Nut/ Bolt description Qty. Nos. Spanner Size Torque Value Nm.

 Auto tensioner 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.

Take the locking pin out & release the Auto

Tensioner.

4. Remove auto tensioner assembly by removing its

mounting bolts.

Replace the components in reverse to the

assembly procedure.

1. Remove Power Steering drive belt before

attempting the said auto tensioner removal.

Using the spanner, rotate the Auto Tensioner in

the direction shown in the figure. Lock the Auto Tensioner in that position using a pin.

3. Remove the belt.

4. Take the locking

pin out & release the Auto

Tensioner.

5. Remove auto tensioner assembly by removing its

2 nos. mounting bolts.

Replace the components in reverse to the

assembly procedure.

 Auto tensioner to be inspected at 60000, 80000kms and to be replaced at 100000kms.  Check the auto tensioner free arm position. Ensure that end of travel is not reached.

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Page 13

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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 drive belts thoroughly if any abnormality noticed.

1. Abrasion – Each side of belt appears shiny or

glazed. In advanced stages, fabric becomes

exposed.

2. Cracking –

Small, yet visible cracks along the

length of a rib or ribs.

3. Improper Install – A belt rib begins separating

from the joined strands. If left unattended, the

cover will often separate, causing the belt to

loosen.

4. Uneven Rib Wear – Belt shows damage to the side with the possibility of breaks in the tensile cord or rough edged ribs. A thumping noise may also be heard when running.

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Page 14

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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 occurred, a belt can fall at any moment.

7. Gravel Penetration – Small pinholes are visible on the backside of the belt. Bumps may be visible and the fabric around the holes can be frayed.

8. Pilling – Belt material is sheared off from the ribs

and builds up in the belt grooves.

 Main accessory Drive Belts to be inspected at 60000, and 80000 kms.  Accessory Drive Belts to be inspected first at 60000 kms and 80000 kms and to be replaced

at every 100000 kms.

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Page 15

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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).

Turn Auto-tensioner in clockwise direction, to loosen drive belt.

5. Remove AC/Water pump belt.

Assembly Procedure –

1. Turn auto-tensioner in clockwise direction and refit accessory drive belt.

2. Refit AC Compressor/Water Pump drive belt.

3. Refit Alternator/power steering drive belt (712-MAT-0009).

4. Refit Fan & shroud and NVH cover.

 Replace Accessory drive belts at every 100000 kms.

Nut/ Bolt description

Quantity Nos.

Spanner Size

Torque Value – Nm.



Cooling Fan mtg. nut

34 mm.

55± 05

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Page 16

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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.

Remove accessory drive belt (On

Alternator/Steering Pump).

Assembly Procedure –

1. Refit accessory drive belt. Turn auto-tensioner

in clockwise direction for ease of belt fitment.

2. Refit Alternator/power steering drive belt.

3. Check Power steering drive belt tension.

4. Refit Fan & shroud.

5. Refit NVH cover.

 Replace Accessory drive belts at every 100000 kms.

Nut/ Bolt description Quantity Nos. Spanner Size Torque Value – Nm.

 Cooling Fan mtg. nut 01 34 mm.

± 05

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Page 17

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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.

Check the coolant level in the degassing

tank [1] – it should be between MAX and MIN marks. If below MIN,

Open the

degassing tank cap and

top it up with

Maximile Coolant.

2. Check for evidence of leakage at Water pump hose, Oil cooler hose. Radiator top and bottom

hoses and HVAC heater hoses.

 Use Maximile ULTRA COOL only.  Never remove the radiator cap when the engine is hot.  Never mix MAXIMILE coolant with water. It is pre-mixed.  Check coolant level and leak at every service interval.

Degassing Tank Cap

Degassing Tank Fluid Level Marking

Page 17

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Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra Ltd.

712-MAT-0011 : 0.60 hrs. COOLANT – REPLACE

Coolant – MAXIMILE ULTRA COOL (Pre-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 required.

6. Start the engine and run at approx. 1200 rpm for 2-3 min.

7. Check coolant level in degassing tank and add coolant as per requirement.

8. Fill coolant in the degassing tank up to MAX level.

9. Refit the degassing tank cap.

10. Start the engine again and run at approx. 1200 rpm for 2-3 min.

11. Check coolant level in degassing tank and top-up as required.

 Never remove the degassing cap when the engine is hot. 

Never mix MAXIMILE coolant with water. Maximile coolant is premixed/ ready to use.

Recommended to change the coolant at 60000kms, 140000kms and then every 80000kms.

 Use Maximile ULTRA COOL  Don’t use other brand coolants for top up.

Page 18

Page 19

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra Ltd.

712-MAT-0012 : 0.25 hrs. AIR FILTER - REPLACE

Nut/ Bolt description Quantity Nos. Spanner Size Torque Value – Nm.

 Air filter top cover allen bolt

 Hose clamps – air cleaner to manifold

07 02

6 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. I

n case vehicle runs in

very dusty condition replace air filter cartridge at 30000kms

or red band in chock indicator

appears.

AIR FILTER ELEMENT – REPLACE

Refer illustration shown above –

1. Open the clean and dirty sides hose clip & remove the hose.

2. Open the Air cleaner Top cover bolts.

3. Remove the Air filter element along with grates and clean the bottom bowl.

4. Separate the top as well as bottom grates and replace the air filter element; assemble the

grates & put the assembly back in place. Position the new element properly. Take care of lug projections.

5. Assemble the top cover & tighten the top cover bolts diagonally.

6. Assemble the clean hose on the air cleaner outlet-Air Mass Sensor neck and tighten the

hose clip.

A B C

Air Filter Assy. – Exploded View

Page 19

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Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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 anticlockwise 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 Filter Element [1]

• Fit a new fuel filter element and tighten it by

hand [4]

• Refit the “Water in fuel” sensor [3]

• Remove the fuel tank cap

• Switch the Ignition to ‘ON’ position

• Bleed the system using hand primer and bleed

screw on the banjo.

•

Bleed the fuel system by operating the priming pump several times until you feel more

resistance. The engine may take longer to start [B].



Always replace with genuine fuel filter assembly.

Fuel Filter Location in Xylo mHawk

WATER SEDIMENT DRAIN PLUG IN FUEL FILTER

Page 20

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Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra Ltd.

712-MAT-0014 : 1.00 hrs. FUEL TANK AND STAINER – CLEAN

Pre removal activities –

• Lift vehicle on certified hoist.

• Keep tray below the fuel tank to avoid spillage of fuel while tank removal.

• Remove the fuel tank drain 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 fuel lines – Main and return

line hoses.

• Disconnect the fuel filler hose and the

breather hose.

• Disconnect the tank unit WH connector.

Xylo mHawk Fuel Tank – Top Side View

• Remove the fuel tank from the vehicle, by

removing 04 nos. mounting bolts. Refer sketches.

• Remove the ‘Fuel Strainer with main line

assembly’ by removing the fastening bolts.

Fuel Strainer - Schematic

• Blow the compressed air gradually with low

pressure as per the direction indicated by the arrow in the illustration above.

• Clean the fuel tank.

• Refit the fuel tank and reconnect the main

line, return line, filler hose, breather hose and tank unit connections.

Post installation activities -

• Refill fuel in the fuel tank. (Use recommended fuel. Tank MAX capacity is 60L approx.)

• Bleed the fuel system, if required. (Refer 712-MAT-0013)

Page 21

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Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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 anticlockwise direction.

• ‘Water in Fuel Sensor’ to be rotated by 2 turns

[1] to open.

• Allow the Water

accumulated in the filter to

drain out.

• Tighten the Water in Fuel Sensor [2] by rotating

in clockwise direction.

• Bleed the fuel system by operating the priming pump several times until you feel more

resistance. The engine may take longer to start.



Always replace with genuine fuel filter assembly.

FUEL FILTER LOCATION IN XYLO mHawk

WATER SEDIMENT DRAIN PLUG IN FUEL FILTER

Page 22

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Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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 surface.

• Remove the Filler plug [A]; refer illustration.

• Place oil collection tray under transmission.

• Loosen & remove the drain plug [B].

• Allow the oil to drain out completely.

• Assemble & torque tight the drain plug with

new washer – 27.5 ± 2.5 Nm.

•

Fill fresh transmission oil as per specified

capacity & assemble the filler plug with new washer with 27.5 ± 2.5 Nm torque.

• Check for Oil leakage / seepage at –

- Transmission Housing Joints.

- Transmission Oil drain plug.

Page 23

Page 24

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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 Syntec F2. The oil change interval has to be first at

10000kms & then 100000kms. Inspect oil for level and leak at 50000kms.

• If Maximile GO Synchro 80W-90 is used, the oil change interval has to be reduced to 40,000 km.

For other than Maximile brand, the oil change interval has to be reduced to 20000 km if the oil meets minimum of API GL-4 SAE 80W-90 specification.

Page 24

Page 25

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra Ltd.

712-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 specification.

Differential Oil – Replace. Refer illustration shown.

1. Remove the Filler plug [A]

2. Place drained oil collecting tray below the axle.

3. Remove the drain plug [B]. Allow the oil to drain out completely.

4. Clean the metal particles if any deposited on the drain plug. Assemble & torque tight the

drain plug with new washer – 47.5± 6.5 Nm.

5. Fill fresh transmission oil as per specified capacity & assemble the filler plug with new

washer and torque to 47.5± 6.5 Nm.

6. Check Oil leakage / seepage at –

• Differential covers joint face

• Differential Oil drain plug.

Banjo Axle – Oil Replacement

Page 25

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Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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

Vehicle Load

Condition:

FULL

Psi

35 41

Kg/cm. sq.

2.4 2.8

• The proper cold tyre inflation pressure is listed in the Tyre Label (Vehicle Placard), located

on the front passenger side inner B-pillar.

• Ensure to check and adjust the tyre pressure in the spare tyre.

• Ensure to replace dust cap on valve seats after checking tyre pressure.

Xylo mHawk Tyre Rotation Illustration - Schematic

Page 26

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Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra Ltd.

712-MAT-0020 : 0.15 hrs. BRAKE/CLUTCH FLUID – LEVEL & LEAK - CHECK

Brake/ Clutch Fluid – DOT4 standard.

 Xylo variants are fitted 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 system.  Recommended fluid: SHELL CLUTCH & BRAKE FLUID DOT 4/ Brake Fluid Meeting SAE J1703;

FMVSS No.116 DOT 4 or IS 8654 Type-2 Specification.

 Check fluid level and leak at every service interval after 10000kms.

BRAKE/CLUTCH FLUID – LEVEL & LEAK - CHECK

Refer above illustration –

1. Check for Brake/Clutch Fluid Level up ‘Max’ mark on the brake/clutch fluid reservoir.

2. Check for Brake/Clutch Fluid leakage and correct fitment at all joints –

 Hose connected from reservoir and Clutch master cylinder.  Clutch Master Cylinder inlet and outlet.  Clutch Bundy tube to flexible hose joint.  Concentric clutch slave cylinder hose joint and bleeder screw.

Common Fluid Reservoir for Brake & Clutch System

----MAX------

----MIN------

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Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra Ltd.

712-MAT-0021 : 0.70 hrs. BRAKE/CLUTCH FLUID – REPLACE

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 bleeding can be done normally as per the defined sequence. It is recommended to do diagnostic bleeding in case pedal found spongy.

1. Perform base brake bleeding. Sequence is RL/FL/FR/RR.

(Rear L

eft

- Front L

eft

-Front R

ight

- Rear Rig

ht)

2. Top up

master cylinder fluid level and verify proper brake operation before moving vehicle.

Base brake bleeding procedure -

1. Open the fluid reservoir cap and f

ill the

brake fluid reservoir to the MAX mark.

*This is Sample illustration

2. Connect

the bleed tube to the Rear Right

caliper bleed screw and place the other end

submerged in a transparent container

containing sufficient brake fluid.

Page 28

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Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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.

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 bubbles at the end of the bleed tube.

Now follow the same procedure at the other wheels as per the sequence given below.

1. Rear left 2. Rear right

3. Front left 4. Front right

Refer below schematic for brake fluid bleeding sequence –

7. After the bleeding sequence is completed, remove the bleed tube and place the dust cap on the

bleed screw.

8. Ensure that the bleed screw is tightened to the specified torque.

Brake Booster

& TMC

Front RHS

Brake Caliper

Rear RHS

Brake Drum

Rear LHS

Brake Drum

Front LHS

Brake Caliper

EHCU Assembly

Page 29

Page 30

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra Ltd.

CLUTCH FLUID REPLACEMENT / CLUTCH 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 bleeding screw on slave cylinder by ½ to ¾ turn and allow all the air escape in to the container bottle.

5. Repeat the exercise till no air bubble appears in the bottle.

6. During this operation ensure fluid level in reservoir.

7. Tighten the bleed screw properly.

8. Remove bleeding tube and place the dust cap on bleed screw.

9. Check the fluid level in container and top up it to the ‘max’ level.

Clutch Housing

Slave Cylinder

Hose from Clutch Master Cylinder

Bleeder on Concentric

Slave Cylinder

Bleeder Screw on Concentric

Slave Cylinder

Concentric Slave Cylinder

mounting

bolts – 3 nos.

Slave Cylinder

Connector

Page 30

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Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra Ltd.

•

Before bleeding the brake system refer to general brake service practice and brake fluid

pre-cautions.

• Always use the recommended and specified brake fluid.

• Do not reuse the drained fluid and always use brake fluid from the sealed bottle.

• 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 EHCU the inlet valve is normally open, hence the complete brake bleeding can be done normally as per the defined sequence.

• Do not spill brake fluid on the vehicle, it may damage the paint, if the brake fluid does contact

the paint, wash it off immediately with water.

• Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.

• At all times during the bleeding process, it has to be ensured that the fluid level in the

reservoir does not drop below minimum.

• The Brake fluid reservoir cap/ container should not be opened with dirty hands.

• Avoid direct water spray on reservoir while washing engine compartment.

• Brake fluid meeting SAE J1703 FMVSS NO. 116 DOT 4 or IS 8654 TYPE- 2 specification.

• Durin

g the bleeding operation ensure the container & pipe used is of transparent for better

visual.

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Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra Ltd.

712-MAT-0022 : 0.60 hrs. FRONT BRAKE - CHECK

 If any pad is worn out (inboard /outboard) then replace both the pads.  If pads on one wheel only are worn, even then replace the other wheels also. 

Any excessive difference between inboard and 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 is

21mm. Do not check disc thickness near the outer edge of disc)

2. Loosen & remove the bottom side sliding pin bolt. Swing up the caliper. Remove the pads

& check the pad thickness. The minimum usable pad thickness is 7 mm. (without backing plate) if observed less; replace the pads. (The groove at the center of the pad can also be used as a reference. If the pad has worn up to the end of the groove; it should be replaced)

3. Measure the thickness at the thinnest and worn area of the pad. Replace pad assembly

when pad thickness is less than the limit value.

4. Mechanical Pad wear indicator is provided to know pad wear limit; which will make rattle

noise when pad is worn out.

5. Check for the oil leakage from Calipers/piston seals.

7 mm

21 mm

Check Disc Thickness

Check Pad Thickness

FRONT BRAKE –

CHECK SCHEMATIC

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Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra Ltd.

712-MAT-0023 : 0.80 hrs BRAKE DRUMS/LINERS - CHECK

 Park the vehicle in inspection pit/ 2 post lift/ 4 post lift  Whenever the brake 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 shown.

1. Rear Brake – Open the drum & clean the brakes by blowing compressed air. Check the wheel

cylinder for oil leakage [1]

. (It is recommended to check the oil seepage from wheel cylinder

by lifting the dust boots.)

2. Check the brake lining for wear/cracks. The minimum usable thickness [2] of the liner is 4.5

mm (The brake shoe must be replaced before the rib starts touching the drum).

3. Replace brake shoes when the liner thickness will remain 1 mm.

4. Measure the wear of the brake lining at the place worn the most.

5. Before removing brake shoes, collapse the auto-adjuster assembly which will help to remove

shoes easily.

6. After re-assembly, check the wheel freeness in both forward & reverse direction.

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Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra Ltd.

712-MAT-0024 : 0.30 hrs PARKING BRAKE - CHECK

TYPE – Mechanical Hand operated acting on rear wheels brake Drum.

• Check Brake & Clutch Pedals for free play & sponginess. Refer SOP given in Repair Manual.

• Switch off the engine, keep transmission in neutral position.

• Check Parking Brake Lever operation & setting.

Xylo Parking brake Layout - Schematic

Page 34

Page 35

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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.

• After parking brake cable adjustment, release the handle and check for free rotation of both the

Rear Wheels.

Before parking brake adjustment –

- Check the parking cables for correct routing, before start adjustment.

After parking brake adjustment -

- Park the vehicle on a slope and apply Parking Brake to check the effectiveness.

- Release the Parking Brake & check the free rolling.

Page 35

Page 36

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra Ltd.

712-MAT-0025 : 0.25 hrs. & 712-MAT-0026 : 0.20 hrs. FRONT/REAR SUSPENSION BOLT TORQUE - CHECK

Type/Description: [A] Front - Double Wish-Bone Type IFS. [B] Rear – Multi Link (5 Link) Rear Suspension.

Location

Torque Nm

FRONT SUSPENSION

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

FRONT & REAR SUSPENSION BOLT TORQUE – CHECK

Refer suspension bolt torque chart.

1. Check front suspension bolt torque at -

 Camber bolt production level marking cross verification.  If marking found distrub then follow step [a] otherwise follow step [b],

(a) Re-adjust the position and apply the 200 N-m torque. (b) Apply 200 N-m torque to camber bolt with-out disturbing camber bolt position

If front suspension camber bolts found loose then the wheel alignment has to be done. Please refer the Front Suspension section of the Repair Manual for details.

2. Apply 120 N-m torque to shock absorber to lower arm joint.

3. Apply 150 ± 10 N-m torque to rear suspension bolts at –

 Upper link, Lower link, Panhard Rod on chassis and axle mounting bolts.

 Always use 4-post lift or park vehicle on pit while checking suspension torque.  Use calibrated torque wrenches & Do not over torque than recommended values.  Inspect first at 5000kms, 10000kms, 20000kms and then every 20000kms.

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Page 37

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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.

3. Check the ball joint boots for damage, cracks. Replace if necessary.

4. Check Shock Absorber Bushes, dust boot & Stabiliser Bar Links and Bush for wear & tear,

cracks and shift. Replace if necessary.

 Observe following conditions even after wheel alignment – (a) Problem in vehicle ride and handling. (b) Noise from suspension joints even after specified joint torque values.

 Refer illustration shown below for direction of fitment of voided bush.  Inspect front suspension bush at 40000kms and 80000kms.

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Page 38

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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;

Refer SOP in Repair Manual

VOIDED BUSH - CORRECT POSITION ON

UPPER ARM

BUSH-LCA FRONT END

BUSH-LC A REAR END

BUSH - UCA

 Upper arm is fitted with voided bush on both sides.  Lower arm is fitted with voided bush at its rear end.  Ensure that while fitting the voided bush on Upper arm or lower arm rear end, the Bush solid

rubber portion should be parallel to the Arm.

Page 38

Page 39

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra Ltd.

712-MAT-0028 : 0.20 hrs REAR SUSPENSION BUSH - CHECK

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 Links & Pan hard Rod for damage/ bent etc.

3. Check shock absorber bushes for wear, crack and shift.  Observe following conditions even after wheel alignment –

(d) Noise from suspension joints even after specified joint torque values.

 Refer illustration shown below for direction of fitment of voided bush.  Inspect link bushes at 40000kms and then every 20000kms.

Rear Suspension – Exploded View

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Page 40

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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-Axle Side

VOIDED BUSH – CORRECT POSITION ON UPPER LINK

Pan hard Rod Bush-Frame Side



While tightening the link & torquing ensure that wheels are resting on the ground/ 4 post lift. If

it is not done, the ride quality will get adversely affected.



Ensure that while fitting the voided bush on Upper link both ends, the Bush solid rubber portion

should be parallel to the Arm.

Page 40

Page 41

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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. Check the steering oil level in the reservoir [1] – it should be between MAX and MIN marks.

If below MIN, top it up with recommended oil.

2. Check hose joints for oil leakage / seepage at –

 Reservoir  Power Steering Pump  Rack & Pinion – Pipe ends & boots.

 Brand Specific and no other brand fluid should be used.  Inspect Steering Fluid Level & Leak at every 10000kms.  M&M Part No for

SHELL SPIRAX S3 ATF MD3

Lubricants is

1102EA0032N.

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Page 42

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra Ltd.

712-MAT-0031 : 0.40 hrs WHEEL ALIGNMENT

Camber Bolt initial setting for wheel alignment –

Note:- 1. With front camber bolt easy to adjust camber value.

2. With rear camber bolt easy to adjust castor value.

CASTOR ADJUST

CAMBER ADJUST

Page 42

Page 43

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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 Projection Height – 26.0 ± 1.0 mm.

Refer below sketch and photo to adjust Shock Absorber Projection Height. Use MST No.0401BAA0005ST & refer Repair Manual for SOP.

Runout

•Do the runout compensation

Camber

•Adjust the camber setting by adjusting the front bolts (refer sketch above)

Castor

•Adjust the castor setting by adjusting the rear bolts (refer sketch above)

Indivudal

Toe In

•Set toe-in using the track rod ends.

Turning

angle

•Check the each wheel turning angle.

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Page 44

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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 absorber. Also confirm if the shock absorber projection is as per the specification. Last parameter to be checked should be the rubber bushes of the LCA and UCA.

Wheel alignmnet Parameters

Toe-in partial 0 to 1 mm ( 0 to 13’) Toe-in Total 0 to 2 mm ( 0 to 26’) Camber - 30' to + 10'

Difference between LH & RH camber 30’

Caster 1°45' to 3°45' Difference between LH & RH caster 1° King pin Inclination 42

Wheel turning angle- Inner (Max) 35˚ to 38˚

Wheel turning angle- Outer (Max) 34˚ to 36˚

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Page 45

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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 required clean it and fix it tightly.

3. Check the other end of battery cables for tightness.

Battery Electrolyte Level Check

 Battery rating: 12V, 65Ah.  Toping up should be done with distilled water only.  Never use normal water or mineral water to top battery electrolyte.  Vent holes should be clear.  Clean the terminals.  Use petroleum jelly in case of terminals gets rusty.  Tighten the terminals along with cable fitments properly.

 Battery Electrolyte Level Check to be inspected at every 10000kms.

Page 45

Page 46

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra Ltd.

712-MAT-0033 : 0.10 hrs BATTERY SPECIFIC GRAVITY - CHECK

Battery testing includes two basic procedures.

1. Visual Inspection 2. State of charge (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 terminals

and the battery case top with mixture of water and baking soda. A battery wire brush tool can also be used to clear heavy corrosion on the terminals.

3. Check for a loose battery hold down and tighten it if necessary.

4. Check the electrolyte level by viewing through the translucent plastic case or removing the

vent caps and looking directly into the battery. Top up required amount of distilled water.

5. Check for cloudy or discolored electrolyte caused by overcharging or vibration of the battery.

This will cause high self discharge. Correct the cause or replace the battery if necessary.

Refer below chart for Specific gravity, Charge & Output Current Voltage comparison –

BATTERY SPECIFIC GRAVITY - CHECK

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Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra Ltd.

State of Charge:

The state of charge of the battery can be easily checked in two ways:

Specific gravity test:

The hydrometer compares the specific gravity of electrolyte with water.

Specific gravity readings:

• By measuring the specific gravity of the electrolyte, you can identify whether the battery is fully

charged, requires charging, or must be replaced. The battery must be at least 75% charged to perform load test or each cell must have a 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.

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 the specific gravity indicated on the float. Be sure the float is drifting free, and does not

contact with sides of the barrel. Read the hydrometer at eye level. Disregard t

he slight

curvature of liquid on the float.

5. Note the reading for all the cells. The difference in specific gravity readings should not be more

than 0.05.

 Battery Specific Gravity to be inspected at every 10000 kms.  Do not allow battery fluid to contact with skin, eyes, fabrics, or painted surfaces. Do not touch

or rub your eyes until you have thoroughly washed your hands. If acid contacts eyes, immediately flush with water and seek medical attention if necessary.

 Specific gravity varies with the temperature. If the electrolyte temperature is substantially

above 27 deg. C add seven points (0.007) to the observed specific gravity reading for every 10 deg. C by which the actual temperature is above 27 deg. C. Deduct seven points per 10 deg C where th

e observed reading is below 27 deg. C to obtain the temperature corrected reading at

27 deg. C.

Page 47

Page 48

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra Ltd.

712-MAT-0034 : 0.30 hrs LIGHTS/ HORN/ WIPER/ WASHER - CHECK

Parking Brake/Low Brake Oil Warning Lamp *

High Engine Coolant Temperature Warning Lamp *

Turn Lamp - Left

Turn Lamp - Right

Check Engine Lamp *

Low Engine Oil Pressure Warning Lamp **

Water-in-Fuel Warning Lamp *

Low Fuel Warning Lamp *

Fog Lamp - Rear

Head Lamp High Beam Lamp

Anti-Brake System (ABS) Warning Lamp *

Seat Belt Warning Lamp *

Vehicle Armed Status Lamp

Door Ajar Warning Lamp

OBD Check Lamp (BS IV only) **

Electronic Brake Distribution (EBD) Lamp *

Airbag Warning Lamp *

Cruise Control Lamp *

Battery Charging System Lamp **

Fog Lamp - Front

* These indications will come ON momentarily when the ignition is switched ON and will go OFF in few seconds.

** These indications come ON momentarily when the ignition is switched ON and will remain ON till the engine is started.

If any of the warning lamps marked * or ** do not come ON or remain ON after the engine is started, it is an indication of a malfunction of that lamp or system. Check the vehicle with help of Diagnostic tool and take corrective action.

Xylo mHawk – Instrument Cluster Schematic

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Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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 hazard warning flasher switch is located

below the DDAS in the instrument panel. Press

the switch to turn ON the hazard warning

flashers, all directional turn signals should.

Electric ORVM Adjustment -

The switch houses the Left (L) / Right (R) ORVM selection button and a four way navigation button.

Pressing L / R selects Left / Right side exterior

mirror respectively. Pressing the navigation knob in the required direction

moves that

particular mirror (left or right) accordingly to the desired position.

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Page 50

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra Ltd.

Exterior Lamps –

Lighting Control Stalk

The lighting control stalk controls operations of parking 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 signal lamps on the instrument panel flash faster than normal, there may be a possibility that one or more of the turn signal lamp bulbs have blown. Replace the blown bulb immediately.

Rotate the outer rotary switch on the lighting control stalk aligning the “dot” on the switch to “OFF” on the stalk to switch OFF all lamps.

Parking Lamp ON

Rotate the outer rotary switch on the lighting control stalk aligning the “dot” on the switch to

the “1st detente” position on the stalk to

switch ON the parking lamps.

The tail lamp, license plate lamp, side marker lamps, instrument panel illumination lamps and all interior switches are also activated when the Parking lamp is switched ON.

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Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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 lighting control stalk down [B] away

from steering wheel to switch ON the head

lamp high beam.

Head Lamp Flash

Pull the lighting control stalk (from the head lamp low beam position) towards the steering wheel to instantaneously flash the head lamp

high beam. The head lamp flash works even

when the head lamp is OFF.

Front Fog Lamps ON

To switch ON the front fog lamps, switch ON the ignition and the parking lamps. Turn the inner rotary switch on the lighting control stalk to align to the inner fixed stalk as shown.

Page 51

Page 52

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & 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 neutral position (B).

Flick-Wipe (Mist)

Push the wipe control stalk to position A for a flick-

wipe, hold to operate the wipe

continuously (simultaneously lift the wiper

stalk towards the steering wheel to operate

the wash).

The stalk automatically comes back to position B when released.

Intermittent (INT) Mode

Intermittent (INT) wiping is selected when the wipe control stalk is pushed down to position C. In the INT mode, the wiper

operates on

preset intervals of 4

sec. The delay between

each wipe can be programmed from 1 to 60 sec according to the rain by the user.

Page 52

Page 53

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra Ltd.

Programming of the INT delay time is as follows -

• Turn the wiper stalk to position C, wiper 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 Wiping

Push the wiper control stalk down to position E to operate the wiper at a fixed high speed.

Wipe/Wash

Pull/Lift the wiper control stalk towards the steering wheel from any position to activate wipe/wash function. Washer fluid is sprayed on the front windshield and the wipers wipe the windshield 3 times after the washer spray is stopped and wipe once after 5 sec.

Rear Wiper

Rotate the outer rotary switch on the wiper

control stalk to align the “dot” on the switch to the “1st detente” position on the wiper stalk to operate the rear wiper.

Auto-rear Wiping

With the front wipers ON and rear wipers OFF, engaging the reverse gear activates the rear wiper.

Page 53

Page 54

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra Ltd.

Windshield Washer – Front

There are two 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 direct the washer jet to hit the middle of rear windshield using a pin. Rear windshield washer fluid is supplied from rear washer reservoir located in the back door. Press the tab on the lid and pull open the lid to access the rear wash reservoir.

Puddle Lamps

The Puddle lamps are provided at the bottom

of the front doors. They are switched ON

automatically when either of the front doors is opened.

Horn

Press the pad on

the steering wheel to

blow/sound the horn.

The horn should

function even when the

ignition has been switched OFF.

•

All Lights, Horns, Wipers & Washers to be inspected at every service interval.

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Maintenance Manual MAN-00167

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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.

712-MAT-0035 : 0.30 hrs HEADLAMP AIMING/ALIGNMENT – CHECK AND ADJUST

Headlamp alignment by visual Method (Refer below illustraon):

Ensure that:

a. Vehicle & screen/ board both are placed on the same Level surface. b. Check and ensure all four tyre pressures as per speciﬁcaon. c. Head lamp leveling switch posion is on zero (0). d. Keep the vehicle at a distance (Y) of 10 meter

from the screen/ board.

Refer below illustraon for the headlamp bulb

arrangement –

High & Low Beam - Halogen Bulb

Turn Indicator lamp

Bulb Shield

Reﬂector Assembly

Park Lamp

Schemac – Headlamp alignment by Visual Method

A C

C B

LH Side Head Lamp RH Side Head Lamp

Page 55

Y=10meters

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Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

he 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.

Head Lamp Alignment Procedure –

STEP 1 – Seng the Low Beam STEP 2 – Checking High Beam

STEP 1 – Low Beam Seng Procedure:

Refer below illustraon for the headlamp low beam cut oﬀ paern:

Xylo Head Lamp alignment Dimensions are - X: 869mm. h=(X-130)=739mm. Z: 1261mm.

h=X-1.3% of Y. Y=10meters (distance between vehicle and board)

 Set LH & RH head lamp (Low Beam) by seng the cut oﬀ paern at a height marked on the board.

Refer above illustraon for low beam cut oﬀ paern.

Xylo LH side head lamp – Rear View

 Refer illustraon for LH & RH side head lamp low

beam alignment seng.

• Use 250mm size star screw driver and set

screw [A] to adjust low beam vercal mo

vement.

Page 56

Page 57

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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 off pattern and horizontal dimensions.

 Use 250mm size star screw driver and set screw

[B] to adjust low beam horizontal movement.

Refer above illustration for low beam cut off

pattern.

Horizontal movement Setting screw [B] can be accessed from Headlamp top side when it is assembled on vehicle.

LH side head lamp Assembly – Rear View

Rotation of the Screw driver –

Down/ Clockwise (Right side movement)

Up/ anti-clockwise (Left side movement)

Page 57

Page 58

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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 screen.

STEP 2 – Checking High Beam

Refer below illustration for the headlamp high beam cut off pattern:

Xylo Head Lamp alignment Dimensions are - X: 869mm. Z: 1261mm.

• Use above High Beam cut off pattern for checking purposes.

• High Beam cut off should automatically come after Low beam setting has been done.

• Do not try to set high beam independently as it will disturb the low beam setting.

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Page 59

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra Ltd.

Xylo mHawk – Head Lamp Dimensions

- All Dimensions are in mm. - Tolerance value is +/- 30 mm.

Page 59

Page 60

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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 Filter Element with air (If compressed

air is used, ensure the pressure is low). If the filter tray found very dusty it can be cleaned using soap solution and water. D

ry it with help of low

pressure air before refitting.

Installation –

Installation process is reverse to the removal.

 Clean mesh every 10000kms  Check the entire system for leaks and recharge if required

Page 60

Page 61

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /prosecution © 2012 Mahindra & Mahindra Ltd.

712-MAT-0037 : 0.65 hrs DOOR SETTING

DOOR STRIKER

DOOR LATCH

STRICKER MOUNTING SCREW - LOOSEN

Door Setting - For Side doors:

Refer photos shown.

1. Open the door and while closing it check whether striker is at the centre of latch. If it is

not 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 are done tighten the striker mounting bolts with torque value 25

N-m to 30 N-m

Door Setting - For Back door:

Refer photos shown.

1. Open the door and while closing it check whether striker is at the centre of latch. If it is

not at the centre of latch, striker will foul with top or bottom portion of latch or dovetail. Loosen the bolts of striker and move the striker up or down to remove the fouling. Similarly loosen the bolts of dovetail and move the dovetail 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 are done tighten the striker mounting bolts with torque value 25

N-m to 30 N-m

Page 61

Page 62

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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 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

Vehicle Load

Condition:

FULL

FRONT REAR

Psi 35 41

Kg/cm. sq.

2.4

2.8

• The proper cold tyre inflation pressure is listed in the Tyre Label (Vehicle Placard), located

on the front passenger side inner B-pillar.

• Ensure to check and adjust the tyre pressure in the spare tyre.

• Ensure to replace dust cap on valve seats after checking tyre pressure.

Page 62

Page 63

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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:

 Body mounts/ triggers on front both are denominated as LH1 & RH1.  Front mounts LH1 & RH1 are smaller in size/ Dia. than rear.  Refer above sketch for body mount location.

 Park the vehicle in inspection pit /2 post lift/ 4 post lift. 

Body mounts to be checked and torque tighten first at 5000 kms then 20000 kms and then at

every 20000 kms.

Page 63

Page 64

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods given by the manufacturer in this docum ent are based on the technical specifications, current at the tim e of release. The methods may be modified as a result of changes introduced by t he m anuf actur er in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, t r ansl ation, transmission, in part of or whole of the present document, are prohibited wit hout the prior written consent of Mahi ndr a & Mahindra Ltd. The use of this document by any person ot her than the trained personnel, at t he A uthorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/pr osecut ion © 2012 Mahindra & Mahindra Ltd.

712-MAT-0040 : 0.10 hrs EXHAUST SYSTEM - CHECK

Xylo mHawk BS-III – Exhaust System Joints & Rubber Hanger Location Schematic

Xylo mHawk BS-IV – Exhaust System Joints & Rubber Hanger Location Schematic

Page 64

Page 65

Maintenance Manual MAN-00167

XYLO mHawk February 2012/ Rev1

The repair methods giv en by the m anuf actur er in this document are based on the t echni cal specif i cations, current at the time of r elease. The m ethods m ay be m odif ied as a re sult 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 & Mahindr a Ltd., will amount to unauthorized use and shall be li able for penalt y /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 20000 kms.

EXHAUST SYSTEM - CHECK

Refer above illustrations.

1. Check all the Exhaust mountings for exhaust pipe fouling, if any and correct fittings if

required.

2. Check all the Exhaust joints shown by arrow marks for leakage and correct fittings.

3. Checks circled area for rubber hangers for crack and shift, replace it if required.

Page 65

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Maintenance Manual MAN-00167

The repair methods given by the manufactur er in this document are based on the technical specif ications, current at the time of release. The methods may be modified as a result of c hanges i ntroduced by the manufacturer in the producti on of the various component units and acce ssories f rom which the v ehicles are manuf actured. The repr oduction, translati on, transmission, i n part or whole of the present document, are prohibited without t he prior written consent of Mahindra & Mahindr a Ltd. The use of this document by any person other t han the trained personnel, at t he Authorized Service Centr e of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

Page 66

Page 67

Maintenance Manual MAN-00167

The repair methods given by the manufactur er in this document are based on the technical specif ications, current at the time of release. The methods may be modified as a result of c hanges i ntroduced by the manufacturer in the producti on of the various component units and acce ssories f rom which the v ehicles are manuf actured. The repr oduction, translati on, transmission, i n part or whole of the present document, are prohibited without t he prior written consent of Mahindra & Mahindr a Ltd. The use of this document by any person other t han the trained personnel, at t he Authorized Service Centr e of Mahindra & Mahindra Ltd., will amount 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 REPLACE

0.30

Engine oil filter REPLACE

0.20

Coolant 3 I

0.05

Water sediments drain-Fuel filter (or when indicator glows)

0.20

Parking brake operation A

0.30

Front Suspension bolts torque I

0.25

Rear Suspension bolts torque I

0.20

Battery electrolyte lev el I

0.10

All Lights, Horns, Wipers & Washers I

0.30

Head light aiming I

0.30

Door setting A

0.65

Tyre pressure A

0.30

Body mounting bolts for tightness I

0.40

Exhaust pipe mountings & damage /

leakage

0.10

Road Test- if any complaints reported I

• Additional Repair Work carried out, if any -

• Observations, Notes if any -

Above Services Performed by –

Job Start Time:

Name of the Technician – Date of Ser vice –

Job End Time:

Repair order No. Repair order date - Standard Time: 03.65 man-hrs.

MAINTENANCE CHECK SHEET

@ 5000 KMS

Page 68

Maintenance Manual MAN-00167

The repair methods given by the manufactur er in this document are based on the technical specif ications, current at the time of release. The methods may be modified as a result of c hanges i ntroduced by the manufacturer in the producti on of the various component units and acce ssories f rom which the v ehicles are manuf actured. The repr oduction, translati on, transmission, i n part or whole of the present document, are prohibited without t he prior written consent of Mahindra & Mahindr a Ltd. The use of this document by any person other t han the trained personnel, at t he Authorized Service Centr e of Mahindra & Mahindra Ltd., will amount 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)

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

0.15

Front Suspension bolts torque I

0.25

Rear Suspension bolts torque I

0.20

Power steering fluid - level & leak check

0.10

Battery electrolyte lev el I

0.10

Battery specific gravity I

0.10

All Lights, Horns, Wipers & Washers I

0.30

Clean mesh C

0.20

Tyre pressure A

0.30

Road Test- if any complaints reported

• Addit iona l Re pair Work carried out, if any -

• Observations, Notes if any -

Above Servi ces Performed by –

Job Start Time:

Name of the Technician – Date of Ser vice –

Job End Time:

Repair order No. Repair order date - Standard Time: 03.10 man-hrs.

MAINTENANCE CHECK SHEET

@ 10,000 KMS

Page 69

Maintenance Manual MAN-00167

The repair methods given by the manufactur er in this document are based on the technical specif ications, current at the time of release. The methods may be modified as a result of c hanges i ntroduced by the manufacturer in the producti on of the various component units and acce ssories f rom which the v ehicles are manuf actured. The repr oduction, translati on, transmission, i n part or whole of the present document, are prohibited without t he prior written consent of Mahindra & Mahindr a Ltd. The use of this document by any person other t han the trained personnel, at t he Authorized Service Centr e of Mahindra & Mahindra Ltd., will amount 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 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

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 fluid - level & leak check

0.10

Battery electrolyte lev el I

0.10

Battery specific gravity I

0.10

All Lights, Horns, Wipers & Washers I

0.30

Clean mesh C

0.20

Tyre pressure A

0.30

Body mounting bolts for tightness I

0.40

Exhaust pipe mountings & damage / leakage

0.10

Road Test- if any complaints reported I

• Addit iona l Re pair Work carried out, if any -

1) 2)

• Observations, Notes if any -

1) 2)

Above Services Performed by –

Job Start Time:

Name of the Technician – Date of Ser vice –

Job End Time:

Repair order No. Repair order date - Standard Time: 05.55 man-hrs.

MAINTENANCE CHECK SHEET

@ 20,000 KMS

Page 70

Maintenance Manual MAN-00167

The repair methods given by the manufactur er in this document are based on the technical specif ications, current at the time of release. The methods may be modified as a result of c hanges i ntroduced by the manufacturer in the producti on of the various component units and acce ssories f rom which the v ehicles are manuf actured. The repr oduction, translati on, transmission, i n part or whole of the present document, are prohibited without t he prior written consent of Mahindra & Mahindr a Ltd. The use of this document by any person other t han the trained personnel, at t he Authorized Service Centr e of Mahindra & Mahindra Ltd., will amount 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)

0.20

Tyre rotation A

0.60

Brake & Clutch fluid - level & leak check B

0.15

Brake pads/ Callipers I

0.60

Power steering fluid - level & leak check I

0.10

Battery electrolyte lev el I

0.10

Battery specific gravity I

0.10

All Lights, Horns, Wipers & Washers I

0.30

Clean mesh C

0.20

Tyre pressure A

0.30

Road Test- if any complaints reported I

• Additional Repair Work carried out, if any -

•

Observations, Notes if any -

Above Services Performed by –

Job Start Time:

Name of the Technician – Date of Ser vice –

Job End Time:

Repair order No. Repair order date - Standard Time: 02.75 man-hrs.

MAINTENANCE CHECK SHEET

@ 30,000 KMS

Page 71

Maintenance Manual MAN-00167

The repair methods given by the manufactur er in this document are based on the technical specif ications, current at the time of release. The methods may be modified as a result of c hanges i ntroduced by the manufacturer in the producti on of the various component units and acce ssories f rom which the v ehicles are manuf actured. The repr oduction, translati on, transmission, i n part or whole of the present document, are prohibited without t he prior written consent of Mahindra & Mahindr a Ltd. The use of this document by any person other t han the trained personnel, at t he Authorized Service Centr e of Mahindra & Mahindra Ltd., will amount 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 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

Link bushes- inspect I

0.20

Power steering fluid - level & leak check I

0.10

Battery electrolyte lev el I

0.10

Battery specific gravity I

0.10

All Lights, Horns, Wipers & Washers I

0.30

Clean mesh C

0.20

Tyre pressure A

0.30

Body mounting bolts for tightness I

0.40

Exhaust pipe mountings & damage /

leakage

0.10

Road Test- if any complaints reported I

•

Additional Repair Work carried out, if any -

• Observations, Notes if any -

Above Services Performed by –

Job Start Time:

Name of the Technician – Date of Ser vice –

Job End Time:

Repair order No. Repair order date - Standard Time: 05.95 man-hrs.

MAINTENANCE CHECK SHEET

@ 40,000 KMS

Page 72

Maintenance Manual MAN-00167

The repair methods given by the manufactur er in this document are based on the technical specif ications, current at the time of release. The methods may be modified as a result of c hanges i ntroduced by the manufacturer in the producti on of the various component units and acce ssories f rom which the v ehicles are manuf actured. The repr oduction, translati on, transmission, i n part or whole of the present document, are prohibited without t he prior written consent of Mahindra & Mahindr a Ltd. The use of this document by any person other t han the trained personnel, at t he Authorized Service Centr e of Mahindra & Mahindra Ltd., will amount 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)

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 steering fluid - level & leak check I

0.10

Battery electrolyte lev el I

0.10

Battery specific gravity I

0.10

All Lights, Horn s , Wi pers & Washers I

0.30

Clean mesh C

0.20

Tyre pressure A

0.30

Road Test- if any complaints reported I

• Additional Repair Work carried out, if any -

• Observations, Notes if any -

Above Services Performed by –

Job Start Time:

Name of the Technician – Date of Ser vice –

Job End Time:

Repair order No. Repair order date - Standard Time: 02.85 man-hrs.

MAINTENANCE CHECK SHEET

@ 50,000 KMS

Page 73

Maintenance Manual MAN-00167

The repair methods given by the manufactur er in this document are based on the technical specif ications, current at the time of release. The methods may be modified as a result of c hanges i ntroduced by the manufacturer in the producti on of the various component units and acce ssories f rom which the v ehicles are manuf actured. The repr oduction, translati on, transmission, i n part or whole of the present document, are prohibited without t he prior written consent of Mahindra & Mahindr a Ltd. The use of this document by any person other t han the trained personnel, at t he Authorized Service Centr e of Mahindra & Mahindra Ltd., will amount 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 REPLACE

0.30

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

0.25

Rear Suspension bolts torque I

0.20

Link bushes- inspect I

0.20

Power steering fluid - level & leak check I

0.10

Battery electrolyte lev el I

0.10

Battery specific gravity I

0.10

All Lights, Horns, Wipers & Washers I

0.30

Clean mesh C

0.20

Tyre pressure A

0.30

Body mounting bolts for tightness I

0.40

Exhaust pipe mountings & damage / leakage

0.10

Road Test- if any complaints reported I

• Addit iona l Re pair Work carried out, if any -

• Observations, Notes if any -

Above Services Performed by –

Job Start Time:

Name of the Technician – Date of Ser vice –

Job End Time:

Repair order No. Repair order date - Standard Time: 06.85 man-hrs.

MAINTENANCE CHECK SHEET

@ 60,000 KMS

Page 74

Maintenance Manual MAN-00167

The repair methods given by the manufactur er in this document are based on the technical specif ications, current at the time of release. The methods may be modified as a result of c hanges i ntroduced by the manufacturer in the producti on of the various component units and acce ssories f rom which the v ehicles are manuf actured. The repr oduction, translati on, transmission, i n part or whole of the present document, are prohibited without t he prior written consent of Mahindra & Mahindr a Ltd. The use of this document by any person other t han the trained personnel, at t he Authorized Service Centr e of Mahindra & Mahindra Ltd., will amount 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)

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

0.10

Battery electrolyte lev el I

0.10

Battery specific gravity I

0.10

All Lights, Horns, Wipers & Washers I

0.30

Clean mesh C

0.20

Tyre pressure A

0.30

Road Test- if any complaints reported I

• Addit iona l Re pair Work carried out, if any -

• Observations, Notes if any -

Above Services Performed by –

Job Start Time:

Name of the Technician – Date of Ser vice –

Job End Time:

Repair order No. Repair order date - Standard Time: 02.75 man-hrs.

MAINTENANCE CHECK SHEET

@ 70,000 KMS

Page 75

Maintenance Manual MAN-00167

The repair methods given by the manufactur er in this document are based on the technical specif ications, current at the time of release. The methods may be modified as a result of c hanges i ntroduced by the manufacturer in the producti on of the various component units and acce ssories f rom which the v ehicles are manuf actured. The repr oduction, translati on, transmission, i n part or whole of the present document, are prohibited without t he prior written consent of Mahindra & Mahindr a Ltd. The use of this document by any person other t han the trained personnel, at t he Authorized Service Centr e of Mahindra & Mahindra Ltd., will amount 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 REPLACE

0.30

Engine oil filter 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 bolts torque I

0.20

Front suspension bushes- inspect I

0.20

Link bushes- inspect I

0.20

Power steering fluid - level & leak check I

0.10

Battery electrolyte lev el I

0.10

Battery specific gravity I

0.10

All Lights, Horns, Wipers & Washers I

0.30

Clean mesh C

0.20

Tyre pressure A

0.30

Body mounting bolts for tightness I

0.40

Exhaust pipe mountings damage / leakage I

0.10

Road Test- if any complaints reported I

•

Additional Repair Work carried out, if any -

•

Observations, Notes if any -

Above Services Performed by –

Job Start Time:

Name of the Technician – Date of Ser vice –

Job End Time:

Repair order No. Repair order date - Standard Time: 08.00 man-hrs.

MAINTENANCE CHECK SHEET

@ 80,000 KMS

Page 76

Maintenance Manual MAN-00167

The repair methods given by the manufactur er in this document are based on the technical specif ications, current at the time of release. The methods may be modified as a result of c hanges i ntroduced by the manufacturer in the producti on of the various component units and acce ssories f rom which the v ehicles are manuf actured. The repr oduction, translati on, transmission, i n part or whole of the present document, are prohibited without t he prior written consent of Mahindra & Mahindr a Ltd. The use of this document by any person other t han the trained personnel, at t he Authorized Service Centr e of Mahindra & Mahindra Ltd., will amount 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)

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

0.10

Battery electrolyte lev el I

0.10

Battery specific gravity I

0.10

All Lights, Horns, Wipers & Washers I

0.30

Clean mesh C

0.20

Tyre pressure A

0.30

Road Test- if any complaints reported I

• Addit iona l Re pair Work carried out, if any -

•

Observations, Notes if any -

Above Services Performed by –

Job Start Time:

Name of the Technician – Date of Ser vice –

Job End Time:

Repair order No. Repair order date - Standard Time: 02.75 man-hrs.

MAINTENANCE CHECK SHEET

@ 90,000 KMS

Page 77

Maintenance Manual MAN-00167

The repair methods given by the manufactur er in this document are based on the technical specif ications, current at the time of release. The methods may be modified as a result of c hanges i ntroduced by the manufacturer in the producti on of the various component units and acce ssories f rom which the v ehicles are manuf actured. The repr oduction, translati on, transmission, i n part or whole of the present document, are prohibited without t he prior written consent of Mahindra & Mahindr a Ltd. The use of this document by any person other t han the trained personnel, at t he Authorized Service Centr e of Mahindra & Mahindra Ltd., will amount 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 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 bolts torque I

0.20

Link bushes- inspect I

0.20

Power steering fluid - level & leak check I

0.10

Battery electrolyte lev el I

0.10

Battery specific gravity I

0.10

All Lights, Horns, Wipers & Washers I

0.30

Clean mesh C

0.20

Tyre pressure A

0.30

Body mounting bolts for tightness I

0.40

Exhaust pipe mountings & damage /

leakage

0.10

Road Test- if any complaints reported I

• Additional Repair Work carried out, if any -

• Observations, Notes if any -

Above Services Performed by –

Job Start Time:

Name of the Technician – Date of Ser vice –

Job End Time:

Repair order No. Repair order date - Standard Time: 07.25 man-hrs.

MAINTENANCE CHECK SHEET

@ 100,000 KMS

Page 78

Maintenance Manual MAN-00167

The repair methods given by the manufactur er in this document are based on the technical specif ications, current at the time of release. The methods may be modified as a result of c hanges i ntroduced by the manufacturer in the producti on of the various component units and acce ssories f rom which the v ehicles are manuf actured. The repr oduction, translati on, transmission, i n part or whole of the present document, are prohibited without t he prior written consent of Mahindra & Mahindr a Ltd. The use of this document by any person other t han the trained personnel, at t he Authorized Service Centr e of Mahindra & Mahindra Ltd., will amount 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)

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

0.10

Battery electrolyte lev el I

0.10

Battery specific gravity I

0.10

All Lights, Horns, Wipers & Washers I

0.30

Clean mesh C

0.20

Tyre pressure A

0.30

Road Test- if any complaints reported I

• Addit iona l Re pair Work carried out, if any -

• Observations, Notes if any -

Above Services Performed by –

Job Start Time:

Name of the Technician – Date of Service –

Job End Time:

Repair order No. Repair order date - Standard Time: 02.75 man-hrs.

MAINTENANCE CHECK SHEET

@ 1,10,000 KMS

Page 79

Maintenance Manual MAN-00167

The repair methods given by the manufactur er in this document are based on the technical specif ications, current at the time of release. The methods may be modified as a result of c hanges i ntroduced by the manufacturer in the producti on of the various component units and acce ssories f rom which the v ehicles are manuf actured. The repr oduction, translati on, transmission, i n part or whole of the present document, are prohibited without t he prior written consent of Mahindra & Mahindr a Ltd. The use of this document by any person other t han the trained personnel, at t he Authorized Service Centr e of Mahindra & Mahindra Ltd., will amount 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 REPLACE

0.30

Engine oil 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 torque I

0.20

Front suspension bushes- inspect I

0.20

Link bushes- inspect I

0.20

Power steering fluid - level & leak check I

0.10

Battery electrolyte lev el I

0.10

Battery specific gravity I

0.10

All Lights, Horns, Wipers & Washers I

0.30

Clean mesh C

0.20

Tyre pressure A

0.30

Body mounting bolts for tightness I

0.40

Exhaust pipe mountings & damage /

leakage

0.10

Road Test- if any complaints reported I

• Additional Repair Work carried out, if any -

• Observations, Notes if any -

Above Services Performed by –

Job Start Time:

Name of the Technician – Date of Ser vice –

Job End Time:

Repair order No. Repair order date - Standard Time: 06.95 man-hrs.

MAINTENANCE CHECK SHEET

@ 120,000 KMS

Mahindra XYLO mHawk, MAN-00167 Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual