Mahindra XYLO mHawk, MAN-00167 Maintenance Manual

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

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.

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.

• 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

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

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 -

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.

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

Page 8

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

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-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

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-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

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-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.

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-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.

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.

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.

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.

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

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-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

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-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

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

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

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

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

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

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

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

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Mahindra XYLO mHawk, MAN-00167 Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual