MAINTENANCE MANUAL

MAN-00147

RELEASED BY –

TECHNICAL PUBLICATION CELL

MAHINDRA & MAHINDRA LTD.

Rev1 – SEPTEMBER 2011

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.

© 2011 Mahindra & Mahindra Ltd. All rights reserved. This book may not be reproduced or copied, in whole or in
part, without the written permission of Mahindra & Mahindra Ltd.
Page 1
About the Maintenance Manual

The maintenance manual outlines the correct standard operating procedures (SOPs) for carrying
out maintenance operations in a Mahindra XUV500 vehicle. Carrying out the periodic
maintenance operations, as specified, is crucial for safe and trouble-free operation of the vehicle.

The recommended maintenance schedule /operations are published in the owner’s handbook.

This manual covers the correct method of carrying out the maintenance operations, using the
correct process/procedures, tools, parts and lubricants. The manual consists of –

Maintenance Schedule – The maintenance schedules outlines the operations to be carried

out a specified interval. These operations are Adjust (A), Inspect & Correct (I), Replace (.R),
Clean (C). The maintenance periods are specified in Kilometers (Kms).

Standard Operating Procedures (SOP) – Each maintenance operation is coded by an

operation code – 710-MAT-xxxx. Here 710 stands for the model family code, MAT indicating it
is a maintenance operation and xxxx the operation number.

Each maintenance operation is explained step-by-step, in the SOP section of the manual. The
man-hours required to complete the operation is also mentioned along with the operation code.
The correct grade of lubricants /coolants to be used, torque values, special tools are also
mentioned wherever applicable.

Check Sheets – Check sheets for each service list outs the operation which need to be carried
out by the technician, when the vehicles report for scheduled maintenance service. These check
sheets need to be attached to the Repair order.

Job Description
Repair Time {Manhours}

Repair Code Torque Specified

Lubricant Quantity Tool Specified

Lubricant Recommended Nut/ Bolt Quantity

This chart is only a sample.

© 2011 Mahindra & Mahindra Ltd. All rights reserved. This book may not be reproduced or copied, in whole or in
part, without the written permission of Mahindra & Mahindra Ltd.
Page 2
 Good Workshop Practices

Attire/Dress

 Always wear clean uniform

 Wear safety shoes
 Wear gloves, when required
 Wear belt cover

Vehicle Protection

 Put seat cover, fender cover, steering wheel cover, before starting the operations.

Safety

 When working with 2 or more persons, be sure to check safety for one another
 When working with engine running, make sure to provide ventilation for exhaust
fumes in the workshop
 If working on high temperature, high pressure, rotating, moving or vibrating parts,
you should wear appropriate safety gear and take extra care not to injure yourself or
others.
 When jacking up the vehicle, be sure to support the specified location with a safety
stand.
 When lifting up the vehicle, use appropriate safety equipment.

Parts and tools

 Before starting operation, prepare tool 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.

© 2011 Mahindra & Mahindra Ltd. All rights reserved. This book may not be reproduced or copied, in whole or in
part, without the written permission of Mahindra & Mahindra Ltd.
Page 3
 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 here

Locate / Show

Move forward / Fit

Rotate / Turn Clockwise

Rotate / Turn anti-clockwise

© 2011 Mahindra & Mahindra Ltd. All rights reserved. This book may not be reproduced or copied, in whole or in
part, without the written permission of Mahindra & Mahindra Ltd.
Page 4
Maintenance Manual MAN-00147
XUV500 Sept 2011/Rev 1

 Refer below chart for XUV500 Maintenance Schedule recommendations ‐

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra
Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

Page 5
Maintenance Manual MAN-00147
XUV500 Sept 2011/Rev 1

 Refer below chart for XUV500 Lubricant recommendations –

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which
the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service
Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Page 6
Maintenance Manual MAN-00147
XUV500 Sept 2011/Rev 1

 Table Of Content –

XUV500 (710‐MAT‐xxxx)
Sr. JOB REPAIR
JOB DESCRIPTION PAGE NO.
No. CODES
1 ENGINE OIL 710‐MAT‐0010 8
2 ENGINE OIL ‐ LEVEL CHECK 710‐MAT‐0020 9
3 ENGINE OIL FILTER 710‐MAT‐0030 10
4 ACCESSORY DRIVE BELTS ‐ INSPECT 710‐MAT‐0100 11
5 ACCESSORY DRIVE BELT ‐R&R 710‐MAT‐0121 12
6 AUTO TENSIONER ‐ R&R 710‐MAT‐0070 13
7 COOLANT ‐ CHECK 710‐MAT‐0130 14
8 COOLANT ‐ REPLACE 710‐MAT‐0140 15
9 AIR FILTER ELEMENT ‐ REPLACE 710‐MAT‐0150 16
10 FUEL FILTER CARTRIDGE‐ REPLACE 710‐MAT‐0165 17
11 EXHAUST PIPE MOUNTINGS & DAMAGE / LEAKAGE ‐ CHECK 710‐MAT‐0510 19
12 WATER SEDIMENTS DRAIN‐FUEL FILTER 710‐MAT‐0180 20
13 TRANSAXLE OIL ‐REPLACE 710‐MAT‐0210 22
14 IRDA OIL‐ REPLACE 710‐MAT‐0230 23
15 PTU OIL‐REPLACE 710‐MAT‐0570 24
16 BRAKE & CLUTCH FLUID ‐ LEVEL & LEAK 710‐MAT‐0290 25
17 BRAKE OIL REPLACE & BRAKE SYSTEM BLEEDING 710‐MAT‐0031 26
18 PARKING BRAKE CABLE ADJUSTEMENT 710‐MAT‐0330 28
19 BRAKE PADS/ CALIPERS ‐ CHECK (FRONT & REAR) 710‐MAT‐0310 29
20 FRONT SUSPENSION BOLTS TORQUE ‐ CHECK 710‐MAT‐0340 35
21 REAR SUSPENSION BOLTS TORQUE ‐ CHECK 710‐MAT‐0350 39
22 FRONT SUSPENSION BUSHES‐ INSPECT 710‐MAT‐0360 45
23 REAR SUSPENSION LINK BUSHES‐ INSPECT 710‐MAT‐0380 46
24 POWER STEERING FLUID ‐ LEVEL & LEAK 710‐MAT‐0390 47
25 WHEEL ALIGNMENT 710‐MAT‐0420 48
26 BATTERY ELECTROLYTE LEVEL 710‐MAT‐0430 49
27 BATTERY SPECIFIC GRAVITY ‐ CHECK 710‐MAT‐0440 49
28 ALL LIGHTS, HORNS, WIPERS & WASHERS ‐ CHECK 710‐MAT‐0450 53
29 HEAD LIGHT AIMING ‐ CHECK & ADJUST 710‐MAT‐0460 72
30 HVAC FILTER ‐ CLEAN 710‐MAT‐0470 74
31 TYRE PRESSURE ‐ CHECK & ADJUST 710‐MAT‐0490 75
32 UNDERBODY NUTS & BOLTS FOR TIGHTNESS 710‐MAT‐0540 76
33 TYRE ROTATION 710‐MAT‐0180 77
34 SERVICE REMINDER INDICATOR RESET IN DIS 710‐MAT‐0580 78
35 MAINTENANCE CHECK SHEET (ALL SERVICE INTERVALS) ‐ ‐ 81

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra
Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.

Page 7
Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1

710‐MAT‐0010:0.30 hrs.
ENGINE OIL REPLACE

Nut/ Bolt description Quantity Nos. Spanner Size Torque Value (Nm)
Oil Sump drain plug 01 22 mm 27.5 ± 2.5Nm
Engine Oil ‐ Maximile CROWN
Engine Oil Quantity ‐ 06 Lit
Engine Oil Replace - Procedure
1. Open the oil filler cap [A].
2. Put the oil collecting tray below the sump, loosen
& remove the oil sump drain plug [B]. Allow the oil to
drain completely.

3. Fit the drain plug [B] with a new gasket/ washer.

Torque tighten the Drain Plug Torque 27.5 ± 2.5Nm.
4. Fill fresh oil as per the recommended quantity and
specification.
5. Refit the oil filer cap & check the oil level as per
procedure (710‐MAT‐0020).

• Park vehicle on level ground/2 post lift/ 4 post lift

• Engine should be hot while draining the oil.
• Engine oil to be replaced first at 5000kms, 20000kms and then at every 20000kms.
• Always use Mahindra "Maximile CROWN" genuine oil.
• For other than Maximile brand, oil change interval has to be reduced to 10000kms, if the oil meets the min.
of API CH‐4 SAE 15W‐40 specification.

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Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1
710‐MAT‐0020:0.05 hrs.
ENGINE OIL ‐ LEVEL & LEAK ‐ INSPECT
Engine Oil ‐ Procedure
1. Pull out the dip stick gauge [A] 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:
• Oil sump & crankcase joint.
• Oil sump drain plug.
• Oil filter joint.

• Ensure that the vehicle is parked on level ground/ 2 post lift/ 4 post lift.
• Ensure that the engine is not running.
• Check engine oil level at every service interval.

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Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1

710‐MAT‐0030:0.15 hrs.
ENGINE OIL FILTER ‐ REPLACE
Engine Oil Filter ‐ Maximile UNIVERSE
Engine Oil Filter Replace - Procedure
1. Remove the oil filter [A] by unscrewing it in anti‐
clockwise direction, using an oil filter wrench.
2. Smear a layer of fresh engine oil on the new oil
filter “O” ring.

3. Fit the oil filter [A] & turn it clockwise till the “O”
ring touches to oil cooler face.
4. Turn the filter another 3/ 4th turn by hand.
5. Check for Oil leakage/ seepage at
• Oil pan & crankcase joint
• Oil pan Drain Plug
• Oil filter joint.

• Never use a wrench/spanner to tighten the oil filter.

• Engine oil filter element to be replaced first at 5000kms, 20000kms and then at every 20000kms.
• Always use Mahindra "Maximile UNIVERSE" genuine oil filter.

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Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1
710‐MAT‐0100:0.15 hrs.
DRIVE BELT ‐ INSPECT
Drive Belt ‐ Gates 6PK/ Length ‐ 2245mm
Drive Belt Inspect ‐ Procedure
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.

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. Piling: Belt material is sheared off from the ribs
and builds up in the belt grooves.

• Clean all the pulleys and ensure that the accessory drive belt does not slip during installation.
• Ensure that the accessory drive belt is correctly positioned in the grooves of the pulley.

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Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1

710‐MAT‐0121:0.30 hrs.
DRIVE BELT ‐ REPLACE
Drive Belt ‐ Gates 6PK/ Length ‐ 2245mm
Drive Belt Replace ‐ Procedure
1. Remove the front RHS wheel.
2. Remove the four retaining clips [A] and detach the
accessory drive belt dust cover [B] from the chassis.

3. Using a 15mm spanner, rotate the accessory drive

belt tensioner [A] in clockwise direction, and remove
the accessory drive belt [B] from the engine.

• The drive belt is recommended to be inspected at 60000kms, 80000kms and replace at 100000Kms.
• Ensure that the accessory drive belt is correctly positioned in the grooves of the pulley.
• Ensure that the Recommended Belt Tension is applied, check the belt tension in the specified points [C].

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Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1
710‐MAT‐0070:0.45 hrs.
DRIVE BELT AUTO TENSIONER ‐ REPLACE
Drive Belt Auto Tensioner Replace ‐ Procedure
1. Remove the accessory drive belt.
2. Loosen the 18mm mounting bolt from the drive
belt third idler [A], and remove the drive belt third
idler.

3. Using a 8mm Allen key, remove the mounting bolt

from the drive belt tensioner [A].

4. Detach the drive belt tensioner separately from the

engine, along the AC compressor side as shown in the
direction below.

• The auto tensioner is recommended to be inspected at 60000kms, 80000kms & replace at 100000Kms.
• The drive belt auto tensioner has to be inspected during the 60000Kms and 80000Kms service interval,
replace if required.
• Ensure that the drive belt auto tensioner is replace if it is worn out or sounds grinding noise.

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Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1

710‐MAT‐0130:0.05 hrs.
COOLANT LEVEL AND LEAK ‐ INSPECT
Engine Coolant ‐ Maximile ULTRA COOL
Engine Coolant Quantity ‐ 08 Lit
Coolant Level And Leak Inspect ‐ Procedure
1. Check the coolant level when the engine is cold.
2. Check the coolant level in the degassing tank it
should be between MAX and MIN marks. If below
MIN, top it up with Maximile Coolant.
3. Check for evidence of leakage at Water pump hose,
Oil cooler hose. Degassing top and bottom hoses and
HVAC heater hoses.

• Never check the coolant level when the engine is hot.

• Never mix MAXIMILE ULTRA COOL with water, Maximile ULTRA COOL is premixed.
• Coolant level and leaks to be checked first at 5000kms, then at every 10000kms and replace at 80000kms.

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Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1
710‐MAT‐0140:0.25 hrs.
COOLANT ‐ REPLACE
Engine Coolant ‐ Maximile ULTRA COOL
Engine Coolant Quantity ‐ 08 Lit
Coolant Replace ‐ Procedure
1. Open the degassing tank cap [B] as shown in the
below sketch
2. Remove the drain plug [A] from the Radiator.
3. Drain the coolant and collect in drain tray.
4. Refit the drain plugs & fill new coolant in radiator.
5. Check all the hoses & clips for leakage and correct
fitment.
6. Start the engine and run at Aprox. 1200rpm for 2‐3
min.

7. Check coolant level in degassing tank and add

coolant as per requirement.
8. Refit the degassing cap.

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

• Never mix Maximile ULTRA COOL with water, Maximile ULTRA COOL is premixed.
• In case of emergency, coolant meeting JIS K2234 specification should be used (30% concentration diluted
with distilled water), and coolant change period to be reduced as 30000kms.
• Coolant level & leak to be inspected at every service interval & it has to be replaced at 80000 kms.
• Do not overfill the system, allow free space in the degassing tank for expansion of the fluid.

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Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1

710‐MAT‐0150:0.15 hrs.
AIR FILTER ELEMENT ‐ REPLACE
Air Filter Element Replacement ‐ Procedure
1. Remove the six 5mm Allen key mounting bolts [A]
from top of the air filter.

2. Remove the air filter top cover [A].

3. Remove the air filter element separately from the

bottom cover.

• Replace Air filter element at every 40000 kms or early if required.

• Under extreme operating/ Dusty conditions replace air filter element every 20000kms.
• Please do not clean & reuse the air filter element.

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Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1
710‐MAT‐0165:0.25 hrs.
FUEL FILTER ELEMENT ‐ REPLACE
Fuel Filter Element Replace ‐ Procedure
1. Press and Release the lock [A] and pull out the fuel
temperature sensor electrical connector [B] from the
fuel filter.

2. Press and pull out the inlet [A] and outlet hoses [B]
of the fuel filter.

3. Unlock and pull out the electrical connector [A]

from the water sediment.

4. Remove the water sediment sensor [A] by rotating

anti‐clockwise direction from the fuel filter.

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Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1

5. Remove the 12mm fuel filter mounting bolt [A] and

detach the fuel filter assembly.

6. Using a fuel filter wrench, remove the fuel filter

cartridge separately from the fuel filter assembly.
7. Collect the fuel and the sediment with water in a
tray for proper disposal.
8. Fit the new genuine cartridge hand tight and refit
all other parts leaving out let connection open for
bleeding.

• Always use recommended filters only.

• Before removing the fuel filter, open the fuel tank cap to release the pressure from the tank and fuel lines.
• Bleed the air in the fuel system till pump reaches the rigid condition. Connect the outlet hose to the fuel
filter.
• It is recommended to replace the fuel filter element at every 20000kms.
• Fuel Filter cartridge needs to be replaced earlier in case of repeat warning even after the water is drained
from the system.

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Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1
710‐MAT‐0510:0.10 hrs.
EXHAUST PIPE MOUNTINGS AND DAMAGE ‐ CHECK
Exhaust Pipe Mountings And Damage Check ‐ Procedure
1. Check the exhaust pipe insulators [A], replace if
elongates or damaged.

2. Check the two insulators [A] from the muffler pipe,

replace if elongates or damaged.

3. Check the two insulators [A] from the RHS muffler,

replace if elongates or damaged.

4. Check the two insulators [A] from the LHS muffler,

replace if elongates or damaged.

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Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1

5. Check the exhaust mountings [A] for exhaust pipe

fouling and correct fittings.

• Do not work when the exhaust system is hot. Failure to follow this instruction will result in personal injury.
• Check all the exhaust joints for leakage and correct fittings. If leakage is found, check the exhaust pipe
gasket. Replace if required.

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Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1
710‐MAT‐0180:0.10 hrs.
WATER SEDIMENTS DRAIN ‐ FUEL FILTER
Water Sediments Drain‐Fuel Filter ‐ Procedure
1. Unlock and pull out the electrical connector [A]
from the water sediment sensor.

2. Loosen the water sediment sensor [A] by rotating

two turns in anticlockwise direction and drain the
water from the fuel filter.
3. Collect the water and sediment mixed with fuel in
a tray for disposal.

• Water sediments to be drain from Fuel filter first at 5000kms and then at every 10000kms.
• Do not over tight the sediment sensor, over tightening will lead to damage of O‐ring and sensor.
• Water needs to be drained if the water in fuel tell tale lights up in the cluster.

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Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1

710‐MAT‐0210:0.35 hrs.
TRANSAXLE OIL ‐ REPLACE
Transaxle Oil ‐ Maximile SYNTEC 75W‐90
Transaxle Oil Quantity ‐ 03 Lit
Transaxle Oil Replace ‐ Procedure
1. Lift the vehicle.
2. Remove all 10 mm mounting bolts [A] of engine
underbody cover [B].
3. Remove the cover for accessing the transaxle assy.

4. Using a 8 mm allen key, remove the transaxle oil

filling plug [D] from transaxle [C].

5. Place a large drain pan below the drain plug.

6. Using a 8 mm allen key, remove the oil draining
plug [E] from the transaxle [C] and drain the oil
completely. Refix the drain plug once the oil is
completely drained.
7. Fill the oil through filler plug [D] with Maximile
SYNTEC 75W‐90 EXL fluid using a oil filling machine or
clean and transparent pipe attached to the
mechanical hand pump.

• Recommend to use only Mahindra "MAXMILE SYNTEC 75W‐90" Oil.

• Replace the transaxle oil first at 20000Kms & then at 100000Kms.
• As alternate, Castrol Syntrans 75W‐90 can be used. Avoid mixing of these two brands.

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Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1
710‐MAT‐0230:0.25 hrs.
IRDA OIL ‐ REPLACE (Only for AWD models)
IRDA Oil ‐ Maximile DO 80W‐90 EXL
IRDA Oil Quantity ‐ 1.2 Lit
IRDA Oil Replace ‐ Procedure
1. Lift the vehicle.
2. Using a 8 mm allen key, remove the IRDA oil filling
plug [A] from IRDA [B].

3. Place a large drain pan below the drain plug.

4. Using a 8 mm allen key, remove the oil draining
plug [C] from IRDA [B] and drain the oil. Refix the
drain plug once the oil is completely drained
5. Fill the oil through filler plug [A] with Maximile DO
80W‐90 EXL fluid using a oil filling machine or clean
and transparent pipe attached to the mechanical
hand pump.

• Recommended to use only Mahindra "MAXMILE DO 80W‐90 EXL" Oil of recommended quantity 1.2 liters.
• Replace the IRDA oil first at 5000Kms, 50000Kms and then at 100000Kms.
• Other than Maximile brand, oil change interval has to be reduced to 20000kms. If the oil meets the
minimum of API GL5 SAE 80W‐90 specification.

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Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1

710‐MAT‐0570:0.25 hrs.
PTU Oil ‐ REPLACE (Only for AWD models)
PTU Oil ‐ Maximile DO 80W‐90 EXL
PTU Oil Quantity ‐ 0.8 Lit
PTU Oil Replace ‐ Procedure
1. Lift the vehicle.
2. Remove all 10 mm mounting bolt [A] of engine
underbody cover [B].

3. Using a 8 mm allen key, remove the PTU oil filling

plug [C] from PTU [D].

4. Place a large drain pan below the drain plug.

5. Using a 8 mm allen key, remove the oil draining
plug [E] from PTU [D] and drain the oil. Refix the
drain plug once the oil is completely drained.
6. Fill the oil through filler plug [C] with Maximile DO
80W‐90 EXL fluid using a oil filling machine or clean
and transparent pipe attached to the mechanical
hand pump.

• Recommend to use only Mahindra "MAXMILE DO 80W‐90 EXL" Oil of recommended quantity 0.8 litres.
• Replace the IRDA oil by 5000Kms and replace by 50000Kms/ 100000Kms.
• Other than Maximile brand, oil change interval has to be reduced to 20000kms. If the oil meets the
minimum of API GL5 SAE 80W‐90 specification.

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Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1
710‐MAT‐0290:0.15 hrs.
BRAKE AND CLUTCH FLUID LEVEL ‐ LEAK ‐ INSPECT
Brake Fluid ‐ CASTROL “Brake fluid DOT 4”/ SHELL make “Brake & clutch fluid DOT 4”
Brake Fluid Quantity ‐ 01 Lit
Brake and Clutch Fluid Level & Leak Inspect ‐ Procedure
1. Check for Brake Fluid Level up [Max] mark on the
brake fluid reservoir.
2. Check for Brake Fluid leakage and correct fitment
at all joints.
• Brake Master Cylinder outlets.
• Brake tube to flexible hose joint.
• Brake bundy tube at all 'Tee' joints.
• Flexible hose joints at brake callipers.

• Use recommended fluid & do not mix different brand fluids.

• In case brake fluid reservoir replaced, brake and clutch system needs to bleed.
• Brake and clutch fluid level & leak check to be done first at 20000kms, 30000kms and then check every
40000 kms.
• Use the same brand fluid for top up; do not top up with used and unsealed brake fluid container.
• 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.

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Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1

710‐MAT‐0031:0.25 hrs.
BRAKE FLUID REPLACEMENT / BRAKE BLEEDING
Brake Fluid ‐ CASTROL “Brake fluid DOT 4”/ SHELL make “Brake & clutch fluid DOT 4”
Brake Fluid Quantity ‐ 01 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. Do not pump
the brake pedal at any time while bleeding. Air in the system will be compressed into small bubbles that are
distributed through out the hydraulic system. This will make necessary additional bleeding operations.
1. Fill the brake fluid reservoir to the MAX mark.
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.
3. Depress the brake foot pedal and hold it down.

4. Open the bleed screw [A]. The fluid will flow into
the transparent container [B].
5. Tighten the bleed screw and release the pedal.
6. After the pedal returns, allow an interval of 3 to 4
seconds before making the next stroke. Steps 4 to 6
should be repeated until there are no more air
bubbles at the end of the bleed tube.

Now follow the same procedure at the other wheels as per the sequence given below.
a) Rear right
b) Front left
c) Front right
d) Rear left
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.

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CLUTCH FLUID REPLACEMENT / CLUTCH BLEEDING

1. Fill the clutch fluid reservoir to the MAX mark.

2. Remove bleeder plug cap [A] from clutch operating slave cylinder pipe [B]. Attach a vinyl tube [C] to bleeder
plug and insert the other end into container [D]. (Ensure the other end of the tube is completely sub-merged
inside the bottle).

[A]

[B]

3. Operate clutch pedal 3 or 4 times slowly to the full stroke and then while holding it depressed, press the lock
on the connector [B] and pull the pipe [A] by one notch. Please ensure not to pull out the pipe completely.
4. Repeat this operation until there are no more air bubbles in hydraulic line.
5. When bubbles stop hold clutch pedal, push pipe connector and pull clip such that it gets fixed in its position.
6. Then attach bleeder plug cap.
7. After completing bleeding operation, apply fluid pressure to pipe line and check for leakage.
8. Check clutch pedal for spongins. If found spongy, repeat entire procedure of bleeding.

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• Before bleeding the brake system refer to general brake service practice and brake fluid pre‐cautions.
• Always use the brake fluid recommended in the specification list.
• Do not reuse the drained fluid.
• Entire bleeding operation should be done with ENGINE ON (running).
• Always use brake fluid from the sealed bottle.
• 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.

• 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.
• During the clutch and brake bleeding operation ensure fluid level in reservoir.
• During the bleeding operation ensure the container and pipe used is of transparent for better visual.

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710‐MAT‐0330:0.10 hrs.
PRAKING BRAKE CHECK AND ADJUST
Parking Brake Check and Adjust ‐ Procedure
1. Switch off the engine, keep transmission in neutral
position and release the parking brake.
2. Pull and remove the center console top cover [A].

3. Tighten the 10mm parking brake cable adjusting

nut [A] located in the parking brake mechanism.
4. Tighten the hand brake lock nut, and check the
hand brake lever for 4‐6 notches.

• After jacking up the vehicle release the hand brake, then one wheel needs to be blocked while other needs
to be rotated and checked vice versa. Confirm that both the rear wheels are still rotating freely.
• The parking brake has to be inspected first at 5000Kms, 20000Kms and then at every 20000Kms.
• After the adjustment, drive the vehicle up a gradient and verify that the parking brake's operation is
satisfactory.

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710‐MAT‐0310:0.80 hrs.
FRONT AND REAR BRAKE PADS ‐ CHECK
Front Brake Pads Check ‐ Procedure
1. Press the lock and pull out the wear pad sensor
connection.

2. Loosen the brake bleeding nipple to one thread,

compress the caliper piston and allow the oil to drain.
Then tighten the brake bleeding nipple.
3. Loosen the 16mm front caliper lower retaining bolt
[A] from the caliper assembly and carefully move the
caliper upwards without disconnecting the caliper
hose.

4. Remove the brake pads [A] attached with the anti‐

rattle clips.
BRAKE PAD INSPECTION:
Measure the pad lining thickness if it is found to be
10mm or less, it has to be replaced
PAD Thickness:11mm
Useful PAD Thickness:10mm

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5. Remove the anti rattle clips [A] from the caliper
bracket.

• 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.
• Check brake pads at every 10000 kms.
• The inboard pads are provided with wear indicator assembly. Hence the brake pads are not interchangeable.
• DO NOT use grease to the pad shims/ anti‐rattle shims.

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Rear Brake Pads Check ‐ Procedure
1. Remove the rear wheels.

2. Lift the parking brake lever [A], and detach the

parking brake cable from the caliper.
3. Loosen the bleed screw and allow the brake fluid
to get drained.

4. Remove two 12mm caliper mounting bolts [A] from

the caliper bracket.

5. Remove the brake pads [A] from the anti‐rattle

clips.

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6. Detach the anti‐rattle clips [A] from the caliper

bracket.

7. Piston Screwing direction same as lever rotation for

moving piston inside caliper housing.

8. After piston screwing in caliper housing, final

position of piston to be such that piston slot to be
aligned to caliper reference point.

9. Groves on piston to be matched.

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10. Using the tool push the piston inside by rotating

11. Special tool used for screwing caliper piston (MST
no.0604BAA0001ST).

• 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.
• Check brake pads at every 10000 kms.
• While screwing piston inside, check the piston boot get back in its housing with out deformation and
without over hanging of the piston face. This could result in boot cut by pads at caliper assembly, or boot
burning by contact with hod pads during service.
• Check that pin at the back of inner pads are placed inside piston face groove.
• DO NOT use grease to the pad shims/ anti‐rattle shims.

• Always replace all four brake pads at a time. If the pads are to be reused make sure they are assembled
back in the same position as they where when they removed. piston side pad on to the piston side and out
side pad on to the outer side. This is possible only when at the time of removal of these pads ar marked for
their position and kept outside.
• Never lubricate the pad seating areas as this may lead to jamming.
• After assembly of pads, apply brake pedal 5 ‐ 6 times in static condition in order to make the pads align
properly.
• It is recommended to apply light braking during the road test and avoid heavy and continuous braking
during the initial 200kms of run or until the new pads are performing satisfactorily.
• Measure the pad lining thickness (Front & Rear) if it is found to be 10mm or less, it has to be replaced.

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710‐MAT‐0340:0.25 hrs.
FRONT SUSPENSION BOLT TORQUE ‐ INSPECT
Front Suspension Bolt Torque Inspect ‐ Procedure
1. Two M16 mounting bolts [A] and nuts [B] at
bottom of the strut assembly (145 ± 25 Nm).

2. Three M10 mounting nuts [A] at upper part of the

strut assembly (52.5 ± 10 Nm).

3. One M12 pinch bolt [A] and M12 mounting nut [B]
at the lower control arm ball joint (110 ± 10 Nm).

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4. Two M14 front and rear pinch bolts [A] and nut
from the lower control arm (145 ± 25 Nm).

5. Two M10 anti roll bar bush mounting clamp bolts

[A] (52.5 ± 7.5 Nm).

6. Two M12 wheel bearing mounting bolts [A] two

M12 wheel bearing mounting bolts ‘B’ of the wheel
knuckle (110 ± 10 Nm).

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7. Two rear mounting bolts [A] and 18mm nut ‘B’ on
both sides of the cradle bracket. [A]

8. One front mounting nuts [A] on sides of the cradle

bracket.

9. Four 21mm cradle mounting bolts [A] at the

chassis.

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10. Remove the lock pin [A], Tighten the nut ‘B’ of
the steering ball joint connected to the knuckle.

• 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.
• The suspension bolts torques has to be inspected by 5000kms, 20000kms and every 20000kms.
• For suspension bolt tightening, refer the below torque chart.

Description Torque Values (Nm)

Lower control arm front 150 ± 20
Lower control arm Rear 150 ± 20
LCA knuckle ball joint 100 ± 10
Bracket stab mtg. Front 53 ± 7
Stab bar link mtg. Front 95 ± 15
Front shock absorber bottom 150 ± 20
Front shock absorber Top 53 ± 7

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710‐MAT‐0350:0.20 hrs.
REAR SUSPENSION BOLT TORQUE ‐ INSPECT
Front Suspension Bolt Torque Inspect ‐ Procedure
1. One M14 shock absorber mounting bolt and nut
[A] on the rear lower link (145 ± 25 Nm).

2. Two M10 top mounting nuts [A] at the shock

absorber (52.5 ± 7.5 Nm)

3. Four M14 shock absorber bracket mounting bolts

[A] (145 ± 25 Nm)

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4. Two M14 bolts [A] at the RH side of the stabilizer
bar.

5.Two 16mm bolts [A] at the LH side of the stabilizer

bar.

6. Two 19mm link rod mounting bracket bolts ‘A’ and

nuts [B].

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7. Link lower front mounting nut [A] at the knuckle
side.

8. Link lower front mounting bolt [A] at the chassis

side.

9. Link upper front bolt [A] and nut [B].

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10. Link upper front cradle side mounting bolt [A] and
nut [B].

11. Rear lower link bolt and nut [A] on the knuckle
side.

12. Toe bar mounting nut and bolt [A] on the cradle
side.

13. Two 24mm bolts [A] and nuts [B] on the cradle
assembly

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14. Mounting bolts [A] on the wheel bearing.

• 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.
• The suspension bolts torques has to be inspected by 5000kms, 20000kms and every 20000kms.
• For suspension bolt tightening, refer the below torque chart.

Description Torque Values (Nm)

Upper control link front knuckle 150 ± 20
Upper control link front Frame 150 ± 20
Upper control link rear knuckle 95 ± 15
Upper control link rear Frame 150 ± 20
Lower control link front knuckle 150 ± 20
Lower control link front Frame 150 ± 20
Lower control link front knuckle 150 ± 20
Lower control link rear Frame 160 ± 10
TOE Bar frame 150 ± 20
Toe bar ball joint knuckle 150 ± 20
Rear Toe bar center nut - 2nos 90 ± 10
Brkt Stab bar mtg. Rear 53 ± 7
Stab Bar link mtg. Rear 95 ± 15
Rear frame front & rear mtg. 210 ± 30
Rear shock absorber bottom 150 ± 20
Rear shock absorber Top 53 ± 7

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710‐MAT‐0360:0.20 hrs.
FRONT SUSPENSION BUSHES ‐ INSPECT
Front Suspension Bushes Inspect ‐ Procedure

A. Strut Bush D. Rear lower Control Bush

B. Upper Cradle Mounting Bush E. Anti Roll Bar Bush
C. Front lower Control Bush

1. Check lower control arm front and rear bush condition (both LH & RH) for wear & tear, cracks & shift. Replace
if necessary.
2. Check the ball joint boots for damage, cracks, Replace if necessary.
3. Check Shock Absorber Bushes, dust boot & Stabilizer Bar Links and Bush for wear & tear, cracks and shift,
Replace if necessary.

• 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.
• The suspension bushes are to be inspected by 40000kms and every 40000kms.

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710‐MAT‐00380:0.20 hrs.
REAR SUSPENSION BUSHES ‐ INSPECT
Rear Suspension Bushes Inspect ‐ Procedure

A. Link Upper Rear Bush F. Link Lower Front Bush

B. Cradle Bush G. Rear Stabilizer Bar Bush
C. Link Upper Front Bush H. Toe Bar Bush
D. Shock Absorber Bush I. Link Lower Arm Bush
E. Link Upper Rear Bush

1. Check all the suspension link Rubber Bushes for, wear, ageing, cracks and metal sleeve separation.
2. Check the Upper & Lower Links and link Rod for damage/ bent etc.
3.Check shock absorber bushes for wear, crack and shift.

• 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.
• The suspension bushes are to be inspected by 40000kms and every 40000kms.

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710‐MAT‐0380:0.20 hrs.
SUSPENSION ARMS AND LINKS ‐ INSPECT
Suspension Arms and Links Inspect ‐ Procedure

• 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.
• The suspension bolts torques has to be inspected by 5000kms, 20000kms and every 20000kms.

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710‐MAT‐0390:0.10 hrs.
POWER STEERING LEAK AND LEVEL ‐ INSPECT
Power Steering Fluid ‐ SHELL Make”SPIRAX S3 ATF MD3” (0.7 lit for FWD/ 0.9 lit for AWD)
Power Steering Fluid ‐ CALTEX Make”TEXAMATIC 1888” (0.7 lit for FWD/ 0.9 lit for AWD)
Power Steering Fluid Part Number ‐ 1102EA0032N (1lit)
Power Steering Leak and Level Inspect - Procedure
1. Check the power steering reservoir level which
should be between the MAX and the MIN.

2. Check the links and the hoses for the leakage, top
up if required.

• Power steering oil level and leak to be inspected first 5000 kms then at every 10000kms.
• Recommended brands: SHELL Make "SPIRAX S3 ATF MD3"/ CALTEX Make "TEXAMATIC 1888".
• Brands are specific, No other brands recommended.

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710‐MAT‐0420:0.70 hrs.
WHEEL ALIGNMENT ‐ INSPECT
Wheel Alignment and Sequence Of Operation ‐ Procedure

Step 1:
Toe Adjustment
Step 2:
Rear Toe Camber Adjustment
Adjustment
Step 3:
Toe and
Camber Setting

1. Refer the wheel alignment specification chart for the Front and Rear Suspension.
2. Before doing wheel alignment, ensure front and rear tyre pressure are as per specifications. Vehicle to be run
for some distance before starting the wheel alignment. This will settle the load on each tyre.
3. Park the vehicle on wheel alignment machine and do the wheel mapping w.r.t. Machine.
4. Do the setting of Front steering wheel for Straight ahead Position (SAP) and lock the steering column rotation.
5.Wheel alignment for Rear Suspension to be done first and then Front Suspension to be carried out.
a. Firstly Toe adjustment to be done for which Toe bar with threaded Hex Nut is provided.
b. Then Camber adjustment to be done for which eccentric screw is provided on Frame lower Mtg.
6. STEP 1: On Rear RH side, first adjust the RH toe by shifting the hex nut and bring to specified band.
STEP2: Then adjust the RH camber by rotating the Camber bolt and bring to the specified values. Full
Torque Torque to be applied on camber nut by ensuring the specified camber values.
STEP 3: Then RH toe to be adjusted if gone out of specs and full torque to be applied on RH toe bar.
7. The same sequence to be followed on Rear LH side for LH toe and LH Camber adjustment. The total toe
should be within specified values.

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8. Front wheel alignment includes adjustment of Front Toe angle & camber angle (if required).
• Toe: First loose the lock nut on Toe rod assy by holding the OBJ housing and then adjust the toe by rotating
the IBJ shank. After setting the toe, torque the lock nut by holding the OBJ housing as shown in figure.
• Camber: There is no provision given for front camber adjustment. If camber value is found out of
specification range, then use following hardware in place of existing M16 strut mounting bottom hardware.
Bolt Hex Fl. M14 X 1.5X 80 X 8.8
Nut Hex Fl.M14 X 1.5 X14
9. After assembling above hardware, required camber specs is to be ensured by puling/ pushing the wheel end
assy. as required. Torque value of 150 ± 10 Nm to be ensured on these hardware
Ride Height:
Ride height is to be measured from wheel center to the wheel arc for both front and rear in unladen condition
(Ride Height ‐ 516 ± 10mm). Refer front & rear ride height.

• Wheel alignment to be carried if abnormal conditions are noticed or at 40000kms, whichever is earlier.
• Wheel alignment for Rear Suspension to be done first and then Front Suspension to be carried out.

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• After wheel alignment toe setting adjustment, tightening torque on Rear toe bar nut and Steering tie rod
nut is MUST required. The torque delivery to this nut joint has to be ensured with open end torque range
tool (shown below). Manual torque tightening on this joint will not deliver intended torque.
Wheel Alignment Specification
Front Suspension:

Parameter Specification Max difference between LH and

RH side
Caster 2º 30´ to 4º 30´
Camber ‐0º30´ to +0º 30´ 0º 30´
Toe RH ‐1.0 mm to +1.0 mm
Toe LH ‐1.0 mm to + 1.0 mm
Toe Total ‐2.0 to + 2.0 mm 2.0 mm
Tyre Pressure 32 psi
Ride Height 480mm ±10mm

Rear Suspension:
Parameter Specification Max difference between LH and
RH side
Camber 0 to 1º 0º 30´
Toe RH - 1 mm to + 1.0 mm
Toe LH ‐ 1 mm to +1.0 mm
Toe Total ‐ 2 mm to + 2.0 mm 2.0 mm
Tyre Pressure 30 psi
Ride Height 516mm ±10mm

Special Tool:

Image Tool Part No Description

0402BAA0021ST Rear Toe Bar center Nut

Torque tightening tool

0401BAA0032ST Steering Toe Bar Nut torque

tightening tool

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710‐MAT‐0430:0.10 hrs and 710‐MAT‐440:0.20 hrs.
BATTERY ELECTROLYTE LEVEL AND SPECIFIC GRAVITY ‐ INSPECT
Battery Inspect ‐ Procedure

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 any cracked or broken cables/ connections, and replace the cables if necessary.
3. 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.
4. Check for a loose battery hold down and tighten it if necessary.
5. 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.
6. 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.

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AMARON BATTERY:

Specific Gravity v/s With% Charge Specific Gravity v/s With OCV

EXIDE BATTERY:

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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.
2. Squeeze the hydrometer bulb and insert the pickup
tube into the cell close to the battery positive
terminal.
3. Slowly release the bulb to draw in only enough
electrolyte 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 the 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.

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

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710‐MAT‐0450:0.30 hrs.
All LIGHTS, HORNS, WIPERS AND WASHER ‐ INSPECT
All Lamp ‐ Inspect

1.

.11
2.
.10
3.

4.

5. 6. .9

.8

Camping lamp (on tail gate).7

1. Roof lamps [1] and [2] are LED based roof lamps with three position ON/OFF/DOOR, the lamp will ON when
the door opens.
2. MAP reading lamps [9] are also LED based lamps with lens operated toggle type switch for ON/OFF, MAP
reading lamps are only available in W3/W4 versions in 2nd & 3rd row.
3. Door puddle lamp [6] & Door marker lamp [5] are part of door trims. These lamp will operate with the door
open condition.
4. Entry assistance lamp [11] is located in the ORVM & LED based. It operates only during vehicle unlock
through remote, with previous ignition cycle with park switch on condition.
5. Ambience lighting is controlled by MBFM. This feature can be ON/OFF by pressing courtesy lamp switch in
central bezel switch.

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EXTERIOR LIGHTING - INSPECT

Head Lamp Low Beam ‐ INSPECT

1. To inspect, rotate the outer switch clockwise to the
second position to switch ON the head lamp low
beam.

2. The headlight is a replaceable headlight (Blue ray /

halogen) bulb. A bulb can be replaced from inside the
engine compartment.
3. The head lamp low beam bulb location is shown in
below.

Head Lamp High Beam ‐ INSPECT

1. To inspect, turn ON head lamp low beam, push the
head lamp lever down to switch ON the head lamp
high beam. The head lamp high beam indicator in the
instrument cluster is also illuminated.

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2. The headlight is a replaceable headlight (Blue Ray /
halogen) bulb. A bulb can be replaced from inside the
engine compartment.
3. The head lamp high beam bulb location is shown in
below.

• The ignition switch must be in “ON” position to turn ON headlights.

Bulb Description Bulb Type Volts, Power Qty / Veh

Front High Beam H7 55W 12V, 55W 2
Front Low Beam H7 55W 12V, 55W 2
Front Position / Parking Lamp (if W 5W 12V, 5W 2
equipped)
Front Turn Indicator Lamp P 21W 12V, 21W 2
Front Static Bending Lamp H1 55W 12V, 55W 2
Front Fog Lamp H8 35W 12V, 35W 2
Stop Lamp P 21W 12V, 21W 2
Rear Turn Indicator Lamp PY 21W 12V, 21W 2
Reverse Lamp P 21W 12V, 21W 2
Rear Position / Parking Lamp W 5W 12V, 5W 6
Rear Side Marker Lamp W 5W 12V, 5W 2
Rear Fog Lamp PR 21W 12V, 21W 2

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Flashing the Headlight - Inspect
1. To inspect, to flash the headlights, pull the lever
fully towards the steering wheel. This does not
require the head lamp to be switched ON and the
lever will return to the normal position when
released.

• The ignition switch must be in "ON" position to turn ON the headlights.

Head lamp levelling ‐ Inspect

1. To inspect, turn the thumb wheel downward to
lower the beams and upward to raise the beam. Head
lamp low beam can be adjusted using head lamp
levelling switch. It has positions marked ‐ 0, 1, 2, 3.
Please select the suitable switch position.

• The head lamp levelling can be done only in the low beam condition.

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Hazard Warning Indicator ‐ Inspect
1. To inspect, press the hazard warning switch to
operate the hazard warning lamps. All of the direction
indicator lamps will flash together.

• The direction indicators do not work when the hazard warning is activated. Check local regulations about
the use of hazard warning lamp while the vehicle is being towed or while driving

Turn Signal Indicator ‐ Inspect

1. To inspect, the key must be in "ON" position. To
signal a turn, move the lever all the way up or down.
The lever returns automatically after you make a turn,
but should be disengaged manually while changing
lanes.
2. An arrow or indicator lamp in the instrument
cluster will flash in the direction of the turn or lane
change.

3. The turn indicator lamp location is shown in the

picture.

• If an indicator lamp stays "ON" without flashing or if it flashes abnormally, the direction indicator bulb may
be burnt out.

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Front Fog Lamp ‐ Inspect
1. To inspect, switch ON the position lamps and/or
head lamp. Rotate the fog lamp rotary switch in
clockwise direction to switch ON the front fog lamps.
The front fog lamp indicator illuminates in the
instrument cluster.

2. The switch will spring back to its initial position

after switching ON the fog lamp.
3. The Fog lamp location is shown in the picture.

Horn ‐ Inspect
1. Check the horn for operation and connectors if
required.

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Rear Turn Lamp - Inspect
1. To inspect, the key must be in "ON" position. To
signal a turn, move the lever all the way up or down.
The lever returns automatically after you make a turn,
but should be disengaged manually while changing
lanes.

2. An arrow or indicator lamp ON the instrument

cluster will flash in the direction of the turn or lane
change
3. Rotate the indicator bulb holder in antic lock wise
direction and remove the bulb from the holder.
4. Follow the same procedure for the other rear
bulbs.

• If rear turn lamp stays "ON" without flashing or if it flashes abnormally, the direction indicator bulb may be
burnt out.
High Mounted Stop lamp ‐ Inspect

1. The high mounted stop lamp will illuminate, when the brake pedal is pressed.

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710‐MAT‐0460:0.50 hrs.
HEAD LIGHT AIMING/ALIGNMENT ‐ CHECK AND ADJUST
Headlamp Alignment by Visual Method (Refer Below Illustration):

Ensure that the:

a. Vehicle & screen/ board both are placed on the same Level surface.
b. Check and ensure all four tyre pressures as per specification.
c. Head lamp levelling switch position is on zero (0).
d. Parking brake is ON and the gear lever is in neutral mode.
e. Keep the vehicle at a distance of 10 meter from the screen/ board.
Refer the below illustration for the headlamp bulb arrangement ‐

A ‐ High Beam C ‐ Low Beam

B ‐ Static Bending Lamp D ‐ Turn Indicator Lamp

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Headlamp Alignment Process:
STEP 1 ‐ Setting the low beam
STEP 2 ‐ Setting the high beam
STEP 1 ‐ Low Beam Setting Procedure:
Refer below illustration for the headlamp low beam cut off Pattern:

X = 935mm Y = 905mm
X- 1.3% = 922mm V = 495mm
Z = 645mm
 Set LH & RH head lamp (Low Beam) by setting the cut off pattern at a height marked on the board. Refer
above illustration for low beam cut off pattern.
Refer below illustration for LH & Rh side head lamp low beam alignment settings.
• Set screw [A] to adjust low beam horizontal movement.
• Set screw [B] on leveling motor to adjust low beam vertical movement.

[A] Horizontal Adjustment

Left: Anti‐clockwise
Right: Clockwise
[B] Vertical Adjustment
Up: Anti‐clockwise
Down: Clockwise

XUV500 LH side Head Lamp ‐ Rear View

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Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1
 Check the function of system, by operating the switch from '0' to '3' and observe the cutoff pattern
movement in downward direction accordingly.
At zero position of switch, the cut‐off should come at ‐1.3% heights (9Ϯ2mm) on screen.
STEP 2 ‐ High Beam Setting Procedure:
Refer below illustration for the headlamp High beam cut off Pattern:

X = 935mm Y = 905mm
X- 1.3% = 922mm V = 495mm
Z = 645mm
 Set LH & RH head lamp (High Beam) by setting the cut off pattern at a height marked on the board. Refer
above illustration for high beam cut off pattern.
Refer below illustration for LH & RH side head lamp high beam alignment settings.
• Set screw [C] to adjust low beam horizontal movement.
• Set screw [D] to adjust low beam vertical movement.

[C] Vertical Adjustment

Up: Anti‐clockwise
Down: Clockwise

[D] Horizontal Adjustment

Left: Anti‐clockwise
Right: Clockwise

XUV500 LH side Head Lamp ‐ Rear View

Page 63
Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1

• As far as possible High beam setting (Horizontal/ Vertical) should not to be disturbed.
• Refer below vehicle head light dimension in unladen conditions.
• Since the high beam spreads out, it is very difficult to identify the center/ Hot spot. Hence it is not
recommended to change the aim of high beam unless otherwise warranted by an accident repair or front
end damage

Page 64
Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1
710‐MAT‐0470:0.15 hrs.
HVAC PARTICAL FILTER ‐ CLEAN
HVAC Particle Filter Removal ‐ Procedure
1. Remove the RHS trim of the center console [A].

2. Press lock [A] and remove the particle filter cover

[B].
3. Pull out the two particle filter from the HVAC
housing.

HVAC PARTICAL FILTER ‐ INSPECTION AND CLEANING

1. Check if the particle filter is completely blocked or dusty. Clean if required or replace if necessary.
2. Clean the particle filter by using soap solution if it is blocked completely and dry the filter by blowing low
pressure air.

• Check if the particle filter is completely blocked or dusty. Clean if required or replace if necessary.
• While installing the filters check the slot seating position and install them in proper position.

• Clean the particle filter element for every 10,000 kms under normal operating conditions. Under highly
dusty or polluting conditions, early replacement may be required.

Page 65
Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1
710‐MAT‐0490:0.30 hrs.
TYRE PRESURE ‐ INSPECT AND ADJUST
Tyre Pressure Inspect and Adjust ‐ Procedure
Proper tyre inflation pressure is essential to the safe and satisfactory operation of your vehicle. Three primary
areas are affected by improper tyre pressure.
a. Safety
b. Economy
c. Ride Comfort and Vehicle Stability
Proper tyre inflation contributes to a comfortable and safe ride. Overinflating produces harsh and uncomfortable
ride. Both under inflation and over inflation affect the stability of the vehicle and can produce a feeling of
sluggish response or over responsiveness in the steering. Unequal tyre pressures can cause erratic and
unpredictable steering response or may cause the vehicle to drift left or right Improper inflation pressures can
cause uneven wear patterns to develop across the tyre tread. These abnormal wear patterns will reduce tread
life resulting in a need for earlier tyre replacement. Underinflation also increases tyre rolling resistance and
results in higher fuel consumption.
Tyre Pressure Label:
• It is located at the bottom side of B pillar near
driver's door.

TYRE INFORMATION
TYRE SIZE RECOMMENDED TYRE PRESSURE
FRONT P235/65 R17 32 psi/2.2 bar/ 220kpa
REAR P235/65 R17 30 psi/2.0bar/ 200kpa

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Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1
710‐MAT‐0540:0.50 hrs.
UNDER BODY, NUTS AND BOLTS TIGHTNESS ‐ INPSECT AND ADJUST
For under body nuts and bolts tightness please refer the below torque chart.

Description Torque Values (Nm)

Steering
Steering gear to cradle bolt 85.0 ± 5.0
OBJ slotted nut 80.0 ± 5.0
Front Suspension
LCA with cradle front and rear side 145.0 ± 25.0
LCA ball joint to knuckle 100.0 ± 10.0
Front LCA mounting nut 80.0 ± 5.0
Stabilizer bar link to strut 90.0 ± 10.0
Shock absorber mounting to LCA 145.0 ± 25.0
Rear Suspension
Rear stabilizer bar to knuckle 90.0 ± 110.0
Lower link to knuckle side 145.0 ± 25.0
Camber cam nut side 160.0 ± 10.0
Upper link front to knuckle 145.0 ± 25.0
Upper link rear to knuckle 90.0 ± 10.0
Toe bar to frame/ Knuckle side 145.0 ± 25.0
Rear cradle (FWD) to BIN 205.0 ± 35.0
Rear cradle (AWD) to BIN 205.0 ± 35.0
Front cradle to BIW (Special bolt) 190.0 ± 10.0
Wheels
Wheel Nut M14 (Rim) 95.0 ± 10.0
Wheel Nut (Alloy Wheel) 120.0 ± 10.0

Page 67
Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1
710‐MAT‐0180:0.30 hrs.
TYRE ROTATION
Tyre Rotation ‐ Procedure
Tyres on the front and rear axles of vehicles operate at different loads and perform different steering, handling,
and braking functions. For these reasons, they wear at unequal rates and develop irregular wear patterns.
Rotation will increase tread life, help to maintain mud, snow, and wet traction levels, and contribute to a
smooth, quiet ride. Follow the recommended tyre rotation.
It is recommended to rotate the tyres as per "Maintenance Schedule".
Suggested Tyre rotation method:
Steps for tyre rotation:
1. Spare wheel should go to front Left wheel.
2. Rear Left wheel should go to spare wheel.
3. Rear Right wheel should go to Front right wheel.
4. Front Right wheel should go to Rear left wheel.
5. Front Left wheel should go to rear right wheel.

XUV500 Tyre Rotation Schematic

XUV500 TPMS Learning Switch [A] and Warning Indicator[B]

Page 68
Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1
TPMS Learning procedure:
TPMS learning switch is located to the left hand side of the instrument cluster.
1. Press the TPMS switch in the cluster and turn
ignition ON along with the switch pressed,
infotainment will be displayed as below and TPMS
warning lamp in the cluster will start blinking.

2. Start removing air from front left tyre, once the

tyre get learnt, vehicle alarm and hazard lamp will
alert once and the screen in the infotainment will
change as shown in the illustration.

3. Start removing air from front right tyre. Once the

tyre get learnt, vehicle alarm and hazard lamp will
alert once and the screen in the infotainment will
change as shown in the illustration.

Page 69
Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1

4. Start removing air from rear right tyre. Once the

tyre get learnt, vehicle alarm and hazard lamp will
alert once and the screen in the infotainment will
change as shown in the illustration.

5. Start removing air from rear left tyre. Once the tyre
get learnt, vehicle alarm and hazard lamp will alert
once and the screen in the infotainment will change
as shown in the illustration.

6. Start removing air from spare tyre. Once the tyre

get learned, vehicle alarm and hazard lamp will alert
3 times to indicate all the tyres were learned and the
screen in the infotainment will change as shown in
the illustration indicate all tyres were learnt
successfully.
7. If there were any problem in learning, system will
alert through alarm and hazard lamp 5 times to
indicate the tire learning is not complete.

• After tyre rotation or TPMS sensor replacement, receiver must be learnt, otherwise the system will show
TPMS malfunction indicator.
• The TPMS should not be used as a tyre pressure gauge while adjusting vehicle tyre pressure.

Page 70
Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1
710‐MAT‐0580:0.15 hrs.
DIS SERVICE INTERVAL REMINDER ‐ RESET
DIS Service Interval Reminder Reset ‐ Procedure

The service reminder alert will start popping up in the infotainment at 500 kms before the actual kilometers at
which the service is due. This will continue at every ignition cycle when the engine is running and the vehicle
speed is more than 10Kmph. It is necessary to reset the service reminder once the service is rendered to the
vehicle. If not reset, the service alert will continue to pop up at every ignition cycle when the engine is running
and the vehicle speed is more than 10Kmph, till it is reset by using diagnostic tester.
The sequence of service reminder reset is given below.
1) Connect using the "Python 1BConfig0404"
2) Click the "XUV500 Diagnostic Tester " icon present on the desktop
The following window appears:

3) Click on "IC"(Instrument Cluster)

The following window appears

Page 71
Maintenance Manual MAN-00147
XUV500 Sept 2011/ Rev 1

4) Click on "WRITE DATA"

The following window appears

The following window appears

Page 72
Maintenance Manual MAN-00147

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a r esult of changes introduced by the
manufacturer in the pr oduction of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the pr esent 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 t he Authorized Service Centre of Mahindra & Mahindra
Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd. Page 73
Maintenance Manual MAN-00147

@ 5000 KMS

WORK STATUS Time Allotted

WORK NATURE ACTION
Complete Incomplete (Man-hours)
Engine oil REPLACE 0.30
Engine oil filter REPLACE 0.15
Coolant INSPECT 0.05
Water sediments drain-Fuel filter
INSPECT 0.10
(or when indicator glows)
IRDA oil REPLACE 0.25
PTU oil REPLACE 0.25
Parking brake INSPECT 0.10
Front suspension bolts torque INSPECT 0.20
Rear Suspension bolts torque INSPECT 0.20
Power steering fluid- level check INSPECT 0.10
Tyre pressure INSPECT 0.30
Road Test INSPECT -
Service reminder indicator reset INSPECT 0.15

 Additional Repair 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 Service –
Job End Time:
Repair order No.
Repair order date - Standard Time: 02.15 man-hrs.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a r esult of changes introduced by the
manufacturer in the pr oduction of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the pr esent 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 t he Authorized Service Centre of Mahindra & Mahindra
Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd. Page 74
Maintenance Manual MAN-00147

@ 10,000 KMS

WORK STATUS Time Allotted

WORK NATURE ACTION
Complete Incomplete (Man-hours)
Engine oil INSPECT 0.05
Coolant INSPECT 0.05
Exhaust pipe mountings &
INSPECT 0.10
damage/leakage
Water sediments drain-Fuel filter
INSPECT 0.10
(or when indicator glows)
Front and rear brake pads /
INSPECT 0.80
caliper
Power steering fluid- level check INSPECT 0.10
Battery electrolyte level &
INSPECT 0.20
specific gravity
All Light, Horns, Wipers &
INSPECT 0.30
Washers
Head light aiming INSPECT 0.50
Particle filter CLEAN 0.15
Tyre pressure INSPECT 0.30
Under body, nuts and bolts for
INSPECT 0.50
tightness
Road Test INSPECT -
Tyre rotation INSPECT 0.30
Service reminder indicator reset INSPECT 0.15

 Additional Repair 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 Service –
Job End Time:
Repair order No.
Repair order date - Standard Time: 03.60 man-hrs.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a r esult of changes introduced by the
manufacturer in the pr oduction of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the pr esent 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 t he Authorized Service Centre of Mahindra & Mahindra
Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd. Page 75
Maintenance Manual MAN-00147

@ 20,000 KMS

WORK STATUS Time Allotted

WORK NATURE ACTION
Complete Incomplete (Man-hours)
Engine oil REPLACE 0.30
Engine oil filter REPLACE 0.15
Coolant INSPECT 0.05
Fuel filter cartridge REPLACE 0.25
Exhaust pipe mtgs. & leakages INSPECT 0.10
Transaxle oil REPLACE 0.35
Brake & Clutch fluid-level check INSPECT 0.15
Parking brake INSPECT 0.10
Front & rear brake pads / caliper INSPECT 0.80
Front suspension bolts torque INSPECT 0.25
Rear Suspension bolts torque INSPECT 0.20
Power steering fluid- level check INSPECT 0.10
Battery electrolyte & sp. gravity INSPECT 0.20
All Light, Horns, Wipers/ Washers INSPECT 0.30
Head light aiming INSPECT 0.50
Particle filter CLEAN 0.15
Tyre pressure INSPECT 0.30
Under body/nuts & bolts tightness INSPECT 0.50
Road Test INSPECT -
Tyre rotation INSPECT 0.30
Service reminder indicator reset INSPECT 0.15

 Additional Repair 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 Service –
Job End Time:
Repair order No.
Repair order date - Standard Time: 05.20 man-hrs.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a r esult of changes introduced by the
manufacturer in the pr oduction of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the pr esent 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 t he Authorized Service Centre of Mahindra & Mahindra
Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd. Page 76
Maintenance Manual MAN-00147

@ 30,000 KMS

WORK STATUS Time Allotted

WORK NATURE ACTION (Man-hours)
Complete Incomplete
Engine oil INSPECT 0.05
Coolant INSPECT 0.05
Exhaust pipe mountings &
INSPECT 0.10
damage/leakage
Water sediments drain‐Fuel filter
INSPECT 0.10
(or when indicator glows)
Brake & Clutch fluid‐level check INSPECT 0.15
Front and rear brake pads / caliper INSPECT .80
Power steering fluid‐ level check INSPECT 0.10
Battery electrolyte & sp. gravity INSPECT 0.20
All Light, Horns, Wipers & Washers INSPECT 0.30
Head light aiming INSPECT 0.50
Particle filter CLEAN 0.15
Tyre pressure INSPECT 0.30
Under body, nuts and bolts for
INSPECT 0.50
tightness
Road Test INSPECT ‐
Tyre rotation INSPECT 0.30
Service reminder indicator reset INSPECT 0.15

 Additional Repair 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 Service –
Job End Time:
Repair order No.
Repair order date - Standard Time: 03.75 man-hrs.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a r esult of changes introduced by the
manufacturer in the pr oduction of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the pr esent 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 t he Authorized Service Centre of Mahindra & Mahindra
Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd. Page 77
Maintenance Manual MAN-00147

@ 40,000 KMS

WORK STATUS Time Allotted

WORK NATURE ACTION
Complete Incomplete (Man-hours)
Engine oil REPLACE 0.30
Engine oil filter REPLACE 0.15
Coolant INSPECT 0.05
Air filter element REPLACE 0.15
Fuel filter cartridge REPLACE 0.25
Exhaust pipe mtgs & damage/leakage INSPECT 0.10
Water sediments drain-Fuel filter INSPECT 0.10
Brake & Clutch fluid-level check REPLACE 0.35
Parking brake INSPECT 0.10
Front and rear brake pads / caliper INSPECT 0.80
Front suspension bolts torque INSPECT 0.25
Rear Suspension bolts torque INSPECT 0.20
Suspension bushes INSPECT 0.20
Suspension arms & links INSPECT 0.20
Power steering fluid- level check INSPECT 0.10
Wheel alignment INSPECT 0.70
Battery electrolyte & sp. gravity INSPECT 0.20
All Light, Horns, Wipers & Washers INSPECT 0.30
Head light aiming INSPECT 0.50
Particle filter CLEAN 0.15
Tyre pressure INSPECT 0.30
Under body, nuts/bolts for tightness INSPECT 0.50
Road Test INSPECT -
Tyre rotation INSPECT 0.30
Service reminder indicator reset INSPECT 0.15

 Additional Repair Work carried out, if any -

1)
 Observations, Notes if any -
1)

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: 06.40 man-hrs.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a r esult of changes introduced by the
manufacturer in the pr oduction of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the pr esent 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 t he Authorized Service Centre of Mahindra & Mahindra
Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd. Page 78
Maintenance Manual MAN-00147

@ 50,000 KMS

WORK STATUS Time Allotted

WORK NATURE ACTION
Complete Incomplete (Man-hours)
Engine oil INSPECT 0.05
Coolant INSPECT 0.05
Exhaust pipe mountings &
INSPECT 0.10
damage/leakage
Water sediments drain-Fuel filter INSPECT 0.10
IRDA oil REPLACE 0.25
PTU oil REPLACE 0.25
Brake & Clutch fluid-level check INSPECT 0.15
Front and rear brake pads / caliper INSPECT 0.80
Power steering fluid- level check INSPECT 0.10
Battery electrolyte level & specific
INSPECT 0.20
gravity
All Light, Horns, Wipers & Washers INSPECT 0.30
Head light aiming INSPECT 0.50
Particle filter CLEAN 0.15
Tyre pressure INSPECT 0.30
Under body, nuts and bolts for
INSPECT 0.50
tightness
Road Test INSPECT -
Tyre rotation INSPECT 0.30
Service reminder indicator reset INSPECT 0.15

 Additional Repair Work carried out, if any -

1)

 Observations, Notes if any -

1)

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: 04.25 man-hrs.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a r esult of changes introduced by the
manufacturer in the pr oduction of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the pr esent 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 t he Authorized Service Centre of Mahindra & Mahindra
Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd. Page 79
Maintenance Manual MAN-00147

@ 60,000 KMS

WORK STATUS Time Allotted

WORK NATURE ACTION (Man-hour)
Complete Incomplete
Engine oil REPLACE 0.30
Engine oil filter REPLACE 0.15
Auto tensioner & belt INSPECT 0.15
Coolant INSPECT 0.05
Fuel filter cartridge REPLACE 0.25
Exhaust pipe mtgs. & damage/leakage INSPECT 0.10
Water sediments drain‐Fuel filter INSPECT 0.10
Brake & Clutch fluid‐level check INSPECT 0.15
Parking brake INSPECT 0.10
Front and rear brake pads / caliper INSPECT 0.80
Front suspension bolts torque INSPECT 0.25
Rear Suspension bolts torque INSPECT 0.20
Power steering fluid‐ level check INSPECT 0.10
Battery electrolyte & specific gravity INSPECT 0.20
All Light, Horns, Wipers & Washers INSPECT 0.30
Head light aiming INSPECT 0.50
Particle filter CLEAN 0.15
Tyre pressure INSPECT 0.30
Under body, nuts &bolts for tightness INSPECT 0.50
Road Test INSPECT ‐
Tyre rotation INSPECT 0.30
Service reminder indicator reset INSPECT 0.15

 Additional Repair Work carried out, if any -

1)

 Observations, Notes if any -

1)

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: 05.10 man-hrs.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a r esult of changes introduced by the
manufacturer in the pr oduction of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the pr esent 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 t he Authorized Service Centre of Mahindra & Mahindra
Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd. Page 80
Maintenance Manual MAN-00147

@ 70,000 KMS

WORK STATUS Time Allotted

WORK NATURE ACTION (Man-hour)
Complete Incomplete
Engine oil INSPECT 0.05
Coolant INSPECT 0.05
Exhaust pipe mtgs. & damage/leakage INSPECT 0.10
Water sediments drain‐Fuel filter INSPECT 0.10
Brake & Clutch fluid‐level check INSPECT 0.15
Front and rear brake pads / caliper INSPECT 0.80
Power steering fluid‐ level check INSPECT 0.10
Battery electrolyte & sp. gravity INSPECT 0.20
All Light, Horns, Wipers & Washers INSPECT 0.30
Head light aiming INSPECT 0.50
Particle filter CLEAN 0.15
Tyre pressure INSPECT 0.30
Under body, nuts & bolts for tightness INSPECT 0.50
Road Test INSPECT ‐
Tyre rotation INSPECT 0.30
Service reminder indicator reset INSPECT 0.15

 Additional Repair Work carried out, if any -

1)

 Observations, Notes if any -

1)

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: 03.75 man-hrs.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a r esult of changes introduced by the
manufacturer in the pr oduction of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the pr esent 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 t he Authorized Service Centre of Mahindra & Mahindra
Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd. Page 81
Maintenance Manual MAN-00147

@ 80,000 KMS

WORK STATUS Time Allotted

WORK NATURE ACTION (Man-hour)
Complete Incomplete
Engine oil REPLACE 0.30
Engine oil filter REPLACE 0.15
Auto tensioner & belt INSPECT 0.15
Coolant REPLACE 0.25
Air filter element REPLACE 0.15
Fuel filter cartridge REPLACE 0.25
Exhaust pipe mtgs. & damage/leakage INSPECT 0.10
Brake & Clutch fluid‐level check REPLACE 0.35
Parking brake INSPECT 0.10
Front and rear brake pads / caliper INSPECT 0.80
Front suspension bolts torque INSPECT 0.25
Rear Suspension bolts torque INSPECT 0.20
Suspension bushes INSPECT 0.20
Suspension arms & links INSPECT 0.20
Power steering fluid‐ level check INSPECT 0.10
Wheel alignment INSPECT 0.70
Battery electrolyte & specific gravity INSPECT 0.20
All Light, Horns, Wipers & Washers INSPECT 0.30
Head light aiming INSPECT 0.50
Particle filter CLEAN 0.15
Tyre pressure INSPECT 0.30
Under body, nuts &bolts for tightness INSPECT 0.50
Road Test INSPECT ‐
Tyre rotation INSPECT 0.30
Service reminder indicator reset INSPECT 0.15

 Additional Repair Work carried out, if any -

1)
 Observations, Notes if any -
1)
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: 06.65 man-hrs.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a r esult of changes introduced by the
manufacturer in the pr oduction of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the pr esent 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 t he Authorized Service Centre of Mahindra & Mahindra
Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd. Page 82
Maintenance Manual MAN-00147

@ 90,000 KMS

WORK STATUS Time Allotted

WORK NATURE ACTION (Man-hour)
Complete Incomplete
Engine oil INSPECT 0.05
Coolant INSPECT 0.05
Exhaust pipe mountings &
INSPECT 0.10
damage/leakage
Water sediments drain‐Fuel filter (or
INSPECT 0.10
when indicator glows)
Brake & Clutch fluid‐level check INSPECT 0.15
Front and rear brake pads / caliper INSPECT 0.80
Power steering fluid‐ level check INSPECT 0.10
Battery electrolyte & specific gravity INSPECT 0.20
All Light, Horns, Wipers & Washers INSPECT 0.30
Head light aiming INSPECT 0.50
Particle filter CLEAN 0.15
Tyre pressure INSPECT 0.30
Under body, nuts & bolts for tightness INSPECT 0.50
Road Test INSPECT ‐
Tyre rotation INSPECT 0.30
Service reminder indicator reset INSPECT 0.15

 Additional Repair Work carried out, if any -

1)

 Observations, Notes if any -

1)

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: 03.75 man-hrs.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a r esult of changes introduced by the
manufacturer in the pr oduction of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the pr esent 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 t he Authorized Service Centre of Mahindra & Mahindra
Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd. Page 83
Maintenance Manual MAN-00147

@ 100,000 KMS

WORK STATUS Time Allotted

WORK NATURE ACTION (Man-hour)
Complete Incomplete
Engine oil REPLACE 0.30
Engine oil filter REPLACE 0.15
Auto tensioner & belt REPLACE 0.75
Coolant INSPECT 0.05
Fuel filter cartridge REPLACE 0.25
Exhaust pipe mtgs. & damage/leakage INSPECT 0.10
Transaxle oil REPLACE 0.35
IRDA oil REPLACE 0.25
PTU oil REPLACE 0.25
Brake & Clutch fluid‐level check INSPECT 0.15
Parking brake INSPECT 0.10
Front and rear brake pads / caliper INSPECT 0.80
Front suspension bolts torque INSPECT 0.25
Rear Suspension bolts torque INSPECT 0.20
Power steering fluid‐ level check INSPECT 0.10
Battery electrolyte & specific gravity INSPECT 0.20
All Light, Horns, Wipers & Washers INSPECT 0.30
Head light aiming INSPECT 0.50
Particle filter CLEAN 0.15
Tyre pressure INSPECT 0.30
Under body, nuts & bolts for tightness INSPECT 0.50
Road Test INSPECT ‐
Tyre rotation INSPECT 0.30
Service reminder indicator reset INSPECT 0.15

 Additional Repair Work carried out, if any -

1)
 Observations, Notes if any -
1)

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: 06.45 man-hrs.

The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a r esult of changes introduced by the
manufacturer in the pr oduction of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the pr esent 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 t he Authorized Service Centre of Mahindra & Mahindra
Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd. Page 84