Manual de Servicio XUV500

REPAIR MANUAL
MAN-00162
Supersedes MAN-00161
RELEASED BY –
TECHNICAL PUBLICATION CELL

MAHINDRA & MAHINDRA LTD.
www.teknetmahindra.com Rev2 – NOVEMBER 2011
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.
MAN-00162
Repair Manual Table Of Contents Nov 2011/ Rev 2
GENERAL INFORMATION ............................................................................. 1

ENGINE ........................................................................................................... 2
AIR INTAKE SYSTEM ..................................................................................... 3
ENGINE COOLING ......................................................................................... 4
FUEL CHARGING SYSTEM ........................................................................... 5
EMISSION CONTROL SYSTEM .................................................................... 6
EXHAUST SYSTEM........................................................................................ 7
IGNITION SYSTEM ......................................................................................... 8
STARTING SYSTEM ...................................................................................... 9
CHARGING SYSTEM ................................................................................... 10
CLUTCH ........................................................................................................ 11
TRANSAXLE................................................................................................. 12
DRIVE SHAFT ............................................................................................... 13
ALL WHEEL DRIVE (AWD) SYSTEM........................................................... 14
SUSPENSION ............................................................................................... 15
WHEELS AND TYRES ................................................................................. 16
BRAKE SYSTEM .......................................................................................... 17
STEERING SYSTEM .................................................................................... 18
INSTRUMENT CLUSTER ............................................................................. 19
INSTRUMENT PANEL .................................................................................. 20
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) ................... 21
SUPPLEMENTRY RESTRAINT SYSTEM (SRS) ......................................... 22
PROPELLER SHAFT .................................................................................... 23
REVERSE PARKING ASSISTANCE SYSTEM (RPAS) .............................. 24
TYRE PRESSURE MONITORING SYSTEM (TPMS).................................... 25
CRUISE CONTROL SYSTEM ...................................................................... 26
INCAR ENTERTAINMENT ........................................................................... 27
LOCKS AND KEYS ...................................................................................... 28
INTERIOR TRIMS ......................................................................................... 29
LIGHTING SYSTEM ...................................................................................... 30
SEATS ........................................................................................................... 31
BUMPERS ..................................................................................................... 32
DOORS ......................................................................................................... 33
TAILGATE..................................................................................................... 34
WIPERS AND WASHERS ............................................................................ 35
All copyrights reserved by

The repair methods given by the manufacturer in this document are based on the technical specifications current at the time of
release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in
part of whole of the present document, are prohibited without the prior written consent of © 2011 Mahindra & Mahindra Ltd.
MAN-00162
Repair Manual General Information Nov 2011/ Rev 2
GENERAL INFORMATION
CONTENTS
Introduction .....................................................................................1
Important Instructions............................................................................. 1
Contents in the manual .......................................................................... 2
Description and Operation ..................................................................... 2
Component Location Index .................................................................... 2
Service Tips And Precautions ................................................................ 2
Incar Repairs .......................................................................................... 2
Disassembly and Assembly ................................................................... 2
Trouble Shooting Chart .......................................................................... 2
Component Inspection and Action Table ............................................... 2
Mahindra Service Tools (MST) .............................................................. 2
Technical Specification .......................................................................... 2
Torque Specification .............................................................................. 2
Fuel Handling Precautions ..................................................................... 2
General Precautions ........................................................................3

Preparation before dismantling the vehicle parts ................................... 4
Dismantling of the vehicle parts ............................................................. 4
Noise ...................................................................................................... 4
Accessories and Conversions................................................................ 4
Towing the Vehicle................................................................................. 5
Front Tow Hook ...................................................................................... 5
Rear Tow Hook ...................................................................................... 5
Towing Equipment ................................................................................. 5
Towing the vehicle during emergency .................................................... 6
Warning Triangle .................................................................................... 6
Removal of Parts.................................................................................... 7
Disassembly of Parts ............................................................................. 7
Inspection during Removal/Disassembly ............................................... 7
Arrangement of Parts ............................................................................. 7
Cleaning of Parts.................................................................................... 7
Adjustment ............................................................................................. 7
Rubber Parts and Tubing ....................................................................... 7
Vise ........................................................................................................ 7
Component Cleaning ............................................................................. 7
ECU and electrical parts precautions..................................................... 8
Electrical Parts ....................................................................................... 8
Precautions for Engine Control Unit (ECU) ............................................ 9

MAN-00162
Sensors, Switches, and Relays ............................................................. 9

Fuse Replacement................................................................................. 9
Identification Information ............................................................. 11

Vehicle Identification Number (VIN) Location ...................................... 11
Vehicle Identification Number (VIN) System ........................................ 11
Engine Number Location ..................................................................... 14
After Sales Service Sticker .................................................................. 15
Jacking and Lifting ........................................................................ 16

Jacking & Lifting Points ....................................................................... 16
Jacking up the vehicle .......................................................................... 16

MAN-00162
Introduction The danger, warning, caution and notice are

included wherever it is required. Anyone using the
This Workshop/Repair manual is designed to assist service procedures or tools must make sure that
technicians to repair and maintain Mahindra XUV500 neither personal safety nor vehicle safety is
vehicles. This manual provides general information compromised.
on removal and installation, disassembly and
assembly, inspection and adjustment and trouble
shooting. It also provides functioning of the system in
brief.
Important Instructions
Individuals who undertake repairs should have
essential skills or training. Following correct service
methods and repair procedures are essential for
the safe, reliable operation of all motor vehicles as
well as the personal safety of the individual while
carrying out the work. This manual cannot possibly
predict all such variations and offer warnings or
cautions as to each. Deviation from the instructions
provided in this manual could lead to personal
injury or damage to the vehicle.
DANGER, WARNING, CAUTION and NOTICE
symbols are given right through this manual to alert
the service technician to an area of potential
hazard or to note something of importance.
DANGER
DANGER Indicates an imminently hazardous
situation which, if not avoided, will result in
serious injury.
WARNING
WARNING indicates a potentially hazardous
situation which if not avoided could result in
serious injury.
CAUTION
CAUTION used with safety alert symbol
indicates a potentially hazardous situation
which if not avoided may result in minor or
moderate injury and property damage.
Notice
Notice is used to highlight information useful
to the technician to properly complete the
work.

release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various 1-1
MAN-00162
Contents in the manual Trouble Shooting Chart

This manual contains the procedures for performing Diagnosis test steps are used in the section to
the required service operations. The procedures identify the source of concern in a step-by-step
are separated into the following important approach. Diagnosis tests have three columns:
operations. symptom, possible causes and remedy. The first
• Description and Operation column is used exclusively for indication of a
concern, the second column for possible causes
• Component Location Index and the third column for remedies or the direction
• Service Tips and Precautions to another analysis step.
• Incar Repairs Component Inspection and Action
• Assembly and Disassembly Table
• Troubleshooting Chart The table has three column. The first column
• Component Inspection and Action Table names the component. The second column
suggest’s the tests that need’s to be carried out on
• Mahindra Service Tools (MST) the component. The last column suggest’s possible
• Technical Specification actions.
• Torque Specification Mahindra Service Tools (MST)
Description and Operation The special tools table lists the Mahindra Service
This section provides a brief information of the Tools (MST) required to repair the vehicle.
system construction, description and operation. Illustrations are provided to support identifying the
special tool.
Component Location Index
Technical Specification
This section contains overview illustrations of the
system with annotations for identifying the system This section gives the technical specification of the
components. system/component, wherever necessary.
Service Tips And Precautions Torque Specification

These are the general sevice tips and precautions This section gives the torque values applicable to
that need to be followed while servicing the parts, the specified components while tightening them,
working in the workshop or during assembling and wherever applicable.
disassembling the parts. Fuel Handling Precautions
Incar Repairs • Always disconnect the vehicle battery before
working on the fuel system.
This section gives information on removal and refit
of components from a vehicle. • Avoid prolonged and frequent skin contact with
oils, particularly engine oils.
Disassembly and Assembly • Properly ventilate the area so that the
This section gives information on disassembling flammable fumes do not become concentrated.
and assembling a component and/or a system,
• Never smoke or have an open flame in the
wherever applicable.
work area.
• Always check for leaks after fuel system
repairs.
• Clean up fuel spills immediately with absorbent
materials, by using proper disposal procedures.
• Wear protective clothing, including resistant
gloves wherever required.
• Avoid wearing contaminated clothes.
• First-aid treatment must be given immediately
for open cuts and wounds.

1-2 release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various
MAN-00162
Do not operate the engine for unlimited period of time General Precautions
without proper exhaust ventilation. Keep the work
When working on the vehicle in the workshop
area well ventilated and free of any flammable mate-
always follow the below mentioned procedures:
rials. Special care should be taken when handling
• Make sure that the area has adequate
any flammable or toxic materials such as gasoline,
ventilation to disperse exhaust gases such as
refrigerant gas, etc. carbon monoxide and other fumes.
• When the engine is running, use adequate
ventilation or an extraction hose to remove
exhaust fumes.
• Make sure that the work area such as floors,
workbenches, tools are clean and free from
EL
debris.
FU • Be sure that all necessary tools and measuring
equipment are available before starting any
work.
• Use Mahindra Service Tools when they are
required.
• Do not allow other people near the vehicle
during servicing.
• Always engage the parking brake and/or use
wheel chocks to prevent the vehicle from
DANGER moving.
Fuels and vapors are extremely flammable. • Ensure there is adequate room to raise the
Use extreme caution when working with fuel, vehicle and remove the wheels, if necessary.
fire or explosion may occur causing severe • Do not let fuel, coolant and other fluids spill
personal injury or death. over electrical and hot vehicle parts.
• Avoid repeated contact with fluids.
• The battery should be disconnected while,
CAUTION working on the engine, underneath the vehicle
or if the vehicle is raised.
Petrol and diesel fuels are irritants. Wash • Cover seats and carpets, wear clean overalls
hands thoroughly after handling the fuels. and wash hands or wear gloves before working
inside the vehicle.
• Avoid spilling hydraulic fluid or battery acid on
paint work. Wash off with water immediately on
contact. Use Polythene sheets to protect
carpets and seats.
• Protect temporarily exposed screw threads by
fitting plastic caps.
• While using the welding equipment on the
vehicle, keep a suitable fire extinguisher readily
available.

MAN-00162
Preparation before dismantling the

vehicle parts
• Clean components and surrounding area prior
WARNING
to removal. Fitment of non-approved accessories could
• Blank-off any openings exposed by component lead to vehicle not performing as intended
removal using grease proof paper and masking resulting in personal injury or death in case of
tape. an accident.
• Use plastic caps or plugs immediately to seal
fuel, oil or hydraulic lines when separated to
prevent loss of fluid and entry of dirt.
• Close the open ends of oil ways, exposed by
WARNING
component removal with tapered hardwood Improper maintenance, including incorrect
plugs or readily visible plastic plugs. removal and installation of the SRS, will lead
• After a component is removed, place it in a to personal injury caused by accidental activa-
suitable container/tray. Use a separate tion of the system.
container/tray for each component and its
associated parts.
Dismantling of the vehicle parts

• Observe cleanliness while dismantling the
components, particularly brake, fuel or
hydraulic system parts. A particle of dirt or
cloth fragment can cause dangerous
malfunction if trapped inside the system.
• Use marking ink to identify mating parts and
ensure correct reassembly. If a centre punch or
scriber is used they may initiate cracks or
distortion of components.
• Label parts which are to be renewed and those
which require further inspection before
reassembly. Place these parts in separate
containers from those containing parts for
rebuilding.
• Do not discard a part due for renewal until it
has been compared with the new part, to
ensure that its correct replacement has been
obtained.
Noise
Several operations may produce high noise levels,
which might damage hearing. In these cases,
proper ear protection must be worn.
Accessories and Conversions

Do not fit unapproved accessories or conversions,
as they could affect the safety of the vehicle.
Mahindra will not accept liability for death, personal
injury or harm to property which may occur as a
direct effect of fitting non-approved conversions to
the vehicle.

MAN-00162
Towing the Vehicle Towing Equipment

Front Tow Hook Towing Equipments are of three Types
Front tow hook is welded to front cradle assembly Flat-bed equipment: The vehicle is loaded on the
back of a truck. This is the safest and best way of
towing.
Tow hook
Rear Tow Hook

1. Remove the tow cover using a small screw
driver Wheel-lift equipment: The tow truck uses two
pivoting arms that go under the tyres (front or rear)
and lift them off the ground. The other two tyres
remain on the ground.
Sling-type equipment: The tow truck uses metal
cables with hooks on both ends. These hooks go
around parts of the frame or suspension and lift the
end of the vehicle off the ground. This is not a good
method of towing as it may damage the vehicle's
suspension and body. Avoid tow with sling type
equipment.
2. Rotate in anti-clockwise direction to tighten the

tow hook.
If the vehicle cannot be transported by flat-bed

equipment, it should be towed by wheel-lift
equipment with the front wheels off the ground.

MAN-00162
Notice Notice
Improper towing procedure will damage the • Use only a cable or chain specifically
transmission. Follow the towing instructions intended for use in towing vehicles. Securely
precisely. fasten the cable or chain to the towing eyelets
provided.
• Do not tow with sling type truck, either from
the front or rear. Doing so may cause body
CAUTION damage.
AWD vehicles:
Warning Triangle
While towing on two wheels, propeller shaft
needs to disconnected in order to protect Use the warning triangle in an emergency. It is
the coupling. Propeller shaft need not be located inside the tailgate compartment.
disconnected while towing on all four Unclip the warning triangle cover clips and remove
wheels. the warning triangle from the location as shown in the
image below.
Towing the vehicle during emergency
If a towing service is unavailable in an emergency,
the vehicle may be temporarily towed by a cable or
chain secured to the towing eyelet under the front
bumper, welded with the front cross member.
Use only the eyelet for towing in an emergency.
Otherwise the vehicle may get damaged.
CAUTION
• A driver must be present in the vehicle being
towed to steer and operate the brakes. Towing
in this manner must be done only on hard
surfaced roads for short distances and at low
speeds. Also, the wheels, axles, drive train, Arrange the warning triangle as shown in the image
steering and brakes must all be in good below.
condition.
• Avoid sudden starts or erratic driving
manoeuvers, which would place excessive
stress on the towing eyelet and towing cable
or chain, and result in breaking of the eyelet or
the chain.
• If the engine is not running, the power assist
for the steering and brakes will not work and it
will be much harder than usual.
o
60

MAN-00162
Removal of Parts • Specified oil/lubricant should be applied to the

moving components or parts.
While correcting a problem, try to determine its
cause. Begin to work only after first learning which • Specified oil or grease should be applied at the
parts and subassemblies need to be removed and prescribed locations such as oil seals before
disassembled for replacement or repair. After reassembly.
removing the part, plug all holes and ports to prevent
entering of foreign materials.
Adjustment
Use recommended/appropriate gauges and testers
Disassembly of Parts while making adjustments.
If the disassembly procedure is complex and
requires many parts to be disassembled, all parts
Rubber Parts and Tubing
should be temporarily marked in a place that will not Prevent fuel or oil from spilling on rubber parts or
affect their performance or external appearance and tubing.
identified so that reassembly can be performed with
ease and efficiency.
Vise
When using a vise, use protective padding in the
Inspection during Removal/ jaws of the vise to prevent damage to parts.
Disassembly
When removed, each part should be carefully
Component Cleaning
inspected for malfunctioning, deformation, damage, To prevent the ingress of dirt, accumulation of
and other problems. loose dirt and greasy deposits should be removed
before disconnecting or dismantling components or
Arrangement of Parts assemblies. Components should be thoroughly
All disassembled parts should be carefully arranged cleaned using appropriate cleaning agent before
for reassembly. Be sure to separate or otherwise inspection and prior to reassembly.
identify the parts to be replaced from those that will
be reused.
WARNING
Cleaning of Parts
Wear eye protection while cleaning vehicle
All parts to be reused should be carefully and
thoroughly cleaned by using the appropriate components with compressed air, a steam
cleaning agent and method. cleaner or power washer. Failure to follow this
instruction will result in personal injury.
CAUTION CAUTION
Using compressed air will cause dirt and other
To prevent damage to the electrical
particles to fly out, and cause injury to the
connectors in the engine compartment, do
eyes, wear protective goggles to avoid proba- not use a steam cleaner or power washer to
ble injury. clean the engine compartment.
Reassembly
• Standard values, such as torques and certain
adjustments, must be strictly adhered to while
reassembling the parts. CAUTION
• If removed, these parts should be replaced When testing sensitive components and
with new ones: electrical circuits with an ohmmeter or
3. Oil seals voltmeter, make sure that the vehicle
electrical system is not getting damaged by
4. O-rings improper use of tool.
5. Cotter pins
6. Lock washers
7. Nylon nuts

MAN-00162
ECU and electrical parts precautions Electrical Parts

• Never reverse the polarity of battery terminals. Battery Cable
• Install only the parts specified for that particular • Before disconnecting connectors or removing
vehicle. electrical parts, switch OFF the ignition and
• Do not apply too much force while disconnect the negative battery cable, unless
disconnecting the connector. battery voltage is required to perform diagnosis
or repair.
• Do not apply excessive shock to the ECU by
dropping or hitting it. Connectors
• Be careful to prevent condensation in the ECU
due to rapid temperature changes and do not
allow water or rain to enter the ECU. CAUTION
• Be careful not to let oil into the ECU connector. Inserting a jumper wire probe into the data
link connector terminal may damage the
• Avoid cleaning the ECU with volatile oil.
terminal
• Do not disassemble the ECU, do not remove
the upper or lower covers. • When disengaging the electrical connectors,
never pull on the wire. Always pull the
connector apart by disengaging the locking tab
DANGER and pulling on the connector body.
During normal operation, batteries generate Disconnecting Connector
dangerous explosive gases that may explode • When disconnecting two connectors, grasp the
if exposed to open flames or sparks resulting connectors not the wires.
in personal injury or death.
• Connectors should be disconnected by
pressing or pulling the lock lever.
Locking Connector
CAUTION • When locking connectors, listen for a click that
Do not reverse the negative (-) and positive will indicate that they are securely locked.
(+) battery cable connections. This may lead Connector Inspection
to serious damage to the vehicle electrical
system. • When a tester is used to check for continuity or
to measure voltage, insert the tester probe
from the wiring harness side.
• Check the terminals of waterproof connectors
from the connector side, as they cannot be
accessed from the wiring harness side.
CAUTION
To prevent damage to the terminal, wrap a
thin wire around the lead before inserting it
into the terminal.
Terminals Inspection
• Pull individual wires lightly to check that they
are secured firmly in the connector.

MAN-00162
Precautions for Engine Control Unit

(ECU)
Before connecting or disconnecting ECU harness
connector:
• Turn ignition switch to “OFF” position.
M
• Disconnect the negative battery terminal and E
C
wait for at least 2 minutes before disconnecting NO HEAT !

NO WATER !
the ECU connector. Ensure the battery
negative terminal is disconnected while
connecting the ECU connector.
• Do not forcefully pry off the ECU connector. EC
M NO SHOCK !
WARNING
Sensors, Switches, and Relays
Avoid touching the terminals and connectors • Handle the sensors, switches, and relays with
of sensitive electrical components, static elec- care. Do not drop them or strike them against
tricity may damage the vehicle ECU and other other objects.
sensitive electrical components. This may
cause electric shock and cause personal
Fuse Replacement
injury. • While replacing a fuse, be sure to replace it
with the specified capacity. Check the circuit
before replacing the fuse.
• Be sure that the negative battery terminal is
disconnected before replacing a main fuse.
• While replacing a pullout type fuse, use the
fuse puller.
Efficient diagnosis
1. Obtain detailed information about the
conditions and the environment when the
incident occurred. The following key
information provides a good study of the
incident:
• WHAT - Vehicle Model, Engine, Transmission
and the System.
• WHEN - Date, Time of Day, Weather
Conditions, Frequency, speed of the vehicle,
CAUTION Engine rpm, which gear, Whether 2WD or
Do not expose the ECU or other sensitive AWD.
electrical components to water, heat, or • WHERE - Road Conditions, Altitude and Traffic
shock of any type, leading to component Situation.
damage.
• HOW - System Symptoms, Operating
Conditions. Service History and if any after
market accessories have been installed.
2. Operate the system, perform the road test if
necessary and verify the parameter of the
incident.

MAN-00162
3. Get the proper diagnostic materials together

including
• Power Supply Routing
• System Operation Descriptions
• Applicable Service Manual Sections
• Check for any Service Bulletins
• Identify where to begin diagnosis based upon
your knowledge of the system operation and
the customer comments.
4. Inspect the system for mechanical binding,
loose connectors or wiring damage. Determine
which circuits and components are involved
and diagnose using the power supply routing
and harness layouts.
5. Repair or replace the incident circuit or
component.
6. Operate the system in all modes. Operate and
verify whether the all the relevant systems
which were affected during repairs works
properly under all conditions. Make sure you
have not inadvertently created a new incident
during your diagnosis or repair steps.

MAN-00162
Identification Information
Vehicle Identification Number (VIN) Location
Vehicle Identification Number is the legal identity of your vehicle. It is used in registering the ownership. It is
located at the bottom of B pillar, near the driver's door.
LTD
& MAHINDRA
MAHINDRA
3
AB087541212
4
AB087541212
5
AB087541212
MANUFACTURED BY
MAHINDRA & MAHINDRA LTD.

MODEL
AAW4DPEH7 TU 01JC0RU
VEHICLE SR. NO.
MA1YL4HJUB6D60039
ENGINE NO.
HJB4D50528
Vehicle Identification Number (VIN) System
WMI - World Manufacturer Identification

VDS - Vehicle Description Number
VIS - Vehicle Indicator System

MAN-00162
Table - II
Table II
Code Manufacturing Plant - location
1 Kandivili (KVL)
2 Nasik (NSK)
3 Zahirabad (ZBAD)
4 Igatpuri (IGT)
5 Haridwar (HAR)
6 Chakan
Table - III
TABLE - III (I,O,Q.U,Z,0 - NOT ALLOWED)
Year Code
1997 V
1998 W
1999 X
2000 Y
2001 1
2002 2
2003 3
2004 4
2005 5
2006 6
2007 7
2008 8
2009 9
2010 A
2011 B
2012 C
2013 D
2014 E

MAN-00162
TABLE - III (I,O,Q.U,Z,0 - NOT ALLOWED)
2015 F
2016 G
2017 H
2018 J
2019 K
2020 L
2021 M
2022 N
2023 P
2024 R
2025 S
2026 T
2027 V
2028 W
2029 X
2030 Y
2031 1
2032 2
2033 3
2034 4
2035 5
2036 6
2037 7
2038 8
2039 9
2040 A

MAN-00162
Table - IV
TABLE - IV
(I - NOT ALLOWED)
Month Code
January A
February B
March C
April D
May E
June F
July G
August H
September J
October K
November L
December M
Engine Number Location

Engine number is located on the bottom of the intake
manifold near the starter motor.
EAD094G0007

MAN-00162
After Sales Service Sticker

MAN-00162
Jacking and Lifting Jacking & Lifting Points
Jacking Precautions
CAUTION
When jacking, be sure to observe the following
to reduce the possibility of personal injury:
• Follow jacking instructions
• Do not start or run the engine while your
vehicle is supported by the jack
• Stop the vehicle on a level firm ground and
firmly apply the parking brake. Block the wheel
diagonally opposite to the one being changed.
Jacking up the vehicle
Position the jack at the correct jacking point as
shown. Make sure the jack is positioned on a level
CAUTION and solid place.
Make sure to set the jack properly in the
jacking point. Raising the vehicle with jack
improperly positioned will damage the under -
body of the vehicle or may allow the vehicle to
fall off the jack and cause personal injury.
• Never get under the vehicle when the
vehicle is supported by the jack alone.
• Use the jack only for lifting your vehicle
during wheel changing.
• Do not raise the jack with someone in the
vehicle.
• When raising the vehicle, do not place any
objects on top of or underneath the jack.
To raise the vehicle, insert the jack operating lever
• Raise the vehicle only high enough to into the jack and turn it clockwise with the handle. As
remove and change the wheel. the jack touches the vehicle and begins to lift, check
that it is properly positioned.
Raise the vehicle high enough so that the fully
inflated spare tyre can be installed. To do this, you
will need more ground clearance than is required to
remove the flat tyre.
WARNING
Never get under the vehicle when the vehicle
is supported by the jack alone.

MAN-00162
Repair Manual Engine Nov 2011/ Rev 2
ENGINE
CONTENTS
Description and Operation ..............................................................1
Component Location Index .............................................................2

Description and Operation ................................................................. 3
Cylinder Block .................................................................................... 3
Piston ................................................................................................. 3
Connecting Rod ................................................................................. 4
Crankshaft .......................................................................................... 5
Valves ................................................................................................ 5
Roller Finger Follower (RFF) and Hydraulic
Lash Adjuster (HLA) Assembly .......................................................... 6
Valve Gear Drive ................................................................................ 6
High Pressure Pump (HPP) ............................................................... 7
Lubrication System............................................................................. 7
Service Tips and Precautions ........................................................9
General Procedures .......................................................................10

Bearing Inspection ........................................................................... 10
Camshaft Bearing Journal Diameter ................................................ 10
Crankshaft End Play Inspection ....................................................... 11
Cylinder Bore Taper Check .............................................................. 12
Piston Diameter ................................................................................ 13
Piston Inspection.............................................................................. 13
Piston Ring End Gap ........................................................................ 13
Piston Ring-to-Groove Clearance .................................................... 13
Valve Seat Inspection ...................................................................... 14
Valve Stem Diameter ....................................................................... 14
In Car Repairs .................................................................................14

Cylinder Compression Pressure Test .............................................. 14
Engine Cylinder Head Gasket Failure Test ...................................... 15
Hydrostatically Locked Engine ........................................................ 15
Timing Procedure............................................................................. 16
Engine Oil Draining Procedure......................................................... 17
Engine oil filling procedure ............................................................... 18

MAN-00162
Fuse Box ..................................................................................... 19

Removal ........................................................................................... 19
Installation ........................................................................................ 20
Engine Oil Filter ........................................................................ 20

Removal ........................................................................................... 20
Installation ........................................................................................ 21
Engine ........................................................................................ 21
Removal ........................................................................................... 21
Installation ........................................................................................ 25
Crankshaft Front Seal ................................................................ 26

Removal .......................................................................................... 26
Inspection......................................................................................... 26
Installation ........................................................................................ 26
Crankshaft Rear End Oil Seal ................................................... 28

Removal ........................................................................................... 28
Inspection ......................................................................................... 28
Installation ........................................................................................ 29
Timing Chain and Sprockets ................................................... 30

Removal ........................................................................................... 31
Installation ........................................................................................ 36
Camshaft .................................................................................... 42
Removal ........................................................................................... 43
Inspection ......................................................................................... 44
Installation ........................................................................................ 45
Hydraulic Lash Adjuster (HLA) ................................................. 48

Removal ........................................................................................... 48
Inspection......................................................................................... 48
Installation ........................................................................................ 49
Cylinder Head............................................................................. 50
Removal ........................................................................................... 51
Inspection......................................................................................... 51
Installation ........................................................................................ 52

MAN-00162
Assembly Accelerator Pedal .................................................... 53

Removal ........................................................................................... 53
Inspection ......................................................................................... 54
Installation ........................................................................................ 54
High Pressure Pump (HPP) ....................................................... 54

Removal ............................................................................................. 4
Installation ........................................................................................ 58
Intake Manifold ..........................................................................64

Removal ........................................................................................... 64
Inspection ......................................................................................... 67
Installation ........................................................................................ 67
Oil Pan/Oil Sump ........................................................................ 67

Removal ........................................................................................... 67
Inspection......................................................................................... 68
Installation ........................................................................................ 68
Oil Pan Strainer .......................................................................... 69

Removal ........................................................................................... 69
Inspection ......................................................................................... 69
Installation ........................................................................................ 69
Vacuum Pump ............................................................................70

Removal ........................................................................................... 70
Inspection......................................................................................... 71
Installation ........................................................................................ 71
Engine Mounting ....................................................................... 71

RHS (Hydro) Mount Removal .......................................................... 71
RHS (Hydro) Mount Inspection ........................................................ 72
RHS (Hydro) Mount Installation ....................................................... 72
LHS Mount Removal ........................................................................ 73
LHS Mount Inspection ...................................................................... 73
LHS Mount Installation ..................................................................... 73
Front Engine Mount Removal .......................................................... 74
Front Engine Mount Inspection ........................................................ 74
Front Engine Mount Installation ....................................................... 74
Rear Engine Mount Removal ........................................................... 74
Rear Engine Mount Inspection......................................................... 74

MAN-00162
Rear Engine Mount Installation ........................................................ 74
Disassembly and Assembly ......................................................... 75
Engine ......................................................................................... 75
Disassembly .................................................................................... 75
Inspection ......................................................................................... 83
Assembly .......................................................................................... 85
Cylinder Head ............................................................................ 95

Disassembly ..................................................................................... 95
Inspection ......................................................................................... 97
Assembly .......................................................................................... 97
Sealant Application Pattern .......................................................... 99
Torque Sequence ........................................................................ 104
Diagnosis and Testing ................................................................ 109

Inspection and verification .............................................................. 109
Troubleshooting Chart .................................................................... 109
Mahindra Special Tools (MST) ................................................... 117
Technical Specification .............................................................. 120
Torque Specification ................................................................... 123
Accessory Drive Belt .......................................................................... 129
Description and Operation ......................................................... 129
Component Location Index ....................................................... 129
Service Tips and Precautions .................................................... 130
Incar Repairs ............................................................................... 130
Accessory Drive Belt ............................................................... 130

Removal ......................................................................................... 130
Inspection ....................................................................................... 131
Installation ...................................................................................... 132

MAN-00162
Drive Belt /Pulley Auto Tensioner ...........................................132

Removal ......................................................................................... 132
Installation ...................................................................................... 133
Idlear No 2 and Double Ball Bearing Idlear No 3 ...................133

Removal ......................................................................................... 133
Installation ...................................................................................... 133
Idlear No 1 .................................................................................134
Removal ......................................................................................... 134
Installation ...................................................................................... 134
Diagnosis and Testing ................................................................ 135

Troubleshooting Chart .................................................................... 135

MAN-00162
Engine
Description and Operation
The 2.2 liter Turbocharged with intercooled engine
used on this vehicle. Bosch common rail diesel
injection system with 1600 bar injection pressure is
used and controlled by a 32 bit engine electronic
control unit. The engine performance is optimized
for various engine speed, load and operating
conditions depending upon the various sensors
input.
The piston features re-entrant type combustion
chamber and having ferrous ring insert in the Top
ring groove. A 3-ring pack is used. The top ring is
asymmetrical barrel face and with CKS coating and
keystone shape. The 2nd ring is taper faced. The
3rd is conformable Oil Ring.
The forged connecting rod is connected to
induction-hardened crankshaft. The small end of
the connecting rod is trapezoidal shaped to reduce
the mass as well as to ensure higher loading. The
crankshaft is induction hardened with the filets
hardened & ground.
The high pressure pump and camshaft are chain
driven. There are two overhead camshafts (Inlet
and exhaust). The valves are actuated through HFF
and RLA (hydraulic tappets). There are four valves
per cylinder. This ensures that the charge fill as
well as the purging is optimum.
A variable geometry turbocharger (VGT) is used on
this engine. It has a low inertia of turbine and
compressor wheels which reduce the turbo lag at
low engine speeds and improves the transient
response of the vehicle. This turbocharger
incorporates many movable vanes in the turbine
housing to control the exhaust flow against the
turbine blades which enables higher power, torque,
lower fuel consumption and emissions of the
engine.
The fuel economy and emission has been
optimized at source by means of low engine
friction, faster engine warm up, centralized
injectors, optimized combustion, catalytic converter,
closed loop operation of the turbocharger (VGT)
etc.
The engine NVH is optimized by means of stiffened
engine components, optimized engine mounts
(hydro mounts), multiple injection strategy etc.

MAN-00162
L V
A
U
K
T
B M
S
J C
R
D
N
I
E
H
F O
G
P Q
A. Intake Manifold and Pipe L. EGR Assembly

B. Cylinder Head M. Turbocharger
C. Oil Cooler & Filter N. Exhaust Manifold
D. Clutch Assembly O. Flywheel
E. Oil Dip Stick Pipe P. Oil Pan
F. Alternator Q. Cylinder Block
G. A/C Compressor R. Drive Belt Tensioner
H. Power Steering Pump S. Drive Belt
I. Damper Pulley T. Engine Bracket
J. Water Pump U. Oil Filling Neck
K. Timing Cover V. Fuel Injectors

MAN-00162
Description and Operation The Cylinder block is the basic building of an

engine. It is the place where the power is produced
The main parts of the engine are:
and delivered. Essentially the cylinder block forms
1. Cylinder Block. a housing for most of the components of the
2. Cylinder Head. engine like crank shaft, connecting rod, piston,
piston pin etc. its also houses the water jacket and
3. Piston.
main oil galleries. Which takes away the excess
4. Connecting Rod. heat and disperses it to the atmosphere.
5. Crankshaft. Together with the compression chamber in the cylin-
6. Valves. der head and the piston crown, the cylinder forms the
7. Camshaft. combustion chamber. The cylinder's task is to guide
the piston and to dissipate surplus heat which occurs
8. HLA, Followers. during combustion. In addition, the cylinders,
9. Valve Gear. together with the piston rings, have a sliding and
sealing function.
The engine also consists of the following sub sys-
tems:
Piston
1. Engine Cooling System.
2. Air Intake System.
3. Fuel Charging System.
4. Starting System. A
5. Charging System. B
6. Exhaust and Emission control System.
7. Lubrication System.
Refer to the corresponding sections for further D
details. C F
Cylinder Block E
A. Piston
B. Piston Pin
C. Circlip
A D. Top Compression Ring
E. Bottom Compression Ring
B F. Oil Scrapper Rings
D C
The task of the piston is to receive the pressure
forces that arise as a result of the combustion of
the air/fuel mixture and to transfer them via the
piston pin and the connecting rod to the crankshaft.
The piston has to provide the moving seal between
A. Cylinder Block the combustion chamber and the crank case. Due to
B. Oil Spray Jet its up and down movement it creates vacuum to
C. Crankshaft Rear End Oil Seal induce the air and then compress it. The main task
however is to transmit the pressure of the combus-
D. Bed Plate tion gases through the connecting rod to the crank-

MAN-00162
shaft. Accordingly the piston has to be light in weight Connecting Rod

in order to minimize the inertia forces and also be
able to withstand the combustion heat and dissipate
it. Its thermal expansion should not be too high as
otherwise it could stick to the cylinder bore. A
The piston has the following components, the crown,
B
the ring zone, the skirt and the pin bore. The crown is
the top most part of the piston which is subjected to
the greatest thermal and pressure loads. The crown
also has the combustion chamber incorporated into
it. It also has grooves cut on it to make way for the
valves when they are fully open. In the ring zone 3 C
rings ensure a good sealing in the cylinder. It mini-
mizes the quantity of the combustion gasses that is
D
escaping to the crank case. The piston skirt guides
the piston in the bore. The rings also prevent the
lubricating oil from getting into the combustion cham- A. Connecting Rod Bush
ber. The piston bore accommodates the piston pin B. Connecting Rod
which connects piston to the connecting rod. C. Connecting Rod Cap
There are two types of rings, one is the compression D. Connecting Rod Bolt
rings and other one is oil ring. Compression rings are
located at the top on the piston. They are intended to The connecting rod transfers the movement of the
ensure the gas-tight seal possible to the combustion piston to the crank pin on the crank shaft. A steel
chamber. Compression rings include the plain com- piston pin connects the piston to the connecting
pression ring at the top and second is having an rod. Since it is subjected to very severe alternating
inside bevel and taper-face. The lower piston rings tensile, compressive and buckling loads. its “I”
are the oil scraper rings. These prevent oil from pen- cross section gives the connecting rod the required
etrating into the combustion chamber. The oil scraper stiffness. The piston pin allows the piston to pivot
rings include the slotted oil control ring (with oil pas- the small end of the connecting rod. The large end
sage to the insides of the piston) and the oil ring with of the connecting rod is connected to the crank
an expander or spiral-type expander (narrow running shaft with a bearing cap. The cap is very similar in
surface to increase pressure force). The three rings design and function to the main bearing caps.
are mounted on the pistons at a phase difference of These caps are lined with interlocked split bearing
120 leg. to each other. The piston cooling is by an oil shells. These are cooled by oil supplied from the
jet mounted on the crankcase and on the main oil crank case through the gallery drilled into the body
gallery. of the connecting rod.

MAN-00162
Crankshaft Valves
A B
C
D
E
F
C B
G
A. Crankshaft
A. Hydraulic Lash Adjuster
B. TDC Sprocket
B. Valve Spring Retainer Top
C. Crankshaft Sprocket
C. Valve Lock
The crankshaft changes up and down movement of D. Valve Spring
the pistons into the rotational motion needed to
drive the wheels of the vehicle. The crankshaft is E. Valve Spring Retainer Bottom
mounted in the engine block on U shaped supports F. Intake Valve
that are cast into the engine block assembly. The G. Exhaust Valve
caps called main bearing caps are bolted onto the
supports to secure the crankshaft onto the block. The main function of the valve is opening and
Between the crankshaft and its mounting surfaces closing the ports in the cylinder head during the
are bearings in which the crankshaft is held and is exchange of gases. The four valves per cylinder
able to spin. The main bearing surfaces are design is more precise and efficient. Two inlet
machined to be exactly parallel to the crankshaft. valves are bigger in diameter when compared to
For this reason, main bearing caps must never be the two exhaust valves. They are subjected to
interchanged. The crankshaft transmits the torque extremely high pressure and temperatures.
via the flywheel to the transmission. The crankshaft Although the inlet valves are cooled by the intake
also drives the valve gear, oil pump, HPP, water air it still heats up to high temperatures since it lies
pump and auxiliary equipment like alternator, etc. in the path of hot combustion gases. The valves
are solid and heat treated.
The dual mass flywheel (Adapter ring), which is
bolted to the crankshaft at the rear of the engine also The valve face is the contact point between the valve
helps to run the engine smoothly by storing the and its seat. Both these surfaces are machined to
potential energy. The torsional vibration dampers form a tight seal when closed. Maximum contact is
(also called crankshaft pulley) at the other end of the essential for better heat transfer.
crankshaft help in damping the torsional vibrations. The valve guides keep the valves in precise align-
The crankshaft tends to move back and forth. This is ment in the cylinder head. They allow the valve stem
in addition to the rotary motion. This is prevented by to go through the combustion chamber to the upper
the thrust bearings. The thrust bearings have oil cylinder head area, where the valve springs are
holes that facilitate lubrication of the journal. mounted. The guides are soft alloy inserts that are
pressed into the head.
The valve springs are responsible for closing the
valve firmly on to the valve seat. This is installed on
to the cylinder head around the valve stem. The
upper and lower spring seats prevent wear and keep
the spring in place.

MAN-00162
When the valve moves to the closed position it must Valve Gear Drive
be seated firmly again the valve seat. There must not
be any pressure on the stem side of the valve.
Roller Finger Follower (RFF) and Hy-
draulic Lash Adjuster (HLA) Assem-
bly
C
A B The main function of the engine timing is to coordi-
nate the induction of the fresh gases and expulsion
A of the exhaust gases. The valve gear drives the cam-
shafts by taking drive from the crankshaft via a timing
chain. The timing chain transmit the motion with com-
A. Valve paratively less noise and better efficiency. The chain
and the tensioner are subjected to minimal wear and
B. Valve Spring maintenance is unnecessary. In extreme cases when
C. Hydraulic Lash Adjuster (HLA) the chain wears out it is replaced.
D. Roller Finger Follower (RFF) The timing chain is tensioned using an auto ten-
The RFF and HLA assembly together provide zero sioner. There is no need to constantly reset or ser-
clearance between the valve stem and roller follower. vice the timing chain or the tensioner or the
The HLA damps the spring return force when the crankshaft sprocket. The camshaft sprocket bolted to
valve closes (comes back to original position). This the camshaft is having mark which must be aligned
will result in noiseless and smooth operation of valve appropriately during the assembly to maintain proper
opening and closing. valve timing.
The HLA is operated by hydraulics (oil). Oil for the

HLA is provided from the oil gallery. During valve
closing the cam force initially presses the HLA down,
then the valve is opened. When the valve opens the
HLA dampens the spring force by moving HLA up
and down. As the valve stem gets worn off the HLA
moves up and maintains the zero clearance between
valve stem and roller follower. Thus by this actions
RFF and HLA provides noiseless the valve closing
and opening operation.

MAN-00162
High Pressure Pump (HPP) Lubrication System

The lubrication system provides a steady supply of
pressurized oil to the moving parts of the engine.
A Lubricaton reduces friction heat and keeps parts from
F wearing against each other. A pump draws in oil from
B the oil pan supply via an oil pump screen and forces
it to the engine lubricating points via the oil gallery.
The major components of the lubrication system are:
E C 1. Oil Pan
The oil pan is the reservoir for the oil and also
cover for the crank case. It is secured to the
D engine block by bolts. A liquid sealant is used to
provide an leak proof joint.
A. Pump outlet
B. Pump overflow
C. Gear feed pump
D. Pump inlet
E. Drive shaft
F. Metering unit
The HPP is driven by the engine timing chain. The
sprocket bolted to the main shaft of the HPP is also
marked while setting the timing of the engine. The
HPP pumps in the required quantity of the fuel into
the common rail. The HPP should be replaced as a 2. Oil Strainer
whole assembly. Oil strainer is the first stage in the filtration of the
lubricant. It filters the minute dust particles pre-
sent in the oil before it enters the oil pump.

MAN-00162
3. Oil Pump 6. Oil Dipstick

The oil pump is driven by crankshaft. The main Oil dipstick is used to measure the level of oil in
function of the oil pump is to circulate oil through the pan. It has two marks on it specifying MIN
the engine components. It sucks the oil from the and MAX levels.
oil pan through a strainer which prevents
entrance of any particles into the pump.
MAX
MIN
A
B 7. Low Oil Pressure Switch

Low Oil Pressure switch operates the low oil
A. Timing Cover pressure indicator in the cluster. This serves as
B. Front End Oil Seal a warning indicator to the driver, indicating a
decrease in the oil pressure which might harm
C. Oil Pump
the engine if he continues running the engine.
4. Oil Filter
The oil filter traps the impurities and foreign par-
ticles that may be present in the oil.
OIL FILTER
5. Oil Seals
The oil seals present in various locations pre-
vent the oil from seeping into places where oil
should not be present.

MAN-00162
8. Oil Cooler Service Tips and Precautions

The engine oil becomes hot and has to be
cooled else it loses its properties. The hot oil Observe the following precautions when disassem-
rejects heat to the coolant in the oil cooler. The bling or servicing the engine system and its compo-
oil thus maintains its temperature at optimum nents.
level. • Ensure a dust free environment before starting
the work on the engine.
• Carefully assemble the disassembled parts in
the correct order. If work is interrupted, the dis-
assembled parts must be covered with clean
cover/paper cloth.
• Carefully disconnect all the electrical connection
in the engine compartment before commencing
the work.
• Carefully unscrew the high pressure pipe nut
from the high pressure connector. Always use
two spanner or socket wrench set while tighten-
ing it.
• Ensure that there are no contacts between hard
materials and critical head’s, eccentric shaft, LP
9. Sealing Materials connectors and flange.
The different parts of the system are mated to
• Handle the High Pressure Pump (HPP) with
other parts with a gasket made of either asbes-
extreme care. If the HPP falls down it must be
tos or liquid sealant.
changed though it is not damaged.
DANGER
Do not work on the cooling system until the
engine is OFF and cooled down considerably,
because the pressure within the system is
extremely high and will cause personal injury.
DANGER
Eye protection must be worn while working
near the engine system, failure to follow this
may cause personal injury.
DANGER
Use Extreme Caution while the engine is run-
ning. Do not put your hands near hot compo-
nents, near the turbocharger in the engine
compartment. Failure to follow these instruc-
tions may lead to serious personal injury.

MAN-00162
General Procedures
DANGER Bearing Inspection
Care to be taken while working with heavy Inspect Bearing for the following defects
parts, failure to follow this instruction will lead A. Cratering - fatigue failure
to personal injury and damage to the parts.
B. Spot polishsing - incorrect seating
C. Imbedded dirt engine oil
D. Scratching - dirty engine oil
E. Based exposed - poor lubrication
F. Both edges worn - journal damaged
G. One edge worn - journal tapered or bearing not
seated
H. Tin caoting - bearing excessive wear
F H
C G
A E
Camshaft Bearing Journal Diameter

1. Using a micrometer measure the diameter at
90 degrees intervals to determine if the
journals are out-of-round
2. Measure at two different points on the journal
to determine if there is any tapering
3. If the measurements are out of the specified
range, install a new camshaft
910AM0130N

MAN-00162
Crankshaft End Play Inspection

1. Place the dial indicator and bracket
2. Determine the end float by raising the
crankshaft with the aid of a srewdriver
03
40
20
50
10
60
001
09
70
08

MAN-00162
Cylinder Bore Taper Check • If the measurement is out of the specified

1. Measure the cylinder bore with an internal range, install a new block or hone out the
micrometer cylinder block
• Carry out the measurements in different

directions and at different heights to
determine if there is any out-of-roundness
or tapering
10
15
5
20
-
itoyo
N
0
JAPA
”
25
Mis
E IN
22
”-1
+
28
MAD
25
05
NO.
00
5
20
10
15

MAN-00162
Piston Diameter Piston Ring End Gap

1. Using a Micrometer measure the piston
Diameter.
CAUTION
Do not mix up the piston rings. Install the pis-
ton rings in the same position and location.
1. Take the piston ring and use a piston without

rings to push the piston ring about xx mm into
the cylinder bore.
0
5
75 80 85
10
15
Piston Inspection
CAUTION
Do not use any aggressive cleaning fluid or a
wire brush to clean the piston.
1. Clean the piston skirt, pin bush, ring grooves Piston Ring-to-Groove Clearance
and crown and check for wear or cracks.
Notice
2. If there are signs of wear on the piston skirt,
check whether the connecting rod is twisted or The piston ring must protrude from the pis-
bent. ton groove. To determine the piston ring
clearance, insert the feeler gauge right to the
back of the groove, behind the wear ridge.
1. Using feeler gauge, measure the piston ring

clearance.

MAN-00162
Valve Seat Inspection In Car Repairs

1. Measure the valve seat width using the valve tests and inspection procedures are necessary for
seat width scale. specific engine malfunctions that cannot be is iso-
2. If the values are not to specification rework the lated with the Service Diagnosis charts. In-formation
valve seat. concerning tests and Inspection is provided within
the following:
1. Cylinder Compression Pressure Test
2. Cylinder Combustion Pressure Leakage Test
3. Engine Cylinder Head Gasket Failure Test.
4. Intake Manifold Leakage Test.
5. Engine Oil Leak Test.
6. Inspection for oil seal area leaks
7. Hydrostatically Locked Engine.
Cylinder Compression Pressure Test

The cylinder compression test is performed to deter-
mine the compression pressure of individual cylin-
Valve Stem Diameter ders. The test is performed in two stages.
1. Using a micrometer measures the diameter of 1. Dry Test
the valve stems.
2. Wet Test
2. If the measurements are not to specification,
install a new valve. Before performing the compression test ensure that
the battery is in good working condition. Otherwise
the indicated pressures may not be valid for diagnos-
tic purpose.
Dry Test:
1. Remove all the injectors
2. Fit the dummy injector and connect it with the
0
5 85 80 75
10
15
compression gauge
3. Disconnect the crankshaft position sensor elec-
trical connector.
4. Crank the engine.
5. Note down the max value the gauge indicates.
6. Repeat the procedure for all the other cylinders.
7. Tabulate the results.
Wet Test:
1. Spray 10 to 20 ml of fuel inside the bore through
the injector port with the help of an oil can.
2. Fit the dummy injector and connect it with the
compression gauge
3. Disconnect the crankshaft position sensor elec-
trical connector.
4. Crank the engine.
5. Note the maximum value the gauge indicates.
6. Repeat the procedure for all the other cylinders.
7. Tabulate the results.

MAN-00162
Compare both the dry and the wet values with the Hydrostatically Locked Engine
specifications. The wet test values should always be
higher than the dry test values. If the reading does When an engine is suspected to be hydrostatically
not change during wet test this can hint towards com- locked, regardless of what caused the problem, the
pression leakage from cylinder head or through the following steps should be used
valves. If the wet and dry test values vary consider-
ably between cylinders then the piston rings can be
suspected. CAUTION
DO NOT use starter motor to rotate the
Engine Cylinder Head Gasket Failure engine, severe damage may occur.
Test
1. Inspect air cleaner, air intake system and intake
A leaking engine cylinder head gasket causes power
manifold to ensure system is dry and clear of
loss, coolant loss and engine misfiring, overheating
water and foreign material.
and poor fuel economy. The engine cylinder head
gasket leakage occurs between adjacent cylinders or 2. Remove negative battery cable.
between a cylinder and adjacent water jacket.
3. Place a shop towel around the injectors when re-
The cylinder head gasket failure between cylinders is moving them from the engine. This will catch any
indicated by power loss and engine misfiring. fluid that may possibly be in the cylinder under pr-
essure.
The cylinder head gasket leaking between the cylin-
der and coolant passage results in coolant foaming 4. With all injectors removed, rotate engine cranksh-
or overheating and loss of coolant indicate an engine aft.
water jackets.
5. Identify the fluid in the cylinder(s) (i.e., coolant, fu-
Cylinder to Cylinder Leakage Test el, oil or other).
Check the cylinder compression pressure as already 6. Make sure all fluid has been removed from the cyl-
explained. Leakage between cylinders will be result inders. Inspect engine for damage (i.e., connect-
in drop of compression pressure by nearly 50 to 70% ing rods, pistons, valves, etc.)
in the affected cylinders.
7. Repair engine or components as necessary to pre-
Cylinder to Water jacket Leakage Test vent this problem from recurring.
• Remove the degassing pressure cap.
• Warm up the engine and allow it to warm up until CAUTION
the engine thermostat opens.
Squirt approximately one teaspoon of oil into
• If large combustion pressure leak exist, bubbles will the cylinders, rotate engine to lubricate the
be visible in coolant. cylinder walls to prevent damage on restart.
• If bubbles are not visible, install a radiator pressure
tester and pressurize the cooling circuit. If a cylin- 8. Drain engine oil and remove oil filter.
der is leaking combustion pressure into the water 9. Install a new oil filter.
jackets then the tester’s needle will pulsate with
every combustion stroke of the cylinder. 10.Fill engine with specified amount of approved oil.
11. Connect negative battery cable.
12. Start engine and check for any leaks.

MAN-00162
Timing Procedure 9. Assemble the secondary chain guide and sec-

ondary chain tensioner. Release the primary
chain tensioner by rotating the bolt.
8 10. Turn and hold the exhaust camshaft sprocket
against the tightening direction with the help of
11 the tool as shown in the image and tighten the
bolt of exhaust camshaft sprocket to the speci-
8 fied torque.
10 11. Tighten the bolt of intake camshaft sprocket to
9 the specified torque.
• Remove the tool for locking the camshaft.
• Assemble the front cover and assemble the
9 bolts. Tighten the front cover bolts to the
specified torque and following the specified
sequence.
1. Rotate the engine in such a way that the crank
• Assemble the flywheel. Torque tighten the
shaft key comes at 12’o clock position (facing
flywheel bolts following the specified
towards the camshafts) as shown in the image.
sequence. Lock the flywheel using the
flywheel locking tool.
• Remove the crankshaft locking pin from the
2 block.
• Fit the damper pulley and tighten the bolt to
the specified torque.
• Remove the flywheel locking tool.
Engine Oil Checking

2
1. Park the vehicle on a level surface and apply the
parking brake.
2. Start the engine and let it idle until reaches oper-
ating temperature.
3. Turn off the engine. Wait a few minutes for the
2. Fit the camshaft locator/camshaft linear oil to drain back into the oil pan.
alignment tool (Special Tool No:
4. Remove the dipstick (A) and wipe it clean. Rein-
0301BM002ST) and the TDC locking pin
sert it all the way.
(Special Tool No: 0301BM004ST) as shown in
the sketch above
3. Assemble the crankshaft sprocket, HPP
sprocket and the primary chain. Hand tighten
the sprocket bolts.
4. Assemble the primary chain guide and primary
chain tensioner.
5. Assemble the floating chain guide.
6. Release the primary chain tensioner.
7. Tighten the bolt of HPP Sprocket to the
specified torque.
8. Assemble the Inlet and exhaust camshaft A
sprockets, cam to cam chain guide and
secondary chain. Do not tighten the camshaft
sprocket bolts.

MAN-00162
5. Remove the dipstick again and check the Oil Engine Oil Draining Procedure
level. It should be between the maximum (MAX) 1. Park the vehicle on a level surface and apply the
and minimum (MIN) marks. If the oil level is parking brake.
below the MIN mark, remove the oil filler cap
and pour recommended oil through the opening. 2. Run the engine until it reaches operating tem-
Do not overfill. perature, and then turn it off.
3. Disconnect the negative terminal of the battery.
4. Remove the oil filler cap (A).
MAX
MIN
6. Recheck oil level with the dipstick. It is normal to

add some oil between oil maintenance intervals
or during the break-in period, depending on the 5. Lift the vehicle.
severity of operating conditions.
6. Remove all 10 mm mounting bolts (A) of engine
underbody cover (B).
CAUTION
Oil level should be checked regularly. Operat-
ing the engine with an insufficient amount of
oil can damage the engine and such damage
is not covered by warranty. A
Notice
Use only recommended MAHINDRA "MAX-
B
MILE CROWN"oil of specification Exceeds -
APICH-4; SAE 15W-40.
7. Place a large drain pan below the drain plug.
CAUTION
Be careful not to burn yourself. The engine oil
may be hot.

MAN-00162
8. Remove the 22 mm drain plug (A) and com- 3. Connect the negative terminal of the battery.
pletely drain the oil from oil pan (B). 4. Start the engine. Check for leakage around the
drain plug and oil filter. Correct as required.
5. Turn the engine off and wait several minutes.
Check the oil level with the dipstick. Add engine
A oil if necessary.
WARNING
B Prolonged and repeated contact with used
engine oil may cause skin disease. Try to
avoid direct skin contact with used oil. If skin
contact is made, wash thoroughly with soap or
hand cleaner as soon as possible.
Engine oil filling procedure

1. Clean and reinstall the drain plug and a new
washer. Tighten the drain plug to the specified
torque:
2. Refill the engine with recommended oil and
securely tighten the filler cap (A).
Notice
Use MAHINDRA "MAXMILE CROWN"oil of rec-
ommended quantity of 6 litres.

MAN-00162
Fuse Box 4. Unlock the four fuse box locks (A) and lift the
fuse box.
Removal
1. Disconnect the battery negative terminal. For
Notice
additional information refer to Battery Jently unlock the fuse box locks avoid to dam-
removal and installation section. aming fuse box locks.
2. Remove the 8mm engine wiring harness
electrical connectors mounting nut (A), 10mm
mounting nut (B) and detach the harness from
the engine room fuse box.
A
A
30 F5 K3 K4
40
F20 F4
SF4 SF9
F27 30 F3
40
F26
K17 K5
F2
SF10
F6
30 40
F15 50
K6
SF6 SF1 SF5 K7
30 40
50
B MF2 K1
SF2
K8
F18
F19
50
K9 K16
50
K11
F11
F10
F9
F25
F8
K21
F23
F7
SF8
F24
F16
09
09
SF7
09
09
K15
K18 K12 09
SF3
09
MF1 F12 F13

F21
F17 F1
5. Disconnet the four fuse box electrical;

connectors (A) and detach the fuse box
separately.
3. Remove the four 8 mm fuse box mounting bolts
(A).
30 F5 K3 K4
40
F20 F4
SF9
A
F27 SF4
40 30 F3
F26
K17 K5
F2
SF10
F6
A
30 40
F15 50
K6
SF6 SF1 SF5 K7
30 40
50
MF2 K1
SF2
K8
F18
F19
50
K9 K16
50
K11
F11
F10
F9
F25
F8
K21
F23
F7
SF8
F24
F16
09
09
SF7
09
09
K15
K18 K12 09
SF3
09
MF1 F12 F13

F21
F17 F1
Notice
• Do not shake or twist the electrical
connectors while removing the electrical
connectors.
• Do not pull the wires when removing the
electrical connectors.

MAN-00162
Installation Engine Oil Filter

Notice Removal
Fix the electrical connectors gently to the fuse 1. Disconnect the negative terminal of the battery.
box without damaging the connector pins. Fa- 2. Remove engine NVH cover.
olire will lead to damage the pins and electri-
cal fault. 3. Lift the vehicle.
1. To install, reverse the procedure. underbody cover (B).
5. Place a large drain pan below the oil filter.

6. Remove the oil filter (A) using a suitable tool in
anticlockwise direction.
dra
mahin

MAN-00162
Installation Engine
1. Wipe the engine oil filter mounting surface with a
clean rag. Removal
2. Coat the gasket on the new filter with clean 1. Pull the lever (A) which is located in the driver
engine oil. side to open the bonnet.
OIL FILTER A
3. Tighten the oil filter (A) in clockwise direction 2. Press the bonnet lock (A) as shown in arrow
until a slight resistance is felt, then tighten an direction, to open the bonnet.
additional 2/3 turn.
dra
mahin
3. Open the bonnet and fix the stay rod in

4. Connect the negative terminal of the battery. position to support the bonnet.
5. Start the engine and check for leakage around
the oil filter. Correct as required.
6. Turn the engine off and wait several minutes.
Check the oil level. Add engine oil if necessary.
7. Install the engine underbody cover and tighten
all 10 mm mounting bolts to the underbody
cover.

MAN-00162
4. Remove the two 12mm inches mounting bolts 10. Drain the power steering fluid. For additional
(A) on the bonnet RHS. information refer to Steering Oil Replace
Section.
11.Remove the intercooler assembly from the
engine. For additional information refer to
A Intercooler removal and installation section.
12.Remove the degassing tank. For additional
information refer to Degassing Tank
removal and installation section.
13.Remove the 10mm front wiper reservoir neck
mounting bolt (A).
LOSE
EN C
OP
5. Remove two 12mm inches mounting bolts (A) POWER
G
on bonnet LHS. Detach the bonnet assembly. STEERIN RE
EN WASHING F
LU
FLUID
C ID
DS
IN
W
A
14.Remove the power steering suction hose. For

additional information refer to Power Steer-
ing Suction Hose removal and installation
section.
CAUTION
6. Remove the fuse box. For additional Avoid spillage of power steering fluid on
information refer to Fuse Box removal and other components and wipe off immediately
installation section. if any spillage is noticed.
Notice
Drain the engine oil and transmission oil only
Notice
if required. Plug the inlet & outlet hole of the power
steering pump to avoid entry of foreign parti-
7. Remove the battery tray. For additional cles.
information refer to Battery Tray removal
and installation section. 15. Remove the air filter housing. For additional
8. Recover A/C gas from the HVAC system. For information refer to Air Filter Housing
additional information refer to Refrigerant removal and installation section.
Recovery Recycling and Recharging 16. Pull the lock and remove the clutch slave cylin-
Section. der inlet hose. For additional information refer
9. Drain the engine coolant from the radiator. For to Concentric Slave Cylinder removal and
additional information refer to Engine Cool- installation section.
ant Replacement/Filling and Bleeding Proce- 17. Disconnect the gear shifting cable. For
dure: Section. additional information refer to Gear Shifter
Cable removal and installation section.

MAN-00162
18. Disconnect the neutral, reverse switch and 21. Press the lock (A) and pull out the fuel suction
vehicle speed sensor electrical connectors. For hose (B) from the fuel primary pump.
additional information refer to Transaxle
19. Remove 12mm battery ground cable mounting
bolt connected to the Transmission. For
B
20. Press the lock (A) and pull out the vacuum
hoses (B) of the EGR and turbocharger.
A
A
B
22. Press the lock (A) and pull out the fuel return
hose (B).
A B
23.Pull out the vacuum pump outlet hose (A) from

the vacuum pump.
24. Press the lock and pull out the heater core
inlet and outlet hoses. For additional
information refer to Front HVAC Unit

MAN-00162
25. Unlock the engine wiring harness clips 36.Support the front cradle assembly using the
mounted on the engine room body and place it suitable stand.
aside. 37.Remove the four 21mm mounting bolts on the
26. Press the clip, and pull out the radiator top, front cradle. For additional information refer
bottom and by-pass hoses from the radiator. to Front Cradle Assembly removal and
For additional information refer to Radiator installation section.
removal and installation section. 38.Remove the 18mm engine mounting bracket
27. Press the lock, and disconnect the A/C com- bolts and nuts. For additional information
pressor electrical connector. For additional refer to Engine Mounting removal and
information refer to Compressor removal installation section.
and installation section. 39.Remove the two 13mm top mounting bolts on
28. Remove the 13mm A/C low and high pressure transmission. For additional information refer
pipe mounting nuts. For additional information to Transaxle removal and installation
refer to Compressor removal and installation section.
section. 40. Using a rope chain (B), hook the engine
carefully at its lifting brackets (A).
Notice
Plug the inlet & outlet hole of the A/C com-
pressor to avoid entry of foreign particles. DANGER
Improper tie-up of the lifting rope chain will
29. Remove the two 12 mm intermediate shaft cause damage to the vehicle and the persons
upper Universal Joint mounting bolt (A) involved.
connecting upper and lower intermediate
shafts. For additional information refer to
Intermediate Shaft Upper with Universal
Joint removal and installation section.
30.Remove the 12mm connector intermediate
shaft from the steering gear. For additional A A
information refer to Connector Intermediate
Shaft removal and installation section.
31. Remove the 15mm catalytic converter joint
mounting nut and insulator. For additional
information refer to Catalytic Converter
B
32. Press the lock and pull out the brake pad
sensor electrical connector. For additional
information refer to Front Brake Pad
33.Remove the 16mm front brake caliper
mounting bolts on both sides. For additional
information refer to Front Brake Caliper
34. Remove the 18mm front stabilizer bar link
bottom mounting nuts on both sides. For
additional information refer to Front
Stabilizer Bar Link removal and installation
section.
35. Remove the 21mm front strut mounting bolt
and nuts on both sides. For additional
information refer to Front Strut Assembly

MAN-00162
41.Lift the vehicle slowly to pull out the engine care- 44.Remove all 14mm transmission mounting bolts
fully along with the transmission and rest it on (A) and detach the transmission from the engine.
suitable stand.
Installation
42.Remove the drive shafts LH & RH. For
1. To install, reverse the removal procedure.
additional information refer to Front
HalfShaft LH removal and installation 2. Tighten all bolts and nuts to the specified
section. For additional information refer to torque.
Front HalfShaft RH removal and installation 3. Refill the power steering fluid. For additional
section. information refer to Steering Oil Replace
43.Remove the 18 mm transmission front & rear Section.
centre mounting nuts (A), remove the 17mm 4. Refill the engine coolant. For additional infor-
mounting bolts and detach the cradle. mation refer to Engine Coolant Replacement/
Filling and Bleeding Procedure: Section.
5. Recharge the A/C freon gas to the HVAC
system. For additional information refer to
Refrigerant Recovery Recycling and
A Recharging Section.
6. Check all the electrical functions.
7. Check the wheel alignment. For additional
information refer to Wheel Alignment

MAN-00162
Crankshaft Front Seal 5. Using a suitable tool (A), remove the oil seal (B)
from the timing cover.
Removal
1. Remove the accessory drive belts. For addi-
tional information refer to Accessory Drive
Belt removal and installation section.
2. Remove the starter motor assembly from the
engine. For additional information refer to A B
Starter Motor removal and installation sec-
tion.
3. Install the flywheel locking tool (A) (Special Tool
No: 0302EAM0001ST) on the transmission and
lock it.
Inspection
1. Check and clean the oil seal seating area thor-
oughly for any damage.
CAUTION
The oil seals should never be reused.
Installation
1. Install the new oil seal (A) on front end of the
crankshaft.
4. Remove the 24mm mounting bolts (A) of the
crankshaft damper pulley.

MAN-00162
2. Insert the dolly for front cover oil seal (A) (Spe- 6. Remove the flywheel locking tool (A) (Special
cial Tool No: 0311DAM0001ST) on the timing Tool No: 0302EAM0001ST) from the transmis-
cover and tap it using a mallet. sion.
7. Install the starter motor assembly to the engine.

Notice For additional information refer to Starter
Visually inspect the oil seal for proper seating. Motor removal and installation section.
8. Install the accessory drive belts. For additional
3. Visually check if the oil seal is seated properly in information refer to Accessory Drive Belt
the slot. removal and installation section.
4. Install the damper pulley on the timing cover.
Align the damper pulley flat surfaces with the oil
pump.
5. Tighten the 24mm crankshaft damper pulley
mounting bolt (A) to the specified torque.

MAN-00162
Crankshaft Rear End Oil Seal 4. Using a suitable tool (A), pull out the oil seal (B)
from rear end of the crankshaft.
CAUTION
Care should be taken while pulling out the oil
seal from the crankshaft, to avoid damage to
the oil seal seating edge of the crankshaft.
A
B
Removal
1. Remove the Power transfer unit (PTU). For
additional information refer to Power Take
Off Unit (PTU) removal and installation
section.
Notice
PTU removal must be carried out only in- Inspection
case of AWD vehicles.
1. Check the oil seal seating area for any damage,
and clean it thoroughly.
2. Remove the transmission.For additional infor-
mation refer to Transaxle removal and instal-
lation section. CAUTION
3. Remove the flywheel. For additional informa-
The oil seal should never be reused.
tion refer to Dual Mass Flywheel (DMF)

MAN-00162
Installation
Notice
Clean the oil seal seating edge of the crank
shaft, before installing the oil seal.
1. Install the new oil seal (A) on rear end of the

crankshaft.
2. Insert the rear oil seal pressing dolly (A)

(Special Tool No: 0301BM007ST) on the rear
end crankshaft and tap it using a mallet.

4. Tighten all bolts to the specified torque.

MAN-00162
Timing Chain and Sprockets

A
K C
J
L D
I H
G F
A. Guide Cam Shaft H. Primary Tensioner Guide

B. Secondary Timing Chain I. Tensioner Arm Secondary
C. Circlip Secondary Guide J. Secondary Tensioner
D. Secondary Chain Guide K. Inlet & Exhaust Camshaft Sprocket
E. HPP Sprocket L. Hydraulic Tensioner Primary
F. EGR cooler mixer M. Primary Timing Chain
G. Crankshaft Sprocket

MAN-00162
Removal 9. Remove the four 12 mm engine bracket mount-

1. Remove the engine from the vehicle and place it ing bolts (A) and detach the bracket (B).
on work bench. For additional information
refer to Engine removal and installation sec-
B
tion.
2. Drain the engine oil. For additional information A
refer to Engine Oil Draining Procedure Sec-
tion.
3. Remove the starter motor assembly.For addi-
tional information refer to Starter Motor
4. Remove the accessory drive belts. For addi-
5. Remove the alternator.For additional informa-
tion refer to Alternator removal and installa-
10.Install the flywheel locking tool (A) (Special Tool
tion section.
No: 0302EAM0001ST) on the transmission and
6. Remove the power steering pump. For addi- lock it.
tional information refer to Power Steering
Pump removal and installation section.
A
7. Remove the A/C compressor bracket with idler.
For additional information refer to Disassem-
bly and Assembly removal and installation
section.
8. Remove the two 10mm engine oil filling neck
mounting bolt (A) and detach the filling neck (B).
B
A
11.Remove 24mm crankshaft damper pulley
mounting bolt (A) and detach the damper
pulley.

MAN-00162
12.Remove the flywheel locking tool (A) (Special 15.Remove the twenty three 12 mm timing cover
Tool No: 0302EAM0001ST) on the transmission mounting bolts (A) as per recommended
and lock it. sequence and detach the timing cover case (B).
13.Remove the First and second drive belt idler 16. Rotate the crankshaft sprocket such that the
mounting bolts (A) and water pump pulley key slot reaches 12’O clock position.
mounting bolt (B), detach from the timing case
cover.
A
B
14.Remove the drive belt tensioner mounting bolts

(A) and detach tensioner (B) from the timing
case cover.
A B

MAN-00162
17. Remove the TDC lock plug and insert the TDC 20. Loosen the 22mm center mounting bolts (A) of
locking pin (A) (Special Tool No: 0301BM004ST) the left primary and secondary timing chain
at bottom of starter motor. guide.
18. Using a 6mm allen key, loosen the timing chain 21.Remove the 12mm secondary timing chain auto-
top guide allen bolts (A) an remove the top guide tensioner mounting bolts (A) and remove the
bracket. auto-tensioner (B).
19.Lock the front end timing tool for camshaft (A) 22. Release the right secondary chain guide mount-
(Special Tool No: 0301BM001ST) on the inlet ing circlip locks (A) and remove the right second-
and exhaust camshaft key slot located on back ary chain guide (B).
of the camshaft sprocket.
A
A
B

MAN-00162
23. Remove the camshaft secondary timing chain 26. Remove the primary timing chain (A) between
(A) between the pump and the sprocket. the crankshaft and HPP.
24. Remove the 10 mm primary timing chain auto- 27.Remove the 22mm HPP sprocket mounting nut
tensioner mounting bolts (A) and 22 mm center (A).
guide mounting bolts (B) of the left primary and
secondary timing chain guides and detach the
chain guides.
B
A
25. Using 5mm allen key, remove the allen key

bolts (A) and remove the right primary chain
guide (B).

MAN-00162
28.Install the cam chain tensioning tool (A) (Special 30.Fix the HPP removal tool (A) (Special Tool No:
Tool No: 0301BM011ST) into the inlet & exhaust 0305BAM0007ST) to match the HPP shaft to
camshaft sprocket holes and hold it. Remove the the tool centre mounting bolt and tighten the
15mm camshaft sprocket mounting bolt (B) and 22mm centre mounting bolt (B). Detach the
detach inlet & exhaust camshaft sprocket (C). HPP sprocket and pump.
Notice
Perform the same action on the other cam-
shaft sprocket and remove it.
A
CAUTION
Inlet and exhaust Camshaft sprocket should
B
not be interchanged during removal and
installation. Failure to follow the instruction
may lead to engine malfunctioning.
31.Detach the Crankshaft Sprocket (A) from the

B Crankshaft.
A C
A
29.Remove the HPP fuel outlet pipe lock nut (A)

and three 12 mm HPP mounting bolts (B) from
the engine.
Notice
Remove the Crankshaft sprocket lock key-
while removing Crankshaft sprocket and keep
it in a secured place.

MAN-00162
Installation 2. Ensure the TDC locking pin (A) (Special Tool

No: 0301BM004ST) in lock position.
Notice
Clean the outer and inner surface of the timing
chain area of the engine and timing chian
cover.
Notice A
Check for any damages or cracks in timing

chain, sprockets, tensioners and timing chain
cover post installation. If found replace the
affected components.
3. Install the three 12 mm HPP mounting bolts

CAUTION (B) and HPP fuel outlet pipe lock nut (A) to the
engine.
Check and confirm the TDC Position of the
piston for cylinder-1 before installation, in
case the same was not followed while
Notice
removing the timing chain. Do not reuse the HPP O-ring post installation.
If removed use new HPP O-ring only.
Notice
Do not remove the camshaft locking tool & the
Crankshaft TDC plug from its location, else CAUTION
the engine timing could get disturbed. For Tighten the HPP sprocket mounting nut
additional information refer to Timing Proce- after installing the chain guides and auto-
dure. tensioner.
1. Rotate the crankshaft (clockwise) such that the

key slot (A) in the crankshaft comes at 12’O
clock position and install the crankshaft sprocket
in its position.
A
A

MAN-00162
4. Ensure the front end timing tool for camshaft 6. Install primary timing chain (A) connecting HPP
(A) (Special Tool No: 0301BM001ST) is on the pump and Crankshaft.
both camshaft key slot located on back of the
sprocket.
7. Install the right primary chain guide (A) and

using 5 mm allen key, tighten the right primary
5. Install the inlet, exhaust camshaft sprocket (A) chain guide allen key bolts (B).
on the camshaft and tighten the 15mm
mounting bolt (B), install the HPP sprocket and
tighten the 22mm mounting nut (C).
CAUTION
Inlet and exhaust camshaft sprocket
mounting nut should be tightened only after
installing the chain guides and auto-
tensioner.
B
A
A

MAN-00162
8. Install left primary and secondary chain guide 10. Engage the tensioner lock pin (A) into the
(A) and secure its 22mm center mounting bolt tensioner. Release the tension of the tensioner
(B). by disengaging the tensioner lock pin from the
tensioner.
CAUTION
Tighten the guide center mounting bolt after
installing primary and secondary timing
chain auto-tensioners.
A
A
B
11.Install the secondary timing chain (A)

connecting HPP pump sprocket and camshaft
A sprocket.
9. Install the primary chain auto tensioner and

tighten 10mm mounting bolts (A) of primary A
chain auto-tensioner.
12. Install the right secondary chain guide (A).

Secure the mounting circlip locks (B) of the
right chain guide.
A

MAN-00162
13. Install the secondary chain guide (A) and 16.Remove the front end timing tool for camshaft
auto-tensioner. Tighten 12mm mounting bolts (A) (Special Tool No: 0301BM001ST) on the
(B) of secondary timing chain auto-tensioner. camshaft key slot located near to the sprocket.
A
A
14. Install the cam chain tensioning tool (A) 17. Remove the crankshaft TDC locking pin (A)
(Special Tool No: 0301BM011ST) into the (Special Tool No: 0301BM004ST) at bottom of
camshaft sprocket holes and hold it. Tighten the starter motor and install the TDC plug.
both 15mm camshaft sprocket mounting bolt to
the specified torque (B).
A
TM
US
iPL
Tekn P-25
T
B
A
15.Using sprocket and wrench (A), tighten the 22

mm mounting nut (B) of the HPP sprocket to
specified torque.
TM
TP-100

MAN-00162
18.Install the top support bracket. Using 6mm 20.Install the filling neck (A) and tighten the two
allen key, tighten allen key bolts (A) of the 10mm engine oil filling neck mounting bolt (B)
timing chain top support bracket to the to the specified torque.
specified torque.
TM
TP-2
5
A
B
21.Install the engine mounting bracket and tighten

the four 12mm mounting bolts (A) to the
specified torque.
CAUTION
Use only the recommended sealant, failure
to follow the instruction may lead to A
leakages. While tightening the timing cover
mounting bolts follow torque sequence as
shown in the illustration.
Notice
Apply loctite 5900 to the timing cover.
19.Install the timing cover assembly (A) to the

engine. Tighten 12mm timing cover mounting
bolts (B) as per recommended sequence to the
specified torque. 22.Install crankshaft front end oil seal. For
additional information refer to Crankshaft
Front Seal removal and installation section.

MAN-00162
23.Install the flywheel locking tool (A) (Special 26.Install water pump pulley and tighten four
Tool No: 0302EAM0001ST) and lock the 12mm water pump pulley mounting bolts (A).
Flywheel.
27.Install the Drive belt tensioner to the engine

24.Install crankshaft damper pulley and tighten the block and tighten the mounting bolt (A) to the
24mm mounting bolt (A) to the specified specified torque.
torque.
A TM
S
LU0
k niPTP-10
Te
28.Install the First and second Idlers to the engine

25.Remove the mounting bolts of flywheel locking timing case cover and tighten the mounting
tool (A) (Special Tool No: 0302EAM0001ST) bolts (A) to the specified torque.
and remove the flywheel locking tool from its
position.

MAN-00162
29.Install the alternator.For additional information Camshaft

refer to Alternator removal and installation
section.
30.Install the power steering pump. For additional
information refer to Power Steering Pump A
31.Install the A/C compressor bracket with idler. For C
additional information refer to Disassembly
and Assembly Section.
B
32.Install the accessory drive belts. For additional
information refer to Accessory Drive Belt
removal and installation section. D
33. Install the starter motor. For additional infor-
E
mation refer to Starter Motor removal and
installation section.
34. Install the engine to the vehicle.For additional A. Exhaust Camshaft
information refer to Engine removal and B. Intake Camshaft
C. Exhaust Camshaft Sprocket
35. Refill the engine oil. For additional informa-
tion refer to Engine oil filling procedure Sec- D. Intake Camshaft Sprocket
tion. E. Sprocket Bolt
The camshaft controls the valve opening and
closing events. It is driven by the crankshaft
through a chain connection. The camshaft rotates
at half the speed of the crankshaft to maintain
proper timing of the four cycle of combustion. The
opening and closing of the valves are done by
lobes on the camshaft. The engine has two
camshafts one for operating intake valves and the
other for exhaust. The exhaust camshaft is
identified by the presence of a ring for the purpose
of operating a cam phase sensor.
The timing of the valve depends on the position of
the camshaft and shape of the lobes on it.
The valve lift is the distance the valve is lifted off its
seat when fully opened. This is determined by the
height of the cam lobe.The valve need enough lift to
allow air to flow freely into the cylinder and for
exhaust gases to flow out of the cylinder, without
interfering with piston or binding the spring.
The duration is the length of time the cam lobe keeps
the valve open. it is measured in degrees of cam-
shaft rotation and is determined by the shape of the
cam lobe. The camshaft

MAN-00162
Removal 3. Remove the six 12mm the oil separator

1. Disconnect the engine wiring harness electrical mounting bolts (A) and oil filling neck mounting
connectors (A) from the engine. bolt (B) and camphase sensor (C).
A
B
A
2. Press the lock (A) and detach the fuel suction 4. Remove the fuel rail unit from the cylinder
and return hoses (A) from the HPP. head assembly. For additional information
refer to Fuel Rail removal and installation
section.
A 5. Remove the fuel injectors from the cylinder
head assembly. For additional information
refer to Fuel Injector removal and
A installation section.
6. Remove the timing chain and sprocket from the
engine assembly. For additional information
refer to Timing Chain and Sprockets removal
and installation section.
7. Remove vacuum pump assembly. For
additional information refer to Vacuum
8. Remove the thirty one 10mm cam cover
mounting bolts (A) as per the recommended
sequence and remove the cam cover (B).

MAN-00162
Inspection
1. Check the inlet camshaft and the exhaust
CAUTION camshaft for any damage and replace it if
Handle the cam cover carefully such that necessary.
the cam phase sensor is not damaged
during the removal and installation.
N0310M00130 4S
9. Remove the stefa plug (A) at rear side of the

camshaft (intake manifold side).
A IS 69
2. Check the camshaft cover bearing for any

scoring mark, crack or scratches.
10. Remove both the inlet and exhaust cam shafts

(A) from the cylinder head assembly.
Notice
Cam shafts should not be interchanged dur-
ing the removal. Exhaust camshaft has the
trigger wheel for the cam phase sensor
mounted on it.

MAN-00162
Installation 3. Rotate the crankshaft such that the key slot (A)
reaches 12’O clock position.
CAUTION
Check and confirm the TDC Position of the A
removing the timing chain.
1. Install both the cam shafts (A) on the cylinder

head assembly.
Notice
Cam shafts should not be interchanged dur-
ing the installation. Exhaust camshaft has
the trigger wheel for the cam phase sensor
mounted on it. 4. Lock the front end timing tool for camshaft (A)
(Special Tool No: 0301BM001ST) on the cam-
shaft key slot located at back part of the
sprocket.
A A
2. Install the camshaft locator / camshaft linear

alignment tool (A) (Special Tool No:
5. Insert the stefa pin locator (A) (Special Tool
0301BM002ST) and align the camshafts (B) to
No:0301BM009ST) at the rear side of the
properly fix in its position.

MAN-00162
6. After aligning the cam lobes properly on the 8. Insert thirty one 10mm camshaft cover
Hydraulic lash adjuster (HLA), remove the mounting bolts (A) and tighten them by hand.
camshaft locator / camshaft linear alignment
tool (A) (Special Tool No: 0301BM002ST)
placed on the top of camshafts. A
Notice
The front end timing tool for camshaft (B)
(Special Tool No: 0301BM001ST) as shown in
the image below, should not be removed till
the cam cover is installed on to the engine.
A B
9. Tighten 10mm cam shaft cover mounting bolts

to the specified torque value. For additional
information refer to Torque Sequence
Section.
10.Remove the stefa pin locator (A) (Special Tool
No:0301BM009ST) at the rear side of the
7. Install the camshaft cover (A) on the cylinder

head assembly.

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11. Install the stefa plug (A) at rear side of the

CAUTION
to follow the instruction may lead to
leakages. While tightening the oil separator
A
Notice
17.Insert the fuel suction and return hose (A) to

HPP.
12.Install the timing chain and sprocket from the

engine assembly. For additional information
refer to Timing Chain and Sprockets
13.Install the vacuum pump assembly. For
additional information refer to Vacuum
14. Install the fuel injectors with the cylinder head
assembly. For additional information refer to
Fuel Injector removal and installation
section.
A
15. Install the fuel rail unit with the cylinder head
assembly. For additional information refer to
Fuel Rail removal and installation section.
18.Connect the engine wiring harness electrical
16.Install the six 12mm the oil separator mounting connectors (A).
bolts (A) and oil filling neck mounting bolt (B)
and camphase sensor (C).
B
A

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Hydraulic Lash Adjuster (HLA) Inspection

1. Check the HLA for any damage, and replace it
if necessary.
CAUTION
Do not disassemble the HLA, as it is not a
serviceable component. Incase of a failure
of a HLA, replace the complete assembly.
Removal
1. Remove the camshafts from the engine. For
additional information refer to Camshaft
2. Carefully lift the hydraulic lash adjuster (A)
from the cylinder head assembly and place
them safely in a oil filled container.
CAUTION
Hydraulic lash adjuster should be kept in
straight upward position in an engine oil
filled container only.

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Installation
1. Install the hydraulic lash adjuster (A) into the
cylinder head assembly and properly align
them.
CAUTION
Hydraulic lash adjuster should be kept in
straight upward position in the cylinder
head.
2. Install the camshafts to the engine. For

additional information refer to Camshaft

MAN-00162
Cylinder Head
A B C
F E
G H
A. Cap Oil Filter F. Cam Cover

B. Oil Filling Neck G. Engine Lifting Hook
C. Camphase Sensor H. Glow Plug
D. Vacuum Pump I. Cylinder Head
E. Cam Cover Plug J. Cylinder Head Gasket
The cylinder head is bolted on top of the cylinder block to form the roof of the combustion chamber. The cylinder
head:
• Seals the top of the cylinder block.
• Holds the glow plugs, fuel rail and injectors.
• Provides seats, guides and ports for the intake and exhaust valves.
• Holds the valve train
• Provides mountings for the intake and exhaust
manifold.
The intake and exhaust manifolds are mounted to the cylinder head against the valve ports. The top part of the
cylinder head is designed such that the rocker arm and other parts of the valve train can be mounted on it. The
aluminium alloy gives the head superior heat dissipating capability to that of the cast iron head. The coolant and
oil passages are incorporated in the head for cooling and lubrication purposes.
The cylinder head gasket forms the gas and watertight junction between the cylinder head and block. It also off-
sets any minor irregularities in the mating surfaces. Thus the gasket is made up of flexible material.

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Removal 4. Remove the cylinder head gasket (A) from the

1. Remove the HLAs from the engine.For engine block.
additional information refer to Hydraulic
Lash Adjuster (HLA) removal and
2. Loosen the ten 15mm cylinder head mounting
bolts (A) as per the sequence and remove
them.
Inspection
A
CAUTION
Clean the cylinder head assembly
thoroughly, if any cracks or damages are
3. Firmly hold the cylinder head assembly (A) and found replace the cylinder head.
carefully remove the cylinder head assembly.
1. Check the Cylinder Head for external
damages.
A
2. Check the cylinder head height and if not
meeting the specified value, replace the
cylinder head assembly (A).

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3. Check the Cylinder Head bottom face for 6. Check the length of the Cylinder Head bolts.
distortion.
7. Check the valve seat area for leakages.

4. Check the cylinder head flatness, if any
misalignment or bend found replace the Installation
cylinder head assembly.
CAUTION
Clean the cylinder head assembly
thoroughly, if any cracks or damages are
found replace the cylinder head.
1. Replace the cylinder head gasket (A) to the

engine block.
CAUTION
Replace the cylinder head gasket with a new
one. Failure to follow this will lead to
compression failure.
5. Check the cylinder head for warpage.
CAUTION
The cylinder head mounting bolts cannot be
reused.

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2. Hold the cylinder head assembly (A) and Assembly Accelerator Pedal
carefully place it on the engine block.
3. Tighten the ten 15mm cylinder head mounting Removal

bolts (A) as per the recommended sequence. 1. Remove the negative terminal of the battery.
For additional information refer to Battery
2. Remove the bottom trim of the steering
column. For additional information refer to
Steering Column Assembly removal and
3. Press the lock and pull out the electrical
connector (A) of the accelerator pedal.
4. Install the HLA. For additional information A

refer to Hydraulic Lash Adjuster (HLA)

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4. Remove the three 10mm accelerator pedal High Pressure Pump (HPP)
mounting nuts (A) and separately detach the
accelerator pedal.
A
F
B
E C
D
A
A. Pump outlet
B. Pump overflow
Inspection
1. Check the sensor for physical damage. C. Gear feed pump
2. Check the electric contact points for sulfation D. Pump inlet

and clean the same. E. Drive shaft
Installation F. Metering unit

1. To install, reverse the removal procedure. Removal
2. Tighten the accelerator pedal mounting nuts to 1. Remove the engine from the vehicle and place
the specified torque. it on work bench.For additional information
refer to Engine removal and installation
section.
CAUTION 2. Remove the accessory drive belts. For addi-
Do not overtighten the accelerator pedal tional information refer to Accessory Drive
mounting nuts. It may lead to accelerator Belt removal and installation section.
pedal mounting damage. 3. Remove the two 10mm engine oil filling neck
mounting bolt (A) and detach the filling neck (B).
3. Start the engine and check the accelerator oper-
ation.
B
A

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4. Remove the four 12 mm engine bracket 7. Remove the flywheel locking tool (A) (Special
mounting bolts (A) and detach the bracket (B). Tool No: 0302EAM0001ST) on the
transmission and lock it.
B
A
A
5. Install the flywheel locking tool (A) (Special Tool

No: 0302EAM0001ST) on the transmission and 8. Remove the First and second drive belt idler
lock it. mounting bolts (A) and water pump pulley
mounting bolt (B), detach from the timing case
cover.
A
A
B
6. Remove 24mm crankshaft damper pulley

mounting bolt (A) and detach the damper
pulley. 9. Remove the drive belt tensioner mounting bolts
(A) and detach tensioner (B) from the timing
case cover.
A B
A

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10.Remove the twenty three 12 mm timing cover 13. Using a 6mm allen key, loosen the timing chain
mounting bolts (A) as per recommended top guide allen bolts (A) an remove the top guide
sequence and detach the timing cover case (B). bracket.
11. Rotate the crankshaft sprocket such that the key 14.Lock the front end timing tool for camshaft (A)
slot reaches 12’O clock position. (Special Tool No: 0301BM001ST) on the inlet
and exhaust camshaft key slot located on back
of the camshaft sprocket.
12.Remove the TDC lock plug and insert the TDC

locking pin (A) (Special Tool No:
0301BM004ST) at bottom of starter motor. 15. Loosen the 22mm center mounting bolts (A) of
the left primary and secondary timing chain
guide.
A

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16.Remove the 12mm secondary timing chain auto- 19. Remove the 10 mm primary timing chain auto-
tensioner mounting bolts (A) and remove the tensioner mounting bolts (A) and 22 mm center
auto-tensioner (B). guide mounting bolts (B) of the left primary and
secondary timing chain guides and detach the
chain guides.
A B
B
A
17. Release the right secondary chain guide mount-

ing circlip locks (A) and remove the right second-
ary chain guide (B). 20. Using 5mm allen key, remove the allen key
bolts (A) and remove the right primary chain
guide (B).
A
B
18. Remove the camshaft secondary timing chain
(A) between the pump and the sprocket.
21. Remove the primary timing chain (A) between
the crankshaft and HPP.

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22.Remove the 22mm HPP sprocket mounting nut Installation

(A).
Notice
Clean the outer and inner surface of the timing
chain area of the engine and timing chain
cover.
A
Notice
Check for any damages or cracks in timing
chain, sprockets, tensioners and timing chain
cover post installation. If found replace the
affected components.
23.Remove the HPP fuel outlet pipe lock nut (A)

and three 12 mm HPP mounting bolts (B) from CAUTION
the engine.
Check and confirm the TDC Position of the
removing the timing chain.
Notice
A Do not remove the camshaft locking tool & the
Crankshaft TDC plug from its location, else
the engine timing could get disturbed. For
additional information refer to Timing Proce-
B dure.
24.Fix the HPP removal tool (A) (Special Tool No: Notice
0305BAM0007ST) to match the HPP shaft to Replace the gaskets to the intake manifold /
the tool centre mounting bolt and tighten the throttle valve whenever removed from the
22mm centre mounting bolt (B). Detach the engine.
HPP sprocket and pump.

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1. Ensure the TDC locking pin (A) (Special Tool 3. Install the HPP sprocket and tighten the 22mm
No: 0301BM004ST) in lock position. mounting nut (A).
CAUTION
Inlet and exhaust camshaft sprocket
mounting nut should be tightened only after
installing the chain guides and auto-
A tensioner.
2. Install the three 12 mm HPP mounting bolts

(B) and HPP fuel outlet pipe lock nut (A) to the
engine.
A
Notice
Do not reuse the HPP O-ring post installation.
If removed use new HPP O-ring only.
4. Install primary timing chain (A) connecting HPP
pump and Crankshaft.
CAUTION
Tighten the HPP sprocket mounting nut
after installing the chain guides and auto-
tensioner.

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5. Install the right primary chain guide (A) and 7. Install the primary chain auto tensioner and
using 5 mm allen key, tighten the right primary tighten 10mm mounting bolts (A) of primary
chain guide allen key bolts (B). chain auto-tensioner.
B
A
A
6. Install left primary and secondary chain guide 8. Engage the tensioner lock pin (A) into the
(A) and secure its 22mm center mounting bolt tensioner. Release the tension of the tensioner
(B). by disengaging the tensioner lock pin from the
tensioner.
CAUTION
Tighten the guide center mounting bolt after
installing primary and secondary timing
chain auto-tensioners.
A
A
B
9. Install the secondary timing chain (A)

connecting HPP pump sprocket and camshaft
A sprocket.

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10. Install the right secondary chain guide (A). 13.Using sprocket and wrench (A), tighten the 22
Secure the mounting circlip locks (B) of the mm mounting nut (B) of the HPP sprocket to
right chain guide. specified torque.
B A
TM
TP-100
11. Install the secondary chain guide (A) and auto- 14.Remove the front end timing tool for camshaft
tensioner. Tighten 12mm mounting bolts (B) of (A) (Special Tool No: 0301BM001ST) on the
secondary timing chain auto-tensioner. camshaft key slot located near to the sprocket.
A
A
12. Install the cam chain tensioning tool (A) 15. Remove the crankshaft TDC locking pin (A)
(Special Tool No: 0301BM011ST) into the (Special Tool No: 0301BM004ST) at bottom of
camshaft sprocket holes and hold it. Tighten the starter motor and install the TDC plug.
both 15mm camshaft sprocket mounting bolt to
the specified torque (B).
A
TM
US
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Tekn P-25
T
B
A

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16.Install the top support bracket. Using 6mm 18.Install the filling neck (A) and tighten the two
allen key, tighten allen key bolts (A) of the 10mm engine oil filling neck mounting bolt (B)
timing chain top support bracket to the to the specified torque.
specified torque.
TM
TP-2
5
A
B
19.Install the engine mounting bracket and tighten

the four 12mm mounting bolts (A) to the
specified torque.
CAUTION
to follow the instruction may lead to A
leakages. While tightening the timing cover
Notice
17.Install the timing cover assembly (A) to the

engine. Tighten 12mm timing cover mounting
bolts (B) as per recommended sequence to the
specified torque. 20.Install crankshaft front end oil seal. For
additional information refer to Crankshaft
Front Seal removal and installation section.

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21.Install the flywheel locking tool (A) (Special 24.Install water pump pulley and tighten four
Tool No: 0302EAM0001ST) and lock the 12mm water pump pulley mounting bolts (A).
Flywheel.
25.Install the Drive belt tensioner to the engine

22.Install crankshaft damper pulley and tighten the block and tighten the mounting bolt (A) to the
24mm mounting bolt (A) to the specified specified torque.
torque.
A TM
S
LU0
k niPTP-10
Te
26.Install the First and second Idlers to the engine

23.Remove the mounting bolts of flywheel locking timing case cover and tighten the mounting
tool (A) (Special Tool No: 0302EAM0001ST) bolts (A) to the specified torque.
and remove the flywheel locking tool from its
position.

MAN-00162
27.Install the alternator. For additional informa- Intake Manifold

tion refer to Alternator removal and installa-
tion section.
28.Install the accessory drive belts. For additional A
29. Install the engine to the vehicle.For additional C
information refer to Engine removal and D
B
A. Intake Manifold Pipe

B. Intake Manifold Pipe Gasket
C. Intake Manifold
D. Intake Manifold Gasket
E. O - Ring Water Outlet Pipe
F. Water Outlet Pipe
Removal
7. Remove the engine from the vehicle and place it
on work bench. For additional information
refer to Engine removal and installation sec-
tion.
8. Remove the High Pressure Pump (HPP). For
additional information refer to High Pressure
Pump (HPP) removal and installation section.
9. Remove a 12mm mounting bolt (A) and a
17mm mounting nut (B) from the oil dipstick
pipe.
A
B

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10. Using a 6mm allen key, remove the four EGR 13. Press the lock (A) and pull out the radiator top
cooler inlet pipe mounting bolts (A) from the hose (B) from the coolant outlet pipe.
inlet manifold and detach the EGR cooler inlet
pipe (B).
A A
B
14. Press the lock (A) and pull out the coolant
overflow hose (B) from the coolant outlet pipe.
11. Remove four 12mm mounting bolts (A) from
the inlet manifold top pipe.
A
A
15.Remove the 12mm coolant outlet pipe top

mounting bolt (A) and using a 6mm allen key
12. Press the lock and pull out the electrical remove two coolant outlet pipe bottom mounting
connector (A) from the engine coolant bolts (B), and detach the coolant outlet pipe.
temperature sensor.
A A
B
B

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16. Partially detach the engine coolant 18. Disconnect the electrical connector (A) from
temperature sensor wiring harness (A) from the the oil pressure switch.
inlet manifold.
19.Press the lock (A) and disconnect the inlet and

17. Pull out the suction and return fuel hoses (A) outlet oil cooler hoses (B) from the oil cooler.
from the fuel hose mounting clamp and place it
aside.
A
20. Using a suitable oil filter wrench, remove the
oil filter (A), and remove the three oil cooler
mounting bolts (B) from the crankcase.

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21. Remove nine 12mm inlet manifold mounting Oil Pan/Oil Sump
bolts (A) from the cylinder head.
B
A
A
C
A. O- Ring
22. Detach the inlet manifold (A) from the cylinder
head. B. Strainer
C. Oil Pan
D. Drain Plug & Washer
Removal
2. Lift the vehicle. For additional information
refer to Jacking and Lifting Section.
3. Remove the oil dipstick from the engine and
place it aside.
4. Drain the engine oil. For additional
information refer to Engine Oil Draining
Procedure Section.
Inspection 5. Remove the 17mm mounting lock nut (A) of
1. Check for any physical damages to the intake the oil dipstick pipe and keep the oil dipstick
manifold. pipe aside.
Installation
1. To install, reverse the removal procedure. B
Notice A
Replace the gaskets to the intake manifold
whenever removed from the engine.
2. Tighten all bolts to the specified torque. For

additional information refer to Torque
Sequence Section.
3. Refill the coolant. For additional information
refer to Engine Coolant Replacement/Filling
and Bleeding Procedure: Section.

MAN-00162
6. Remove the 14mm and 13mm mounting bolts Installation

(A) on the oil pan.
Notice
A Clean the oil pan mounting edge and
cylinder block edge before applying the
loctite.
Notice
Apply loctite 5900 to the oil pan.
Notice
Replace with new drain plug washer to avoid
oil leakages.
7. Detach the oil pan with the strainer.
1. Apply the loctite to the oil pan. For additional
information refer to Sealant Application
CAUTION Pattern Section.
Carefully pull out the oil pan and make sure 2. To install, reverse the removal procedure.
that oil pan seating area is not disturbed. If
any damage occur to oil pan seating area, it 3. Tighten the engine oil drain plug bolt to the
will lead to oil leakage. specified torque.
4. Tighten all the bolts to the specified torque.
For additional information refer to Torque
Sequence Section.
5. Refill the engine oil. For additional information
refer to Engine oil filling procedure Section.
Inspection
1. Visually inspect oil pan for crack or damage.

MAN-00162
Oil Pan Strainer 3. Pull out the oil pan strainer (A) from the oil
pan.
Removal 4. Pull out the oil pan strainer O- ring (A).

1. Remove the oil pan. For additional
information refer to Oil Pan/Oil Sump
2. Remove the two 12mm oil pan strainer A
mounting bolts (A) to the oil pan.
A
A
Inspection
1. Check the oil pan strainer filter for blockages.
Installation
Notice
Replace with new strainer pipe O-ring.

2. Tighten the oil pan strainer mounting bolts to

MAN-00162
Vacuum Pump 4. Remove the 12mm heater hose bracket

mounting bolt (A) and keep in aside.
Removal 5. Remove the 10mm radiator bottom hose

1. Remove the intercooler. For additional infor- bracket mounting bolt (A) and keep it aside.
mation refer to Intercooler removal and
2. Remove the EGR inlet and outlet pipe. For
additional information refer to EGR Short
Pipe removal and installation section. For
additional information refer to EGR Long
pipe removal and installation section.
Notice
Don’t disconnect the EGR coolant inlet and
outlet hoses. Disconnection of the hoses A
leads to coolant loss.
3. Disconnect the vacuum hose (A) from the

vacuum pump. 6. Remove the three 12mm vacuum pump
mounting bolts (A) and detach the vacuum
pump.
A A

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Inspection Engine Mounting

1. Visually check the vacuum pump for any
cracks or damage.
2. Check the vacuum pump teeth for any worn
out or damage.
C
Installation B
1. Match the vacuum pump teeth (A) with the
camshaft groove (A).
D
A
A. LHS Mount
B. Front Engine Mount
A C. RHS (Hydro) Mount
D. Rear Engine Mount
Notice
Replace with the new vacuum pump O-ring.
3. Apply the loctite to the vacuum pump. For

additional information refer to Sealant
Application Pattern Section.
4. Tighten all the bolts to the specified torque.
RHS (Hydro) Mount Removal

1. Lift the vehicle to the suitable position. For
additional information refer to Jacking and
Lifting Section.

MAN-00162
2. Remove all 10 mm mounting bolts (A) of engine 5. Remove the 17mm RHS (Hydro) mount
underbody cover (B). bracket mounting bolts (A) and a 18mm nut (B)
on the engine mounting bracket, and detach
the RHS (Hydro) mount mounting bracket.
B
A A
B C
3. Using a suitable stand (A) and wooden block

(B), support the oil pan bottom as shown
below. 6. Remove the two 18mm RHS (Hydro) mount
mounting bolts (A), nut (B) and detach the
RHS (Hydro) mount engine mounting (C).
A
B
A
C
B
4. Remove the four 10mm mounting bolts (A) to
the coolant reservoir and move the coolant
reservoir from its position. RHS (Hydro) Mount Inspection
1. Check the engine mounting hydraulic fluid for
any leakage.
2. Check the engine mounting stud for damage.
RHS (Hydro) Mount Installation

2. Tighten all bolt and nuts to the specified torque.

MAN-00162
LHS Mount Removal 6. Remove two 14mm transmission top mounting

1. Lift the vehicle to the suitable position. For bolts (A) and four 18mm bracket mounting
additional information refer to Jacking and bolts (B). Separately remove the LHS Mount
Lifting Section. (C) from the transmission.

underbody cover (B).
A
B B
LHS Mount Inspection

1. Check the LHS mounting for crack.
3. Using a suitable stand (A) and wooden block
(B), support the oil pan bottom as shown
LHS Mount Installation
below. 1. To install, reverse the removal procedure.
2. Tighten all bolt and nuts to the specified torque.
4. Remove the air filter assembly. For additional

information refer to Air Filter Housing
5. Remove the battery tray. For additional
information refer to Battery removal and

MAN-00162
Front Engine Mount Removal Rear Engine Mount Removal

1. Lift the vehicle to the suitable position.For 1. Lift the vehicle to the suitable position. For
additional information refer to Jacking and additional information refer to Jacking and
Lifting Section. Lifting Section.
2. Remove the underbody cover. For additional 2. Remove the underbody cover. For additional
information refer to Engine Oil Filter information refer to Engine Oil Filter
removal and installation section. removal and installation section.
3. Remove a front engine mounting bolt and nut 3. Remove a rear engine mounting bolt and nut
(A) from front side of the engine. (A) from rear side of the engine.
4. Remove three 17mm front engine mounting 4. Remove three 17mm rear engine mounting
bolts (A) from the front cradle and separately bolts (A) from the front cradle and separately
remove the front engine mount. remove the rear engine mount (B).
Front Engine Mount Inspection Rear Engine Mount Inspection

1. Check the Front Engine Mounting for crack. 1. Check the Rear Engine Mounting for crack.
Front Engine Mount Installation Rear Engine Mount Installation

1. To install, reverse the removal procedure. 1. To install, reverse the removal procedure.
2. Tighten all bolt and nuts to the specified torque. 2. Tighten all bolt and nuts to the specified torque.

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Disassembly and Assembly 7. Remove the two 12mm alternator mounting

bolts and nuts (A) and detach the alternator
Engine assembly.
Disassembly
1. Remove the engine assembly from the vehicle.
For additional information refer to Engine A
2. Install the engine to the mounting stand.
3. Disconnect all engine wiring harness electrical
connectors (A), and detach the wiring harness
(B).
A
B 8. Remove the two 12mm power steering pump

mounting bolts and nuts (A) and detach the
power steering pump.
4. Remove the 22mm engine oil drain plug bolt

(A) from the oil pan (B) and drain the engine
oil in a suitable container.
A
9. Remove the first and second drive belt idler
from the engine. For additional information
refer to Idlear No 2 and Double Ball Bearing
B Idlear No 3 removal and installation section.
For additional information refer to Idlear No
1 removal and installation section.
5. Remove the drive belt from the engine.For

additional information refer to Accessory
Drive Belt removal and installation section.
6. Remove the drive belt tensioner from the
engine. For additional information refer to
Drive Belt /Pulley Auto Tensioner removal

MAN-00162
10. Remove the 12mm water pump mounting bolts 13. Remove the 12mm top mounting bolt (A) and
(A) and detach the water pump. 17mm bottom oil dipstick pipe mounting locknut
(B) from the oil dipstick fuel pipe, and detach
the oil dipstick pipe.
A A
B
11.Remove the four 12mm AC compressor

mounting bolts (A) and carefully place the AC
compressor in secured place. 14. Press the lock (A), and remove the oil cooler
inlet and outlet hoses (B) from the oil cooler
and crankcase.
12. Remove the fuel inlet and outlet couplers (A)

from the HPP.
15. Using a suitable oil filter wrench, remove the
oil filter (A) and remove the three oil cooler
mounting bolts (B) from the crankcase.
A

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16. Remove the three 13mm starter motor 19. Remove the four 6mm allen key EGR outlet
assembly mounting bolts (A), and detach the pipe mounting bolts (A) and EGR cooler hose
starter motor. (B) from the cylinder head.
A
A
17. Using allen key, remove the 12mm top 20. Remove the two 12mm EGR mounting bolts
mounting bolt (A) and two 6mm mounting bolts (A) from the cylinder head.
(B) from the coolant outlet pipe, and detach the
coolant outlet pipe.
21. Remove the three 12mm coolant bypass

mounting bolts (A) from the cylinder head.
18. Remove the four 6mm EGR pipe mounting
bolt (A) from the inlet manifold, and detach the
EGR pipe (B).
A
B
A A

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22. Remove the 13mm coolant bottom pipe 25. Remove the nine 12mm inlet manifold
mounting bolt (A) from the cylinder head. mounting bolts (A), and detach the inlet
manifold from the cylinder head.
23. Remove the 14mm fuel outlet pipe locknut (A),

and 10mm pipe bracket mounting bolt (B), and 26. Remove the four 14mm front AC compressor
remove the 17mm fuel rail pipe mounting bracket mounting bolts (A) from the crankcase.
locknut (C).
A
A
27. Remove the 12mm side AC compressor

24. Remove the four 12mm top air intake pipe bracket mounting bolts (A) from the crankcase.
mounting bolt (A) from the inlet manifold.
A
A
A

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28. Remove the 10mm crankshaft position sensor 30. Remove the 17mm fuel rail outlet pipe
mounting bolts (A), and detach the crankshaft locknuts (A), 14mm injector inlet pipe locknuts
position sensor (B). (B), and two 12mm fuel rail mounting bolts (C),
and detach the fuel rail and pipes.
B
A
B
A
29. Using 8mm socket, remove the four glow

plugs (A) from the cylinder head. 31. Remove the four 14mm injector bracket
locknuts (A) and detach the injector brackets.
32. Using injector removal tool (A) (Special Tool

No:0305BAM0001ST), remove the four
injectors from the cylinder head, and carefully
detach the injectors (B).

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33. Remove the four 13mm catalytic convertor 36. Remove the 14mm turbocharger oil inlet pipe
bracket mounting bolts (A). banjo bolt (A).
34.Remove the 13mm catalytic converter 37.Remove the 14mm turbocharger oil inlet pipe
mounting bolt (A) from the catalytic converter mounting banjo bolt (A) and 12mm
bracket, and detach the catalytic converter. turbocharger oil inlet pipe bracket mounting
bolt (A), and detach the inlet pipe.
35. Remove the five 12mm top and bottom

turbocharger heat shield and exhaust manifold 38. Press the lock (A) and pull out the
teaselled mounting bolts (A). turbocharger oil outlet hose (B), and detach the
hose.
A B

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39. Remove the 12mm mounting bolt (A) and two 42. Remove the timing chain and sprocket. For
12mm mounting nuts (B) from the additional information refer to Timing Chain
turbocharger. and Sprockets removal and installation
section.
43. Remove the camshaft. For additional
information refer to Camshaft removal and
44. Remove the hydraulic lasher adjuster. For
additional information refer to Hydraulic
Lash Adjuster (HLA) removal and
B installation section.
A 45. Remove the cylinder head assembly. For

additional information refer to Cylinder
Head removal and installation section.
46. Remove the flywheel to the crankshaft. For
additional information refer to Dual Mass
Flywheel (DMF) removal and installation
40.Remove the eight 13mm exhaust manifold section.
mounting bolt (A) from the cylinder head.
47. Remove the oil pan mounting bolt (A) and
detach the oil pan (B) from the crankcase.
A
A
41. Remove the three 12mm water pump outlet

pipe (A) from the engine.
48. Remove the eight 10mm connecting rod cap
mounting bolts (A) from the crankcase.

MAN-00162
49. Using a mallet hammer, carefully tap the 52. Mark the shell bearing, and remove the shell
connecting rod (A), and remove the connecting bearing (A) from the cylinder block.
rod with piston (A).
A
A
53. Mark the shell bearing, and remove the shell

50. Remove the ten 8mm crankcase bedplate bearing (A) from the bedplate.
allen key mounting bolt (A) and ten 15mm
crankshaft mounting bolt (B), and detach the
bedplate and crankshaft.
A
B
A
54. Mark the thrust washer inner and outer (A),

and detach the thrust washers from the
crankcase.
51. Remove the four 10mm oil spray jet mounting
bolts (A) from the crankcase.
A
A

MAN-00162
55. Using 5mm allen key, remove the three Inspection

crankshaft TDC sprocket mounting bolts (A)
and detach the TDC sprocket (B). Notice
Clean the mating faces of the cylinder head
and cylinder block with the suitable metal
surface cleaner except cylinder bore and pis-
ton.
All the components should be inspected for wear.

Any components, which are beyond the wear limits,
A have to be replaced
B
Over and above the wear limits: The following
points also need to be ensured.
Piston: Check for scuffing/scoring on the skirt. A
hard thick layer of carbon lacquer on top land is
acceptable. (If the thick layer is present on the
piston check that the liner does not have scuffing).
However scuffing of the top land and skirt giving
indication of overheating which is not acceptable.
Parent Bore: Any scoring on the parent bore is not
acceptable.
Crankshaft: Check for scoring on the main as well
as connecting rod journal. If scoring is nominal and
will not the increase the oil clearance then the
crankshaft can be used in, as it is condition.
However if it is unacceptable then the journal has
to be ground up to service limits only.
Any deep groove in the rear end oil seal seating
area is unacceptable. It will result in oil leaks.
Valve: If valve tip is worn out/ ridged then not
acceptable.
Main bearing and connecting rod bearing — If the
scoring is nominal and oil clearance is not affected,
then it can be reused. However if flaking /peeling of
the bimetal in any particular zone only is present
then use new shell. Look for foreign particle
embedded, deep scratches.
Dampener pulley rubber bonding – Inspect for any
gap between the rubber ring and the outer/inner
ring, Cracks on ring. Any deep groove in the front
oil seal seating area is unacceptable. It will lead to
leakages.
If any deterioration of rubber or gap noticed
between the ring and the rubber replace the
dampener pulley.

MAN-00162
Cylinder Head Gasket
DANGER It is a multi layer steel gasket type. do not use any

oil or shellac on the cylinder head gasket or on the
• While measuring the inner diameter of the block face or the cylinder head face. the gasket
connecting rod big end and main journal has to be fitted dry.
please take the measurements after torque
tightening only. For measurement purpose the The gasket can be assembled any face up or
torque should be 35±b3 Nm +60o. Do not reuse down. however it is suggested that the face with
this bolt. the numbers should be facing up.
• If line boring of the crankshafts journal in Piston and Rings
the block is done to rectify any ovality. Then
please ensure that the material from block half While fitting the piston rings ensure that the rings
is not removed. In absence of taking this end gap are staggered in 120o.
precaution the piston will move up. It will The first ring end gap should not be on the thrust
change the compression, influencing the axis but the minor axis i.e. on the gudgeon pin
performance. In the worst case the valves can axis. please note that the first ring is keystone
hit the piston. shaped hence the top mark has to face up. the 2nd
ring is taper faced. the face, which should be on
To obtain a good life of the rebuilt unit absolute the top, has to be facing up. the 3rd ring is the
cleanliness of the parts is taken as a prerequisite conformable type oil ring. it can be assembled
and also the fact that all the parts have been either way. while assembling the piston on to the
inspected. liner. apply clean oil liberally on the liner surface.
Bolts: The following bolts are recommend to be
replace every time they are opened-if the Maximum
length exceeds the specification. However the DANGER
connecting rod bolt has to be changed every time Bearing shells
without exception. The bearing shells are marked with Red and
The bolts have to be tightened by base torque then Yellow paint mark according to the clearances.
2 stage angular torques. The angular torque°fs The bearing shells need a selective assembly
ensures that the bolts are torque tightened up to for optimum performance of the engine. While
yield point. And the 2 stage ensures that the dismantling when the shells are removed from
clamping load for each bolt is within a very close the Cylinder Block as well as the Bed Plate;
tolerance. please note the colour and while assembly the
bearing shells marked with same colors are to
Cylinder head bolts - 10 no - Length 138mm be fitted at the respective position.
Main Bearing Bolts - 10 no - Length 103mm
Before fitting the bearing shell ensure that the
Connecting Rod Bolts - 8 no - Replace Every parent bore of the block/connecting rod are clean.
Time
Wipe with a clean cloth the back end of shells
Cylinder Block-Top Face: Ensure that the tapping before assembling on to the block or connecting
for the cylinder head bolt as well as the rod.
crankshaft’s main journal is fine. Ensure that no
water or oil after cleaning is in the bolt holes (esp. Ensure that the bearing shells are located properly
the cylinder heads.). If found please remove them, in the notches.
if necessary using cotton cloth (not cotton waste).
If the oil /water is not removed then it is possible
that while tightening the bolt. It may not allow
complete tightening of the bolts and one will get a
false reading.

MAN-00162
Oil Seals Assembly

Ensure that 1. Attach the crankcase to the engine mounting
stand.
• All the oil seals are fitted using the dolly MST.
• Always ensure that the lip is coated with 2. Clean the mating faces of the cylinder head
grease before fitment. and cylinder block with suitable metal surface
cleaner except cylinder bore and piston.
• Apply engine oil on the outside diameter of
seal. The receiving bore should be free of 3. Install the four 10mm oil spray jet mounting
burrs, dent. bolts (A) from the crankcase.
Inspection Point
1. Clean the carbon deposits on the piston,
cylinder block, crankshaft, connecting rods,
A
connecting rod bearing shell, crankshaft
bearing shell and bedplate.
2. Blow the air to all cleaned components of the
engine and wipe it with a clean rag.
3. Check the engine cylinder block thoroughly for
any sign of crack and bend. Repair or replace,
if it is beyond the permissible limit.
4. Check and clean lubrication oil galley holes on
the cylinder block.
5. Check the engine cylinder bore thoroughly for
4. Place the inner and outer thrust washer (A)
any sign of scores and scratches.
into the crankcase.
Notice
Inner diameter of cylinder bore should be
verified carefully by using the inside vernier
caliper or micrometer caliper.
6. Check the crankshaft thoroughly for bend or A

crack, and then replace it if necessary.
7. Check the connecting rod thoroughly for any
bend, and replace it if necessary.
8. Check the connecting rod bearing shells and
crankshaft bearing shells for scratches, wear
and tear, and replace it if necessary.
9. Check the piston for any scratches, scores and
damage, and replace it if necessary.
10. Check the piston rings thoroughly for any
damage, and replace it if necessary.
11. Check the thrust washers for bend, damage,
wear and tear, and replace it if necessary.
12. Check the engine block bedplate for any
scratches, score, dent, bend or damage.
Remove the restriction in the oil strainer, and
replace it if necessary.
13. Check the oil strainer for any restriction during
oil flow, and remove the restriction in the oil
strainer and replace it if necessary.

MAN-00162
5. Install the inner crankshaft bearings shells (A) 7. Install the TDC sprocket (B) to the crankshaft
into the crankcase in correct order. and by using a 6mm allen key (A), tighten the
TDC sprocket allen bolts.
CAUTION
A Carefully place the Crankshaft TDC sprocket
without any damage to the sprocket teeth
which may cause engine starting problems.
6. Install the upper crankshaft bearings shells (A)

on the bedplate.
A
B
CAUTION
Clean the engine block thoroughly before
assembling the bearing shells, wipe the
front and back ends of the shells with a
clean cloth. Ensure that the bearing shells 8. Coat the crankshaft main bearing journal and
are located properly in the notches. the crankshaft bearing shells with the
recommended engine oil.
9. Install the crankshaft assembly (A) to the
crankcase.
CAUTION
Keep the crankshaft and crankshaft bearing
shells in its notches according to the
A installation.

MAN-00162
10. Apply Loctite 574 to the bed plate and install

the bed plate on the engine block. Using a
8mm allen key and 15mm socket and wrench
set, tighten the bedplate mounting bolts (A)
and crankshaft main bearing mounting bolts (B)
to the specified torque. For additional
information refer to Sealant Application
Pattern Section.
CAUTION A
to follow the instruction may lead to
leakages. While tightening the bed plate
mounting bolts follow torque sequence.
12.Using the piston ring compressor (A), tighten
piston rings to ensure easy entry of the piston
into the cylinder block.
A
11. Install the piston rings on the piston and adjust

the ring end gap. Insert the piston in the piston
13. Using a mallet hammer, carefully tap the
ring compressor (A) and close the piston rings.
connecting rod and push the piston inside the
cylinder and observe the correct position,
Notice marking and direction to the crankshaft.
While fitting the piston rings ensure that the
rings end gap is spread out at an angle of
1200. The top mark of the first ring should CAUTION
face upwards. The tapered face of the sec- Place the pistons to their respective
ond ring should be on the top. The third ring cylinders. To avoid crankshaft damage do
or oil ring can be fitted in either way. not interchange the connecting rod shell
bearing and connecting rod cap.
CAUTION
While removing and installing the
connecting rod along with piston, carry out
necessary actions to avoid the damage to
the oil spray nozzle of the cylinder block.

MAN-00162
15. Install the strainer in the oil pan. By using a

Notice 15mm socket and wrench set, tighten the
mounting bolts (A) of the strainer to specified
Before assembling, adequately lubricate the torque.
piston, cylinder walls and connecting rod
bearing shells with clean oil.
A
A
1
3
1
4
2
16. Apply Loctite 574 to the oil pan (B) and install
the oil pan on the engine block. Using a 12mm
socket and wrench set, tighten the oil pan
14. Position the connecting rod in the crankshaft mounting bolts (A) to specified torque.
and install the connecting rod caps. Using a
10mm star socket and wrench, tighten the
connecting rod cap mounting bolts (A) to
specified torque.
CAUTION
Use only recommended sealant to avoid
Notice leakages. While tightening the bed plate
Lubricate the connecting rod caps before shown in the illustration.
tightening the caps.
A
A

MAN-00162
17. Install the engine oil drain plug in oil pan, and 23. Install the hydraulic lasher adjuster.For
tighten to the specified torque. additional information refer to Hydraulic
18. Install the new oil seal on the crankshaft rear Lash Adjuster (HLA) removal and
oil seal installer tool and fix the oil seal installer installation section.
on the crankshaft rear end. 24. Install the timing chain and sprocket.For
19.Using the rear oil seal pressing dolly (A) additional information refer to Timing Chain
(Special Tool No: 0301BM007ST) install the oil and Sprockets removal and installation
seal till the oil seal is completely seated. section.
25. Install the flywheel to the crankshaft. For
Flywheel (DMF) removal and installation
section.
26. Install the flywheel pilot bearing. For
Flywheel Pilot Bearing removal and
27. Install the three 12mm water pump outlet pipe
mounting bolts (A) to the engine.
A
A
20. Replace the cylinder head gasket (A) to the
engine block.
CAUTION
Place the cylinder head gasket to the provided
markings.
28.Install the eight 13mm exhaust manifold

mounting bolt (A) to the cylinder head.
21. Install the cylinder head to the cylinder block.

For additional information refer to Cylinder
Head Section.
22. Install the camshaft. For additional
information refer to Camshaft removal and

MAN-00162
29. Install the 12mm mounting bolt (A) and two 32. Install the 14mm turbocharger oil inlet pipe
12mm mounting nuts (B) to the turbocharger. mounting banjo bolt (A) and 12mm
turbocharger oil inlet pipe bracket mounting
bolt (A), and install the inlet pipe.
30.Install the five 12mm top and bottom

turbocharger heatshield and exhaust manifold
teaselled mounting bolts (A). 33. Install the two 13mm catalytic convertor
bracket mounting bolts (A).
A
31. Press the lock (A) and insert the turbocharger
oil outlet hose (B) into the oil fan. 34. Install the 13mm catalytic converter mounting
bolt (A) to the catalytic converter bracket, and
install the catalytic converter.
A
B

MAN-00162
35. Using injector removal tool (A) (Special Tool 38. Using 8mm socket, install the four glow plugs
No:0305BAM0001ST), install the four injectors (A) to the cylinder head.
to the cylinder head, and carefully install the
injectors (B).
B
39. Install the 10mm crankshaft position sensor
mounting bolts (A), and install the crankshaft
36. Install the four 14mm injector bracket locknuts position sensor (B).
(A) and install the injector brackets.
A
A
40. Install the four 14mm front AC compressor

37. Install the 17mm fuel rail outlet pipe locknuts bracket mounting bolts (A) to the crankcase.
(A), 14mm injector inlet pipe locknuts (B), and
two 12mm fuel rail mounting bolts (C), and
install the fuel rail and pipes.
A
A

MAN-00162
41. Install the 12mm side AC compressor bracket 44. Install the 14mm fuel outlet pipe locknut (A),
mounting bolts (A) to the crankcase. and 10mm pipe bracket mounting bolt (B), and
install the 17mm fuel rail pipe mounting locknut
(C).
A C
42. Install the nine 12mm inlet manifold mounting

bolts (A), and install the inlet manifold to the
cylinder head. 45. Install the 13mm coolant bottom pipe mounting
bolt (A) to the cylinder head.
43. Install the four 12mm top air intake pipe

mounting bolts (A) to the inlet manifold. 46. Install the three 12mm coolant bypass
mounting bolts (A) to the cylinder head.
A
A
A A

MAN-00162
47. Install the two 12mm EGR pipe outlet 50. Using allen key, install the 12mm top mounting
mounting bolts (A) to the cylinder head. bolt (A) and two 6mm mounting bolts (B) to the
coolant outlet pipe, and install the coolant
outlet pipe.
A A
48. Install the two 6mm EGR mounting bolts (A) to

the cylinder head.
51. Install the three 13mm starter motor assembly
mounting bolts (A), and install the starter
motor.
A
49. Install the four 6mm EGR pipe mounting bolt

(A) to the inlet manifold, and install the EGR
pipe (B).
52. Using a suitable oil filter wrench, install the oil
filter (A), and install the three oil cooler
mounting bolts (B) to the crankcase.
A
A
B A

MAN-00162
53. Press the lock (A), and install the oil cooler 56. Install the four 12mm AC compressor
inlet and outlet hoses (B) to the oil cooler and mounting bolts (A), and carefully install the AC
crankcase. compressor.
B A
54. Install the 12mm top mounting bolt (A) and 57. Install the two 12mm power steering pump
17mm bottom oil dipstick pipe mounting locknut mounting bolts and nuts (A), and install the
(B) to the oil dipstick fuel pipe, and install the power steering pump.
oil dipstick pipe.
A
A
A
B
58. Install the two 12mm alternator mounting bolts

55. Install the fuel inlet and outlet couplers (A) to and nuts (A), and install the alternator
the HPP. assembly.
A A
A
A

MAN-00162
59. Install the 12mm water pump mounting bolts Cylinder Head
(A) and detach the water pump.
Disassembly
1. Remove the cylinder head from the engine.
For additional information refer to Cylinder
Head removal and installation section.
2. Using a suitable tool, (A) remove the valve
A spring locks (B).
B
60.Install the first and second drive belt idler to
the engine. For additional information refer
to Idlear No 1 removal and installation
section. For additional information refer to
Idlear No 2 and Double Ball Bearing Idlear
No 3 removal and installation section.
61. Install the drive belt tensioner to the engine. 3. Remove the retainer and upper valve spring
For additional information refer to Drive (A).
Belt /Pulley Auto Tensioner removal and
62.Install the drive belt to the engine. For A
Drive Belt removal and installation section.
63. Connect all engine wiring harness electrical
connectors (A), and install the wiring harness
(B).

MAN-00162
4. Remove the valve spring along with its seating 6. Using a suitable tool, remove the valve stem
washer (A). seal (A).
A
CAUTION
Extreme care should be taken while
removing Valve stem. Failure to follow may
lead to cylinder head damage.
5. Remove the inlet and exhaust valves (A) and

place them in the respective cylinder.
7. Using a suitable tool, remove the valve stem

(A) from the cylinder head.

MAN-00162
Inspection Assembly
1. Check the valve spring height. 1. Using the suitable tool, install the valve stem
(A).
CAUTION
Extreme care should be taken while
installing Valve stem. Failure to follow may
lead to cylinder head damage.
2. Check the valve stem height.
2. Using the suitable tool, install the valve stem

seal (A).
3. Check the valve spring lock for any internal

and external damage.
4. Check the valve and valve stem for any
damages.

MAN-00162
3. Install the inlet and exhaust valves (A) in the 5. Install the upper valve spring with retainer (A).
respective cylinder valve stem (B).
Notice A
Incase of reusing the same valves again,
make necessary marking according to the re-
spective cylinder.
B
6. Using a suitable tool, compress the valve
spring and lock it properly in its position.
4. Install the valve spring bottom retainer (A) to

the cylinder head.

MAN-00162
Sealant Application Pattern

Sealant on Cylinder block:
APPLY LOCTITE 574 SEALANT

IN THIS AREA
Sealant on bed plate:
ENGINE
ENGINE REAR SIDE
FRONT SIDE
SEALANT PROFILE OF BED PLATE
IN THIS AREA

MAN-00162
Sealant on Front cover:
SEAL PROJECTION 0- mm
0.15 X
X
SECTION A-A
FRONT OIL SEAL
RUNOUT
A
SEALANT PROFILE OF FRONT COVER
Sealant between Head and Cam cover:
ENGINE FRONT ENGINE REAR
SIDE SIDE
SEALANT PROFILE OF CAM COVER AND HEAD APPLY LOCTITE 5188 SEALANT
IN THIS AREA

MAN-00162
Sealant between Cam cover and Oil separator:
IN THIS AREA
SEALANT PROFILE ON CAMCOVER
FOR CAMCOVER AND LABYRINTH COVER FACE
Sealant on Oil pan:
ENGINE
FRONT SIDE
ENGINE
REAR SIDE
SEALANT PROFILE OF OIL SUMP

IN THIS AREA

MAN-00162
Water Pump “O” Ring:
IN THIS AREA
SEALANT PROFILE FOR WATER PUMP

(WITH O-RING GROOVE)
SEALANT BEAD THICKNESS 3mm
Sealant on Vacuum Pump:
IN THIS AREA
SEALANT PROFILE ON VACUUM PUMP

MAN-00162
Sealant between Engine Block and Head:
APPLY SILASTIC RIV SILICON SEALANT

MAN-00162
Torque Sequence
Cam cover Bolts:
19 21
20
5 13
28
29
18 12
1
11 4
14
27
ENGINE REAR ENGINE FRONT
START 6
SIDE 15 SIDE
10 3 2 7
22
9 8 16
26 17
25 23
31 24
30
FINISH
AT 4 PLACES IN THIS AREA
TORQUE SEQUENCE FOR CAM COVER MTG. BOLTS
Front Cover:
18/B 17/B
19/C
16/B
20/B 25/B
FINISH
21/B 14/B
2/C
22/C
23/B
3/C
24/B
13/A
4/C
START
TORQUE SEQUENCE FOR FRONT COVER MTG. BOLTS
1/A
5/C BOLT BOLT LENGTH NO. OF BOLTS
12/A
7/A A 50mm 6 Nos.
11/A B 70mm 10 Nos.

8/A
C 63mm 9 Nos.
10/C 9/C

MAN-00162
Head Bolts:
2 8
9 3 6
ENGINE FRONT
ENGINE REAR
SIDE
SIDE
7 5 1 4 10
START FINISH
TORQUE SEQUENCE FOR CYLINDER HEAD MTG. BOLTS
Cylinder Block and Bed Plate Bolts:
EXHAUST
START FINISH
1 4 10
8
5
5 FINISH
START 1 4 8 10
ENGINE REAR
ENGINE FRONT
SIDE
SIDE
6 2 3 7 9
6
2 3 7 9
INTAKE
TORQUE SEQUENCE FOR BED PLATE MTG. BOLTS &
TORQUE SEQUENCE FOR MAIN BEARING MTG. BOLTS

MAN-00162
Oil Separator Bolts:
5 2 3
1 6
TORQUE SEQUENCE FOR LABYRINTH OIL SEPERATOR
Oil Pan:
12 11
14 13
START
1 4
ENGINE FRONT
SIDE
15 10
ENGINE REAR
SIDE
16
9
17 2
FINISH 3 5 6 7 8
TORQUE SEQUENCE FOR THE OIL SUMP MOUNTING BOLTS

MAN-00162
Intake Manifold:
ENGINE FRONT ENGINE REAR

7 5 6
SIDE
8 SIDE
3 1 2 4
TORQUE SEQUENCE FOR INTAKE MANIFOLD
Exhaust Manifold:
3 1 7
5
REAR SIDE
FRONT SIDE
6 2 4 8

MAN-00162
A/C Compressor Mounting Bolt:
THESE TWO BOLTS TO
BE TORQUE FIRST
AC COMPRESSOR MTG. BOLT TIGHTENING SEQUENCE
Accessory Drive Belt Routings:
IDLEAR NO 1
PULLY AUTO TENSIONER
PULLY WATER PUMP
IDLEAR NO 2
PULLY ALTERNATOR
PULLY POWER STEARING PUMP

PULLY COMPRESSOR
PULLY VIBRATION DAMPER

DOUBLE BALL
BEARING IDLEAR NO 3

MAN-00162
Diagnosis and Testing

Inspection and verification
1. Visually inspect for any noticeable signs of 4. All the components should be inspected for
mechanical damage. wear. Any components, which are beyond the
2. If an obvious cause found during the inspection wear limits, have to be replaced.
for the reported concern, correct the same 5. Engine diagnosis is helpful in determining the
before proceeding to the next step. causes of malfunctions not detected and
3. If the cause is not found visually during the remedied by routine maintenance. Refer to the
inspection, refer to the inspection chart given Engine trouble shooting chart, for possible
below. causes and corrections of malfunctions.
Troubleshooting Chart
Symptom Possible Causes Remedy
Engine will not 1. Air intake obstructed. 1. Replace the element.

start and emit
2. Check for free operation of
black smoke Turbocharger.
2. Defective injectors. 3. Replace injectors.
3. Lack of compression. 4. Check compression pres-

sure - if low check for
valve seat, rings and liner
wear.
4. Cylinder head gasket failure. 5. Replace the cylinder head

gasket.
5. Engine timing - Valve. 6. Check timing chain.
6. CR system. 7. Refer diagnostic manual.
Noisy engine and 1. Faulty injectors. 1. Replace injectors.

black smoke.
2. Loose main bearings. 2. Tighten the main bearings.
3. Broken parts. 3. Inspect and replace the

broken parts.
4. EGR valve stuck open mechanically. 4. Check the EGR valve and
replace if required.

MAN-00162
1. Air intake restricted. 1. Replace air cleaner ele-

ment if required.
2. Clogged fuel filter. 2. Replace filter.
3. Defective Injectors. 3. Replace injectors.
4. Air leaks in pressure line after turbocharg- 4. Plug the leaks, replace
er(Turbo to intercooler, intercooler and in- hose or clip if required.
tercooler to intake manifold).
5. Locate the kink/block in re-
5. Fuel return pipe to tank blocked.
turn pipe and rectify.
6. Valve leak. 6. Check the compression,

relap if required.
7. Turbocharger damaged. 7. Replace turbocharger.
8. Gas leaks between exhaust manifold and 8. Replace gaskets.

cylinder head.
Engine does not give
full power. 9. Exhaust gas leak between turbo and mani- 9. Correct the leak.
fold.
10. Gas leak between EGR pipe and joints. 10.Change the gasket or
hose.
11. EGR pipe leak. 11.Replace the pipe.
12. Fuels supply line kink creating restriction. 12. Remove the restriction.
13. Compression leak. 13.Check compression.
14. Jammed piston rings. 14.Replace piston rings.
15. Vacuum leak to the VGT actuator caus- 15.Check the vacuum leak
and rectify. Please note
ing the delayed VGT operation.
that the VGT operation is
sensitive to vacuum leak.
16. Check CR system. 16.Refer Diagnostic Manual.
Noisy engine and 1. Cylinder head gasket defective. 1. Replace Cylinder head
high smoke gasket.
(White/ Grey) 2. Worn out or damaged valve seats. 2. Lap the valve seats or
regrind.
3. Leaking injector holder. 3. Tighten the injector holder.

MAN-00162
1. Air intake restricted. 1. Check for hoses, replace

air cleaner element.
2. Defective Injectors. 2. Check Injectors.
3. Check for leaks between-

3. Air leaks.
Turbocharger to intercool-
er, intercooler and
intercooler to inlet mani-
foldCheck Injectors.
Black smoke.
4. EGR valve stuck open. 4. Check the EGR valve.
5. Restricted exhaust system. 5. Remove restriction or re-

place parts.
6. Gas leak between exhaust manifold and 6. Replace manifold gasket

or parts.
cylinder head.
7. Worn out rings, liners and valves. 7. Overhaul engine.
8. Check and correct.

MAN-00162
1. Cracked vacuum line hoses. 1. Check and correct. Check

for leaks. And vacuum line
to the VGT actuator. Re-
place cracked hoses.
2. Clogged air filter element. 2. Replace air filter element.
3. Restriction in air intake to turbocharger 3. Locate and remove restric-

duct. tion.
4. Restrictions in turbocharger oil drain line. 4. Remove the restriction in

drain pipe.
5. Restriction in crankcase breather. 5. Check the crankcase venti-

lation and rectify.
6. Damaged oil separator. 6. Replace oil separator.
7. Turbocharger damaged. 7. Change oil, filter, service

the Turbocharger and use
recommended oils and
drain intervals.
Excessive oil consump-
tion 8. Worn out rings, liners, and valves. 8. Replace turbocharger.
9. Overhaul engine.
9. External oil leak. 10.Stop the external oil leak-

ages.
10. Leakages through inlet manifold mount- 11.Change the vacuum hos-
ing face allowing dust entry.
es.
12.Change the manifold gas-

ket or replace the mani-
fold.
11. Bend/kink in any of the oil return pipe’s/ 13. Remove the bend or
vacuum hoses. kinks.
12. Defective vacuum pump. 14.Replace the vacuum

pump.

MAN-00162
1. Clogged air filter element. 1. Replace filter element.
2. Restriction in air intake to turbocharger 2. Locate and remove restric-

duct. tion.
3. Air leak between the Turbocharger to in- 3. Locate the leaks, change
take manifold. hose or clamp if required.
4. Excess oil. 4. Correct the oil level.

Blue smoke
5. Wear in valve seal. 5. Check the valve stem

seals, replace if required.
6. Wear in piston rings and liner. 6. Check the compression

pressure, replace rings
and liners.
7. Turbocharger seal leaks. 7. Check the turbocharger if

detective get it attended.
1. Improper timing. 1. Check sprockets and chain

for wear. Rectify.
White smoke 2. Defective cylinder head gasket. 2. Replace the cylinder head-
gasket.
3. Restriction in fuel supply. 3. Remove the restrictions.
1. Weak battery. 1. Check the battery specific

gravity.
2. Corroded or loose battery connection. 2. Clean and tighten battery-

Starter will not
connections.
crank the
engine
3. Faulty starter. 3. Repair starter.
4. Improper earthing. 4. Rectify earthing.

MAN-00162
1. Thin or diluted oil. 1. Change oil.
2. Low oil pressure. 2. Check the oil level.
3. Worn HLA. 3. Replace the HLA.
4. Worn valve guides. 4. Replace the valve guides
Noisy valves
5. Excessive run out of valve seats. 5. Grind valve seats and-
valves.
6. Oil thickening. 6. Replace oil and find the

reasons of thickening, rec-
tify.
7. Aeration in oil.
7. Follow the de-aeration pro-
cedure

MAN-00162
1. Low oil level. 1. Check engine oil level.
2. Replace filter.
2. Clogged oil filter.
3. Clogged oil cooler. 3. Clean the oil cooler.
4. Clean the strainer.

4. Clogged oil strainer.
5. Pressure relief valve in oil filter bracket. 5. Clean the valve and bore
stuck. and assemble.
6. Oil leaks - internal. 6. Check the gasket be-

tween the block and front
cover.
7. Worn parts in oil pump. 7. Replace the worn parts or

pump.
Oil pressure drop
8. Excessive bearing clearances. 8. Check bearing clearances.
9. Thin or diluted oil. 9. Change oil to correct vis-

cosity.
10. Excessive bearing clearance. 10. Replace the bearing.
11. Oil pump relief valve stuck. 11. Remove the valve, in-
spect, clean and refit.
12. Oil pump suction tube loose, bent or 12. Remove pan, inspect the
cracked. parts and replace.
13. Sealant blocking the suction. 13. Check for sealant at the
face of the suction pipe.
14. Oil pump cover warped or cracked 14. Instal new pump.

MAN-00162
1. Worn oil seals. 1. Replace seals.
2. Misaligned or deteriorated gaskets. 2. Replace gasket.

Oil leaks
3. Loose fastener, broken or porous metal 3. Tighten fastener.

parts.
4. Repair or replace.

MAN-00162
Mahindra Special Tools (MST)

MST NO Tool Name Illustration
0301BM001ST Front end timing tool for camshaft
Camshaft locator/ Camshaft linear

0301BM002ST
alignment tool
0311DAM0001ST Dolly for front cover oil seal
0301BM004ST TDC Locking Pin

MAN-00162
0301BM007ST Rear oil seal pressing dolly
0302EAM0001ST Tool for flywheel locking
0301BM009ST Stefa pin locator
0301BM011ST Cam chain tensioning tool

MAN-00162
0305BAM0001ST Injector removal tool
0305BAM0007ST HPP removal tool
0304GAM0001ST Water pump pulley locking tool

MAN-00162
Description Specification
Make MAHINDRA & MAHINDRA LTD
Model mHawk BSIII / BSIV
Type 16 valves, water cooled, Direct injection common

rail, Turbo Charged, Intercooler Diesel Engine.
No. of Cylinders 4 In-line
Bore (D) 85 mm
Stroke (L) 96 mm
Compression Ratio 16.5:1
Cubic Capacity 2179cc
Max Gross Power 103 KW (140 bhp) @ 3750 rpm
Max Gross Torque 330 Nm @ 1600-2800 rpm
Firing Order 1-3-4-2
Direction of Rotation Clockwise from Fan Side
Piston Re-entrant Bowl
Piston Pin Full Floating, Surface Hardened & Ground.
Input speed of power steering pump 1.2 X Engine speed
Input speed of fan pulley/water pump 1.345 X Engine speed
Input speed of A/C compressor 1.279 X Engine speed
Input speed of Alternator 1.345 X Engine speed
Glow plug type Single Pole - 11V - Beru
Glow plug nominal operating voltage 11 V
Oil Grade and Quantity SAE15W40

6 litres for run engine
Inlet valve
OPENS 10 deg BTDC
CLOSES 10 deg ABDC
Valve stem OD Inlet 5.98 +/-0.008
Exhaust valve
OPENS 18 deg BBDC
CLOSES 15 deg ATDC

MAN-00162
Valve stem OD Exhaust 5.96 +/-0.008
Oil Filter By-Pass Opening Pressure 2.25 ± 0.25 bar
Oil Pressure at Idle 1.0 bar min @ 90 deg C
Piston ring End gaps

0.25/0.4
First ring
0.4/0.6
Second ring
0.25/0.5
Third ring
Gudgeon Pin outside diameter 31 +0/-0.006
Connecting Rod- Small Bush End I.D in assembled 31 +0.041/+0.025

condition
Piston ring thickness 2.097 +0.10/-0.029

First ring
2.00 -0.005/-0.030
Second ring
2.5 -0.005/-0.030
Third ring
Gudgeon Pin to Connecting Rod small end bush 0.047/0.025

clearance
Gudgeon Pin to Piston Pin Hole (in piston) Clear- 0.021/0.009

ance
Big End Bore (W/O Shell) 54.018-54.006
Big End Bore (With Shell) 51.022 / 51.05
Connecting rod bend or twist 0.05
Connecting rod end play 0.1 to 0.3
Crankshaft end play 01. to 0.365
Camshaft End Play 0.1 to 0.25
Camshaft Bearing Pin Dia First - 32.0 -0.05/-0.066

Second to fifth - 24.0 -0.040/-0.053
Cam Bore First - 32.0 +0.025/0

Second to fifth - 24.0 +0.021/0
No of teeth in Crankshaft Sprocket 20 teeth

No of teeth in Camshaft Sprocket 28 teeth
No of teeth in HPP Sprocket 30 for primary drive & 21 for secondary drive teeth
Crankshaft Pin OD Dia - 50.9996 / 50.981

Roundness/Cylindricity 50.005 - circularity
0.008 - cylindricity

MAN-00162
Crankshaft Journal OD Dia - Grade Yellow - 61.993 / 61.986

Roundness/Cylindricity Dia - Grade Red - 62.000 / 61.993
0.005 - circularity
0.008 - cylindricity
Main bearing bore dia with shell Dia - Grade Yellow - 62.033 / 62.014
Dia - Grade Red - 62.053 / 62.034
Wall Thickness-main bearing shell Dia - Grade Yellow - 1.993 / 1.987

Dia - Grade Red - 1.987 / 1.981
Maximum no of times following

parts can be used
Cylinder head bolts
Main bearing bolts
Connecting rod bolts Can be used 1 time only
Flywheel bolts
All High pressure pipes
All washers (Including Injector washer)
All Gaskets

MAN-00162
Torque Specification
Bolt Torque in
Part Place of Application Quantity
Specification Nm
M13x1.5x138 Cylinder Head Bolts 10 65
M10x1 Plug M10 5 10-12
M8x1.25x25 Allen Water Outlet Pipe Bolt 2 15-20
M8x1 Glow Plug 4 10-12
M12x1.5 Water Temperature Sensor 1 20-25
M8x1.25x20 Engine Lifting Hook (Intake Side) 2 25 ± 3
M8x1.25x25 Engine Lifting Hook (Exhaust Side) 1 25 ± 3

Cylinder Head
M8x1.25x25 Engine Lifting Hook (Rear Side) Upper 1 25 ± 3
M8x1.25x25 Engine Lifting Hook (Rear Side) Lower 1 25 ± 3
M8x1.25x25 EGR Cooler Mounting 1 25 ± 3
M6x1x16 Water Collector Pipe 2 10-12
M8x1.25x20 Vacuum Pump 2 25 ± 3
M8x1.25x25 Vacuum Pump and Heater Bracket 1 25 ± 3
M10x1 Plug HLA Oil Gallery 1 10-12
M12x1.75x45 CAM Sprocket Mounting Bolt 2 85-95
M6x1x35 CAM Cover Mounting Bolt 31 10-12

Camshaft and
Cam Cover M6x1x20 Elbow Oil Filler 2 10-12
M6x1x12 Phase Sensor Mounting 1 10-12
M34x4 Oil Filler Cap 1 5
Breather System M6x1x20 Assembly CCV System 6 6±1

MAN-00162
Bolt Torque in
Specification Nm
M8x1.25x45 Stud Exhaust Manifold 8 25 ± 3
M8x1.25 Clintch Nut Exhaust Manifold 8 25 ± 3
M8x1.25x25 Stud Turbocharger 2 25 ± 3
M8x1.25 Clintch Nut For Turbocharger 2 25 ± 3
M8x1.25x25 Bolt Turbocharger 1 25 ± 3
M6x1x20 Assyyl.Oil Return T/C 2 10-12

Exhaust System M8x1.25x25 Allen EGR Pipe Short to manifold 2 25 ± 3
M8x1.25x25 Allen EGR Short Pipe To EGR Valve 2 25 ± 3
M8x1.25x25 Allen EGR Cooler (EGR Valve End) 2 25 ± 3
M8x1.25x25 Allen EGR Cooler (EGR Long Pipe End) 2 25 ± 3
M8x1.25x8 Nut On Bracket EGR Cooler 2 25 ± 3
M8x1.25x25 Allen EGR Long Pipe (Intake Pipe End) 2 25 ± 3
M8x1.25x20 Bolt T/C Oil Inlet Pipe Clamp 1 25 ± 3
M10x1.0x23 T/C Oil Supply Banjo On T/C 1 17.5 ± 3
M6x1.0x16 Heater Inlet Pipe On Vacuum Pump 1 10-12
Bolts for Mounting Intake Manifold

M8x1.25x117 5 25 ± 3
Intake System (Top Row)
M8x1.25x25 Bolts for mounting Intake Manifold 4 25 ± 3
M8x1.25x25 Bolts for Air Intake Pipe 4 25 ± 3
M8x1.25x20 Water Outlet Support Bolt 1 25 ± 3
M8x1.25x43 FIP Mounting Bolt 3 25 ± 3
M8x1.25x20 Bolt Common Rail Mounting 2 25 ± 3
High Pressure Pipes Nut on Pump 1 20 ± 3
High Pressure Pipes Nut on Rail 5 35 ± 3

FIP
High Pressure Pipes Nut on Injector 4 27 ± 3
M8x1.25x40 Injector Clamp Stud 4 25 ± 3
M8x1.25 Injector Clamp Nut 4 25 ± 3
M14x1.5x11 FIP Sprocket Nut 1 72.5± 2.5
M6x1.0x12 Clamp Bolt HPP From Pump to Rail 1

10-12
on Intake Manifold

MAN-00162
Bolt Torque in
Specification Nm
M12x1.25x103 Main Bearing Bolts 10 65
M10x1.5x70 BED Plate Bolts 10 50±2
M6x1x12 Bolt Oil JET (Piston Cool ING) 4 10-12
M18x1.5x10 Plug M18 2 20-25
M12x1.5 Plug M12 2 15-20
M10x1 Plug M10 2 10-12
M6x1x12 Speed Sensor Mounting 1 10-12
M6x1x12 Bolt Oil JET (Chain Cool ING) 1 10-12
M8x1.25x50 Bolt Oil Filter Body 3 25±3
M20x1.5 Oil Cooler Stud 1 35±3
Cylinder Block M14x1.5 Drain Plug (Water) 1 35-40
M12x1.0 Oil Pressure Switch 1 25-30
M18x1.5x10 BED Plate Plug (M18) 1 20-25
MC14x1.5 BED Plate Plug (M14) 1 20-25
M10x1.0x23 T/C Oil Supply Banjo on Block 1 17.5±3
M8x1.25x25 Water Inlet Pipe to Block 2 25±3
M10x1.5x30 Engine Mounting Bracket 7 48±3
M12x1.0 M12 Plug For Oil Bracket 1 25±3
M20x1.5 Oil Filter Cartridge (SOGEFI) 1 14±2
M6x1x12 Bolt Water Inlet Pipe Clamp Cylinder 2 10-12

Head
M8x1.25x20 Bolt Water Inlet Pipe Clamp Block 1 25±3
M8x1.25x50 Bolt Front Cover 7 25±3

Front Cover
M8x1.25x63 14 25±3
M8x1.25x105 Bolt Front Engine Mounting Bracket 3 25±3
M8x1.25x90 1 25±3

MAN-00162
Bolt Torque in
Specification Nm
M8x1.25x25 Oil Sump Mounting Bolts 10 25 ± 3
M8x1.25x135 2 25± 3
Oil Sump and Bed plate rear side
M8x1.25x90 2 25± 3
M8x1.25x20 Oil Sump and Front Cover Bolts 3 25 ± 3
Oil Sump M18x1.5x Oil Drain Plug 1 25-30
M8x1.25x20 Oil Strainer Bracket Bolt 2 25 ± 3
M8x1.25x20 Dipstick Mounting Bracket Bolt 1 25 ± 3
Dipstick Nut 1 25 ± 3
Dipstick Adaptor 1 35 ± 3
M8x1.25x15 CCV Heat Shield 2 25 ± 3
M6x1.0x16 Turbo Charger Heat Shield 3 10-12

Heat Shield
M8x1.25x15 EM Heat Shield On Head 2 25 ± 3
M6x1.0x16 EM Heat Shield On Manifold 1 10-12
M10x1.5x90 Fead Bracket (1) 2 30-35
M8x1.25x105 A/C Compressor on Fead Bracket 4 25 ± 3
M8x1.25x30 Water Pump Mounting bolts 5 25 ± 3
M8x1.25x25 Water Pump Pulley Bolts 4 25 ± 3
Fead M8x1.25x50 Alternator on Front Cover 1 25 ± 3
M8x1.25x125 Alternator on Fead Bracket 1 25 ± 3
M10x1.5x90 1 30-35
PSP on Fead Bracket
M10x1.5x75 1 30-35
M10x1.5x55 Auto-tensioner Bolt 1 45 ± 5
M10x1.0x Single Row Bearing Idler 2 45 ± 5
M12x1.75x Double Row Bearing Idler 1 83 ± 5

MAN-00162
Bolt Torque in
Specification Nm
M16x1.5x95 Bolt Damper Pulley 1 150+ 650
M12x1.5x47 DMF Bolts 6 50 + 600

Power Train M9x1.0x50 Bolt Connecting Rod 8 35 + 600
M8x1.25x22 Screw Trigger Wheel 3 15-20
M6 Shoulder Bolt Primary Guide 2 10-12
M8 Shoulder Bolt Secondary Guide 2 22-28
M6 Bolt CAM Guide 2 10-12
Shoulder Bolt ARM 1 35 ± 3

Timing System
Floating Guide 35 ± 3
M6x1x25 Hydraulic Tensioner (Primary) 2 10-12
Hydraulic Tensioner (Secondary Hous- 2

M8x1.25x30 25 ± 3
ing)
M8x1.25x30 Hydraulic Tensioner (Secondary) 1 35 ± 3
NUT HEX FL 1
M12X1.5X12X8
GR Mount with bracket
BOLT HEX FL 1
M12X1.5X115X10
Front mounts .9 70.0±5.0
SCREW HEX FL 3
M12X1.5X25X8.8 Frt.mount bracket to transaxle
XPH
BOLT HEX FL 1
M12X1.5X80X8.8
XPH
BOLT HEX FL 3
Mount to craddle
M12X1.5X90X8.8

MAN-00162
Bolt Torque in
Specification Nm
SCREW HEX FL RHS mount bracket to rail 2

M12X1.5X25X8.8 70.0±5.0
XPH
BOLT HEX FL
M12X1.5X50X10. 2
RHS mounts 9
RHS mount bracket with engine
WASHER PLAIN-
1
M12
NUT HEX FL
M12X1.5X12X8 1
GR
NUT NYLOC RHS mount 110.0±10.0

M12X1.5X14.9X1 1
0,A
NUT HEX FL RHS mount bracket to BIW

M12X1.5X12X8 1 70.0±5.0
GR
BOLT HEX FL
LHS mount bracket to transaxle &
M12X1.5X35X8.8 8 70.0±5.0
LHS mounts BIW
XPH
BOLT HEX FL Mount with bracket

M10X1.5X35X10. 2 70.0±5.0
9
BOLT HEX FL
M12X1.5X115X10 1
.9 Mount with bracket
NUT HEX FL
RR mounts
M12X1.5X12X8 1 70.0±5.0
GR
BOLT HEX FL
Mount to cradle 1
M12X1.5X90X8.8
SCREW HEX FL
M12X1.5X25X8.8 Rear mount bracket to transaxle 4
XPH
BOLT HEX FL
Mount to cradle 2
M12X1.5X75X8.8
Accelerator Pedal NUT HEX FL -

Pedal to BIW dash panel 3 8.0 ± 0.5
M6X1X6X8XZN

MAN-00162
Accessory Drive Belt

The drive belt is a seamless belt that is used to transmit torque and power from one wheel or shaft to another wh-
eel or shaft. The drive belt system has three idlers working together and transmits motion. In the vehicle, it drives
the water pump, power steering pump, and alternator, A/C compressor among other components. The vehicle
has single drive belt.
I
G
F J
H
A
D
E
A. Pulley Alternator F. Pulley Water Pump

B. Pulley Power Steering Pump G. Drive Belt
C. Pulley Compressor H. Pulley Auto Tensioner
D. Double Ball Bearing Idlear No 3 I. Idlear No 1
E. Pulley Vibration Damper J. Idlear No 2

MAN-00162
Service Tips and Precautions Incar Repairs

• Before removal and servicing the accessory Accessory Drive Belt
drive belt, clean the outer side of the parts.
• Inspect the area surrounding the accessory
drive belt tensioner for any contamination.
• Check for any leaks before installing a new
accessory drive belt tensioner.
• Replace the accessory drive belt when crack,
pilling, missing ribs and the presence of foreign
material in the belt.
• Perform functional tests whenever the belt is
replaced with new one.
Removal
1. Remove the front RHS wheel.For additional
information refer to Wheels removal and
2. Remove four retaining clips (A) and detach the
drive belt dust cover (B).
A B

MAN-00162
3. Using a 15mm spanner, rotate the accessory Pilling

drive belt tensioner (A) in clockwise direction,
Pilling is caused by lack of tension, misalignment,
and remove the accessory drive belt (B).
worn pulleys or combination of these factors. Pilling
is observed most frequently in the diesel engines
where the belt material is sheared off from the ribs
and builds up in the belt grooves.
B
Inspection
Abrasion
During motion, the belt contacts with the object such Improper Installation
as a flange or bolts in its path. This is caused by
improper belt tension or pulley bearing size. Each Improper belt installation is a common cause of pre-
side of the belt appears shiny or glazed. mature failure. One of the outer-most belt ribs is
placed outside the pulley groove, causing a belt rib to
Chunk - Out
run without a supporting or aligning pulley groove. A
Pieces or chunks of rubber material have broken off belt rib begins separating from the joined strands.
from the belt. When the chunk-out has occurred, a when left neglected, the cover will separate, causing
belt may fail at any moment. This is caused by heat the belt to become loose.
and stress.

MAN-00162
Misalignment Drive Belt /Pulley Auto Tensioner

Pulley misalignment can be caused by two condi-
tions. Misalignment forces the belt to kink or twist
while running, causing premature wear. Sidewalls of
the belt may appear glazed or the edge-cord may
become frayed and ribs removed. A noticeable noise
may result. In severe cases, the belt can jump off the
pulley.
Removal
1. Remove the drive belt. For additional informa-
tion refer to Accessory Drive Belt removal
2. Loosen the 14mm mounting bolts (A) and 18mm
mounting bolts (B), and detach the Single row
Installation solid pulley Idlers
Notice
Clean all of the pulleys and ensure that the ac-
cessory drive belt does not slip during instal- A
lation.
Notice
Ensure that the accessory drive belt is cor-
rectly routed and positioned in the grooves of
the pulley.

MAN-00162
3. Using an allen key, loosen a 8mm mounting bolt Idlear No 2 and Double Ball
on the drive belt (A).
Bearing Idlear No 3
A
4. Separately detach the drive belt along the

damper pulley side as shown below arrow.
Removal
2. Loosen the mounting bolts from the 14mm Idlear
No 2 (A) and 18mm Double Ball Bearing Idlear
No 3 (B), and detach the idlers.
Installation
1. Insert the tensioner pin (A) into a groove on the
timing case cover, and tighten the 8mm allen key
mounting bolt.
Installation
Notice
A
Ensure that the drive belt idlers are correctly
installed.

MAN-00162
Idlear No 1
Removal
2. Remove the outlet hose of the intercooler. For
additional information refer to Intercooler
3. Loosen 14mm mounting bolts to the Idlear No 1,
and detach the Idlear No 1 (A).
Installation
Notice
Ensure that the drive belt idlers are correctly
installed.

MAN-00162

1. Foreign objects embed- 1. Remove the foreign objects from

ded in pulley grooves. pulley grooves, and replace the
Rib chunking belt.
2. Installation damage.
2. Replace the belt.
1. Pulleys misaligned. 1. Align pulleys.

2. Rusted pulleys. 2. Clean the rust in pulleys.
Rib or Belt wear
3. Sharp pulley groove tips. 3. Replace the pulley.
4. Rubber deteroated. 4. Replace the belt.
1. Belt mistracked from the 1. Replace the belt.

pulley groove.
Cracks between two ribs 2. Pulley groove tip has
worn away from rubber to
tensile member.
1. Insufficient tension 1. Replace the belt tensioner

2. Incorrect belt. 2. Replace the belt.
3. Belt or pulley with 3. Replace belt and clean the pulley.
reduced friction.
Belt slips 4. Replace the faulty idler.
4. Idler bearing failure.
5. Replace the belt.
5. Belt hardened and slip-
page.
Belt not in position 1. Belt tension is too high or 1. Replace the belt tensioner.
low.
2. Belt routed incorrectly. 2. Verify the belt routing.
4. Pulley misalignment. 4. Check and replace the pulley.
5. Foreign objects in 5. Remove the foreign objects from
grooves. groove.
1. Excessive tension. 1. Replace the belt and tensioner.

Belt broken 3. Belt misalignment. 3. Check and replace the belt.
4. Bracket, pulley, or bear- 4. Replace the defective component
ing failure. and belt.
1. Belt slippage. 1. Replace the belt and tensioner.

2. Bearing noise. 2. Locate and repair the bearing.
Belt noise
3. Belt misalignment. 3. Replace the belt.
4. Belt to pulley mismatch. 4. Install the correct belt.

MAN-00162
Repair Manual Air Intake System Nov 2011/ Rev 2
AIR INTAKE SYSTEM
CONTENTS

Crankcase Ventilation System Layout ............................................... 2
Component Location Index............................................................. 3
Service Tips and Precautions .........................................................4
Incar Repairs ....................................................................................5
Air Cleaner Duct - Dirty Side .......................................................5

Removal ............................................................................................. 5
Installation ........................................................................................... 6
Air Filter Element ..........................................................................6

Removal ............................................................................................. 6
Installation .......................................................................................... 7
Air Filter Housing .........................................................................8

Removal ............................................................................................. 8
Installation .......................................................................................... 8
Air Cleaner Outlet Hose - Clean Side .........................................9

Removal ............................................................................................. 9
Installation .......................................................................................... 9
Oil Separator ..............................................................................10

Removal ........................................................................................... 10
Installation ........................................................................................ 11
Oil Separator Hose .....................................................................11

Removal ........................................................................................... 11
Installation ........................................................................................ 12
HFM Sensor ................................................................................ 12

Removal ........................................................................................... 12
Installation ........................................................................................ 13

MAN-00162
Repair Manual Air Intake System Nov 2011/ Rev 2
Boost Pressure Sensor ............................................................. 13

Removal ........................................................................................... 13
Installation ........................................................................................ 14
NVH Cover .................................................................................. 14

Removal ........................................................................................... 14
Installation ........................................................................................ 14
Intercooler ................................................................................. 15
Removal ........................................................................................... 15
Installation ........................................................................................ 16
Intercooler Inlet Hose ................................................................ 16

Removal ........................................................................................... 16
Installation ........................................................................................ 17
Intercooler Outlet Hose ............................................................. 17

Removal ........................................................................................... 17
Installation ......................................................................................... 18
Intercooler Bracket ................................................................... 18

Removal ........................................................................................... 18
Installation ........................................................................................ 18
Diagnostics and Testing ............................................................... 19

Troubleshooting Chart...................................................................... 19
Component Inspection and Action Table ......................................... 21
Technical Specification ................................................................ 21
Torque Specification ..................................................................... 21

MAN-00162
Repair Manual Air Intake Systerm Nov 2011/ Rev 2
Air Intake System

Air Intake
Duct
Air Filter
Mass Air Flow
Sensor
Exhaust Gas To
Catalytic Converter
Turbo
Charger
Exhaust Manifold
Intercooler
Engine
Inlet Manifold
Boost
Pressuer
Sensor
EGR Cooler
EGR Valve
By virtue of suction created in the system, air is EGR (Exhaust Gas Recirculation) system is used to
sucked through the intake hose. The unfiltered air reduce the NOx emission levels. A part of the
enters the air cleaner housing at the bottom and exhaust gas is tapped from the exhaust manifold
leaves through the top after passing through a filter and made to mix with the air coming from the
element. The filter element has multiple filtering intercooler before entering the intake manifold.
media layers which have different porosities and Theses exhaust gases from EGR is made to pass
cleaning efficiencies. Dust and other fine particles through a cooler called EGR Cooler before allowing
are sucked inside along with air get trapped in the it to mix with air coming from intercooler.
air cleaner while passing through the filter element.
A Hot Film air Mass Flow rate (HFM) sensor is
attached to an outlet of the air cleaner. Clean air
coming out of the air cleaner passes through the
sensor mounted on the air cleaner housing. The
HFM sensor measures the air mass, flow rate and
temperature of air inside the system.
The filtered air enters the turbocharger (VGT type)
where the air is compressed. The heated com-
pressed air then passes through the intercooler
where the heat gets dissipated. From here it is drawn
into the intake manifold and into the engine.
The Variable Geometry Turbocharger (VGT) controls
the boost pressure. The boost temperature sensor
fitted on the outlet hose of the intercooler unit mea-
sures the boost pressure. The boost signal is given
to the ECU. Based on the load, engine speed and
temperature, the ECU controls the boost pressure by
manipulating the VGT.

MAN-00162
Crankcase Ventilation System Layout

Fresh Air
From Air Filter
To Intake Manifold
Turbocharger
Cylinder Head Cover Oil

Seperator
Cylinder Head
Cylinder Block
Sump
In order to reduce the blow by gas emission, the blow

by gas is directed to the intake manifold through the
oil separator which separates the oil from the blow by
gas and allows the air to pass to the intake manifold.
Blow by gases are drawn from crankcase and
cylinder head cover.
Certain amount of oil will be carried from the oil
separator to the Air inlet hose, which is normal.
However if it is excessive please look for all the
causes mentioned in the high blow-by.

MAN-00162
D
A
E
B
C
A. Air Cleaner Assembly D. Clean Side Hose

B. Dirty Side Duct E. Oil Separator Hose
C. HMF Sensor

MAN-00162
Service Tips and Precautions • Check the oil separator system, in particular for
any leak in vacuum leak. As any vacuum leak
Observe the following precautions when disassem- will lead to a high pressure build up and then it
bling and servicing the air intake system and its ele- will go through the intake system and give a sig-
ments. nal of high blow by or be confused with com-
pressor oil leak.
• Always wear hand gloves before starting any
servicing. • Do not place any tool or parts over the inter-
cooler as it will damage the fins which will lead
• Stay clear of rotating vehicle parts.
reduced performance of intercooler.
• Stay clear of hot vehicle parts.
• Avoid repeated contact with fluids.
• Do not let fuel, coolant and other fluids to spill CAUTION
over electrical and hot vehicle parts. Replace air filter element every 40,000 kms
• Before removing and servicing, clean the outer under normal operating conditions. Under
surface of the parts. Highly dusty or polluting conditions early
• Care must be taken when handling the air intake replacement will be required 20,000 kms. In
system components. Components should not be case Air filter element is not replaced on time,
lifted by using their hoses or pipes. vehicle's performance gets affected.
• Hoses and lines must not be subjected to any
twists or stress.
• Ensure that hoses are positioned in their correct
run before tightening the couplings, and ensure CAUTION
that all clips and supports are used.
Before starting work on the engine always
• To achieve an optimum cooling of the com-
pressed air it is vital that the vehicle’s number switch off the engine and disconnect the HFM
plate position is not changed and/ or an oversize connection.
number plate does not block the aperture for the
air draft for the intercooler.

MAN-00162
Incar Repairs Air Cleaner Duct - Dirty Side

It should be noted that if the engine run with a
clogged air filter element, then it will lead to the seep-
age of oil from the turbocharger into the air intake
system.
Notice
Ensure that only the recommended engine oil
is used and the specified drain intervals are
maintained.
Check for oil leaks in the air intake system and if

traces are found check the oil separator system.
Removal
1. Remove the battery. For additional
information refer to Battery removal and
2. Remove the fuse box. For additional informa-
tion refer to Fuse Box removal and installa-
tion section.
3. Remove the front bumper assembly. For addi-
tional information refer to Front Bumper
4. Remove the LHS headlamp Assembly. For
additional information refer to Headlamp
5. Remove the 10mm mounting bolt and two nuts
(A) from the bottom cover of the fuse box.

MAN-00162
6. Remove the 10mm mounting clamp bolt (A) of Air Filter Element
the air cleaner duct.
Removal
7. Remove the air cleaner duct hose (A) from the
1. Remove the negative terminal of the battery. For
air cleaner assembly and detach the air cleaner
additional information refer to Battery
duct.
Notice
The air cleaner element should be replaced
every 40,000 kms under normal driving
conditions.under extremely dusty conditions
replace at 20,000 kms.
A Notice
It should be noted that if the engine is run
with clogged air cleaner, then it will lead to
seepage of oil from turbocharger into the air
intake system.
Installation 2. Press the lock and pull out the electrical

connector (A) of the HFM sensor.
CAUTION
Care should be taken while installing the fuse
box. Damage in the fuse box connectors and
fuses may cause short circuit or starting
problem in the vehicle.
Notice A
Install the air cleaner duct properly with the
air cleaner to avoid the air noise from the
engine compartment.

MAN-00162
3. Loosen the air cleaner outlet hose clamp (A) 6. Remove the air cleaner top cover (A) separately.
from the air cleaner.
7. Remove the air filter element (A) from the air

4. Disconnect the tags (A) from both sides of the air cleaner bottom cover.
cleaner.
5. Using a 5mm allen key remove the seven air Installation

cleaner top cover mounting bolts (A). 1. To install, reverse the removal procedure.
Notice
Clean the air cleaner bottom cover before
installing the air filter element.do not over
tight the air cleaner mounting bolts, over
tightened will lead to damage of housing
threads.

MAN-00162
Air Filter Housing 4. Press the lock and disconnect the electrical con-
nector (A) of the fuel temperature sensor.
Removal
5. Loosen the 13mm mounting bolt (A) of the air
1. Remove the negative terminal of the battery. For cleaner assembly and detach the air filter hous-
additional information refer to Battery ing assembly.
2. Press the lock and pull out the electrical connec- Notice
tor (A) of the HFM sensor.
Carefully remove the air cleaner assembly, to
avoid the damage of air cleaner mountings.
3. Loosen the air filter outlet hose clamp (A) from

the air filter housing.
Installation
Notice
Install the air cleaner properly with the air
A cleaner duct to avoid the air noise from the
engine compartment.

MAN-00162
Air Cleaner Outlet Hose - Clean 3. Unclip and remove the oil separator hose (A)
from the air outlet hose.
Side
4. Loosen the air cleaner outlet hose clamp (A)

Removal and remove the outlet hose (B) from the turbo
charger.
2. Unclip the vacuum modulator hose clip (A) and
remove the vacuum modulator hose (B) from the A
air outlet hose. B
B
Installation

MAN-00162
Oil Separator 2. Remove the two 12mm oil separator heat shield
mounting bolts (A), and detach the shield from
the oil separator.
The oil separator separates oil from the blow by of

the engine and sends it back to engine oil sump.
The remaining air and other gases are sent to the 3. Unclip the clip (A) and remove the oil separator
inlet manifold. hose (B) from the oil separator unit.
There is also a spring loaded diaphragm valve
provided on the oil separator outlet to the inlet
manifold. This prevents the flow of excessive of
blow by from the oil separator to the inlet manifold
in case the air filter is chocked and high suction
starts acting on outlet port of oil separator.
No leakage past diaphragm or top cover of oil
separator is permitted. Replace the assembly if
B
there is any leakage or found defective.
Removal
removal and installation section. A
Notice 4. Detach the oil separator hose (A) from the clip
(B).
Check oil separator system, in particular for
any leak.

MAN-00162
5. Remove the six 10mm oil separator bolts (A), Oil Separator Hose
and detach the oil separator from the engine.
Removal
A additional information refer to Battery
Notice
Check oil separator system, in particular for
any leak.
2. Unclip and remove the oil separator hose (A)

from the air outlet hose.
Installation
Notice
Before installing the oil separator into the en-
gine, clean the oil separator and apply rec-
ommended sealant in the oil separator.

MAN-00162
3. Detach the oil separator hose (A) from the clip HFM Sensor
(B).
4. Unclip the clip (A) and remove the oil separator HFM Sensor is mounted between air filter and
hose (B) from the oil separator unit. turbocharger. This sensor gives Information about
the amount of air quantity and temperature of the
air entering in the engine. This input is used by the
ECU for corrections of fuel quantity based on
amount of air availability for optimization of exhaust
gas circulation & the turbocharger control.
Removal
B removal and installation section.
1. Remove the air cleaner top cover. For addi-
tional information refer to Air Filter Element
2. Using a 5mm Allen key Loosen the two HFM
A sensor mounting bolts (A) and remove the
HFM sensor from the air cleaner top cover.
Installation
1. To install, reverse the removal procedure. Notice
Handle the HFM Sensor carefully while re-
Notice moving to avoid damage.
Before installing the oil separator hose in-
spect for any damaged. Any vacuum leak will
lead to a high-pressure build up and then it
will go through the intake system. A
Notice
High-pressure build up in the intake system
give a signal of high blow by or be confused
with compressor oil leak.

MAN-00162
Installation Boost Pressure Sensor

Notice
Do not over tighten the HFM mounting
bolts.over tightening will lead to damage the
air cleaner mounting threads.
Notice
While installing, the HMF sensor the point of
the arrow should be towards the Turbo
charger at the time of installation.
Boost Pressure Sensor is fitted on intercooler outlet

near the pipe connecting intercooler to engine
intake. Measures the boost pressure for VGT
calibration.
Removal
2. Remove the engine NVH cover. For additional
information refer to NVH Cover removal and
3. Press the lock and disconnect the electrical
connector of the boot pressure sensor (A) from
the inter cooler.

MAN-00162
4. Remove the 10mm boost pressure sensor NVH Cover

mounting bolt (A) and detach the boost
pressure sensor from the inter cooler.
Removal
Installation 1. Lift and detach the NVH cover at back side
1. To install, reverse the removal procedure. (A), slide and remove the NVH cover (B)
towards windscreen.
Notice
Inspect the boost pressure sensor 'o' ring
and boost pressure sensor for damaged.
A
A
Installation
1. Insert the NVH cover (A) into the bulk head (B)
and fix the NVH cover into the intercooler.
A
B

MAN-00162
Intercooler 4. Press the lock and disconnect the electrical

connector of the boot pressure sensor (A) from
the inter cooler.
The intercooler is a heat exchanger used to cool

the compressed hot air coming from the VGT 5. Loosen the inter cooler hose clip (A) and
(turbocharger) before it enters the intake manifold. remove the hose (B) from other side of the
It increased the density of the air and avoids the inter cooler.
chance of pre-ignition due to high intake air
temperature.
Removal B
1. Remove the negative terminal of the battery.
2. Remove the engine NVH cover. For additional A
information refer to NVH Cover removal and
Notice
Do not place any tool or parts over the
intercooler as it will damage the fins which
will lead reduced performance of intercooler.
6. Uncap the HFM sensor wiring harness clip (A)
from the inter cooler mounting bracket.
3. Loosen the inter cooler inlet hose clip (A) and
remove the hose (B) from the inter cooler.
B A

MAN-00162
7. Remove the two 10mm inter cooler bracket Intercooler Inlet Hose
mounting bolts (A) from the fire wall side.
8. Remove the two 10mm inter cooler bracket Removal

mounting bolts (A) from the bulk head side and 1. Loosen the intercooler inlet hose clip (A) con-
detach the inter cooler assembly. nected to the inter cooler and remove the inlet
hose from the inter cooler.
A
A
Installation
2. Loosen the intercooler inlet hose clip (A)
connected to the turbo charger and remove the
intercooler inlet hose (B) from the turbo
charger.

MAN-00162
Installation Intercooler Outlet Hose

Notice
Inspect the intercooler inlet hose for any dam-
age. Install the intercooler inlet hose properly
to avoid the poor engine performance.
Removal
1. Loosen the intercooler outlet hose clip (A) con-
nected to the intake manifold and remove the
intercooler outlet hose (B) from the intake mani-
fold.
2. Loosen the intercooler outlet hose clip (A)

connected to the intercooler and remove the
outlet hose (B) from the inter cooler.

MAN-00162
Installation Intercooler Bracket

Notice
Inspect the intercooler outlet hose for any
damage. Install the intercooler outlet hose
properly to avoid the poor engine
performance.
Removal
1. Remove the inter cooler assembly. For addi-
tional information refer to Intercooler
2. Remove the boost pressure sensor. For addi-
tional information refer to Boost Pressure
Sensor removal and installation section.
3. Remove the four 10mm mounting bracket bolts
(A) and detach the bracket from the inter
cooler.
Installation
Notice
Before installing the inter cooler, check the
inter cooler mounting bracket rubbers
condition to avoid rattling noise from the
engine compartment.

MAN-00162
Diagnostics and Testing

1. Air intake obstructed. 1. Check the service indicator light

Engine does not glows.replace air filter element if ex-
start & emits black treme dirt.
smoke 2. Check for free operation of turbo-
charger.
1. Air intake restricted. 1. Replace the air filter element.
2. Air leaks in system after turbocharger. 2. Plug the leaks, replace hose or clip if
required.
3. Air leaks in pipe manifold to FIP. 3. Replace the hose or tighten.
Engine does not
give full power 4. Boost pressure control valve stuck in 4. Correct the control valve and find
open condition. the cause.
5. Boost pressure pipe/hose assembly 5. Check the pipe, washer and rectify.
damaged.
6. Turbocharger damaged. 6. Replace the turbocharger.
1. Air intake restricted. 1. Check the hoses, replace the air fil-
ter element.
2. Air leaks between the turbocharger and 2. Check for leaks between the turbo-
Black smoke inlet manifold. charger and the intercooler and be-
tween the intercooler and the inlet
manifold. Remove the restriction or
replace them if necessary.
1. A clogged air filter element. 1. Clean or replace the air filter ele-
ment.
2. Obstruction in the crankcase breather. 2. Locate and remove the restriction in
crankcase breather.
3. Obstruction in air intake of the turbo- 3. Check the crankcase and replace it
charger compressor. if necessary.
4. Leaks in the inlet manifold mounting 4. Change the manifold gasket or re-
face which allows the entry of dust par- place the manifold.
Excess oil con-
ticles.
sumption
5. Air leakage between the turbocharger 5. Locate the leaks, change the hose
and intake manifold. or clamp if required.
6. Thick oil/sludge or coke in the turbo 6. Change oil, filter, service the turbo
chargers central housing. charger and use recommended oils
and drain intervals.follow the recom-
mended procedure while shutting
down.
7. Turbo charger damaged. 7. Replace the turbo charger.

MAN-00162
1. Clogged air filter element. 1. Clean or replace the air filter ele-
ment.
Black smoke
2. Air leakage between the turbocharger 2. Locate the leaks, and change the
and the intake manifold. hose or clamp if required.
1. Air intake is obstructed. 1. Clean the air filter, replace if re-

quired.
2. Air leak in pressure line after turbo 2. Plug the leaks and replace the hose
Engine underpow- charger (Turbo to intercooler and inter- or clip if required.
ered cooler to manifold).
3. The pressure booster pipe/hose as- 3. Check the pipe or washer of the
sembly is damaged. pressure booster pipe and replace it
if necessary.
1. Indication of air leakage between the 1. Tighten the clamps at the intercool-
turbocharger to inlet manifold. er and the turbocharger inlet and
outlet.
Whining noise
clearly audible after 2. Check the hoses for leakage and
2000 RPM and replace the hoses if necessary.
3. Check and replace the inlet and

outlet pipe of the intercooler.

MAN-00162
Component Inspection and Action Table
Component Inspection Action
Air filter 1. Inspect the air filter element for possible damage. 1. Replace the element.
2. Inspect the air filter element for clogging. 2. Clean the element and re-
place if required.
1. Inspect air intake manifold for cracks or distortion. 1. Replace if cracks or dam-
ages are found.
Air intake mani- 2. Check for air leakage between block and intake mani- 2. Check surface for distor-
fold and hoses fold. tion.
1. Check for fins distortion, damage. 1. Replace the intercooler.

Intercooler 2. Check for blockage.
2. Replace the intercooler.
Air Filter Type Foam
Air Filter Volume 11 liters
Service Interval 40,000 km
Torque in
Part Bolt Specification Place of Application Quantity
Nm
COMBI SCREW
ALLEN TYPE HFMS to air cleaner 2 2.5±0.5
M6X1X18
SCREW HEX FL
Oil separator hose mounting to engine 1 8.0~10.0
M6X1X15X8.8XGR
Air cleaner and at-
tachment
BOLT HEX FL
M8X1.25X30X8.8X Air cleaner to BIW 1 12.0±0.5
ZN
SCREW HEX FL
Dirty side mounting to bolster 1 8.0~10.0
M6X1X15X8.8XGR
HOSE CLIP W
Inlet and outlet hose mounting 4 6.0~8.0
M65X0.9X12XSS
SCREW HEX FL Boost pressure sensor mounting to in-

Intercooler 1 3.5±0.5
M6X115X8.8XGR ter cooler
BOLT HEX FL Inter-cooler craddle to BIW and Front

4 6.0±1.5
M6X1X25X8.8XZN end carrier

MAN-00162
Repair Manual Engine Cooling Nov 2011/ Rev 2
ENGINE COOLING
CONTENTS
Description and Operation .............................................................1
Electric Fan Logic ............................................................................2

Case 1: AC- Off ................................................................................. 2
Case 2: AC- On & AC Pressure < 18Bar (No Signal from MPS) ...... 2
Case 3: AC- On & AC Pressure > 18Bar (Signal from MPS) ............ 3
Service Tips and Precautions......................................................... 5

Precautions with Degassing tank ....................................................... 5
In Car Repairs ...................................................................................6

Engine Coolant Replacement/Filling and Bleeding Procedure: ......... 6
Cooling System Draining ................................................................... 7
Water pump leakage test .................................................................. 7
Cooling system leakage test .............................................................. 7
Radiator......................................................................................... 8
Removal ............................................................................................ 8
Inspection ......................................................................................... 10
Installation ........................................................................................ 10
Radiator Support Cross Bar / Front End Module .................... 11

Removal ........................................................................................... 11
Installation ........................................................................................ 13
Degassing Tank.......................................................................... 13
Removal .......................................................................................... 13
Inspection......................................................................................... 14
Installation ........................................................................................ 14
Assembly Hose Radiator to Degas Tank ................................ 15

Removal ........................................................................................... 15
Installation ........................................................................................ 15
Assembly Hose Engine to Degassing Tank .............................16

Removal ........................................................................................... 16
Installation ........................................................................................ 16

MAN-00162
Assembly Hose Degas Tank to Engine .................................... 17

Removal ........................................................................................... 17
Installation ........................................................................................ 17
Assembly Hose Radiator Bypass ............................................. 18

Removal ........................................................................................... 18
Installation ........................................................................................ 18
Assembly Hose Radiator Inlet .................................................. 19

Removal ........................................................................................... 19
Installation ........................................................................................ 19
Assembly Hose Radiator Outlet ............................................... 20

Removal ........................................................................................... 20
Installation ........................................................................................ 20
EGR Hose (EGR Cooler to Coolant Outlet Hose) .................... 21

Removal ............................................................................................ 21
Installation ........................................................................................ 21
EGR Hose (Engine to EGR Cooler) ......................................... 22

Removal ........................................................................................... 22
Installation ........................................................................................ 22
Heater Hoses (Inlet and Outlet) ................................................ 22

Removal .......................................................................................... 22
Installation ........................................................................................ 22
Oil Cooler Hoses ........................................................................ 23

Removal .......................................................................................... 23
Installation ........................................................................................ 23
Coolant Outlet Joint Hose ......................................................... 24

Removal .......................................................................................... 24
Installation ........................................................................................ 24
Thermostat ................................................................................ 24
Removal .......................................................................................... 24
Installation ........................................................................................ 25

MAN-00162
Water Pump ...............................................................................26

Removal ........................................................................................... 26
Installation ........................................................................................ 27
Engine Oil Cooler .......................................................................28

Removal ........................................................................................... 28
Installation ........................................................................................ 28
Coolant Temperature Sensor .................................................... 29

Removal ........................................................................................... 29
Installation ........................................................................................ 29
Assembly Electric /Cooling Fan and Shroud with Flaps ........ 30

Removal ........................................................................................... 30
Installation ........................................................................................ 31
Cooling Fan Resistor ................................................................32

Removal ........................................................................................... 32
Installation ........................................................................................ 32
Cooling Fan Shroud with Flaps ................................................33

Removal ........................................................................................... 33
Installation ........................................................................................ 33
Diagnosis and Testing ...................................................................33

Inspection and Verification ............................................................... 33
Troubleshooting Chart ...................................................................... 34
Component Inspection Table ........................................................... 36
Mahindra Special Tools (MST) ......................................................36
Technical Specification ................................................................37
Torque Specification .....................................................................38

MAN-00162
Engine Cooling
Vent Hose From radiator
Thermostat
RADIATOR ASSY.
Engine water outlet

ELECTRIC FAN De-gassing tank
Engine water Inlet
Thermostat Bypass hose
Vent Hose From Engine
ENGINE
EGR
Oil Cooler
Make up Hose
Water Pump Heater Core
Above Schematic gives the coolant flow circuit with the components. The coolant flow is controlled by the
thermostat. In addition to the Cylinder head and block, the coolant also circulates through Oil cooler, HVAC
heater core and EGR Cooler. Cooling system is designed to dissipate the excess heat energy liberated from
engine combustion. It maintains the engine temperature in specified range to achieve the maximum
combustion efficiency at all engine speeds, in different operating conditions.

MAN-00162
Electric Fan Logic

Case 1: AC- Off
Case 1: AC-Off
Modulation is based on Coolant Temperature
Low High
Fan off speed speed
94°C 98°C 101°C 105°C
Temperature
Increasing
Low High
Fan off speed speed
94°C 98°C 101°C
Temperature
Decreasing
Case 2: AC- On & AC Pressure < 18Bar (No Signal from MPS - Middle Pressure
Switch)
Case 2: AC-On & AC Pressure < 18Bar (No Signal from MPS)
Low High
Fan off speed speed
94°C 98°C 101°C 105°C
Temperature
Increasing
Low High
Fan off speed speed
94°C 98°C 101°C
Temperature
Decreasing

MAN-00162
Case 3: AC- On & AC Pressure > 18Bar (Signal from MPS - Middle Pressure
Switch)
Case 3: AC-On & AC Pressure > 18Bar (Signal from MPS)
Low Low High

Any speed speed speed
Temp°C 94°C 98°C 105°C
Temperature
Increasing
Low Low High

Any speed speed speed
Temp°C 94°C 98°C 105/101°C
Temperature
Decreasing

MAN-00162
A J
M B
K
D
L E
C C
J G D
B F
I
A
I E M
H G
H
K
F L
A. Degassing Tank H. Radiator

B. Degas Hose from Degas Tank I. CRFM Seal BOTTOM
C. Degas Hose from Engine J. CRFM Seal TOP
D. Electric Fan and Shroud K. CRFM Seal RH
E. Radiator Outlet Hose L. Radiator Inlet Hose
F. CRFM Seal LH M. Degas Hose from Radiator
G. Radiator Bypass Hose

MAN-00162
Service Tips and Precautions • Use cloth to clean the parts, common shop rags
can leave lint that might interfere with the opera-
Observe the following precautions when disassem- tion of the cooling system parts.
bling or servicing the cooling system and its compo- • Avoid twisting or stressing of the engine cooling
nents. hoses.
• Ensure that the work place is a dust free envi- • Always maintain coolant level to the recom-
ronment. mended level.
• Do not remove the radiator drain cock or the
Engine coolant plate drain with the engine in hot
condition. DANGER
• If the coolant is not contaminated then collect Do not commence repair operations of the
the coolant in a clean container so that it can be cooling system until the engine is switched
reused. Replace coolant as per recommenda- OFF and cooled down considerably. The pres-
tion. sure within the system is extremely high which
• Always ensure that Spring band Clamp will cause personal injury.
Position is with respect to hose as per paint
marking.
A CAUTION
Eye protection must be worn while working
near the cooling system, failure to follow this
may cause personal injury.
DANGER
Never open the degas tank pressure cap when
coolant is hot. The pressure within the system
is extremely high, failure to follow this instruc-
tion will cause personal injury.
A. White Marking Engine End Precautions with Degassing tank

1. Do not open pressure cap when coolant in
heated condition.
2. Coolant level shall be between Max line to Min
line.
3. Ensure Proper tightening of the Pressure cap.
B
4. Ensure 70:30 (water + coolant) will be filled.
B. Yellow Marking Radiator End

• Before installing or servicing the cooling
system, clean the outer surface of the parts.
• Prevent entry of foreign objects during servicing
the cooling system parts.

MAN-00162
In Car Repairs 8. Coolant should be filled till the fill level reaches
just below the 'MAX' marking on the degassing
Engine Coolant Replacement/Filling tank. Check the system for any leakages.
and Bleeding Procedure:
1. Park the vehicle on flat-horizontal surface by
applying the parking brake.
2. Verify that the engine and coolant are at normal
temperature. Never remove the pressure cap if
engine is still hot.
3. Turn cabin heater Knob in full hot position
throughout the coolant draining process.
4. Keep a suitable container below the radiator
drain plug to collect the coolant that will drain.
5. Slowly open the degassing tank cap. Never MAX
open the pressure cap quickly. This will cause MIN
progressive pressure release in the system.
9. Start the engine and run it at approximately 2000
to 2200 rpm for approximately 5 to 10 minutes.
10. Press the accelerator pedal slowly then release
it instantly. Repeat this cycle multiple times for
approximately 5 - 10 minutes.
CAUTION
Care should be taken, as the cap is not tight-
ened fully till now, there could be coolant
splashes near the degassing tank.
11. Stop the engine. Press/release the coolant

hoses so as to drive the entrapped air to some
6. Remove the drain cock (A) from the radiator bot- extent.
tom right side corner. Drain the coolant com- 12. Fully tighten the pressure cap on degassing
pletely. Refit the drain cock. Fill the new tank.
(prescribed) coolant mixture in the system from
the degassing tank filler neck. 13. Start the engine and warm it until thermostat
valve opens. This can be verified by touching the
radiator inlet hose with hand and feeling the
warm coolant flowing inside it.
14. Stop the engine and remove the pressure cap.
Let the engine cool down.
15. Check the coolant level in degassing tank. If
required, add coolant so as to bring the level
between 'MIN' and 'MAX' markings. Tighten the
pressure cap fully over degassing tank.
A
CAUTION
Ensure that there are no leakages in the com-
plete cooling system.
7. Loosely fit the degassing tank pressure cap. Do
not tighten it fully.

MAN-00162
16. Once any rework/service is done on cooling 4. Remove the drain plug (A) from the radiator, and
system, It is highly recommended that coolant drain the coolant completely from the radiator.
level is checked. While checking the level, the
vehicle should be parked on flat-horizontal sur-
face and coolant should be at normal room tem-
perature.
Cooling System Draining

1. Release the cooling system pressure by slowly A
turning the degassing tank cap.
DANGER
Never open the degas tank pressure cap when
the engine is hot. The escaping steam will
cause severe burns and/or injuries.
5. Install the radiator drain plug after draining the
coolant and lower the vehicle to the ground.
A
Notice
E
LY IMIL
ON
E MAX L
US A M OI
DR IU
IN EM
AH PR
M
Always replace the coolant at specified ser-

vice intervals.
Water Pump Leakage Test

Typical sign of failed water pump is leakage through
the seal and bearings. Water pump has a small hole
below where the coolant will seep out if the seal or
bearing is failed. If the water pump is leaking replace
the pump as soon as possible. Water pump failure
can be confirmed by below steps:
2. Remove the degassing tank cap. 1. Rotate the water pump pulley and check for free
3. Raise and support the vehicle. For additional rotation.
information refer to Jacking and Lifting 2. Check for water leakage through the leakage
removal and installation Section. hole.
Cooling System Leakage Test

DANGER 1. Supply low pressure air into the system which
causes the coolant to pour or drip from any leak
Remove the degassing tank cap covered with
in the system.
a thick cloth to prevent scalding resulting from
the cooling system pressure. 2. Using the pressure tester which is essentially a
hand-operated air pump, pressurize the system
for leak detection.
3. Install the pressure tester on the degassing tank
filler neck and check for coolant leakages from
cooling system.

MAN-00162
Radiator Removal
1. Disconnect and isolate the negative terminal of
the battery. For additional information refer to
Battery removal and installation Section.
A 2. Remove the coolant drain plug (A) and drain the

coolant from the RHS bottom corner of the radia-
D tor.
B Notice
Place a container beneath the radiator to avoid
spillage of coolant on shop floor.
A. Thermostat
DANGER
B. Inlet Tank Do not remove the drain cock when engine is
hot with pressurized coolant. Serious burns
C. Core will occur due to splashing of hot coolant.
D. Outlet Tank
The radiator is a heat exchanger that removes the
heat from the coolant passing through it. The
coolant flows inside the Radiator from RH to LH.
The cooling air flows outside the Radiator. The heat
exchange is between the coolant to air.
A
3. Remove the NVH cover of the engine. For addi-

A
tional information refer to NVH Cover
removal and installation Section.
4. Remove the front bumper. For additional infor-
mation refer to Front Bumper removal and
A. Drain Cock installation Section.
Drain Cock Used to Drain the Coolant during
Service. Drain Cock is located in the Inlet tank side.

MAN-00162
5. Remove the two 10mm power steering cooler 8. Using the grip plier, compress the hose securing
bracket mounting bolts (A) from the radiator clips (A), remove the radiator inlet hose and radi-
cross bar. ator bypass hose (B) from the radiator.
A B
A
A A
6. Remove the two front bumper cross bar. For 9. Using the grip plier, compress the hose securing
additional information refer to Front Bumper clip (A) and remove the radiator to degas tank
removal and installation Section. hose (B) from the radiator.
7. Pull the four locks (A) from both sides of the
radiator, and move the A/C condenser
assembly aside. B
A
A
10. Using the grip plier, compress the hose securing
clip (A) and remove the radiator bottom hose
(B).

MAN-00162
11. Remove the two 10mm bolts from both sides of 14. Separately remove the radiator assembly from
the radiator top mounting brackets and detach the radiator support cross bar.
the radiator top mounting brackets.
Inspection
12. Lift the radiator and partially tilt the radiator
assembly (A). 1. Check the radiator for leakages due to core
damage or mounting damage. Replace the radi-
ator if required.
Installation
A 2. Refill the engine coolant. For additional infor-

mation refer to Engine Coolant Replacement/
3. Check for Leakages. For additional informa-

tion refer to Cooling System Leakage Test
Section.
13. Remove the 10mm mounting bolts (A) from both

sides of the radiator and detach the radiator fan
assembly.

MAN-00162
Radiator Support Cross Bar / 8. Release the lock (A) and lift the lever (B)
upwards and disconnect the connector from the
Front End Module ECU.
9. Remove the four 10mm mounting bolts (A) from

Removal the ECU and remove the ECU.
Battery removal and installation Section.
A
installation Section.
3. Remove the two front bumper cross bar. For
additional information refer to Front Bumper
Cross Bar removal and installation Section.
4. Remove the headlamps from both sides. For
additional information refer to Headlamp
5. Remove the condenser. For additional infor-
mation refer to A/C Condenser removal and
installation Section. 10. Remove the 10mm intercooler mounting bracket
6. Remove the radiator. For additional informa- bolts (A) from the radiator front side.
tion refer to Radiator removal and installa-
tion Section.
7. Remove the cooling fan. For additional infor-
mation refer to Assembly Electric /Cooling
Fan and Shroud with Flaps removal and

MAN-00162
11. Unlock the three wiring harness lock clips (A) 14. Remove the 10mm degassing tank mounting
from the radiator support cross bar. bolt (A) from the radiator support cross bar.
A
A
12. Pull out the bonnet cable lock pin (A) from the 15.Remove the 12mm top mounting bolts (A) from
latch and remove the cable. LHS and RHS of the radiator support cross
bar.
A
A A
13. Remove the 10mm mounting bolt (A) from the

wiper reservoir neck.
E
LY IMIL
ON
E MAX L
US A M OI
DR IU
IN EM
AH PR
M

MAN-00162
16. Remove the 10mm bolt (A) from the air duct Degassing Tank
hose mounting clamp.
MAX
MIN
17. Remove the eight 13mm center mounting bolts Function of the Degassing tank is to remove air
(A) from the radiator support cross bar (B) and bubbles or vapor from the cooling system. Proper
separately remove the radiator support cross filling of the coolant inside the cooling system is
bar. must to pressurize the system at 2.1Bar absolute.
Removal
1. Remove the drain plug and drain the coolant
from the radiator. For additional information
refer to Cooling System Draining Section.
Notice
Place a container beneath the radiator to
avoid spillage of coolant on shop floor.
B A
DANGER
Do not remove the drain cock when engine is
Installation hot with pressurized coolant. Serious burns
1. To install, reverse the removal procedure. will occur due to splashing of hot coolant.
2. Refill the engine coolant. For additional infor-

Section.

MAN-00162
2. Using the grip plier, compress the degas inlet 4. Remove the four 10mm mounting bolts (A)
hoses securing clip (A) and pull out the inlet from the coolant degassing tank and detach
hose (B) from the coolant degassing tank. the degassing tank.
A
M
ON
LY IMIL
E MAX L
US A M OI
IN
DR IU
AH PREM
E
B M
ON
LY IMIL
E MAX L
US A M OI
IN
DR IU
AH PREM
E
A
A
3. Using the grip plier, compress the radiator to Inspection

degas tank hose and degas tank to engine
1. Check the coolant degassing tank thoroughly
hose securing clips (A) and pull out the
for any damage or leakage and replace if
radiator to degas tank hose and degas tank to
required.
engine hoses (B) from the coolant degassing
tank. Installation
ON
LY IMIL
E
B
E MAX L

US A M OI
DR IU
IN EM
AH PR
M
A
A

MAN-00162
Assembly Hose Radiator to 5. Using a grip plier, compress the degassing

hose securing clip (A) and pull out the radiator
Degas Tank to degas tank hose (B) from the radiator.
The air bubbles from Radiator will be entrapped Installation

through this hose.
Notice
Removal
Always fix the white paint marking side of
the hose to the Engine side and yellow paint
the battery. For additional information refer
marking to the Radiator side.
to Battery removal and installation Section.
refer to Cooling System Draining Section. 2. Refill the engine coolant. For additional infor-
3. Remove the front bumper grill. For additional
information refer to Front Bumper Grill
4. Using a grip plier, compress the degassing
hose securing clip (A) and pull out the radiator
to degas tank hose (B) from coolant degassing
tank and detach the radiator to degas tank
hose.
E
LY IMIL
ON
E MAX L
US A M OI
DR IU
IN
AH PREM
M

MAN-00162
Assembly Hose Engine to Installation

Degassing Tank Notice

The air bubbles from water outlet pipe will be

entrapped through this hose.
Removal
3. Using the grip plier, compress the degas inlet
hoses securing clips (A) connected to the
water outlet pipe and degassing tank to
remove the inlet hose (B).
ON
LY IMIL
A
E
E MAX L
US A M OI
DR IU
IN
AH PREM
M
B
A

MAN-00162
Assembly Hose Degas Tank to 4. Using the grip plier, compress the outlet hose
securing clips (A) and pull out the outlet hose
Engine (B) from the water pump side and detach the
outlet hose.
During initial filling coolant will be circulated from

De-gassing tank to the engine through this hose. Installation
Removal Notice
refer to Cooling System Draining Section..
3. Using the grip plier, compress the degas outlet
hoses securing clips (A) and pull out the outlet
hoses (B) from the coolant degassing tank.
A B
E
LY IMIL
ON
E MAX L
US A M OI
DR IU
IN
AH PREM
M

MAN-00162
Assembly Hose Radiator Bypass 4. Using the grip plier, compress the assembly
radiator inlet hose securing clip (A) and pull out
the assembly radiator inlet hose (B) connected
to the thermostat valve and the coolant outlet
pipe.
B A
A
A. Engine Side B
B. Radiator Side
When thermostat closed (coolant temperature <
92°C) the coolant water will bypass from the Installation
Radiator.
Notice
Removal
3. Using the grip plier, compress the radiator inlet
hose securing clip (A) and pull out the
assembly radiator inlet hose (B) connected to 3. Check for Leakages. For additional informa-
the thermostat valve. tion refer to Cooling System Leakage Test
Section.

MAN-00162
Assembly Hose Radiator Inlet Installation

Notice

B
A 3. Check for Leakages. For additional informa-
Section.
A. Engine Side
B. Radiator Side
Radiator Inlet Hose in which the coolant form
Engine will enter in to radiator for removing the
Heat from coolant.
Removal
3. Using a grip plier, compress the assembly
hose radiator inlet securing clip (A) and pull out
the assembly hose radiator inlet (B) from the
radiator and coolant inlet pipe.
B
A

MAN-00162
Assembly Hose Radiator Outlet 4. Using a grip plier, compress the assembly
hose radiator outlet securing clips (A) and
remove the assembly hose radiator outlet (B)
from the outlet pipe.
A
B
A
A. Engine Side
B. Radiator Side
Outlet Hose connected on radiator outlet tank side Installation
which will send the cooled coolant to the engine.
Notice
Removal
3. Using a grip plier, compress the assembly
hose radiator outlet securing clips (A) and
remove the assembly hose radiator outlet (B) 3. Check for Leakages. For additional informa-
from the radiator bottom side. tion refer to Cooling System Leakage Test
Section.

MAN-00162
EGR Hose (EGR Cooler to Installation

1.To install, reverse the removal procedure.
Coolant Outlet Hose) 2. Refill the engine coolant. For additional infor-
Removal mation refer to Engine Coolant Replacement/
the battery. For additional information refer 3. Check for Leakages. For additional informa-
to Battery removal and installation Section. tion refer to Cooling System Leakage Test
2. Remove the drain plug and drain the coolant Section.
3. Using a grip plier, compress the EGR cooling
water outlet hoses securing clip (A) and
remove the EGR water outlet hose (B)
connected to the EGR cooler and coolant
outlet pipe.
4. Using a grip plier, compress the EGR cooling

water outlet hose securing clip (A) and
disconnect coolant outlet hose (B) from the
coolant outlet pipe.
B
A

MAN-00162
EGR Hose (Engine to EGR Heater Hoses (Inlet and Outlet)

Cooler) Removal
Removal the battery. For additional information refer
1. Disconnect and isolate the negative terminal of to Battery removal and installation Section.
to Battery removal and installation Section. 2. Remove the drain plug and drain the coolant
from the radiator.For additional information
2. Remove the drain plug and drain the coolant refer to Cooling System Draining Section.
refer to Cooling System Draining Section. 3. Using a grip plier, compress the securing clips
(A) and remove the heater inlet and outlet
3. Using a grip plier, compress the EGR cooling hoses (B) from pre-heater pipes.
water inlet hoses securing clips (A) and
remove the EGR water inlet hose (B).
B A
A
A
B
B
4. Using a grip plier, compress the securing clips

(A) and remove the heater inlet and outlet
Installation hoses (B) from water outlet pipe and detach
1.To install, reverse the removal procedure. the heater hoses.
3. Check for Leakages.For additional informa-

tion refer to Cooling System Leakage Test B
Section. B
A
Installation

MAN-00162
3. Check for Leakages. For additional informa- Oil Cooler Hoses (Oil Cooler to
Section. Coolant outlet Hose and Engine)
Removal
3. Using a grip plier, compress the engine oil
cooler inlet and outlet hoses (A) and separately
remove the Oil cooler hoses (B) from the
engine oil cooler.
A A
A
B
Installation

Section.

MAN-00162
Coolant Outlet Joint Hose Thermostat

Removal
3. Using a grip plier, compress the securing clips
(A) and separately remove the coolant outlet
joint hose (B) from the coolant outlet pipe.
A B A
Thermostat valve is a coolant flow control device

which is operated by virtue of heat received from
the engine coolant flowing across it. Thermostat
valve helps in regulating the operating temperature
of engine by controlling the amount of coolant
flowing through the radiator.
When engine and coolant are relatively colder, the
thermostat valve remains closed thereby preventing
the coolant from flowing through the radiator.
Coolant flows directly to the water pump inlet.
Because of this, coolant and engine progressively
Installation get warmer. Once engine and coolant are warm
1. To install, reverse the removal procedure. enough, the valve start opening up, thereby
allowing a portion of coolant to flow through the
2. Refill the engine coolant. For additional infor- radiator.
Filling and Bleeding Procedure: Section. Thus thermostat keeps the coolant temperature
within the range to improve the combustion efficiency
3. Check for Leakages. For additional informa- of the engine.
tion refer to Water Pump Leakage Test Sec-
tion. Removal
refer to Radiator removal and installation
Section.
Notice

MAN-00162
6. Remove the four 10mm thermostat mounting

bolts and nuts (A) from the thermostat and
DANGER separately remove the thermostat assembly.
Do not remove the drain cock when the engine
is hot and pressurized. Serious burns will
occur due to splashing of hot coolant.
3. Remove the NVH cover. A

4. Using the grip plier, compress the assembly
radiator inlet hose securing clip (A) and
remove the assembly radiator inlet hose (B)
from the thermostat housing.
7. Remove the thermostat O-ring (A) from the

B thermostat.
A
5. By using a grip plier, compress the assembly
hose radiator inlet securing clip (A) and
remove the assembly hose radiator inlet (B)
from the thermostat housing.
Installation
B mation refer to Engine Coolant Replacement/
A

MAN-00162
Water Pump 3. Remove the 14mm banjo mounting bolt (A)

from the turbocharger oil inlet pipe attached to
the cylinder block.
A centrifugal water pump is used to circulate the

coolant through the water jackets, cylinder head, 4. Fix the water pump pulley locking tool (A)
hoses and radiator. The water pump is belt driven (Special Tool Part No:0304GAM0001ST), into
by the engine main drive pulley. the water pump pulley bolt.
The water pump impeller is pressed onto the shaft.
The shaft is supported on two bearings that are Notice
integral to the shaft. The water pump seal is By using the special tool, loosen the four wa-
located between the impeller and the housing. ter pump pulley mounting bolts.
The housing has a small hole to allow the seepage
to escape. That also acts as an indication point if
the water pump seal fails.
The water pump is not serviceable and has to be
changed as an assembly.
Removal
1. Remove the drive belt. For additional A
2. Remove the coolant drain plug and drain the

coolant. For additional information refer to
Cooling System Draining Section.
Notice
DANGER
Do not remove the drain cock when the engine
is hot and pressurized. Serious burns will
occur due to splashing of hot coolant.

MAN-00162
5. Remove the four 12mm mounting bolts (A) from Installation

the water pump pulley and detach the water 1. To install, reverse the removal procedure.
pump pulley.
A
6. Remove the five 12mm mounting bolts (A)

from the water pump.
7. Separately remove the water pump (A) from

the drive shaft side.

MAN-00162
Engine Oil Cooler 3. Using a grip plier, compress the securing clips
(A) and remove the inlet and outlet hoses (B)
from the oil cooler.
B
A
The multi plate aluminum oil cooler in the engine

coolant system provides passages in which some 4. Remove the three 12mm oil cooler mounting
are used for oil circulation and some passages are bolts (A) from the cylinder block and separately
used for coolant circulation. Hot oil from the remove the engine oil cooler assembly (B).
cylinder block enters the cooler and circulates
through the passages which are surrounded by the
cooling water on both sides. The cooled oil then
flows from the cooler into the oil filter.
The cooling water for the cooler is taken from the B
cylinder block water gallery.
Removal
1. Remove the intercooler. For additional
information refer to Intercooler removal and
installation Section. A
2. Using a oil filter wrench, remove the oil filter
(A) from the engine oil cooler assembly.
A Installation
Notice
While removing the engine oil cooler, replace
the engine oil cooler gasket.


MAN-00162
Coolant Temperature Sensor 3. Remove the 19mm coolant temperature sensor

lock nut (A), and separately remove the
coolant temperature sensor (B) from the
engine coolant inlet pipe.
A B
Coolant Temperature sensor is a made of semi

conductor material (NTC) which changes its
resistance when exposed to variable temperature
source. Resistance decreases as temperature
Installation
increases. It is located on the water outlet box, 1. To install, reverse the removal procedure.
near thermostat. Monitors the coolant temperature. 2. Refill the engine coolant. For additional infor-
Removal Filling and Bleeding Procedure: Section.
DANGER
Do not remove the drain cock when engine is
hot with pressurized coolant. Serious burns
will occur due to splashing of hot coolant.

connector (A) from the coolant temperature
sensor.

MAN-00162
Assembly Electric /Cooling Fan 3. Remove the two 10mm power steering cooler
bracket mounting bolts (A) from the radiator
and Shroud with Flaps cross bar.
A A
B
A. Fan Side Connector 4. Using a grip plier, compress the securing clip
B. Rubber Flaps (A) and remove the radiator overflow hose (B).
The Electric fan pulls the ambient air through the
radiator core that cools the hot water circulating B
through the radiator. The fan will be connected
through connector to the electrical circuit.The
rubber flap openings provided on Radiator shroud A
to aid the extra air through the Radiator at high
vehicle speeds. The Fan and Shroud Assembly
Mounted on Radiator Top with bolt and bottom by
snap Fit.
Removal
2. Remove the radiator. For additional 5. Press the lock and pull out the electrical
information refer to Radiator removal and connector (A) from the cooling fan.

MAN-00162
6. Remove the two top mounting shroud bolts (A), 8. Lift the radiator and slightly rotate it towards
and remove the top mounting shroud from both the LHS and separately remove the cooling fan
sides of the radiator. assembly (A) from the radiator.
Notice
CAUTION Electric fan and fan motor are not separately
Do not remove the radiator bottom hose to serviceable. They should be replaced as a
avoid coolant loss. single unit only.
7. Unlock the bottom mounting snap fit (A) of the Installation

cooling fan.

MAN-00162
Cooling Fan Resistor Installation

Removal
connectors (A) from both sides of the fan
motor resistor.
2. Remove the resistor mounting screw (A) from

the shroud, and open the lock and separately
remove the cooling fan resistor.

MAN-00162
Cooling Fan Shroud with Flaps Diagnosis and Testing

Inspection and Verification
1. Visually inspect the cooling system for any
noticeable signs of leakages and mechanical
damage.
2. If an obvious cause is found, correct the same
before proceeding to the next step.
3. If the cause is not found visually, refer to the
troubleshooting chart given below.
4. All the components should be inspected for
wear and replaced if required.
Mechanical
• Check the electric fan for any damage.
Removal • Check for any leakage in the degassing tank

and radiator.
• Check the hoses in the cooling system for any
damage or leakage.
• Check the thermostat and its housing for any
2. Remove the cooling fan. For additional leakages and damages.
information refer to Assembly Electric /
Cooling Fan and Shroud with Flaps removal
and installation Section..
3. Remove the cooling fan shroud mounting

screws (A) and detach the cooling fan shroud
with flaps.
Installation

MAN-00162
Engine does not 1. Thermostat valve stuck at partial/fully 1. Replace it if necessary.

reach normal open condition.
operating
temperature.
1. Mechanical damage in shrouds. 1. Tighten the bolts on shroud, and

replace the shrouds if necessary.
2. Loose water pump impeller or bearing 2. Repair or replace the water pump.
failure.
Cooling system 3. Belt damaged. 3. Replace the belt.

component
4. Stretched or damaged fan belt. 4. Replace the serpentine belt.
noisy.
5. Rough surface on the drive pulley. 5. Replace the drive pulley.
6. Improper belt alignment. 6. Check the belt alignment and rectify.
7. Cooling fan bearing failure. 7. Replace the cooling fan.
1. Coolant level is too low or too high. 1. Maintain the coolant level between
MIN and MAX marking on the degas-
sing tank when coolant is at normal
room temperature and the vehicle is
parked on flat-horizontal surface.
2. Leakages at inner side the cooling 2. Check and repair any coolant leakag-
system. es from radiator, hose, joints, thermo-
stat housing, water pump, cylinder
head, crank case, cabin heater etc.
3. External blockages in heat exchang- 3. Check and clean/clear external block-
Engine getting ers restricting the air flow. ages from core/fins of the radiator,
over heated (ex- condenser.
cessively high
engine coolant 4. Contaminated or aged coolant mixture 4. Drain and refill specified coolant mix-
temperature) inside system. ture.
5. Thermostat valve stuck at partial/fully 5. Check and replace the thermostat

closed condition. valve if necessary.
6. Insufficient water flow due to faulty wa- 6. Check the seal, shaft and impeller and
ter pump. replace the water pump if necessary.
7. Faulty pressure cap. 7. Check and replace the pressure cap if

necessary.
8. Faulty or damaged Drive Belt. 8. Replace the Drive Belt.

MAN-00162
1. Fan blades striking a surrounding ob- 1. Locate the fan blade contact and re-
ject. pair it if necessary.
Noisy cooling 2. External blockages in the heat ex- 2. Check and clean/clear external
fan. changers restricting the air flow. blockages from core/fins of radiator,
condenser.
3. Defective cooling fan bearing. 3. Replace the cooling fan.
1. Low cylinder head torque. 1. Replace the cylinder head gasket, and
Coolant entry adjust the torque as per procedure.
into crankcase
or cylinder 2. Faulty cylinder head gasket. 2. Replace the cylinder head gasket.
black.
1. Coolant level is too high. 1. Park the vehicle on flat horizontal sur-
face and allow the coolant to cool
down to ambient temperature. Check
and correct coolant level.
Coolant spill 2. Coolant level is too high and insuffi- 2. Check wether the cap is tightened suf-
over from de- cient sealing between the degassing ficiently. Check sealing of pressure
gassing tank. tank neck and pressure cap. cap. If required replace the degassing
tank assembly.
3. Engine getting over heated. 3. Follow the corrective measures as

suggested for overheating in the trou-
ble shooting chart.
1. Coolant Mixes with Oil. 1. Check and rectify.
2. Oil Cooler Punctured/Damaged be- 2. Carry out the Pressure Test.

Observed Wa- tween Coolant and oil Passage.
ter in Oil Cooler 3. Check and rectify.
3. Blow holes causing the coolant and oil
to mix with each other in crankcase
galleries.
High Tempera- 1. Faulty coolant temperature sensor. 1. Connect diagnostic tool and rectify.
ture Indication
1. Restricted return inlet in water pump. 1. Remove restriction.
No coolant flow 2. Heater hoses collapsed or restricted. 2. Pressure test to isolate & repair.
trough Heater
3. Restricted heater core. 3. Remove flash or restriction.
Core
4. Restricted outlet in the thermostat 4. Remove restriction.
housing.

MAN-00162
Component Inspection Table

Drive belt 1. Check the accessory drive 1. Replace the drive belt.
belt for abrasion, cracking,
improper installation, uneven
rib wear, misalignment,
chunk-out, gravel penetration
and piling.
Water Pump 1. Check for leakages. 1. Replace the water pump.

2. Check for bearing noise. 2. Replace the water pump.
Cooling Fan 1. Check for physical damage. 1. Replace the fan.

2. Check for fan noise. 2. Replace the fan.
Degassing Tank 1. Check for physical damage 1. Replace the degas tank.
like cracks, wear and tear.
Thermostat 1. Check for physical damage. 1. Replace the thermostat as-

2. Check thermostat normal op- sembly.
eration. 2. Perform thermostat valve test
and replace if required.
Radiator 1. Check for physical damage, 1. Replace radiator if required.

fin distortion etc. 2. Flush the radiator, replace
2. Check for radiator blockage. only if required.
Pressure cap 1. Check the cap for physical 1. Replace if required.

damage.
2. Check pressure cap for leak- 2. Perform pressure cap test
age. and replace if required.
Coolant Hoses 1. Check hoses for cracks, dis- 1. Replace the concerned hose
tortion or flaring. and perform coolant pressure
test.

0304GAM0001ST Water pump pulley locking tool

MAN-00162
Component Description Specification
Type Cross Flow
Coolant Mixture 70:30 (Water: Ethylene glycol)

Radiator MAHINDRA "MAXIMILE ULTRA 8.0 Liters
COOL"
(READY TO USE COOLANT. NO
NEED TO MIX WATER)
Type Electric
Fan and Shroud Max fan speed - 2511RPM

Speed
Min fan speed - 1400 RPM
Type of Thermostat Wax type
Thermostat Thermostat starts opening @ 92 + 2°C with 0.1mm travel
Thermostat complete opening @ 98 + 2°C with 8mm lift
Max coolant volume 1.4 Litres
Min Coolant Volume 0.5 Litre

Degassing tank
Expansion Volume 0.6 Litre
Total Volume 2.0 Litres + 0.2

MAN-00162
Bolt Torque in
Specification Nm
SCREW HEX FL
Radiator assem- Radiator assembly to front end carrier
M6X1X20X8.8XG 2
bly bracket
R
SCREW HEX FL
Degassing tank
M6X1X20X8.8XG Degassing tank to BIW 4 10.0±2.0
assembly
R
SCREW HEX FL
Byepass hose
M6X1X20X8.8XG Byepass hose bracket mounting 1
bracket
R
BOLT HEX FL
CRFM seals M6X1X25X8.8XZ CRFM seals mounting on condenser 4
N.3
8.0~10.0
SCREW HEX FL
Top seal M6X1X15X8.8XG Top seal mounting on front end carrier 2
R

MAN-00162
Repair Manual Fuel Charging System Nov 2011/ Rev 2
FUEL CHARGING SYSTEM
CONTENTS
Description and Operation...............................................................1
CRDE Schematic .............................................................................2
Component Location Index ............................................................ 3
In Car Repairs ...................................................................................5
High Pressure Pump (HPP) ........................................................ 5

Removal ............................................................................................. 5
Fuel Line - Fuel Filter to HPP ......................................................6

Removal ............................................................................................. 6
Installation .......................................................................................... 6
Fuel Line from HPP towards Tank ............................................. 7

Removal ............................................................................................. 7
Installation .......................................................................................... 7
Fuel Priming Procedure............................................................... 8
Fuel Filter ......................................................................................8

Removal ............................................................................................. 8
Installation ........................................................................................ 10
Water Drain from Fuel Filter ...................................................... 10

Removal ........................................................................................... 10
Installation ........................................................................................ 10
Water Sediment Sensor .............................................................11

Removal ........................................................................................... 11
Installation ........................................................................................ 11
Fuel Temperature Sensor ..........................................................12

Removal ........................................................................................... 12
Installation ........................................................................................ 12

MAN-00162
Fuel Injector................................................................................ 13
Removal ........................................................................................... 13
Installation ........................................................................................ 14
Fuel line (HPP to Fuel rail) ........................................................ 15

Removal ........................................................................................... 15
Installation ........................................................................................ 15
Fuel Rail ...................................................................................... 15

Removal ........................................................................................... 15
Installation ........................................................................................ 16
Fuel Rail Pressure Sensor ........................................................ 17

Removal .......................................................................................... 17
Installation ........................................................................................ 17
Fuel Tank .................................................................................... 18

Fuel Tank Filling ............................................................................... 18
Guaging of Fuel Tank ....................................................................... 18
Working of Fuel Tank ....................................................................... 19
Transfer of Fuel from Secondary Side to Primary Side .................... 20
Low Fuel Condition - Fuel Suction from Primary to Primary side ..... 20
Safety Valve on FDM ....................................................................... 20
Pressure Relief Valve....................................................................... 21
Removal ........................................................................................... 21
Installation ........................................................................................ 23
Fuel Delivery Module (FDM) Primary ...................................... 23

Removal ........................................................................................... 23
Installation ........................................................................................ 25
Fuel Delivery Module (FDM) Secondary .................................. 25

Removal ........................................................................................... 25
Installation ........................................................................................ 26
Fuel Return Line ......................................................................... 27

Removal ........................................................................................... 27
Installation ........................................................................................ 27

MAN-00162
Fuel Suction Line ....................................................................... 28

Removal ........................................................................................... 28
Installation ........................................................................................ 28
Fuel Filler Pipe Assembly ..........................................................29

Removal ........................................................................................... 30
Installation ........................................................................................ 31
Fuel Tank Ventilator Pipe .......................................................... 31

Removal ........................................................................................... 31
Installation ........................................................................................ 31
Fuel Filler Neck ...........................................................................32

Removal ........................................................................................... 32
Installation ........................................................................................ 32
Diagnosis and Testing ..................................................................33

Technical Specification .................................................................35
Special Tools ..................................................................................35

MAN-00162
Fuel charging system

The piezo common rail diesel injection system is a
pressure accumulator fuel injection system in which
production of pressure and fuel injection are decou-
pled.
The fuel injection system is a pressure storage
injection system. This means that the fuel pressure
is continuously available at the injectors in this
system.
The system consists of a high-pressure system with
a common rail diesel pump, a fuel rail (fuel injection
supply manifold) with the High pressure fuel lines,
piezo electrically controlled fuel injectors, low-
pressure system with the fuel supply, return lines,
and pressure regulating valve. The fuel filter unit
includes fuel filter, water in fuel sensor, fuel
temperature sensor and fuel priming unit.
Generation of pressure and fuel injection are
performed separately on the common rail diesel
fuel injection system. Because of this, the increase
of injection pressure is largely independent of
engine speed and injection quantity.
The HPP supplies fuel through the high pressure
pipes into the common rail and to the injectors, and
raises the injection pressure.
Injection timing and quantity are calculated by the
EMS Electronic Control Unit (EMS ECU). Using
various input variables, the EMS ECU controls the
piezoelectrically operated injectors, which inject the
required quantity of fuel into the combustion
chamber.
The fuel pressure sensor on the common rail
provides rail pressure information to the EMS ECU.
Excess fuel passes through the fuel return pipe to
the fuel tank.
In the fuel tank, a venturi pump ensures that the
returned fuel fills the fuel supply unit in the tank.

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CRDE Schematic
High pressure pump HFR - Hot Forged Rail
CP1H with Gear Rail Pressure Sensor
pump RDS
Inj. 1 Inj. 2 Inj. 3

Inj. 4
Metering unit Check valve

MPROP
Sensors
Actuators
Fuel filter with hander

primer and Integrated
water seperator, water
level sensor and Fuel Accelerator
heater optional Pedal
Crank Shaft
Injector
Control unit CRI 2.2
EDC 17
Cam Shaft
Tank with prefilter

MAN-00162
K
J
A
B
L
H
G I
C
S
N M
D
R
O P
F
E Q
A. Fuel Filler Neck K. Fuel Priming Pump

B. Filler Pipe Locking Cap L. Overflow Hose
C. Fuel Filler Pipe M. Fuel Injector
D. Fuel Tank Ventilator Pipe N. Fuel Injection Lines
E. Fuel Tank O. Fuel line (HPP to Fuel rail)
F. Fuel Delivery Module Secondary P. Fuel Rail
G. Fuel Delivery Module Primary Q. High Pressure Pump (HPP)
H. Fuel Suction Line R. Fuel Rail Pressure Sensor
I. Fuel Return Line S. Fuel line (Fuel Filter to HPP)
J. Fuel Filter

MAN-00162
Service Tips and Precautions • If engine does not start check the respective
uses related to common rail components.
Before attempting any service on fuel system,
following precautions should be always followed for • When Injectors are replaced/Changed Injector
personal safety and to avoid system damages. IQA values must be loaded correctly as per
cylinder order. For additional information
• Disconnect negative cable at battery. refer to EMS diagnostic manual.
• Do not smoke, and place 'NO SMOKING" sign
near work area make sure to have fire
extinguisher handy.
• Make sure to perform work in well ventilated 2209
area and away from any open fire/flames. 939
• Wear Safety glasses
• Small amount of fuel may drip after the fuel 22
93
9
09
0VV
51
18
lines are disconnected. In order to reduce the 00
5110 260
260
7P0V718
risk of personal injury, cover the pipe/ hose
V 7
ends with suitable plugs with no rust or
contamination. 7P0
• After servicing, make sure that the fuel hoses
and clamps are properly connected.
• After servicing, check for fuel leakages at fuel • Plug the port of Common rail system
hose joints. components whenever any pipe connections
are removed.
DANGER • Tighten the mounting nuts / cap nuts etc. only
to the specified torque values.
• Keep open flames and sparks away from the
• Carefully install the removed parts in the
work area. Failure to follow these instructions
correct order. If work is interrupted, the
will result in personal injury.
removed parts must be covered with a nylon or
• Before working on the fuel system, switch off paper cloth.
the engine, wait for two minutes. This will • Fuel lines should not be twisted or stressed
allow the static current in the injector to dis- and the bending radii of fuel lines and high
charge. Failure to follow this instruction may pressure lines should not be altered at any
lead to serious personal injury. circumstances.
• Avoid repairing the fuel injection system • Replace high pressure lines if they are loose.
while the engine is running. The fuel pressure This may lead to leaks at fuel line union
within the system is very high. Failure to fol- connectors.
low this instruction will result in personal
injury. Don’ts
• Eye protection and a mask must be worn at • Do not leave open inlets and outlets of
all times while working near any fuel related Common rail components- Cap them
components. Failure to follow this instruction immediately.
will result in personal injury. • Flushing of common rail components should be
avoided.
Do’s • Do not remove battery, sensor & Actuator
• Drain water from sedimenter / filter at regular connections when ignition key is ON.
intervals. • Do not spray water on the ECU.
• EMS W/H to be properly routed as specified • Sensor connections should not be removed
using clamps / clips and brackets. unnecessarily.
• Do check for any faults /malfunctioning in the • HP pipe lines should not be bent and force
system using diagnostics tool before cranking should not be applied.
the engine (after any repair).

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• Failed or broken common rail components In Car Repairs

should not be used, leakage may cause
malfunction.
High Pressure Pump (HPP)
• Don't let ECU body touch any metallic part
while the ECU is powered ON (Ignition key
switched "ON").
F A
• Don't keep any sensor branch hanging /loose
while assembly. Fix them properly using clips B
provided in W/H.
• Don't try to crank the engine without E
connecting any of the sensors.
C
• Don't remove any sensor /injector connector
once fitted and locked properly.
• Do not run the vehicle with 'OBD' lamp ON.
• Do not bleed the air by removing or loosening
the HP pipes. D
• Do not start the vehicle if battery voltage is
low. A. Pump Outlet to Rail
• The ECU gets tripped if the battery voltage is B. Pump Overflow
below 6 volts. Replace / Recharge the battery
C. Gear Feed Pump
and then start the engine.
• Do not clean the Injectors with pressurized D. Pump Inlet
water. The injector is not designed to be E. Drive Shaft
washed with pressurized water.
F. Metering Unit
• Do not clean the HP pipes with compressed
air, oil or water. Cleaning may dirt HP pipes The fuel pump unit has a feed pump and a HPP.
and Common rail system. The feed pump is a gear type pump which sucks
the fuel from the tank and feeds the HPP i.e. radial
• Do not use any failed/ broken water
piston pump. High pressure is generated by the
Sedimenter /fuel filters, even if there's no
radial piston pump having three pistons located at
external sign of damage.
120 degree intervals. The three cylinders are
arranged radially in which the plungers reciprocate
and increase the fuel pressure to the required level.
The high pressure pump maximum pressure is
1600 bar and the maximum pump speed is 3000
rpm. The flow into the pump is controlled by an
electrical solenoid valve called metering unit. This
valve is located at the inlet of the pump. This
meters and controls the amount of fuel that is
sucked into the pump in accordance with desired
pressure to be maintained at the rail. The metering
unit is an integral part of the HPP and is not
serviceable.
Removal
For additional informtion refer to Battery
2. Remove the High pressure pump (HPP). For
additional informtion refer to High Pressure
Pump (HPP) removal and installation
section.

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Fuel Line - Fuel Filter to HPP 4. Press the lock and disconnect other ends of
the fuel suction line (A) connected to the fuel
filter assembly.
Removal
1. Remove the negative terminal of the battery. 5. Unhook the fuel line clips (B) and remove the
For additional informtion refer to Battery fuel suction line (A) connected in the engine
removal and installation section. compartment.
2. Remove the intercooler. For additional inform-
tion refer to Intercooler removal and installa-
tion section.
DANGER
Keep open flames and sparks away from the
B
3. Press the lock (white color) and remove the
fuel suction line (A) connected to the HPP.
A
Installation
Notice
Fix the fuel lines properly, to avoid fuel leak.

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Fuel Line from HPP towards Tank 4. Press the lock and disconnect other ends of
the fuel return line (A), Unhook the fuel line
clips (B) and remove the fuel return line (C)
connected in the engine compartment.
Removal C
For additional informtion refer to Battery Installation
removal and installation section..
tion refer to Intercooler removal and installa- Notice
tion section.
Fix the fuel lines properly, to avoid fuel leak.
DANGER
3. Press the lock (white color) and remove the

fuel return line (A) connected to the HPP.

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Fuel Priming Procedure Fuel Filter

1. Remove the outlet hose (A), bleed the air in
the fuel system by pressing the feed pump (B).
Notice
Feed the pump into the fuel filter till rigid
condition. Connect the outlet hose to the fuel
filter.
A
B
The fuel filter filters the fuel of small impurities that

may be present in the fuel. The fuel system
operates under high pressure which makes it
absolutely essential for the fuel to be dust free and
moisture free. The fuel filter also has the water
separator which filters the moisture that may have
crept into the fuel. The high pressure line in the
fuel system operates at high speeds and fine
clearance which needs the diesel to be dust free
and also be free of moisture at the same time.
Since the diesel itself lubricates the HPP, moisture
content may lead to formation of rust on the pump
elements. This makes it advisable not to use diesel
with additives which may cause damage to the
HPP.
Removal

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2. Release the lock (A) and pull out the fuel 4. Unlock and pull out the electrical connector (A)
temperature sensor electrical connector (B). from the water sedimentor.
A
B
5. Loosen the 12mm fuel filter mounting bolt (A)

CAUTION and detach the fuel filter assembly.
Before removing the fuel filter open the fuel

tank cap to release the pressure from the tank
and fuel lines. A
DANGER
Do not smoke or carry lighted tobacco or open
flame of any type when working on or near any
fuel related components. Highly flammable
mixtures are always present and can ignite.
Failure to follow these instructions may result
in personal injury.
6. Remove the water sediment sensor (A) by
3. Press the lock and pull out the inlet (A) and rotating anticlockwise from the fuel filter (B).
outlet hoses (B) of the fuel filter.
B
B

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7. Using a fuel filter wrench, separately remove

the fuel filter from the fuel filter assembly.
Water Drain from Fuel Filter
Installation Removal
2. Bleed the air in the fuel system. For additional DANGER
informtion refer to Fuel Priming Procedure
section. Keep open flames and sparks away from the
1. Unlock and pull out the electrical connector (A)

from the water sediment sensor.
2. Loosen the water sediment sensor (A) by

rotating anticlockwise to drain the water.
Installation
Notice
Do not overtighten the sediment sensor, over-
tightening will lead to damage of O-ring and
sensor.

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Water Sediment Sensor 2. Remove the water sediment sensor (A) by

rotating anticlockwise.
It measures the water percentage in fuel and gives

indication on the instrument cluster. The water
Installation
collected to be drained when the indicator glows in 1. To install, reverse the removal procedure.
Instrument cluster.
Notice
Removal
Do not overtighten the sediment sensor, over-
tightening will lead to damage of O-ring and
DANGER sensor.

1. Unlock and pull out the electrical connector (A)

from the water sediment sensor.

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Fuel Temperature Sensor 3. Loosen the 17mm nut fuel temperature sensor
(A) and remove the fuel temperature sensor
(B) from the fuel filter assembly.
B
Removal
1. Remove the negative terminal of the battery. Installation
For additional informtion refer to Battery 1. To install, reverse the removal procedure.
2. Release the lock (A) and pull out the fuel Notice
temperature sensor electrical connector (B)
from the fuel filter assembly. Feed the pump into the fuel filter till rigid
condition. Connect the outlet hose to the fuel
filter.
DANGER
in personal injury.

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Fuel Injector 2. Slide the lock towards right side, press and pull
out the electrical connectors (A) of the fuel
injectors.
The top (fuel entry) end of the fuel injector is

attached to an opening on the fuel rail. The injector 3. Pull out the injector over flow fuel line clip (A)
uses piezo electric actuation for precise control of and remove the injector over flow fuel hose (B)
injection. When electric current is passed through a from the fuel injectors.
stack of electrodes, the stack is compressed.This
Compression of electrodes is used to open the
passage for high pressure fuel leading to fuel
injection. Piezo electric actuation is very fast so the B
injections can be very precisely controlled.
The piezo injectors can inject very small quantities A
of fuel. This reduces noise while having the
advantage of lesser particulate emissions.
Removal
informtion refer to Intercooler removal and
DANGER
in personal injury.
Notice
Clean the injector areas before removing the
injectors. To avoid dust entry into the cylinder
head.

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4. Loosen the 17mm (A) and 14mm (B) lock nuts Installation
and remove fuel supply lines from the fuel injec- 1. To install, reverse the removal procedure.
tors.
CAUTION
While installing the fuel injector, the injector
B washers should be changed to avoid fuel
rail pressure variation. And clean the
injectors while installation.
5. Remove four 12mm lock nuts (A) with washer

from the mounting bracket (B) of the fuel
injector and detach the mounting bracket.
6. Using the injector removal tool (A) (Special

Tool Part No:0305BAM0001ST), remove the
fuel injector (B) from the cylinder head.

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Fuel line (HPP to Fuel rail) Fuel Rail

Removal
1. Disconnect the battery negative cable. For
additional informtion refer to Battery

tion section.
DANGER
A. Rail Pressure Sensor
3. Loosen the 17mm (A) HPP outlet pipe lock nut
The common fuel rail is a high pressure
from the fuel rail.
accumulator in which the fuel from HPP is
accumulated and is maintained at required
pressure.
Removal
1. Disconnect the battery negative cable.For
additional informtion refer to Battery
tion section.
3. Press the lock and pull out the rail pressure
A sensor connector (A) from the fuel rail.

and remove the outlet pipe from the HPP.
4. Remove the glow plug wiring harness. For

additional informtion refer to Glow Plug
Wiring Harness removal and installation
section.
Installation 5. Remove the fuel supply lines from the fuel rail.
1. To install, reverse the removal procedure. For additional informtion refer to Fuel
Injector removal and installation section.

MAN-00162
6. Loosen the 17mm (A) HPP outlet pipe lock nut Installation
from the fuel rail. 1. To install, reverse the removal procedure.
DANGER
work area for safety. Clean the spilled fuel.Fail-
ure to follow these instructions will result in
personal injury.

in the HPP.
8. Remove the two 12mm mounting bolts (A) on

the fuel rail and detach the fuel rail.
A A

MAN-00162
Fuel Rail Pressure Sensor Installation

DANGER
work area for safety. Clean the spilled fuel near
the fuel rail pressure sensor. Failure to follow
these instructions will result in personal injury.
This pressure sensor is fitted on the fuel rail and

gives a close loop control of the rail pressure. Fuel
is maintained at a high pressure in the fuel rail
depending on requirement of the engine.
Removal
1. Disconnect the battery negative cable. For addi-
tional informtion refer to Battery removal and
tion section.
3. Press the lock and pull out the rail pressure
sensor connector (A) from the fuel rail.
4. Loosen the 24mm fuel rail sensor lock nut and

remove the sensor from the fuel rail.

MAN-00162
Fuel Tank Fuel Tank Filling
I A
H
B
G Common: 10 Litres
C
Secondary Side: 28 Litres
D Primary Side: 32 Litres
F E
During filling, fuel gets filled first in the primary side,
A. Nut plastic FDM
overflows to the secondary. During draining, fuel
B. Fuel delivery module primary gets drained first in the secondary then in the
C. Gasket FDM primary.
D. Fuel Tank Guaging of Fuel Tank
E. Assembly heat shield fuel tank Cluster
F. Screw heat shield

L2 L1
L1+L2
G. Fuel delivery module secondary
H. Fuel lines on tank
R2 R1
I. Wiring harness fuel guage

MAN-00162
Working of Fuel Tank

Return Line Fuel
Fuel Flowing
Through Restricted
Opening
Return Line fuel from the engine enters the chamber as shown where two restricted openings are provided to
create suction pressure. One opening helps in suction pressure causes fuel to suck from secondary to
primary side. The other opening helps in creating suction from primary to primary side when the fuel falls
below the reservoir level.
Return Line Fuel

MAN-00162
Working of Fuel Tank - Transfer of Fuel from Secondary Side to Primary Side
Return Line
Fuel
Secondary Side FDM Fuel Flowing

into the
Reservoir
Return Line
Fuel
Suction of Fuel From

Secondary Side
Low Fuel Condition - Fuel Suction Safety Valve on FDM

from Primary to Primary side
Fuel Flowing
into the
Reservoir
Return Line Fuel
The safety valve is provided to releive excess

pressure across the fuel line.

MAN-00162
Pressure Relief Valve 7. Press the lock (A) and pull out the electrical
connector (B) from the fuel tank.
Pressure Relief Valve
B
When the pressure across the fuel line is higher,
the relief valve opens and allows the fuel to go 8. Press the green locks (A) and pull out the fuel
through valve and store in the reservoir. suction pipe and fuel return pipe (B) from the
fuel tank.
Removal
Notice
Notice
Use the container to avoid spilling of diesel
Check the fuel level in the instrument cluster from the fuel lines.
to avoid spilling of diesel from the fuel lines.

2. Remove the muffler and tail pipe assembly. For
A
additional informtion refer to Muffler removal
and installation section. For additional
informtion refer to Exhaust Intermediate Pipe
3. Remove the propeller shaft (Only AWD B
vehicle). For additional informtion refer to
Propeller Shaft removal and installation
section.
4. Remove the parking cable. For additional
informtion refer to Parking Brake Cable -
Front removal and installation section.
DANGER
Notice
Drain and store the fuel. work area for safety. Failure to follow these
instructions will result in personal injury.
5. Remove the fuel delivery module primary. For
additional informtion refer to Fuel Priming
Procedure removal and installation section.
6. Remove the fuel delivery module secondary.
For additional informtion refer to Fuel
Delivery Module (FDM) Secondary removal

MAN-00162
9. Loosen the fuel filler pipe mounting clip (A) and 11. Loosen two 13mm bolts (A) on the fuel tank
detach the fuel filler pipe from the fuel tank. mounting straps at front end and detach the
fuel tank from the vehicle.
Notice
A A
from the fuel lines.
12. Remove the seven fuel tank heat shield

screws and detach heat shield (A) from the
fuel tank.
10. Press the red color lock (A) and detach the
fuel tank vent pipe. A
Notice
Support the fuel tank with the suitable
hydraulic jack to avoid spilling of diesel from
the fuel tank.

MAN-00162
Installation Fuel Delivery Module (FDM) Pri-

Notice mary
Using a suitable hydraulic jack to install the
fuel tank.
Notice
To avoid the damage of fuel tank electrical
wirings and fuel lines fouling.make sure all are
properly routed, before installing the fuel tank.
Notice
Connect the nut plastic FDM to the fuel tank as
per the torque specification.
Removal
1. To install, reverse the removal procedure. 1. Remove the fuel tank. For additional
informtion refer to Fuel Tank removal and
CAUTION
At the end of the strap assembly, connect
the wiring harness fuel gauge of fuel tank DANGER
with the Wiring routing on underbody.
work area for safety. Failure to follow these
instructions will result in personal injury.

connector (A) of the primary fuel sender unit.

MAN-00162
3. Press the lock and pull out the fuel suction (A) 6. Detach the fuel delivery module primary unit
and return hoses (B) from the fuel delivery and release the lock (A) and pull out the hose.
primary module.
A A
B
7. Press the fuel gauge lock (A) and remove the

4. Using the FDM CAP tool (A) (Special Tool Part fuel gauge assembly attached with the fuel
No:1001AAA0001ST), loosen the fuel delivery delivery module primary unit.
module primary unit mounting nut plastic FDM
from the fuel tank.
5. Pull out the fuel delivery module primary unit

with the gasket FDM (A) from the fuel tank.

MAN-00162
8. Using soldering iron, disconnect the wires (A) Fuel Delivery Module (FDM) Sec-
from the fuel sender unit.
ondary
CAUTION
While using the soldering iron, the fuel
delivery module primary unit is must be dry
condition. Highly flammable mixtures are
always present and can ignite. Failure to
follow these instructions result in personal
injury.
Removal
1. Remove the fuel tank. For additional
informtion refer to Fuel Tank removal and
2. Remove the fuel delivery module primary. For
additional informtion refer to Fuel Delivery
Module (FDM) Primary removal and
Installation
connectors (A) of the primary and secondary
fuel delivery module.
CAUTION
Appropriately fix the gasket FDM with the
fuel delivery module primary unit to avoid
fuel leakage and malfunction.
A
CAUTION
While soldering the fuel delivery module
primary unit, make sure the unit is
completely dry. Highly flammable mixtures
are always present and can ignite. Failure to
follow these instructions result in personal
injury.
Notice
Connect the nut plastic FDM to the fuel tank as
per the torque specification.

MAN-00162
4. Using the FDM CAP tool (A) (Special Tool Part 6. Using soldering iron, disconnect the wires (A),
No:1001AAA0001ST), loosen the fuel delivery press the fuel gauge lock (B) and remove the
module secondary unit mounting nut plastic fuel gauge from the fuel delivery module.
FDM from the fuel tank.
CAUTION
While using the soldering iron, the fuel
delivery module secondary unit is must be
dry condition. Fuel in the sender unit cause
of human personal injury.
5. Pull out the fuel delivery module secondary

unit with the gasket FDM (A) from the fuel
tank. B
A
Installation
CAUTION
Appropriately fix the gasket FDM with the
fuel delivery module secondary unit to avoid
fuel leakage and malfunction.
CAUTION
While soldering the fuel delivery module
secondary unit, make sure the unit is
completely dry. Fuel in the sender unit
cause of human personal injury.

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Fuel Return Line 3. Press the lock and disconnect the fuel return
line (A) from the engine compartment.
B A
C A
A. Fuel lines on engine 4. Unhook the fuel return line from the clips (A) in
B. Bracket fuel line clamp the under chassis and remove the fuel return
C. Clip fuel Line 2 way line (B) separately.
D. Clip fuel line 5 way
Removal
2. Press the lock (A) and disconnect ends of the
fuel return line (B) connected to the fuel tank.
A
Notice
from the fuel lines. B
Installation
B
CAUTION
Ensure that fuel return lines are securely
locked.
A

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Fuel Suction Line 3. Press the lock and disconnect other ends of
the fuel suction line (A) connected to the fuel
primary pump.
Removal
1. Remove the negative terminal of the battery. 4. Unhook the fuel suction line from the clips (A)
For additional informtion refer to Battery in the under chassis and remove the fuel
removal and installation section. suction line (B) separately.
2. Press the lock (A) and disconnect ends of the
fuel suction line (B) connected to the fuel tank.
Notice
from the fuel lines.
B
A
Installation
A
CAUTION
Ensure that fuel suction and return hoses
are securely locked.

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Fuel Filler Pipe Assembly

A
I
B J
H
C
N
E
G M
A. Gasket Filler Neck H. Pipe Ventilator Fuel Tank

B. Assembly Filler Neck I. Cap Locking Filler Pipe
C. Filler Pipe J. Nozzle Guide
D. Clamp Filler Pipe K. Assembly Filler Neck
E. Worm Clamp L. Gasket Filler Pipe
F. Heat Shield Hose Fuel Filter M. Filler Pipe
G. Hose Fuel Filter N. Cap Locking Filler Pipe

MAN-00162
Removal 5. Loosen the filler pipe locking cap (A) and

1. Remove the negative terminal of the battery. remove the fuel filler pipe (B) separately from
For additional informtion refer to Battery the fuel filler neck.
Notice
2. Remove the rear LHS wheel arch.For
additional informtion refer to Rear Wheel Fuel filler pipe and fuel filler neck are fixed
Arch removal and installation section. with 'o' ring.
3. Loosen the fuel filler pipe mounting clip (A) and
detach the fuel filler pipe from the fuel tank.
6. Loosen two 10mm mounting bolt (A) and nut

4. Press the lock (A) and detach the fuel tank (B) of the fuel filler pipe.
ventilator pipe from the fuel tank.
B
A
Notice
Drain and store the fuel.

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7. Unclip the two filler pipe clamps (A) from the Fuel Tank Ventilator Pipe
fuel filler pipe and remove fuel filler pipe
separately.
Removal
Installation 1. Remove the negative terminal of the battery.
1. To install, reverse the removal procedure. For additional informtion refer to Battery
removal and installation section.n.
Notice 2. Remove the fuel filler pipe. For additional
informtion refer to Fuel Priming Procedure
To avoid spilling of diesel from the fuel lines, section.
check the fuel lines and clips are fixed
properly. 3. Remove the fuel tank ventilator pipe (A) from
the fuel filler neck.
Installation
Notice
To avoid spilling of diesel from the fuel lines,
check the fuel lines and clips are fixed
properly.

MAN-00162
Fuel Filler Neck 5. Remove the two fuel filler neck mounting
screws (A) and separately remove the fuel filler
neck.
A
A. Nozzle Guide
Removal Installation
1. Remove the negative terminal of the battery. 1. To install, reverse the removal procedure.
2. Remove the fuel filler pipe. For additional
informtion refer to Fuel Filler Pipe
Assembly removal and installation section.
3. Remove the fuel tank ventilator pipe. For addi-
tional informtion refer to Fuel Tank Ventilator
Pipe removal and installation section.
4. Remove the fuel filler cap (A) by rotating
anticlockwise.

MAN-00162

Engine will not start and 1. Clogged fuel filter/ fuel lines. 1. Change fuel filter and
emit black smoke Check fuel supply line.
2. Defective injectors. 2. Refer Diagnostic Manual.
Noisy engine & black 1. Injector coking. 1. Clean external coking.

smoke. 2. Refer Diagnostic Manual.
2. Common rail system.
Engine speed falls off. 1. Clogged fuel filter/fuel lines. 1. Change fuel filter.
2. Check fuel supply line.

3. Refer Diagnostic Manual.
Engine does not give full 1. Clogged fuel filter/ fuel lines. 1. Change fuel filter.
power. 2. Check fuel supply line.
3. Replace filters.
4. Locate the kink/block in re-
turn pipe and rectify.
2. Defective injectors. 5. Refer Diagnostic Manual.
1. Defective injectors. 1. Check injectors.

Black smoke.
2. Common rail system. 2. Refer Diagnostic Manual.
1. Weak battery. 1. Check the battery specific

gravity.
2. Corroded or loose battery connection. 2. Clean and tighten battery
connections.
Engine will not start
3. Faulty starter. 3. Repair starter.
4. Common rail system. 4. Refer Diagnostic Manual.

MAN-00162

1. Check for Physical damage 1. Replace the High pressure

especially on the sprocket pump if any part found dam-
and union connectors. aged.
High Pressure Pump
2. Check high pressure pump 2. Replace high pressure pump
for any signs of fuel leakage. if any signs of leakage is
found.
1. Check for fuel rail physical 1. Replace the fuel rail assem-
damage. bly.
Fuel Rail
2. Check for malfunction of rail 2. Replace the defective part.
pressure sensor.
1. Check fuel lines for physical 1. Replace the fuel lines if dam-
damage. age is found.
Fuel Lines (High pressure side)
2. Check for leakage from the 2. Replace the lines if leakage is
lines. found.
1. Check lines for physical dam- 1. Replace the line if damage is

age especially crimping. found.
Fuel lines (Low pressure side)
2. Check for signs of leakage 2. Replace the line if required.
especially at joints.
1. Check for physical damage. 1. Replace injector if damage is

found.
2. Check for signs of leakage. 2. Replace the injector if leak-
Fuel Injectors
age is found.
3. Check for carbon deposition 3. Clean the tip and refix.
at the nozzle tip.
1. Check fuel filter for clogging. 1. Replace the fuel filter ele-
ment.
2. Check for physical damage 2. Replace the fuel filter assem-
on the filter body or connec- bly.
Fuel Filter
tors.
3. Check corroded terminals in 3. Clean the corroded part and
filter heater connectors and refix.
water sensors.
1. Check for physical damage. 1. Replace the fuel tank.

Fuel Tank 2. Check for dirt accumulation in 2. Clean the tank and replace
tank. the fuel.

MAN-00162
Component Description Specification
Type 3 Cyl. Radial plunger
Maximum Pressure 1600 Bar

HPP Pump
Component MPROP and Integral Gear Pump
Maximum Pump Speed 3000 RPM
Type CRI 2.2
Fuel Injector Maximum Pressure 1600 bar
IMA 7 digit
Type HFR (Hot Forged Rail)
Maximum Pressure 1600 Bar

Fuel Rail
Rail components RDS 4.2
Mounting Lugs 2
Special Tools
FDM CAP Removal and

1001AAA0001ST
Refit tool
0305BAM0001ST Injector Removal Tool

MAN-00162
Torque in
Nm
Bolt Hex. Headed

FL M10 x 1.5 x 30 x Fuel tank to underbody 4 45.0±5.0
8.8 ZN
SCREW PHCR
Filler pipe flange mounting 2 4.0±0.5
Fuel Tank and M6X1X16X8.8XBK
Filler Pipe
HOSE CLIP W M51 For filler hose mounting 2 6.0~8.0
Assembly
SCREW HEX FL
1
M6X1X15X8.8XGR
Filler pipe bracket. 10.0±2.0
NUT HEX FL
1
M6X1X6X8 GR
COPPER WASHER
4 NA
14
Fuel lines to fuel filter
Fuel Filter BANJO BOLT M14 2 25.0±2.5
Assembly
BOLT HEX FL
Fuel filter to fuel filter mounting
M8X1.25X30X8.8XZ 2 25.0±2.5
bracket
N
Bolt Hex. Headed

FL M8 X 1.25 X 10 X 1 12.0~15.0
8.8 ZN
Fuel lines Fuel line mounting bracket to engine
Bolt Hex. Headed
FL M6 X 1 X 12 X 1 10.0±2.0
8.8 ZN

MAN-00162
Repair Manual Emission Control System Nov 2011/ Rev 2
EMISSION CONTROL SYSTEM
CONTENTS
Exhaust Gas Recirculation (EGR) Description and Operation ....1
Component Location Index ............................................................2
Incar Repairs .................................................................................... 3
EGR Valve ....................................................................................3

Removal ............................................................................................. 3
Installation .......................................................................................... 4
EGR Cooler ...................................................................................4

Removal ............................................................................................. 4
Installation .......................................................................................... 5
EGR Short Pipe ............................................................................ 6

Removal ............................................................................................. 6
Installation .......................................................................................... 6
EGR Long pipe ............................................................................7

Removal ............................................................................................. 7
Installation .......................................................................................... 7
EGR Modulator .............................................................................7

Removal ............................................................................................. 7
Installation .......................................................................................... 8
EGR Modulator Vacuum Hoses ..................................................9

Removal ............................................................................................. 9
Installation ........................................................................................ 10
VGT Modulator ............................................................................11

Removal ........................................................................................... 11
Installation ........................................................................................ 12
VGT Modulator Vacuum Hoses .................................................12

Removal ........................................................................................... 12
Installation ........................................................................................ 13

MAN-00162
Vacuum Pump ............................................................................ 14

Removal ........................................................................................... 14
Installation ........................................................................................ 14
Vacuum Reservoir ..................................................................... 15

Removal ........................................................................................... 15
Installation ........................................................................................ 15
Diagnosis and Testing .................................................................. 16


MAN-00162
Emission Control System

Exhaust Gas Recirculation (EGR) Description and Operation
Brake ECU
Booster
Vacuum
NRV Reservoir
VGT
Modulator Vacuum EGR
pump Valve
Cooler
EGR
EGR
Manifold
Manifold
Exhaust
Intake
Modulator
VGT Engine
HFMS
Sensor
Air
Filter
Inter Cooler
Boost Pressure Sensor
During acceleration and in higher loads the engine The ECU monitors the air flow, coolant temperature,
generates high combustion temperatures. The high engine speed, and accelerator pedal position. Based
combustion temperatures increase the NOx on the above parameters the ECU operates a switch
generation. The higher percentage of NOx (pressure modulator VGT) that in turn controls the
generated in the combustion chamber come out amount of vacuum going to the EGR valve. The
through the tail pipe in the atmosphere thereby amount of vacuum applied controls the lift of the
increasing air pollution. EGR valve.
To reduce the amount of NOx coming through the tail EGR cooler is provided in order to further reduce the
pipe, the EGR system adds exhaust gases into the recalculating exhaust gas temperature. This results
fresh air that is going into the combustion chamber. in the reduction in the amount of NOX.
Since the exhaust, gas is already burnt hence when
During cold starts, till the glow plug remains "ON",
mixed with fresh air acts an inert gas. The role it does
the EGR system does not function thus avoiding any
is that it reduces the amount of oxygen available for
hunting or vibration during initial start conditions.
combustion. The net effect is that it reduces the peak
combustion temperatures. This results in lower
amount of NOx being generated.
To control the amount/percentage of exhaust gases
to be circulated back to the combustion chamber,
engine ECU is used.

MAN-00162
D
C
A
B
F
I
E
G J
A. Turbocharger Assembly - VGT Type F. Clean Side Hose to EGR Modulator and VGT
B. VGT to VGT Modulator Hose (Green Colour) Modulator Hose (Yellow Colour)
C. Clean Side Hose G. VGT Modulator
D. Vacuum Reservoir H. EGR Modulator
E. EGR valve I. EGR valve to EGR Modulator Hose (Red

Colour)
J. Vacuum Reservoir to EGR Modulator and VGT
Modulator Hose (Blue Colour)

MAN-00162
Incar Repairs 3. Unlock the clip (A), and pull out the vacuum
hose (B) from the EGR valve.
EGR Valve
Vacuum Connection
Exhaust Gas
Outlet
Exhaust Gas 4. Using a 6mm allen key, remove the EGR valve
Inlet
short pipe mounting bolts (A) from the EGR
The EGR valve is a vacuum controlled valve which valve side.
recirculates a specific amount of exhaust gas back
into the intake manifold, to prevent the formation of
nitrogen related gases.
The EGR valve is a diaphragm valve that is actuated
by vacuum from the Vacuum pump through Pressure
modulator VGT. The valve is fitted to EGR cooler
which is mounted on the inlet manifold. It has three
connections, one for the vacuum, and one for the
exhaust gas inlet from the exhaust manifold and one
for the exhaust gas outlet to the inlet manifold. The
valve opens to allow the Exhaust gas to re-circulate
to the intake manifold. A
WARNING 5. Using a 6mm allen key, remove the two

Do not open the EGR when it is hot. Failure to mounting bolts (A) from the EGR cooler which
follow this instruction will result in personal is mounted on the EGR valve.
injury.
Removal
1. Remove the NVH cover. For additional
information refer to NVH Cover removal
A
and installation section
2. Remove the air filter housing. For additional
6. Separately remove the EGR valve.

MAN-00162
Installation EGR Cooler

Notice
Inspect the EGR gaskets condition. Replace
if damaged.
The EGR cooler is an air-to-liquid heat exchanger

which reduces the temperature of the exhaust
gases before circulating to the EGR. The EGR
cooler has metal tubes that are surrounded by
coolant for cooling the exhaust gases passing
through the metal tubes.
Removal
removal and installation section
WARNING
Do not open the EGR cooler when it is hot.
Failure to follow this instruction will result in
personal injury.
3. Unlock the clip (A) and pull out the outlet

vacuum hose (B) from the EGR valve.

MAN-00162
4. Unlock the clip (A), and pull out the EGR 7. Using a 6mm allen key, remove the two
cooler inlet coolant hose (B). mounting bolts (A) from the EGR cooler and
the two mounting bolts (B) from the inlet
manifold, and separately remove the EGR pipe
(C).
B B
A
A C
5. Unlock the clip (A), and pull out the EGR

cooler outlet coolant hose (B).
B 8. Remove the two 12mm EGR cooler mounting

bolts (A) from the cylinder head, and
A separately remove the EGR cooler.
6. Using a 6mm allen key, remove the two

mounting bolts (A) from the EGR cooler which
is mounted on the EGR valve.
Installation
Notice
A
Check the maximum level of the coolant, and
top up the coolant in the coolant reservoir to
the maximum level.

MAN-00162
EGR Short Pipe 3. Using a 6mm allen key, remove the two EGR
short pipe mounting bolts (A) from the exhaust
manifold side.
EGR short pipe is connected between Exhaust

manifold to EGR valve. Through this pipe the hot 4. Using a 6mm allen key, remove the two EGR
exhaust gases are routed to EGR cooler. short pipe mounting bolts (A) from the EGR
side.
Removal
2. Remove the air cleaner clean side hose. For
additional information refer to Air Cleaner
Outlet Hose - Clean Side removal and
WARNING
Do not open the EGR short pipe when it is hot. A
personal injury.
5. Remove the EGR short pipe from the engine.
Installation
Notice
Inspect the EGR short pipe gaskets
condition. Replace if damaged.

MAN-00162
EGR Long pipe EGR Modulator

To Vacuum Pump
To EGR Valve To Air filtter
To ECU
EGR long pipe is connected between EGR cooler EGR modulator is an electro pneumatic solenoid
to intake manifold. Through this pipe the cold switch, which is controlled more precisely by the
exhaust gases are routed to intake manifold and EMS ECU based on the Engine speed, Coolant
mixes with fresh air. Temperature and Accelerator pedal position etc.
Removal Notice
information refer to NVH Cover removal Care should be taken to connect the ports of
and installation section. the EGR modulator to their respective hoses.
Any interchanging of the connections will
2. Using a 6mm allen key, remove the two
lead to malfunctioning of the EGR system.
mounting bolts (A) from the EGR cooler and
the two mounting bolts (B) from the inlet
manifold, and separately remove the EGR long Removal
pipe (C). 1. Disconnect the battery negative terminal. For
removal and installation section
B information refer to Air Filter Housing
3. Press the lock, and disconnect the EGR
A modulator block colour electrical connector (A).
C
Installation
Notice
Inspect the EGR long pipe gaskets condition,
Replace if damaged. A

MAN-00162
4. Unlock the clip (A), and pull out the vacuum 7. Remove the two 10mm EGR Modulator
hose (B), which is marked in blue colour, from mounting bolts (A).
the vacuum reservoir.
B
A
8. Separately remove the EGR modulator.

5. Unlock the clip (A), and pull out the vacuum
hose (B), which is marked in yellow colour, Installation
from the EGR modulator. 1. To install, reverse the removal procedure.
Notice
Check the EGR system for proper operation
B
after installation.
6. Unlock the clip (A), and pull out the vacuum

hose (B), which is marked in red colour, from
the EGR modulator.

MAN-00162
EGR Modulator Vacuum Hoses 4. Unlock the clip (A), and disconnect a vacuum
hose (B) which is marked in blue colour, from
Removal the vacuum reservoir.
2. Unlock the clip (A) and disconnect a vacuum
the VGT Modulator.
B B
A
5. Separately remove the blue colour vacuum

hose.
hose inlet (B) which is marked in yellow colour,
from the VGT Modulator.
3. Unlock the clip (A), and disconnect a vacuum

the EGR modulator.
B
B
A

MAN-00162
7. Unlock the clip (A), and pull out the inlet 10.Unlock the clip (A), and pull out the outlet
vacuum hose (B), which is marked in yellow vacuum hose (B) which is marked in red colour,
colour, from the EGR modulator. from the EGR modulator.
B
B
8. Unlock the clip (A) and disconnect a vacuum 11.Unlock the clip (A), and pull out the outlet
hose (B) which is marked in yellow colour, from vacuum hose (B) which is marked in red
the air cleaner outlet hose. colour, from the EGR.
B
B
9. Separately remove the yellow colour vacuum 12. Separately remove the red colour vacuum
hose. hose.
Installation
Notice
Check the EGR system for proper operation
after installation.

MAN-00162
VGT Modulator 4. Unlock the clip (A) and disconnect a vacuum

the vacuum reservoir.
To Vacuum Pump
To EGR Valve To Air filtter

B
To ECU
VGT Modulator is an electro pneumatic solenoid

switch, which is controlled more precisely by the 5. Unlock the clip (A) and disconnect a vacuum
EMS ECU based on the Engine speed, Coolant hose inlet (B) which is marked in yellow colour,
Temperature and Accelerator pedal position etc. from the VGT Modulator.
Removal
Notice
Care should be taken to connect the ports of
the VGT modulator to their respective hoses.
Any interchanging of the connections will
B
lead to malfunctioning of the EGR system.
1. Disconnect the negative terminal of the battery. A

3. Press the lock and disconnect the white colour hose (B) which is marked in green colour,
electrical connector (A) from the VGT coming from the VGT to VGT modulator.
modulator.

MAN-00162
7. Loosen two 10mm mounting bolts (A) on the VGT Modulator Vacuum Hoses
vacuum modulator (B) and remove the VGT
Modulator. Removal
A hose (B) which is marked in blue colour, from
B the vacuum reservoir.
Installation
Notice
A
Check the VGT system for proper operation
after installation.
3. Unlock the clip (A), and pull out the inlet
vacuum hose (B), which is marked in yellow
colour, from the EGR modulator.

MAN-00162
4. Unlock the clip (A) and disconnect a vacuum 8. Unlock the clip (A) and disconnect a vacuum
hose inlet (B) which is marked in yellow colour, hose (B) which is marked in green colour, from
from the VGT Modulator. the VGT Modulator.
B
A
5. Unlock the clip (A) and disconnect a vacuum 9. Separately remove the green colour hose.
hose (B) which is marked in yellow colour, from
the air cleaner outlet hose. Installation
A Notice
Check the VGT system for proper operation
after installation.
6. Separately remove the yellow colour hose.

7. Unlock the clip (A) and disconnect the vacuum
hose outlet (B) which is marked in green colour
from the VGT.

MAN-00162
Vacuum Pump 5. Remove the three 13mm vacuum pump

mounting bolts (A), and detach the vacuum
pump from the engine.
Vacuum Pump supplies vacuum to brake booster

and EGR systems. This unit is driven by the exhaust
cam shaft. Installation
Removal
1. Remove the fuel filter assembly. For additional
information refer to Fuel Filter removal and
3. Remove the EGR cooler.For additional
information refer to EGR Cooler removal and
4. Unlock the clip (A), and detach the vacuum
hose (B) from the vacuum pump.
Notice
B When installing the vacuum pump into the
engine, align the vacuum pump blade to
A match the engine groove at proper position.

MAN-00162
Vacuum Reservoir 4. Unlock the clip (A), and detach the vacuum
hose (B) which connects the modulators to
vacuum reservoir.
Vacuum Pump supplies vacuum to brake booster

and EGR systems. This unit is driven by the exhaust 5. Remove the 13mm vacuum reservoir mounting
cam shaft. bolts (A) and nut (B), and detach the vacuum
Removal reservoir from the fire wall.
1. Remove the fuel filter assembly. For additional
A
2. Remove the air cleaner clean side hose. For B
additional information refer to Air Cleaner
Outlet Hose - Clean Side removal and
3. Unlock the clip (A), and detach the vacuum
hose (B) which connects the vacuum pump to
vacuum reservoir.
A
B
Installation
Notice
Before installing the vacuum reservoir
inspect the reservoir for leaks or damage.

MAN-00162

Engine growling noise 1. Exhaust manifold is 1. Replace the exhaust manifold.

cracked or broken.
2. EGR pipe Leakages. 2. Replace the gasket. Tighten the

mounting bolts to specified
torque.
1. Leaks at pipe joints. 1. Tighten the nuts to specific

torque.
2. Broken or rusted exhaust 2. Replace the exhaust pipe.
pipe.
Noisy exhaust and leaking exhaust 3. The exhaust pipe leaking 3. Tighten/replace the flange mount-
gases at the manifold flange. ing nuts/bolts.
4. Leakage between the ex- 4. Replace the gasket. Tighten the

haust manifold and cylin- nuts between the exhaust mani-
der head. fold and cylinder head.
Engine power lose 1. Gas leakage between 1. Change the gasket or the hose.
EGR pipe joints.
2. EGR pipe leakage. 2. Change the EGR pipe.
3. Improper functioning of 3. Check the EGR valve.
the EGR valve.
4. Vacuum hose crack, 4. Ensure proper connection of vac-
loose, fallen off. uum hose at the vacuum modula-
tor, reservoir, and alternator.
Check for cracks and replace the
vacuum hose if necessary.

1. Check for physical damage. 1. Replace the tail pipe and muf-
Tail Pipe and muffler
fler.
EGR valve 1. Check for physical damage. 1. Replace the EGR valve.

MAN-00162
Repair Manual Exhaust System Nov 2011/ Rev 2
EXHAUST SYSTEM
CONTENTS
Service Tips and Precautions ........................................................ 3
Incar Repairs ...................................................................................4
Turbocharger ................................................................................4
Removal ............................................................................................. 4
Installation .......................................................................................... 5
Exhaust Manifold.......................................................................... 6
Removal ............................................................................................. 6
Installation .......................................................................................... 7
Catalytic Converter ......................................................................8

Removal ............................................................................................. 8
Installation .......................................................................................... 9
Exhaust Intermediate Pipe .......................................................... 9

Removal ............................................................................................. 9
Installation ........................................................................................ 10
Muffler ........................................................................................10
Removal ........................................................................................... 10
Installation ........................................................................................ 11


MAN-00162
Exhaust System
The exhaust system consists of a closed coupled
catalytic converter, twin mufflers connected by
exhaust pipes. The exhaust pipes are supported
using rubber hangers.
The catalytic converter is provided to reduce the
exhaust emission, whereas the silencers are
provided to dampen the sound of the exhaust
gases coming out of the engine.
Variable Geometry turbocharger (VGT)

The VGT has a set of movable vanes in the turbine
housing, and they control the boost. At low engine
speeds when exhaust flow is low, the vanes are
partially closed. This increases the pressure of the
exhaust gases pushing against the turbine blades,
making the turbine spin faster and generating more
boost. As engine speed increases, so does the
exhaust flow, so the vanes are opened to reduce
turbine pressure and hold boost steady or reduce it
as needed. By reading the manifold pressure
sensor, the ECU can adjust turbine inlet pressure
(by varying the Geometry of Vanes) instantaneously
to control the boost at any speed/ load and to limit
boost at full load.
Advantages / Features
• Good low end torque
• Good transient response
• Good fuel economy
• Increased useful engine operating range
• It provides more matching level of pressure
boost even to a slow spinning turbine without
providing too much of a boost at higher speed
• VGT is electronically controlled and
pneumatically actuated
• Low engine noise
• Lower emission

MAN-00162
C
E
A. Turbocharger D. Exhaust Intermediate Pipe

B. Exhaust Manifold E. Muffler
C. Catalytic Converter

MAN-00162
Service Tips and Precautions
WARNING CAUTION
To avoid the danger of being burned, do not touch • Ensure exhaust system and catalytic
exhaust system when the system is hot. Any ser- converter is not blocked and is free from
vice on the exhaust system should be performed obstruction.
when the system is cool.
• Blockages in the exhaust can create back
pressure, low top speed, poor pick up, black
At every interval of periodic maintenance service
smoke, carbon build up and low mileage.
and when vehicle is raised for other service, check
exhaust system as follows: • Check and ensure EGR Valve & control
• Check rubber mountings for damage, system is clean and functioning properly
deterioration or out of position.
• Keep sufficient clearance between exhaust
system component and underbody.
• Check exhaust system for leakage, loose
CAUTION
connection, dent & damage. If bolts or nuts are The Catalytic converter should not be
loosened, tighten them to the specified torque. dropped from a height. If dropped, it should
not be used.
• Check nearby body areas for damage, missing
or mis-positioned part, open seam, hole, loose
Precautions for VGT
connection or any other defect which could
permit exhaust fumes to seep into vehicle. • Avoid Lifting the turbocharger by holding the
VGT actuator.
Precautions For Catalytic Converter
• Avoid Lifting turbocharger holding the rod end.
In the event of following symptoms, drive the • Avoid Lifting turbocharger holding the
vehicle at slow speed without rapid acceleration. compressor side.
• Engine misfires or runs irregularly, following a • Hold the turbocharger at the turbine housing /
cold start. center housing.
• A significant loss of power is noticed. • No foreign particles (dust/dirt) should enter the
• In case OBD lamp remains ON even after vacuum line.
engine has been started. • If the turbocharger is dropped, then it should
be inspected. If it is damaged, it should not be
used.
WARNING
Parking Warning
Avoid parking of vehicle over inflammable
materials, such as dry leaves; grass etc. as
exhaust system is hot enough to initiate fire.

MAN-00162
Incar Repairs 4. Uncilp a turbocharger vacuum hose clip (A)

and remove the vacuum hose (B) from the
turbocharger.
Turbocharger
5. Loosen the air cleaner outlet hose clamp (A)

Removal and remove the outlet hose (B) from the turbo
charger.
1. Remove the intercooler assembly. For addi-
tional informati on refer to Interc ooler
information refer to Air Filter Housing A
B
WARNING
Do not open the Turbocharger when it is hot.
personal injury.
3. Remove a two 12mm heat shield mounting bolt

(A) from top of the turbocharger.
6. Remove a 12mm heat shield mounting bolt (A)
from bottom of the turbocharger.

MAN-00162
7. Remove a 14mm banjo bolt (A) from the

turbocharger oil inlet pipe and remove the pipe
from the turbocharger.
10. Remove a 12mm mounting bolt (A) and 13mm

two mounting nuts (B) from the exhaust
manifold.
8. Remove three 12mm catalytic converter
mounting bolts (A) from the turbocharger and
detach the catalytic converter.
A A
11. Remove the turbocharger from the exhaust

manifold.
9. Remove two 10mm oil outlet pipe mounting Installation

bolts (A) from the turbocharger, and detach the 1. To install, reverse the removal procedure.
oil outlet pipe (B).
Notice
Replace the turbocharger banjo bolt washer
CAUTION with new one. Tighten the banjo bolt as per
Care should be taken oil will drop when specification.
removing the oil outlet pipe.
Notice
The oil outlet pipe 'O' ring must be replace
once the oil outlet pipe removed. Care
should be taken while installing the 'O' ring.

MAN-00162
2. While installing, fix the turbocharger gasket in

catalytic converter side, in such a manner that a
Exhaust Manifold
groove in the gasket facing upward direction.
The exhaust manifold is attached to the cylinder

head to combine the exhaust gases from each
Notice cylinder into one pipe.
Check the turbocharger gasket condition Removal
before installing, replace if damaged. 1. Remove the catalytic converter. For additional
WARNING
Do not open the Exhaust system when it is
hot. Failure to follow this instruction will result
in personal injury.
2. Remove the two 12mm heat sealed mounting

bolts (A) from top of the exhaust manifold and
detach the heat shield.

MAN-00162
3. Using a 6mm allen key, remove the two EGR

pipe mounting bolts (A) from the exhaust Notice
manifold. Tighten the exhaust manifold nuts as per
specification. Over tighten will lead to
damage the manifold stud and nuts.
4. Remove the turbocharger. For additional

information refer to Turbocharger removal
5. Remove the eight 13mm exhaust manifold
mounting nuts (A) from the cylinder head.
6. Remove the exhaust manifold and the exhaust

manifold gasket from the cylinder head.
Installation
Notice
Install the exhaust manifold gasket properly
to avoid noise from the exhaust system.
Check the gasket condition before installing.
Replace if necessary.

MAN-00162
Catalytic Converter 3. Remove the 12mm heat shield mounting bolt

(A) from the bottom of the turbocharger and
remove the heat shield.
The catalytic converter is mounted between the

exhaust manifold and the muffler. It converts 4. Remove the three 12mm catalytic converter
harmful carbon monoxide and hydrocarbons into mounting bolts (A) from the turbocharger.
water vapor and carbon dioxide. It also reduces
harmful nitrogen oxides.
Removal
1. Remove the intercooler. For additional infor-
A
WARNING
in personal injury.
2. Remove the two 12mm heat shield mounting

bolts (A) from the top of the turbocharger. 5. Remove the two insulators (A) from the
catalytic converter bracket.

MAN-00162
6. Remove the two 15mm flange mounting nuts

(A) which is connecting the catalytic converter
Exhaust Intermediate Pipe
and exhaust pipe.
The Exhaust intermediate pipe is mounted between

7. Remove the two 12mm mounting bolts (A) the catalytic converter and the muffler. It carries the
from the catalytic converter bracket. exhaust gas out from the catalytic converter.
WARNING
in personal injury.
Removal
1. Remove the Exhaust intermediate pipe
insulator (A).
8. Remove the catalytic converter with gasket

from the vehicle.
Installation
A
Notice
Install the catalytic converter gasket properly
to avoid noise from the exhaust system.
Check the gasket condition before installing.
Replace if necessary. 2. Remove the flange mounting nuts from the
catalytic converter side. For additional
3. Remove the flange mounting nuts from the
muffler. For additional information refer to
Muffler removal and installation section.
4. Separately remove the Exhaust intermediate
pipe.

MAN-00162
Installation Muffler
Notice
Install the gaskets properly both sides of the
Exhaust intermediate pipe to avoid noise
from the exhaust system. Check the gasket
condition before installing. Replace if
necessary.
The main function of the muffler is to reduce the

amount of noise emitted by the engine exhaust
gases flow. It typically makes use of the change in
the cross sectional area which can be made as a
chamber to filter or reduce the sound waves which
the engine produces.
The muffler is typically installed along the exhaust
pipe as part of the exhaust system of the engine. It
has a resonating chamber, which is specifically
designed such that opposite sound waves collide to
cancel each other out.
WARNING
in personal injury.
Removal
1. Remove the two 15mm flange mounting nuts
(A) which is connecting the Exhaust
intermediate pipe and muffler.

MAN-00162
2. Remove the insulators (A) from both sides of Installation

the mufflers. 1. To install, reverse the removal procedure.
Notice
A
Install the muffler insulators properly to
avoid rattling noise. Check the insulators
condition before installing. Replace if
necessary.
3. Remove the two insulators (A) from the RHS

muffler.
4. Remove the two insulators (A) from the LHS

muffler.
5. Remove the muffler assembly separately.

6. Loosen the two 10mm mounting bolts and
detach the heat shield from the muffler.

MAN-00162

Engine is underpowered 1. Boost pressure pipe/hose 1. Check the pipe and washer, and
assembly is damaged. rectify it if necessary.
2. Turbocharger or vacuum 2. Replace the Turbocharger or vac-

modulator is damaged. uum modulator if required.
3. For additional diagnosis refer

to Diagnostic Manual
1. Air leakage at the turbo- 1. Locate the leaks, change the

charger intercooler inlet hose or clamp if required.
and outlet connections.
Blue smoke
2. Turbocharger oil return 2. Locate the blockage or damage in
tube is blocked or dam- the oil return tube, and replace
aged. the tube if necessary.
1. Restrictions in the turbo- 1. Remove the restriction from the

charger oil drain pipe. drain pipe.
2. Turbocharger is dam- 2. Replace the Turbocharger.

aged.
Excessive oil consumption 3. Air leakage in the intake 3. Locate the leaks, change the
system. hose, gasket or clamp if neces-
sary.
4. Usage of non recom- 4. Change the oil and filter and use
mended oil. recommended oil only.
1. Leaks at pipe joints. 1. Tighten the nuts to specific

torque.
2. Rusted or blown out muf- 2. Replace the muffler.
fler.
3. Broken or rusted exhaust 3. Replace the exhaust pipe.
Noisy exhaust and leaking exhaust pipe.
gases 4. The exhaust pipe leaking 4. Tighten/replace the flange mount-
at the manifold flange. ing nuts.
5. Leakage between the
exhaust manifold and cyl- 5. Replace the gasket. Tighten the
inder head. nuts between the exhaust mani-
fold and cylinder head.

MAN-00162

1. Check for physical damage. 1. Replace the turbocharger.

2. Check for carbon deposition 2. Clean and check operation on
and dirt accumulation in all the vehicle.
openings.
3. Check the pneumatic linkages 3. Replace the turbocharger.
Turbocharger for damages and/or bend.
4. Check all vacuum lines for 4. Replace the lines if required.
blockage, deterioration, dam-
ages.
5. Check the impeller and turbine 5. Replace the turbocharger.
blades for damages.
1. Check for physical damage. 1. Replace the modulator.

Vacuum Modulator 2. Check for operation. 2. Perform the vacuum test and
replace if required.
Exhaust Intermediate Pipe and 1. Check for physical damage. 1. Replace the Exhaust interme-
muffler diate pipe and muffler.

MAN-00162
Bolt Torque in
Specification Nm
SCREW HEX FL
M8X1.25X20X8.8 Front pipe bracket mounting 2
XZN
SCREW HEX FL
M8X1.25X20X8.8 Flange at turbo charger end 2
XZN
20.0~30.0
NUT HEX FL -
M8X1.25X8X8XZ Flange at turbo charger end 1
N
SCREW HEX FL
Front pipe bracket mounting on engine
Exhaust M8X1.25X20X8.8 2
block
XZN
NUT HEX FL
Inlet pipe flange mounting to frront
M10X1.5X12X8 2
pipe
ZN 45.0±5.0
NUT HEX FL
M10X1.5X12X8 Muffler mounting to inlet pipe 2
ZN
SCREW HEX FL
M6X1X12X8.8XG Heat Shield to Steering gear 2 8.0~12.0
R

MAN-00162
Repair Manual Ignition System Nov 2011/ Rev 2
IGNITION SYSTEM
CONTENTS
Incar Repair ......................................................................................2
Glow Plug Wiring Harness ..........................................................2

Removal ............................................................................................. 2
Installation .......................................................................................... 2
Glow Plug ......................................................................................3

Removal ............................................................................................. 3
Installation .......................................................................................... 3
Troubleshooting Chart ....................................................................4

Component Inspection and Action Table ........................................... 4
Torque Specification .......................................................................4

MAN-00162
Repair Manual Ignition System Oct 2011/ Rev 1
Ignition System
Description and Operation Service Tips and Precautions
The ignition system consists of one glow plug per
combustion chamber, a glow indicator light and cor-
responding electrical connections. DANGER
Glow plug is a pencil-shaped piece of metal with a Never attempt to work on ignition system, If
heating element at the tip, heats due to electrical the engine temperature is too high. When the
resistance and begins to emit light in the visible spec- instruction is not followed, it leads to personal
trum. injury.
The heat generated by the glow plugs is directed into
the cylinders and serves to warm the engine block • Wear safety hand gloves while working on
immediately surrounding the cylinders. This aids in ignition system.
reducing the amount of thermal diffusion which will
occur when the engine attempts to start.
DANGER
The glow plugs are controlled by the EMS ECU The Before working on the ignition system, switch
ECU decides the actuation of the glow plugs based OFF the engine, and remove the key from the
on operating conditions, engine temperature and ignition switch.
environment temperature.
• Always switch OFF the ignition system before
connecting or disconnecting the ignition system
wiring or tester cables.
• Always switch OFF the ignition before
connecting or disconnecting the battery,
otherwise the engine control unit may be
damaged.
• Keep the unplugged electrical connectors clean
and dry. Make sure connections are dry while
connecting the ignition system.

MAN-00162
Incar Repair 3. Detach the fuel suction and return hoses (A)
from the mounting bracket clips (B).
Glow Plug Wiring Harness
B
A
4. Unclip the glow plug wiring harness from the

inlet manifold (A) and disconnect the glow plug
connectors (B) from the glow plugs.
Removal
2. Release the lock and detach the electrical
connectors (A) of the glow plug wiring harness.
A
A
5. Detach the glow plug wiring harness from the

glow plugs.
Installation
Notice
Properly install the glow plug wiring harness
into the glow plugs before starting the engine.

MAN-00162
Glow Plug
1. Remove the glow plug wiring harness. For
additional informtion refer to Glow Plug
Wiring Harness removal and installation
section.
2. Using a 8mm deep socket, remove the glow
plugs (A) from the cylinder head.
CAUTION
Do not remove the glow plug when engine
is hot condition.Faliure to follow this cause
of personal injury .
The purpose of the glow is to make quickly

available hot surface, where the air fuel mixture
vaporizes and ignite during the compression stroke.
Glow plug will support the engine run up during the
engine start. It also helps to improve the idle A
running and to reduce the emission of blue smoke,
pollutants and smoke after the engine starting.
Removal
CAUTION
Do not smoke or carry lighted tobacco/open
flame while working near any fuel related
components. The fuel may ignite and cause Installation
personal injury.
CAUTION
Tighten the glow plug to specific torque.
CAUTION Over tightening of glow plug will damage
Always follow fuel handling precautions to the glow plug.
avoid personal injury.
CAUTION
Special care should be taken for the heating
portion of the glow plug while removal or
installation and storing.
CAUTION
When there is visible damage or if the
resistance of the glow plug is out of
specification, do not reuse the glow plug.

MAN-00162
1. One or more glow plugs 1. Check the glow plugs and take
are faulty. corrective action.
2. Glow plugs not installed 2. Check the glow plug for prop-
properly or coupler loose er installation & inspect the
to glow plugs. coupler to the glow plug for
loose contact / damaged.
Engine has poor starting up character- 3. Glow plug wiring har- 3. Check via Diagnostic tool for
istics ( idling not stable or poor emis- ness has a short or open faults and take corrective ac-
sions). circuit. tion.
4. EMS-ECU is faulty. 4. Check via Diagnostic tool for

faults and take corrective ac-
tion.
5. Battery weak, does not 5. Check the battery, charge if

supply enough power. required and recheck. Take
corrective action if necessary.

1. Check for physical damage. 1. Replace the glow plug.

2. Check for dust or dirt accu- 2. Clean the terminals.
mulation on terminals.
Glow Plug 3. Check resistance of the glow 3. The Glow plug resistance val-
plug. ue is below 5 ohms, the glow
plug is OK. Replace glow
plug, if the Glow plug resis-
tance value is above 5 ohms.
1. Check for dust or dirt accu- 1. Clean the terminals and pins.
mulation on terminals and
Glow plug wires and modules. pins.
2. Check for physical damage 2. Replace the wiring harness.
like wear, breakage etc.
Description Bolt Size Torque in Nm
Glow Plug M8 X1 10-12

MAN - 00162
Repair Manual Starting System Nov 2011/ Rev 2
STARTING SYSTEM
CONTENTS

Starting System .................................................................................. 1
Start/Stop system............................................................................... 2
Introduction ........................................................................................ 2
Schematic View ............................................................................... 5

Starting System ................................................................................. 5
Immobilizer ......................................................................................... 6
Incar Repairs ....................................................................................7
Starter Motor .................................................................................7

Removal ............................................................................................. 7
Inspection ........................................................................................... 7
Installation .......................................................................................... 7
Diagnosis and Testing..................................................................... 8

Inspection and Verification ................................................................. 8
Troubleshooting Chart ........................................................................ 9
Technical Specification .................................................................12
Torque Specification .................................................................... 12

MAN - 00162
Starting System
Starting System
• The Starting System enables the cranking of
the engine when the authorized key is turned
to START position.
• The Starting System includes a starter motor
and starter solenoid that is attached to the
starter motor. The starter motor requires very
high current to crank the engine and is
connected to the battery with high tension
cables. The negative (ground) cable connects
the "-" battery terminal to the starter motor. The
positive cable connects the "+" battery terminal
to the T30 terminal of the Starter Motor.
The solenoid switch works as an electric switch
which when actuated, closes the circuit and
connects the starter motor to the battery. At the
same time, it pushes the pinion gear of the
starter motor forward to mesh with the Ring
Gear.
Starting System components
1. Battery
2. Starter Motor
3. Starter Relay
4. Mahindra Body Function Module (MBFM)
5. Immobilizer
6. Ignition Switch.
7. Transponder Key
Notice
For cranking the vehicle:
• The original vehicle keys should be used.
• Battery voltage should have the nominal
recommended voltage.
• The wiring harness should be securely con-
nected.

MAN - 00162
Start/Stop system
Introduction
• When a vehicle is stationary and engine is idling particularly at traffic signals/traffic jams, considerable
amount of fuel is consumed and emission(CO2) is caused
• If the engine is stopped during idling, we can save fuel and reduce emission.
Engine is shut
Stop at Switch to Release Cluster
down
red light neutral clutch pedal indication - ON
automatically
Switch into
To drive ... pedal Engine restarts Cluster
1st gear
on ... clutch immediately indication - OFF
and drive on
How does the Start / Stop System work?

Let's take a simple example of driving in traffic
conditions within the city. Assume that your vehicle
has stopped at a traffic junction due to red signal.
The following steps illustrate how the system
functions.
1. Vehicle has come to a halt due to traffic signal /
To activate the Start / Stop System, ensure the switch
jam. The vehicle is in neutral gear and the clutch
located in the center of the instrument panel is in
pedal is fully released.
pressed condition.
2. Immediately after releasing the clutch pedal fully,
the indicator in the cluster will blink, indicating
that the engine is going to stop shortly. Engine
will automatically shut down in 2 seconds after
releasing the clutch pedal fully.
3. Once the engine stops, the indicator will
PASSENGER START
illuminate continuously in your instrument cluster @
STOP
indicating the engine was stopped by the Start /
Stop System. ESP
OFF
4. Once the traffic signal turns green, pressing the
clutch pedal will start the engine.
5. Indicator in the cluster goes OFF indicating that
the engine has started again and you are ready
to drive on.

MAN - 00162
For auto stop to happen the following conditions 4. How to activate / deactivate the system?
are to be met:
1. Start / Stop System is activated using the
selection switch
2. Bonnet is fully closed
3. In the current ignition cycle, the vehicle has
crossed approx. 2 kmph at least once PASSENGER START
@
STOP
4. Current status of the engine is idling.
5. Accelerator pedal and clutch pedal are fully ESP
OFF
released
6. Engine is warm enough. This is an extra
precaution to ensure safe working of the engine
For auto start to happen the following conditions
are to be met:
1. Vehicle should have been stopped by the Start / The system can be turned ON or OFF using the Start
Stop System / Stop activation switch.
2. Gear lever is in neutral position
5. Whether AC will function, if the engine is
3. Vehicle speed is zero turned OFF?
4. Start / stop activation switch is in ON state
No, AC will not work during the period when the
Driver presses clutch pedal fully to restart the engine engine is in auto stop. However blower fan will be in
/ vehicle. operation when ignition is ON.
1. What is the advantage of the system? 6. What will happen if I keep the clutch continu-
Start / Stop System aids in attaining better fuel ously pressed at traffic signals/jams?
efficiency on your vehicle and thus reducing your The system will not stop the engine if the clutch is
running costs. However, the mileage improvement continuously pressed since it indicates the driver's
will depend upon various parameters such as intention of moving the vehicle immediately.
prevailing traffic, driving pattern etc.
7. Whether will I be able to operate the engine
2. What are the other advantages of the system? through the normal ignition key?
a. Since the engine is turned OFF during traffic Normal operation through ignition key is always
signals / jams, considerable amount of carbon possible.
dioxide release to the atmosphere is avoided.
This reduces global warming and thus provides 8. Whether the vehicle will start (or) stop in gear?
us with a sustainable planet to live in The vehicle will not start or stop automatically in gear
b. Ability to restart the engine by pressing the to ensure safety. It will do so only in neutral position
clutch pedal of gear shift lever before driving.
c. Reduces noise pollution at traffic signals 9. What will be the effect of frequent number of
starts on battery and starter motor?
3. Is it possible to start the engine through clutch
pedal for the first time? Specially designed starter motor and battery are
used to withstand the increased number of starts.
No, the engine could be cranked only through
ignition key for the first time. If the engine is stopped
automatically by the system, then only it is possible
to start the engine through clutch pedal.

MAN - 00162
10. Whether the system will stop my engine in

moving traffic?
No, the engine will be stopped only when the vehicle
speed is zero continuously for two seconds.
11. Whether audio will be turned OFF, when the
engine gets shut down?
No, audio will not be turned OFF and you can
continue to enjoy the music.
12. If any component involved in the system fails,
what will happen?
Most of the component system has built in diagnostic
module which understands the failure and
immediately goes to by-pass mode. In by-pass mode
the engine can be turned ON and OFF by ignition
key as usual.
13. Are there any indications to show that engine
does not stop due to poor battery charge state?
Yes, if all other conditions except battery charge are
met, start/stop lamp will blink little faster for 7.5
seconds and the engine will not stop.

MAN - 00162
Schematic View
Starting System
EMS-ECU
Ignition Switch Transponder Ring MBFM
Starter relay
Battery Starter motor

MAN - 00162
Immobilizer Service Tips and Precautions

The immobilizer is a vehicle safety system which
The following points must be adhered to when
immobilizes the vehicle when a wrong key is
starting the engine
inserted into the ignition even if the access into the
vehicle is gained. The Immobilizer ECU which is • Check that the battery cables are connected to
integrated in the MBFM prevents the vehicle from the correct terminals.
being started unless it recognizes signals from a • Ensure that all electrical connections to the
right ignition key. starter are secure.
Elements involved in the system • Turn or crank the ignition switch and
1. Transponder based keys. immediately release after the engine is started.
2. Active Transponder Ring • If the engine does not start, wait for 30
seconds before trying again otherwise battery
3. EMS ECU may drain or starter motor may damage.
4. Immobilizer ECU Integrated in MBFM
The transponder ring is fitted in the ignition socket,
when the ignition key inserted in the key cylinder,
CAUTION
the ignition key transponder which is configured Do not operate the starter when the engine is
with Mahindra specific codes will send a Radio
running, this may cause serious damage to the
Frequency (RF) signal to transponder ring. The
transponder ring securely communicates the code Starter Pinion and the Ring Gear teeth.
to the immobilizer ECU integrated in the MBFM.If
the code matches with the code programmed in the
vehicle, then it process the key information and
communicates the correct coded key status to EMS
CAUTION
ECU through CAN. Never disconnect the battery while the engine
is running.
CAUTION
Do not operate the starter with a low charged
battery.
Maintenance
• Ensure that the starter motor mounting bolts to
the engine are securely fastened.
• Check the battery terminals for corrosion and
presence of acids, then clean the terminals
with water.
• Cables should be examined for damage,
particularly where the strands enter the
Terminal Lugs.
• Inspect the fixing brackets for any cracks.
CAUTION
Do not operate the starter if the vehicle is sub-
merged or flooded. Failure to follow this
instruction may cause damage to the engine.

MAN - 00162
Incar Repairs 3. Remove the three 13mm starter motor

mounting bolts (A) and detach the starter motor
assembly from the engine.
Starter Motor
Inspection
Removal 1. Inspect the terminal clamps of the battery cable
1. Disconnect the negative terminal of the battery. for damage. Replace any battery cable if the ter-
For additional informtion refer to Battery minal clamp is damaged or deformed.
2. Inspect the electrical connector of the starter
2. Loosen a 12mm mounting nut (A) and a 10mm
motor for any breakage or damage. Replace the
mounting nut (B) from the starter motor and
remove the starter motor electrical connections. electrical connector if any damage occurs.
Installation
A
B

MAN - 00162

Inspection is carried out visually for obvious signs
of electrical damages in the following components.
• Check the battery condition and battery
terminals.
• Check whether the fuse is blown.
• Check the electrical wiring harness for
looseness.
• Check the starter motor connection for
looseness.
• Inspect the continuity in the starter motor relay.
• Check the starter motor drive gears.
• Check the wiring harness and connectors in
the starter circuit. Physical damage due to
breaking of wires or short circuits.
Battery test
Testing as well as successful operations
require a fully charged battery capable of
supplying current to the Starting System.
Wiring and Switches
Visually inspect all wires and switches in the
Starting Circuit for damages, loose or corroded
connections. This includes all ground
connections. Clean and tighten connections if
required. Replace the damaged wiring and
components if required.

MAN - 00162
1. Faulty battery. 1. Recharge the battery.
2. Battery terminals are 2. Clean the internal surface of

corroded. the connecting lugs and bat-
tery terminal posts.
3. Starter supply is bro- 3. Check the battery earth strap.

ken or in poor state. Check cable connection at the
starter motor and battery. Re-
The starter motor does not operate
place the battery if neces-
when the ignition is cranked
sary. Change the solenoid
switch or rectify the circuit.
4. Starter motor is short 4. Remove and replace the start-

circuited. er motor.
5. Wrong key is inserted. 5. Check the key and use the rec-
ommended key only.
1. Starter motor drive as- 1. Replace the starter motor

sembly meshes with drive assembly.
the gear but does not
drive.
2. Starter motor drive 2. Ensure proper connection of
Starter motor rotates at high/low speed assembly does not the solenoid and the shift le-
mesh with the ring ver.
but does not crank the engine.
gear.
3. Brushes are jammed. 3. Change all brushes.

4. Brushes are worn out. 4. Ensure free movement of the
brushes.
1. High electrical resis- 1. Inspect the internal wiring

tance caused by poor electrical connections and ar-
Starter motor rotates in low speed with
connections, defective mature commutator.
normal or low current leads or dirty commuta-
tor.
1. Poor function of the 1. Replace the solenoid switch.

Starter motor cranks the engine normally, solenoid switch.
and the cranking of the engine continues 2. Short circuit in the wir- 2. Check and replace the wiring
ing harness. harness.
though the solenoid switch is released
(ignition back to ON position) 3. Solenoid shunt wind- 3. Replace the defective sole-
ing is open. noid switch.

MAN - 00162

1. Check the Terminal clamps 1. If the terminal is damaged,

(+ve) for damage / corrosion. then replace the starter mo-
tor.
2. Check the electrical connec- 2. If the electrical connection of
Starter motor
tion to the starter motor for the starter motor is dam-
damage / corrosion. aged, then replace the start-
er motor.
3. Check for external damages 3. If external damage is noticed
to the starter motor. on the body / housing of the
starter motor, then replace
the starter motor.
4. Check if the starter motor for 4. If there are signs of burnt
burning smell. smell of the wiring/ armature
from the starter motor, then
replace the starter motor.
1. Check the starter relay for 1. If the starter relay fails to op-
operation. erate, then replace it.
Starter relay
2. Check the starter relay termi- 2. If the terminals are damaged
nals for damage. then replace the starter motor
3. Check the starter motor relay 3. Clean the terminals with a
terminals for corrosion. suitable agent and check the
operation of the starter relay.
If the relay fails to function,
then replace it
4. Check the seating area of the 4. If there is corrosion on the
starter motor relay for corro- seating area of the starter re-
sion. lay, then clean the area with
a suitable agent and check
the operation of the starter
relay
1. Check for damages /splice/ 1. If damages are found on the

Starter high tension cables brittleness. high tension cable / wire,
then replace the cable.
2. Check for corrosion at the 2. Clean the starter high ten-
contact point. sion cable terminal with a
suitable agent.

MAN - 00162
Remote key (Mechanical key 1. Check for damages to the 1. If there are damages noticed
only) mechanical key track. to the track of the key, then
replace the key
2. Check the ease of key(s) in- 2. If the key is hard to remove /
sertion & removal into the ig- install, then inspect the igni-
nition switch. tion switch first for debris. if
not, use the second key and
check again. If the same
problem is notice, then re-
place the ignition switch as-
sembly
3. Check the ease of operation 3. If it is difficult to insert / re-
of key(s) on the door handle move the key(s) from the
key barrel. door key barrel, then inspect
the barrel for damages
1. Check the ignition switch for 1. Use the key and check if the
operation. ignition switch operates
smoothly (key easily inserted
& removed).
2. Check the ignition switch Ter-
2. If the terminals of the ignition
minals for damage.
switch are found to be dam-
aged / loose, then replace the
ignition switch
3. Check the electrical connec-
3. If any damages are notice to
tor to the ignition switch for
the electrical connector /pins /
damage / burnt.
wiring itself to the ignition
switch, then replace the wir-
Ignition switch with the active ing harness to the ignition
transponder ring switch
4. Check the terminals for corro- 4. Clean the terminals with a
sion. suitable agent
5. Check the transponder ring 5. If any damages are found on
for external damages. the active transponder, then
the ignition switch needs to
be replaced
6. Check if the transponder ring 6. If the mounting brackets /
is mounted properly onto the lugs are broken of the active
ignition switch. transponder, then replace the
ignition switch

MAN - 00162
Starter motor 12V, 2.2KW
Torque in
Nm
M8x1.25 flange nut Battery terminal cable connection

1 14±1
13AF onto starter solenoid output
Starter Motor M5x0.8 flange nut
8AF (Lucas) Engine WH connection to
1 6±0.5
M6x1 flange nut starter solenoid terminal
8AF (Bosch)
NUT HEX
FLANGE NYLOC Alternator B+ line input to BEC 1 75±0.5
BEC M5x0.8x7.3
NUT HEX FL
Battery B+ line input to BEC 1 6.5±0.5
M6X1X6X8 GR
SCREW HEX FL 1
7±0.5
M6X1X12X8.8XGR
BEC ( Mounting
onto Body) NUT HEX FL 2
7±0.5
M6X1X6X8 GR
M6 with special Connector tightening bolts integrated 4

7±0.5
tool used presently with BEC

MAN - 00162
Repair Manual Charging System Nov 2011/ Rev 2
CHARGING SYSTEM
CONTENTS

Do’s and Dont’s of Charging System ................................................. 3
Incar Repairs ....................................................................................4

Battery Testing ................................................................................... 4
Visual Inspection ................................................................................ 4
Checking Battery Condition ............................................................... 4
Battery Charge Indicator .................................................................... 5
State of Charge .................................................................................. 5
a.Specific Gravity ........................................................................... 5
b.Open circuit voltage ................................................................... 6
Factors Affecting Battery Life ............................................................. 6
How to handle the battery .................................................................. 7
Jump Starting ..................................................................................... 7
Battery .......................................................................................... 8
Removal ............................................................................................. 8
Inspection ........................................................................................... 8
Installation .......................................................................................... 8
Alternator ..................................................................................... 9
Removal ............................................................................................. 9
Installation ........................................................................................ 10
Battery Tray ................................................................................10

Removal ........................................................................................... 10
Installation ........................................................................................ 10

Troubleshooting Chart...................................................................... 12

MAN - 00162
Charging System
Description and Operation Service Tips and Precautions
The charging system consists of an alternator, regu- The following points must be adhered to while han-
lator and interconnecting wiring. dling the charging system and its components.
The charging system maintains charge in the vehi- • Swapping the battery connections even for a
cle's battery and provides main source of electrical short period can result in a non reversible dam-
energy while the engine is running. If the charging age or functional failure of the alternator and this
system stop working, the battery's charge would is strictly impermissible.
soon be depleted, leaving a "dead battery” in the • At any case, the alternator should be handled
vehicle. If the battery is weak and the alternator is not carefully. It should not be dropped or exposed to
working, the engine may not have enough electrical any shocks out of normal conditions. Even with
current to start the engine. little stress caused by hitting, an invisible pre-
damage can occur, which leads to malfunction.
An alternator consists of two main electrical compo-
nents and they are rotor and stator. The rotor is con- • The operation of the alternator is only permissi-
nected directly to the alternator pulley. The drive belt ble with an assembled regulator and with con-
drives the pulley, which in turn spins the rotor. The nected 12V battery.
stator is mounted to body of the alternator and The following points should be followed while charg-
remains stationary. There is just enough space in the ing the battery
center of the stator for the rotor to fit and be able to
spin without making any contact.
There is a group of electrical field coils mounted on CAUTION
the rotor. The stator is a group of stationary coils that Do not reverse the connections to the alterna-
line the perimeter of inner side of the alternator case. tor and never disconnect the output terminal
When current is flowing in the rotor's coils, they when the alternator is operating.
induce current flow in the stationary coils. The
induced current is an AC current. To convert this to
DC which is required for vehicle‘s electrical opera-
tions, the current passes through a bridge rectifier.
CAUTION
As long as the engine is running, all of the power for
Do not short across or ground any of the ter-
the accessories is delivered by the alternator. The
minals in the charging circuit, except as
only time that the battery would supply power with
directed by the instructions.
the engine running is when the current capacity of
the alternator is exceeded or when engine is at a
very low idle.
There is a system to warn the driver if any problem CAUTION
exists in the charging system through the warning
Use only approved terminal probe adapters to
indicator in the instrument cluster.
connect the meter leads and the jumper wires
with the connector terminals. Using improper
adapters may damage the terminals and the
charging system.
CAUTION
Batteries produce explosive gases which
may cause personal injury, do not allow
flames, sparks or lighted substances near the
battery.

MAN - 00162
CAUTION CAUTION
While charging or working near the battery • Add only distilled water to the battery. Do
always shield your face and protect your not add electrolyte
eyes. Failure to follow these instructions may
• Do not fill distilled water beyond the upper
result in personal injury.
mark level. Excessive electrolyte could squirt
out of the battery during heavy charging,
causing corrosion or damage.When washing,
ensure that the washing solution does not get
DANGER into the battery.
In case of acid contact with the skin or eyes,
flush immediately for minimum of 15 minutes
and seek prompt medical attention. If the sul-
furic acid is swallowed accidentally, immedi- WARNING
ately make a call for the physician. Failure to
• Do not expose the battery to flames or
follow these instructions will result in personal
electrical sparks. Hydrogen gas generated by
injury.
battery action is explosive. Do not allow
battery fluid to contact your skin, eyes,
Maintenance fabrics, or painted surfaces. After touching a
• Ensure correct electrolyte level in the battery. battery or battery cap, do not touch or rub your
• Check the general conditions of the battery. eyes. Thoroughly wash your hands. If the acid
contacts your eyes, skin or clothing,
• Cables should be examined for cuts, particularly immediately flush with water for at least 15
where the strands enter the terminal lugs. minutes and seek medical attention. Battery
• Ensure that battery ventilation slots are clear. terminals and related accessories contain
• Keep the alternator clean. lead.
• Check and ensure the mounting bolts are torque • Never disconnect the battery when the
tightened. engine is running.
• Ensure that belt of alternator is in good condi-
tion.
CAUTION
CAUTION Do not rely on the alternator to recharge a
completely discharged battery.
• Be sure the engine and all accessories are
turned OFF before performing maintenance
• When washing, ensure that the washing
solution does not get into the battery CAUTION
• Do not remove the battery connection The battery with frozen electrolyte can
while engine is running. This may cause explode if it is used or charged. To prevent
d a m a g e t o E C U a n d t o o t h e r e l e c t ro n i c the battery from freezing, maintain full charge
equipments. in the battery.
• Always disconnect the negative terminal
c a b l e f i r s t f r o m t h e b a t t e r y. B u t w h e n
reconnecting, always connect positive cable
first.

MAN - 00162
Do’s and Dont’s of Charging System
Do’s
1. Ensure that all charging system electrical connections are clean and secure.
2. Ensure that no electrical connection in the circuit including the battery is open. Observe correct polarity
while connecting the battery to alternator i.e. connect negative to negative and positive to positive. Other-
wise the alternator will be damaged.
3. Disconnect all alternator terminals, while carrying out any form of welding on the vehicle.
4. Disconnect the battery earth cable before removing the alternator.
Dont’s
1. Do not flash the alternator output leads to check the working of the alternator.
2. Do not run the alternator with the disconnected battery, it might damage the electronic components.
3. Do not disconnect any lead of the alternator/regulator with the engine in running condition.
4. Do not disconnect the battery cables when the engine is running.
5. Never add acid to the battery.
6. Don't use unregulated high output battery chargers to charge batteries.
7. Don't disconnect battery cables while the engine is running.
8. Don't let a battery get hot to the touch and boil violently when charging.
9. Don't mix different size and types of batteries.
10.Don't add tap water as it may contain minerals that will contaminate the electrolyte.

MAN - 00162
Incar Repairs
Battery Testing A
Battery testing includes two basic procedures. + -
1. Visual inspection
2. State of charge
a. Specific gravity
b. Open circuit voltage
1.Visual Inspection A - vent plugs

Battery service should begin with thorough visual
inspection. This inspection may reveal simple and Once battery is reconnected, following needs
easily correctable problems. to be reset
1. Check for cracks in the battery case and broken 7. Clock
terminals which allows electrolyte leakage. 8. AM, FM (channels memory)
Replace the battery if necessary. 9. Audio adjustments (Bass, Treble, Balance etc.)
2. Check for any cracked or broken cables/connec-
If volume is too high it will automatically come to
tions, and replace the cables if necessary.
normal level.
3. Check for corrosion on terminals and dirt/acid on
the battery case top. Clean the terminals and the Checking Electrolyte Level
battery case top with mixture of water and bak- Check the electrolyte level and specific gravity at
ing soda. A battery wire brush tool can also be intervals of three months. Check all the six cells for
used to clear heavy corrosion on the terminals. proper electrolyte level. If the level is below the lower
4. Check for a loose battery hold down and tighten marker, add distilled water until the level reaches the
it if necessary. upper marker.
5. Check the electrolyte level by viewing through Adding Distilled Water

the translucent plastic case or removing the vent • Remove the vent plugs
caps and looking directly into the battery. • Add distilled water to all the cells that require the
6. Check for cloudy or discolored electrolyte fluid
caused by overcharging or vibration of the bat- • Secure the plugs properly
tery. This will cause high self discharge. Correct
the cause or replace the battery if necessary.
Checking Battery Condition

Battery Exterior
Check the battery exterior for corroded / loose
terminal connections, cracks / loose hold down
clamp. If the battery terminal is corroded, wash it
with a solution of warm water and baking soda.
Prevent further corrosion by applying petroleum
jelly to the outside of the terminals.

MAN - 00162
Battery Charge Indicator 2.State of Charge

Amaron Battery The state of the battery charge can be easily
checked in two ways:
O
K
GE
/CALL AMA a.Specific Gravity
RECH Y
AR
R
RO
BATTE
NHELPLIN Hydrometer is a float-type device used to determine

the State-of-Charge by measuring the specific gravity
of the electrolyte in each cell. It is an accurate way of
E
determining a battery's State-of-Charge and weak or

dead cells.
Battery contains following two different charge indi- Specific gravity test procedure
cators:
1. Wear suitable eye protectors (goggles).
BATTERY OK 2. Remove the vent caps or covers from the bat-
tery.
RECHARGE / CALL AMARON 3. Squeeze the hydrometer bulb and insert the
HELPLINE
pickup tube into the cell close to the battery pos-
Exide Battery itive terminal.
4. Slowly release the bulb to draw in only enough
INDICATOR electrolyte to cause the float to rise. Do not
OK
NEEDS
remove the tube from the battery.
CHARGING
ADD
DISTILLED
5. Read the specific gravity indicated on the float.
WATER
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 cur-
Battery contains following three different charge indi- vature of liquid on the float.
cators:
6. Note the reading for all the cells. The difference
in specific gravity readings should not be more
OK (Battery condition is good)
than 0.05.
NEEDS Specific gravity readings
CHARGING • By measuring the specific gravity of the
electrolyte, you can identify whether the
ADD DISTILLED WATER battery is fully charged, requires charging,
or must be replaced. The battery must be
Notice atleast 75% charged to perform load test or
each cell must have a specific gravity of
Battery charge indicator gives the indication 1.230 or higher to proceed with the load
of the closest cell where it is located. The bat- test.
tery may be defective in case there is any
internal shorting of other cells which needs SUCTION
the attention of the Authorised battery dealer. BULB
FLOAT
HYDROMETER
OUTER TUBE
PICKUP ELECTROLYTE
TUBE

MAN - 00162
b.Open circuit voltage Factors Affecting Battery Life

1. Digital voltmeter checks the battery’s open cir- Overcharging
cuit voltage. Analog meters do not show accu-
• Any charging over and above the specified level
rate readings and should be avoided.
will result in overcharging. It severely corrodes
2. Turn ON the head lamp high beam for 30 sec- positive plate grids which weaken and finally dis-
onds to remove any surface charge. integrate. Overcharging decomposes electrolyte
3. Turn OFF the head lamp, disconnect the battery into hydrogen and oxygen which causes exces-
and connect the digital voltmeter across the bat- sive concentration of the electrolyte because of
tery terminals. loss of water from the mixture of the battery fluid.
This damages the plates and separators. High
4. Note the readings in the voltmeter. A fully
temperatures also show adverse effects on
charged battery will have an open-circuit voltage
plates, separators and container. Excessive gas-
of 12.6V. On the other hand, a totally dead bat-
sing creates the possibility of the active metal
tery will have an open-circuit voltage less than
blowing away from the plate surface and fine
11.0V.
acid spray escaping from the battery.
Notice Undercharging
If the battery voltage is higher than or equal to • Perpetual undercharging results in sulfation of
12.4V, proceed to heavy load test. If the battery plates and running down of cells. Sulfate depos-
voltage is less than 12.4V, the battery must be its are seen on the cell separators, which leak
fully recharged. Before testing be sure to com- through and create short circuits between posi-
pletely remove the surface charge. tive and negative plates. Undercharging also
leads to buckling of plates.
Idle battery
• When the battery is not used for a long time or if
left idle, self-discharge takes place and sulfation
12.4 is observed on battery terminals. Sulfation of the
Volt Meter
X10RPM OFF
battery reduces the life span of the battery.
VDC/AC
CAP
High Specific Gravity
Hz
20A
mA
• High specific gravity destroys positive and nega-
tive plates and also reduces life of the battery.
V Hz %
400 COM
Impure water top-up
mA
• Impure water introduces impurities in the battery.

Iron and Chlorine in the impure water attack the
plates which affects overall life of the battery.
Chlorine bleaches the separators.

MAN - 00162
How to handle the battery attach one clamp to the negative terminal (A) of
the booster battery. Then attach the other end of
Methods of preventing over-discharge that cable to a solid metal part of the engine (eg.
engine lift bracket). Do not connect the cable to
any moving part.
CAUTION
After connecting the battery cables, ensure A B B
that they are securely clamped to battery ter-
minals.
• The battery surface (particularly its top) should

always be kept clean and dry.
GROUND
• The terminal connections should be clean and BOOSTER
secure. At every routine maintenance, clean, BATTERY
tighten and apply petroleum jelly on the termi-
DISCHARGED
nals. BATTERY
• When the vehicle is not going to be used over a A - Negative terminal B - Positive terminal
long period of time, disconnect the negative bat-
tery terminal. Check the charge condition of the
battery. Notice
Jump Starting Always use jump start cables with crocodile
Follow below steps while jump starting the vehicle: clips for connecting the terminals / grounding.
5. Start the engine of the booster battery and let it

run for a few minutes. This will help assure that
the booster battery is fully charged. During the
+ - jumping operation, run the engine in this vehicle
at about 2,000 rpm.
6. Start the engine of the discharged battery using
the normal starting procedure
7. Carefully remove the jumper cables in the
reverse order of attachment.
WARNING
• Improper jump starting procedure can result
1. Use only a 12V supply to start your vehicle. in battery explosion and acid burn hazard
2. If the booster battery is in another vehicle, posi-
tion the two vehicles to bring their batteries near • Connecting a jumper cable near moving
each other. Do not allow the two vehicles to parts (cooling fans, belts) is dangerous. The
touch each other. cable could get caught when the engine starts
and cause serious injury
3. Apply the parking brake.Turn OFF all electrical
systems which are not primarily required.
4. Attach the clamps of the jumper cable as shown
on the illustration. First, attach one clamp of the
jumper cable to the positive terminal (B) of the
CAUTION
discharged battery. Then attach the other end of Loosely connected battery cables could dam-
the same cable to the positive terminal (B) of the age the electronic control units.
booster battery. Next, using the other cable,

MAN - 00162
Battery 2. Open the positive cable cover (A) of the

battery and loosen a 10mm lock nut of the
positive cable. Then disconnect the positive
cable.
The 12V battery is designed to provide safe,

efficient, reliable and mobile means of delivering
and storing electrical energy. This electrical energy 3. Remove the two 13mm mounting nuts (A) of
operates the engine starting system and other the battery holding bracket and remove the
vehicle accessory systems for limited durations bracket (B).
while the engine and/or the charging system are
not operating. The battery system is designed to
function as a resource of electrical energy to
supplement the charging system for short durations
while the engine is running and when the electrical
current demands of the vehicle exceed the output
A
of the charging system.
Removal
1. Loosen a 10mm lock nut (A) of the battery
negative cable and disconnect the negative
cable. B
4. Remove the battery from the battery tray.
Inspection
For additional information on Battery Inspection
Checking Battery Condition section.
A
Installation
Notice
Clean the battery positive and negative cables
before fixing to the battery.
Notice
Visualy inspect the battery for any damage
before installing.

MAN - 00162
Alternator Notice
Remove the oil dipstick from the oil dipstick
pipe and place it aside.
5. Remove the 12mm alternator electrical connec-

tor nut (A) and disconnect the electrical connec-
tor from the alternator.
The alternator with internal cooling fans and an in

built regulator acts as a battery charger in the vehi-
cle. The alternator is designed and matched to form
a part of Integrated Battery Charging System for
automotive applications. This is a three-phase unit of
revolving field and stationary armature. It is venti-
lated and cooled by the two internal fans located on
either sides of the rotor. 6. Press the electrical connector (A) of the alterna-
tor towards inner side, press the lock and pull
Removal out the electrical connector.
CAUTION
Do not rely on the alternator to recharge a
completely discharged battery.
A
3. Remove the accessory drive belt. For addi-
4. Remove the radiator thermostat hoses.For addi-
tional information refer to Thermostat
Notice
Use the tray before removing the thermostat
hoses to avoid spilling of coolant in working
area.

MAN - 00162
7. Remove 12mm mounting nuts (A) and bolts from Battery Tray
the alternator bracket, and Separately detach
the alternator assembly.
Removal
Installation 1. Remove the battery. For additional
1. To install, reverse the removal procedure. information refer to Battery removal and
Notice 2. Loosen four 10mm mounting bolts (A) on the
battery tray, and separately detach the battery
Check the electrical connections are fixed tray.
properly before starting the engine.
Installation

MAN - 00162

1. Verify the customer‘s concern.
2. Visually inspect the charging system for any
noticeable signs of mechanical or electrical
damage.
3. If any obvious cause is found, correct the
same before proceeding to the next step.
Mechanical
• Check for cracks in the battery case and
broken terminals.
• Check the electrolyte level in the battery.
• Check the battery plates for any sign of
sulfation, if required clean it.
Electrical
• Check whether the main fuse MF2 (150A) is
blown.
• Check the alternator cable terminal for
corrosion.
• Check for loose electrical connectors in the
alternator.
• Inspect the battery terminals for corrosion and
loose connection.
• Check the charging system warning indicator
connector for loose connection.

MAN - 00162
1. Wiring connections are 1. Tighten the connections.

loose.
2. Defective voltage regu- 2. Replace the voltage regulator.
lator.
3. Loose battery connec- 3. Tighten the battery connec-
Charging indicator lamp does not glow tors. tions.
when the ignition is switched ON 4. Loose alternator con- 4. Tighten the alternator connec-
nectors. tions.
5. Indicator Lamp burned 5. Replace the instrument clus-
out. ter.
6. Electrical malfunction 6. Investigate through diagnostic
tool.
1. Defective batteries or 1. Check the battery and battery

battery terminal con- terminal connections.
nections.
2. Blown fuse or fusible 2. Check the fuse or fusible link,
link. and replace if needed.
3. Defective wiring har- 3. Check the voltage drop.
ness.
Battery low or not charging 4. Faulty alternator. 4. Replace the alternator.
5. Loose battery connec- 5. Tighten the battery connec-

tors. tions.
6. Loose alternator con- 6. Tighten the alternator connec-
nectors. tions.
7. Defective auto-ten- 7. Replace the auto-tensioner.
sioner.
1. Battery is faulty. 1. Replace the faulty battery.

2. Poor contact at voltage 2. Tighten the connection mount-
Electrolyte spillage (battery electrolyte is detection point of the ing.
alternator.
depleted in a short time)
3. Faulty voltage regula- 3. Replace the voltage regulator.
tor.
1. Faulty/damaged belt. 1. Replace the alternator belt.

2. Faulty/damaged alter- 2. Replace the alternator pulley.
nator pulley.
Abnormal noise from alternator 3. Damaged/defective 3. Rectify or replace the alterna-
tensioner. tor belt auto-tensioner.
4. Worn alternator bear- 4. Replace the alternator.
ing.

MAN - 00162

1. Physical Damage. 1. Replace the alternator as-

sembly
Alternator
2. Undercharging or Overcharg- 2. Replace the alternator as-
ing. sembly
1. Physical Damage. 1. Replace the battery.

2. Battery dead or no charge. 2. Charge the battery as per
recommendation.
Battery 3. Electrolyte leakage from top. 3. Check for blocked vent holes
and clean.
4. Electrolyte leakage from 4. Check for cracks on body
sides. and replace battery.
5. Electrolyte discoloration. 5. Replace the battery.
1. Check for any sulfation at 1. Clean the connectors.

connectors.
Wiring Harness 2. Check for any kinks, chaffing 2. Replace the wiring harness
or any other damage to the assembly
wiring harness.
1. Check for physical damage. 1. Replace the belt if damaged.

FEAD Belt 2. Check for slackness of the 2. Replace the belt if required.
belt.
System voltage 12V
Battery rating 90Ah

MAN - 00162
Torque in
Nm
Mounting flanged
Earth on transaxle 1 24±1
bolt M8 x 1.25 x 10
M8 Eyelet ring Ground on side rail LH (Part of

1 15±1
terminal Battery Negative cable)
Battery Cable
Negative Ground on side rai LH near battery
M8 Eyelet ring
mtg area (Part of Battery Negative 1 15±1
terminal
cable)
NUT HEX FL
Battery negative nut on cable 1 6.5±0.5
M6X1X6X8 GR
Battery Cable NUT HEX FL

Battery positive nut on cable 1 6.5±0.5
Positive M6X1X6X8 GR
FLANGED BOLT
Battery tray 4 7±0.5
M6 X 1X 20
Battery Hold
NUT HEX FL
Hold on mounting 2 8±0.5
M8X1.25X8X8 GR
B+ Line input from BEC to Alterna-

NUT HEX FL tor
Alternator 1 15±1
M8X1.25X8X8 GR
(Part of engine wiring harness)

MAN-00162
Repair Manual Clutch Nov 2011/ Rev 2
CLUTCH
CONTENTS

Dual Mass Flywheel - DMF ................................................................ 1

Clutch Master Cylinder ....................................................................... 4
Concentric Slave Cylinder .................................................................. 5
Dual Mass Flywheel (DMF)................................................................ 5

Clutch System .................................................................................... 6
Clutch/ Brake Fluid ............................................................................. 6
In Car Repairs ...................................................................................8

Clutch Bleeding .................................................................................. 8
Clutch Master Cylinder ..............................................................10

Removal ........................................................................................... 10
Inspection......................................................................................... 11
Installation ........................................................................................ 11
Concentric Slave Cylinder .........................................................12

Removal ........................................................................................... 12
Inspection......................................................................................... 12
Installation ........................................................................................ 12
Clutch Hose ................................................................................13

Removal ........................................................................................... 13
Inspection ......................................................................................... 13
Installation ........................................................................................ 13
Clutch Cover and Disc ..............................................................14

Removal ........................................................................................... 14
Inspection ......................................................................................... 14
Installation ........................................................................................ 14
Dual Mass Flywheel (DMF) ........................................................ 15

Removal ........................................................................................... 15
Inspection ......................................................................................... 16
Installation ........................................................................................ 16

MAN-00162
Dual Mass Flywheel Pilot Bearing ............................................ 16

Removal ........................................................................................... 16
Inspection ......................................................................................... 16
Installation ........................................................................................ 16
Clutch Pedal Position Sensor ................................................... 17

Removal ........................................................................................... 17
Inspection......................................................................................... 17
Installation ........................................................................................ 17
Clutch Pedal Assembly ............................................................. 18

Removal ........................................................................................... 18
Inspection......................................................................................... 18
Installation ........................................................................................ 18
Clutch Pedal Tension Spring .................................................... 19

Removal ........................................................................................... 19
Inspection ......................................................................................... 19
Installation ........................................................................................ 19
Clutch Pedal Nylon Bush .......................................................... 20

Removal ........................................................................................... 20
Inspection ......................................................................................... 21
Installation ........................................................................................ 21
Troubleshooting ........................................................................... 21
Mahindra Special Tool (MST) ....................................................... 27

MAN-00162
Clutch
The clutch disc is a single, dry type with cushion seg-
ment. The clutch disc's friction material is riveted to
this cushion segment.
The clutch cover is a diaphragm type with one-piece
construction. A 260-mm clutch disc is used.
In the engaged position (when the clutch pedal is not
pressed), the diaphragm spring of the clutch cover
assembly holds the clutch pressure plate against the
clutch disc. This enables the engine torque to be
transmitted to the input shaft of the gearbox, without
any slip / loss.
The clutch is hydraulically actuated with self-adjust-
ing features. The complete actuation system com-
prises of a clutch master cylinder with reservoir. The
master cylinder is connected to the concentric slave
cylinder (CSC) by high pressure hydraulic pipe. The Advantages of DMF
travel of the push rod in master cylinder results in lin-
ear movement of the release bearing which is inte- Comfort
grated to the CSC through the cylinder & piston
arrangement. Engine operating range
The clutch release bearing pushes the diaphragm
spring center towards the flywheel. The diaphragm
spring pivots at the fulcrum, relieving the load of
Frequency response
pressure plate from the clutch plate. Steel spring DMF

Standard
straps riveted to the pressure plate cover pulls the clutch
pressure plate away from the clutch disc. When the
amplitude
damper
clamping load on the clutch plate is relieved it slides
on the splines of the input shaft away from the fly-
wheel thus disengaging the engine torque from the
input shaft & enabling the gears to be changed.
600 7000
Advance Features in Clutch System Engine [rpm]
1. Dual Mass Flywheel
Dual Mass Flywheel - DMF • The DMF resonance frequency is well below
the engine idle speed, while classical clutch
• The DMF is made up of two masses, linked disc is at 1500-2500 rpm.
together by a bearing.
• Filtering of engine torsional vibration due to
• The first mass, the primary flywheel is bolted to fuel combustion thus reducing the transmission
the engine crankshaft. to the gearbox shaft gear pair and reducing
• The second mass, the secondary flywheel has gear rattle.
the clutch cover assembly bolted on it together • Noise reduction in drive, coast, idle, creeping,
with the clutch friction disc. tip-in, tip-out.
• The torsional link is made up of two double
DMF Benefit
curved springs.
NVH Comfort Improvement
• Booming noise at low speed.
• Idle filtration.
• Rattle noise reduction under load.

MAN-00162
• Creeping noise reduction (at low speed, low

torque).
• Gear shifting improvement thanks to reduce
disc inertia.
2. Self Adjusting Technology (SAT) of the
Clutch Cover Assembly
Self Adjusting Technology (SAT) clutch is designed
to deliver a constant clutch actuation force during the
entire life of the vehicle. SAT is designed for
maintenance-free automatic operation and
compensates for clutch wear with adjustment in the
pressure plate and detection by position.
Improved driving experience is felt since the clutch
actuation force will remain constant over the entire
life of the vehicle and the life of the clutch itself will be
extended.

MAN-00162
A. Clutch Plate
B. Pressure Plate
C. Pressure Plate Mounting Bolt

MAN-00162
Clutch Master Cylinder

Twist and locked Primary seal
US welding
Secondary seal Rotation welding
Dynamic sealing on
anodized aluminum
Length of guiding

MAN-00162
Concentric Slave Cylinder
US welding
Articulated seal but

attached to the piston
Plastic body
One part hydraulic

chamber Dynamic sealing
on anodized
aluminum
Dual Mass Flywheel (DMF)
CLUTCH COVER ASSY+ CRANK SHAFT MOUNTING

DISC ASSY.INTERFACE ZONE ZONE
(VIEW GERA BOX SIDE) (VIEW ENGINE SIDE)

MAN-00162

Clutch System Clutch/ Brake Fluid
CAUTION DANGER
Make sure that the pressure bleeding equip- Do not allow the clutch or brake fluid to come
ment is filled with new clutch or brake fluid to in contact with eyes or skin. If it happens by
the correct specification. accident, thoroughly wash the affected area
with water and get medical help.
Notice
Before bleeding the clutch system refer to
general clutch service practice and clutch or CAUTION
brake fluid precautions. Clutch or brake fluid can damage paintwork,
hence wash the spilled fluid immediately with
plenty of clean water.
CAUTION
Never use gasoline, motor oil, transmission
fluid, or any fluid containing mineral oil to CAUTION
clean the clutch system components. These Thoroughly clean all clutch disc, hose, clutch
fluids may damage the rubber caps and cover with clutch or brake fluid before com-
seals. mencing work on any part of the clutch sys-
tem. Failure to do so may cause foreign
• If clutch or brake fluid leakage is found in the matter to enter the system and cause damage
clutch master cylinder, clutch hose, clutch slave to seals and pistons which may seriously
cylinder, clutch system, then that particular part impair the efficiency of the clutch system.
should be replaced.
• Disconnect the negative terminal of the battery
before performing any work on the clutch sys-
tem. Notice
• Clean the clutch disc, clutch cover, dual mass Use only recommended clutch or brake fluid to
flywheel with waste cloth. flush the clutch system. Do not use mineral
• Always check the clutch or brake fluid for dirt, oils such as engine oil, any petroleum based
discoloration or separation into distinct layers. cleaning fluids or any proprietary fluids.
Also check the reservoir cap seal for distortion.
• Always replace the clutch or brake fluid with
fresh fluid from a sealed container.
CAUTION
Do not reuse the clutch or brake fluid. Always
use fresh fluid from a sealed container.

MAN-00162
Clutch / Brake fluid level check

The clutch or brake system should be drained and
flushed at recommended service intervals.
When filling the clutch or brake fluid, the electrical
terminals should be carefully covered to avoid entry
of fluid into the terminals.
• Park the vehicle on level ground.
• Check whether the fluid level is between ’MIN’
and ’MAX’ marks on the reservoir. Top up if
required with recommended grade of clutch or
brake fluid.
Notice
Do not fill the reservoir above the maximum
line.
CAUTION
Clutch fluid should be drained and flushed at
recommended service interval.

MAN-00162
In Car Repairs
Clutch Bleeding Bleeding Procedure
• System needs bleeding to remove the trapped 1. Fill the Reservoir to the Max mark with fresh
air in the hydraulic circuit brake fluid conforming to DOT 4 specifications.
• If system is not fully bled, It will not allow full
engagement & disengagement of the disc
• Bleeding to be done whenever clutch Master
Cylinder, Concentric Slave Cylinder or Clutch
Hoses are removed or replaced
Following precautions to be taken while
bleeding procedure:
1. Always use recommended fluid for bleeding
procedure
Type: CASTROL "Brake Fluid DOT 4" or
SHELL MAKE "BRAKE & CLUTCH FLUID
DOT 4"
Qty: 1.0 lit
2. Remove bleeder plug cap from clutch operating
2. If clutch or brake fluid is split on the paint work, slave cylinder pipe (C). Attach a vinyl tube (A) to
the affected area must be immediately washed bleeder plug (D), and insert the other end into
with cold water. container (B). Ensure that the other end of the
tube is fully immersed in the bottle having clean
clutch /brake fluid.
A D

MAN-00162
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 take care not to complete take out
the pipe.
Press the lock as

shown in the
picture and pull
the pipe by one
notch only.
Care to be
exercised not to
completely pull
the pipe out
4 Repeat this operation until there are no more

air bubbles in hydraulic line.
5. When bubbles stop, depress and hold clutch
pedal, push pipe connector, and pull lock 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 the fluid level in container and top up to
the 'max' level.
9. Check clutch pedal for sponginess. If found

spongy, repeat entire procedure of bleeding.
Notice
After Evacuation and feel and during manual
bleeding min 40 pedal strokes for bleeding to
be carried out.

MAN-00162
Clutch Master Cylinder
5. Disconnect the clutch master cylinder push rod

lock (A) from the clutch pedal.
Removal
2. Open the bonnet.
3. Open the brake fluid reservoir cap (A).
A A
6. Remove the lock clip (A) from the outlet hose

of the clutch master cylinder.
4. Using the syringe (A), take out the brake fluid

(B) from the reservoir. For additional
information refer to Brake Fluid Reservoir

MAN-00162
CAUTION
Avoid splitting of clutch or brake fluid on
the vehicle body while removing the clutch Z
master cylinder assembly. The spitted brake
fluid may cause damage to paint work of the
vehicle.
X
7. Disconnect inlet hoses (A) from the clutch
master cylinder.
Inspection
1. Visually inspect for clutch master cylinder fluid
A leakage.
2. Check for clutch master cylinder push rod lock
damage.
Installation
1. Install the clutch master cylinder in clockwise
direction as shown in the below image.
8. Using a suitable spanner (A), rotate the clutch

master cylinder 45° in anti-clockwise direction
and detach the master cylinder from the clutch
pedal housing. Z

3. Refill the clutch or brake fluid reservoir to the
required level.
4. Bleed the clutch system. For additional
informtion refer to Clutch Bleeding section.

MAN-00162
Concentric Slave Cylinder 3. Remove two 10mm concentric slave cylinder

mounting bolts (A) from the transmission.
Removal 4. Pull out the concentric slave cylinder from the

1. Remove the transmission assembly. For transmission.
2. Remove the 10mm concentric slave cylinder
input hose mounting bolt (A) from the
transmission.
Inspection
1. Visually inspect the concentric slave cylinder
for fluid leakage.
2. Check the concentric slave cylinder diaphragm
functions.
Installation
2. Tighten the concentric slave cylinder mounting
bolts to the prescribed torque.
3. Bleed the clutch. For additional informtion
refer to Clutch Bleeding section.

MAN-00162
Clutch Hose (Connected from 3. Unlock and remove the clutch hose (A) from
the routing clips (B).
Transmission Clutch Cylinder to
Clutch Pedal Master Cylinder)
A
B
B E
C
D
F
4. Pull out the inlet hose clip (A) from the
A concentric slave cylinder and detach the inlet
hose (B).
A. Concentric Slave Cylinder
B. Bleeder CSC
C. Rubber Boot
D. Tube Hydraulic Clutch RHD and Clutch Long B
Pipe RHD
E. Clutch Master Cylinder
F. Screw
A
Removal
1. Drain the clutch or brake fluid from the brake
fluid reservoir.
2. Pull out the outlet hose clip (A) from the clutch
master cylinder and detach the output hose
(B).
Inspection
1. Visually inspect the clutch hose for fluid
leakages.
2. Check the clutch outlet hose and clutch inlet
B concentric slave cylinder hose for damages.
A Installation
Notice
Ensure that clutch outlet hose and clutch inlet
hose are interlocked properly to avoid loss of
fluids, leading in clutch operation failure.
2. Bleed the clutch. For additional informtion

refer to Clutch Bleeding section.

MAN-00162
Clutch Cover and Disc 3. Remove nine 13mm clutch cover mounting
bolts (A) on the flywheel and detach the clutch
cover and disc.
Removal
1. Remove the transmission assembly. For Inspection
additional information refer to Transaxle 1. Check diaphragm spring for abnormal wear or
removal and installation section. damage.
2. Using the Mahindra Special Tool (Flywheel 2. Inspect clutch cover for wear or heat spots.
locking tool) part no. 0302EAM0001ST (A),
lock the flywheel to the cylinder block. 3. If abnormality is found, replace clutch cover.
Do not disassemble it into diaphragm spring
and clutch cover.
4. Check the clutch disc lining to the rivet
thickness.
Installation
1. Place the clutch disc and cover (A) on the
A flywheel. Insert the clutch centre guide (B) in
correct position.

MAN-00162
2. Using a flywheel lock tool (Part no. Dual Mass Flywheel (DMF)
0302EAM0001ST) (A) and lock the flywheel.
Tighten the clutch cover mounting bolt (B) and
remove the clutch centering guide (part no.
0801CAA0001ST) (C).
C
B
Removal
1. Remove the clutch pressure plate. For
additional information refer to Clutch
3. Tighten the clutch cover mounting bolt to the removal and installation section.
specified torque. 2. Using a flywheel locking tool (Part no.
4. Remove the flywheel lock tool from the cylinder 0302EAM0001ST) (A), lock the flywheel to the
block. cylinder block.

MAN-00162
3. Remove the 18mm flywheel mounting bolts (A) Dual Mass Flywheel Pilot Bear-
and detach the flywheel.
ing
Inspection
1. Check the flywheel for cracks or damage. Removal
2. Check the flywheel ring gear for worn-out or 1. Remove the clutch cover and disc. For
damage. additional information refer to Clutch Cover
and Disc removal and installation section.
Installation 2. Using a suitable tool, remove the flywheel pilot
1. Install the fly wheel on to the crank shaft. bearing (A) from the flywheel.
2. Using flywheel lock tool, lock the flywheel and
tighten the flywheel mounting bolts to the
specified torque.
3. Remove the flywheel lock tool from its position.
4. To install, reverse the removal procedure. A
Inspection
1. Check the flywheel pilot bearing for smooth
rotation and replace it if abnormality is found.
Installation
1. Using the suitable tool, install the flywheel pilot
bearing to the flywheel.
3. Tighten the all mounting bolt to the specified
torque.

MAN-00162
Clutch Pedal Position Sensor 4. Remove the 12mm clutch pedal position
sensor mounting lock nut (A) and detach the
clutch pedal position sensor (B) from the clutch
pedal box assembly.
B
A
Removal
the battery.For additional information refer to Inspection
Battery removal and installation section. 1. Visually inspect for clutch pedal position sensor
2. Remove the bottom trim of the steering for internal damage or connector breakage.
Steering Column Assembly removal and Installation
installation section. 1. To install, reverse the removal procedure.
connector (A) from the clutch pedal position
sensor.

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Clutch Pedal Assembly 5. Remove the five 12 mm clutch pedal assembly

mounting nuts (A) and detach the clutch pedal
Removal assembly (B) from the fire-wall.
the battery. For additional information refer A
to Battery removal and installation section.
installation section. B
sensor.
Inspection
1. Check the clutch pedal box for crack or
welding damage.
2. Check the clutch pedal for any bend or twist.
Installation
A 1. To install, reverse the removal procedure.
2. Tighten the clutch pedal box mounting nut to
3. Check the operation of the clutch post
4. Disconnect the clutch master cylinder push rod installation.
lock (A) from the clutch pedal.

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Clutch Pedal Tension Spring 5. Compress the clutch pedal tension spring (A)
by hand and remove the tension spring.
Removal
A
sensor.
Inspection
1. Check the tension spring for crack or damage.
2. Check the tension spring bush for damage or
wear out.
Installation
A 2. Check the operation of the clutch pedal tension
spring post installation.
4. Using the outer circlip plier compress the

circlips (A) and detach the circlips.

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Clutch Pedal Nylon Bush 4. Compress the clutch pedal tension spring (A)
by hand and remove the spring.
Removal
1. Remove the Clutch pedal box assembly. For
additional information refer to Clutch Pedal
Position Sensor removal and installation
section A
2. Remove the 12mm clutch pedal position

sensor mounting lock nut (A) and detach the
clutch pedal position sensor (B) from the clutch
pedal box assembly.
B
A
5. Remove the 14mm clutch pedal mounting bolt

and nut (A) from the clutch pedal box.
3. Using the outer circlip plier compress the

circlips (A) and detach the circlips.
6. Pull out the clutch pedal nylon bush (A) from

A the clutch pedal.

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Inspection Troubleshooting
1. Check the clutch pedal nylon bush for crack or
Unless the cause of a clutch problem is extremely
damage.
obvious, accurate problem diagnosis will require a
2. Check the clutch pedal for bend or twist. road test to confirm that the problem exists. To find
out the actual root cause of the problem the clutch
Installation will have to be dismantled and the failed parts
1. Apply recommended lubricant to the clutch examined to determine the cause.
pedal nylon bush.
During road test, drive the vehicle in normal
2. To install, reverse the removal procedure. operating speeds. Shift the gears and observe the
3. Tighten the clutch pedal mounting bolt and nut clutch action. If chatter, grab, slip or improper
the specified torque. release is experienced, remove and inspect the
parts. However if problem is noise or hard shift
then the problem may not be in clutch only but also
the transmission or the driveline.
If the clutch slip is suspected then drive the vehicle
in 1st or 2nd gear at the top speed (corresponding
to the gear). Keeping the accelerator fully pressed;
slowly apply the brake with your left feet. If the
engine stalls then the clutch is not slipping.
Clutch Problem Causes
Fluid contamination is the most frequent cause of
clutch malfunction. Oil, water on the clutch contact
surface will cause faulty operation viz. Slip, grab,
and judder.
During inspection check if any parts in the clutch
are coated with oil or water splash from road.
Oil contamination indicates a leak at either rear
main seal or transmission-input shaft. The oil leaks
from either of these areas will normally coat the
housing interior or clutch cover or flywheel. Heat
buildup due to slippage between the clutch plate
and the flywheel or the pressure plate can result
into the leaked oil literally getting baked. Visually
this will result in a glazed residue varying from
amber to black.
Clutch Misalignment
The clutch component i.e. the clutch plate, flywheel
and the pressure plate have to be aligned with the
crankshaft and the transmission input shaft.
Misalignment caused by run outs/ war page will
cause clutch to grab judder as well as improper
release (also manifesting as hard gearshift).

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Flywheel Run Out Press the clutch pedal completely and start the
engine, the wheels should not be spinning. Now
slowly release the pedal till it has moved about 10
Magnetic base mm, the wheel should still not be spinning. If some
spinning is noticed then it indicates improper lift of
the pressure plate. First check the bleeding and the
Plunger Type dial indicator
pedal travel then check for the pressure plate lift.
ENGINE
0.075 MM MAX.
Clutch Housing Misalignment
The clutch housing has to be aligned with the
engine so that the input shaft is aligned with the
Flywheel Face
crankshaft. Absence of this alignment results in
clutch noise, incomplete release of the clutch plate.
Engine Belt Mounting Plate
It can normally be judged by uneven wear of the
finger and pilot bearing. In severe case it can also
damage the spline of the input shaft and clutch
The flywheel run out needs to be checked hubs well as the clutch splines.
whenever misalignment is suspected. Flywheel run Normally the clutch housing misalignment is a
out should not exceed 0.10 mm. result of:
To measure the run out mount the base of the • Incorrect seating on the engine/transmission
magnetic dial gauge on the block. Locate the dial • Missing alignment dowel holes
gauge’s needle on the outer surface of the
flywheel. • Loose or missing mounting bolt
• Mounting surfaces that are damaged/ not
Some of the common reasons for excessive run
parallel
out are:
• Heat warpage To check the clutch housing misalignment bell
housing run out will also need to be checked.
• Improper machining
• Incorrect bolt tightening
• Foreign material on crankshaft flange or
flywheel
• Improper seating on crankshaft
Clutch Cover and Disc Run Out
A warped cover or diaphragm spring will result in
clutch grab and / or incomplete release of clutch
plate.
If the clutch alignment tool is not used then the
misalignment of the clutch plate can cause
distortion of the cover and also disc damage.
The cover can also get misaligned due to improper
tightening of the cover onto the flywheel. The only
way to avoid is that the bolts must be tightened
alternatively (diagonal pattern) and evenly i.e. 2 to
3 thread a time only.
A noisy gearshift operation especially the 1st and
2nd gear can be due to clutch not getting
disengaged completely. To check it, jack up the
rear axle. Lift the axle till both the wheels are
rotating freely.

MAN-00162
Clutch slippage
1. Normal wear 1. Replace clutch disc

2. Clutch riding 2. Replace clutch plate
3. Insufficient diaphragm spring 3. Replace clutch plate and cov-
clamp load er assembly
4. Faulty release mechanism. 4. Replace and bleed
Disc facing worn out
5. Vehicle being driven despite 5. Customer to be informed
slipping clutch.
6. Bad driving practice of allow- 6. Customer to be informed
ing the clutch to slip far too
long.
Leak at:
1. Crankshaft rear end oil seal 1. Replace seal and disc. Clean
cover assembly
Clutch disc facing contaminated 2. Leak through the input shaft 2. Replace seal and disc. Clean
with oil, grease or clutch fluid. cover assembly
3. Excess amount of grease ap- 3. Apply less grease. Replace
plied to the input shaft splines clutch disc. Clean cover as-
sembly
Clutch is running\ partially disen- 1. Release bearing carrier sticky 1. Replace bearing / carrier
gaged.
1. Improperly machined flywheel 1. Replace flywheel

Flywheel height incorrect
2. Excess machining done
1. Use the correct parts 1. Replace the parts after com-

Wrong disc or pressure plate used
parison
1. Improper tightening or loosen- 1. Replace the parts and tighten

Clutch disc/ cover or diaphragm ing procedure as per sequence
spring warped 2. Rough handling of clutch 2. Replace the parts, ensure that
plate or cover assembly the rough handling is avoided
1. Frequent operation under high 1. Roughen the flywheel face

Clutch disc facing burnt. Exces- loads or hard acceleration with sandpaper. Replace
sive glazing of the flywheel and conditions clutch plate & cover assembly
pressure plate 2. Frequent clutch riding by the 2. The driver has to be alerted to
driver avoid repeat failure
1. Improper storage-clutch plate 1. Replace

Clutch facing broken
dropped prior to fitting
Fouling marks on the torsion 1. Improper fitment-assembled 1. Rectify

the wrong way around
damper

MAN-00162
Clutch grab/chatter
Leak at:
1. Crankshaft rear end oil seal 1. Replace seal and disc. Clean
cover assembly
Clutch disc facing contaminated 2. Leak through the input shaft 2. Replace seal and disc. Clean
with oil, grease or clutch fluid. cover assembly
3. Excess amount of grease ap- 3. Apply less grease. Replace
plied to the input shaft splines clutch disc. Clean cover as-
sembly
Clutch disc / pressure plate 1. Incorrect or substandard parts. 1. Replace disc and cover with
the correct parts
warped.
2. Improper tightening or loosen- 2. Replace the parts and tighten
ing procedure as per sequence
Disc facing show 3. Rough handling of clutch plate 3. Replace the parts, ensure that
unusual wear or cover assembly the rough handling is avoided
1. Clutch pressure plate 1. Replace clutch cover and

position setting incorrect or clutch plate
modified
2. Clutch cover, spring or release 2. Replace clutch plate
fingers bent or distorted due to
Partial engagements of clutch disc rough handling or improper
(One side worn – opposite side assembly
glazed and lightly worn.) 3. Check alignment and run out
3. Clutch disc damaged or
distorted of flywheel disc or cover
4. Clutch misalignment 4. Replace the clutch plate and

cover assembly (if required.
Correct the alignment)
1. Problem related to suspension 1. Further diagnosis required

No fault found with clutch or driveline components Check engine and transmis-
sion mounting insulators. U
components Joint, tyres, body attaching
parts
Clutch master cylinder or slave 1. Piston/ bore damaged or 1. Replace the master and slave
corroded cylinder
cylinder piston jammed/ scuffing
1. Incorrect driving practice 1. Advise the customer of the

• Mostly due to tow starting in consequences
Tangential strap connecting the
1st or 2nd gear
pressure plate to the diaphragm
cover broken Or
• Incorrect gear selection

MAN-00162
Improper Clutch Release
Clutch disc 1. New disc not checked before 1. Check the new disc’s run out &
warped installation replace it
1. Clutch disc hub splines dam- 1. Replace the clutch plate

aged during installation
2. Input shaft splines rough or 2. Replace input shaft is severely
Clutch plate is binding on the input
damaged damaged
shaft’s splines
3. Corrosion or rust formation on 3. Replace the clutch plate. Re-
splines of disc and input shaft place the input shaft if the
scaling can not be removed
1. Low fluid in the clutch master 1. Top off the fluid and check for
cylinder leaks
2. Air in the hydraulic system 2. Bleed and refill the system
3. Clutch cover loose 3. Replace disc
4. Clutch cover diaphragm 4. Replace the cover assembly
Clutch will not disengage properly spring bent / warped during
transmission installation
5. Clutch disc fitted backwards 5. Fit the clutch plate correctly
the hub should be facing the
pressure plate side and the
flywheel side mark towards
the flywheel
1. Vibration / misalignment and 1. Fit new bearings and check

Bush worn out / damaged
clutch misalignment for misalignments
Hard Gear Shift
1. Leaks 1. Replace fluid

Brake fluid less and or contami-
2. Reservoir strainer missing 2. Stop leaks and avoid contami-
nated
nation.
1. Warpage due to handling or 1. Replace

Clutch plate warpage assembly
2. Warpage due to misalignment

MAN-00162
Description Description
Clutch Assembly Single plate, hydraulic self adjusting dry type 260mm
diameter
Clutch Disc Outer Dia : 260mm
Inner Dia : 170mm
Disc Thickness 7.8±0. 2mm
Clutch Disc Run Out 0.3 mm parallism
MiniMum Thickness From Outer Face to Rivet 1.3mm

Head
Clutch Pedal Ratio 5.64
Pressure Plate diaphragm
Master Cylinder Stroke Area = 197.3 mm2
Slave Cylinder Stroke Area = 584 mm2
Flywheel Standard Service limit
1. Flatness 0.2
2. Run Out 0.5
Flywheel Width from Mounting Face to Clutch Face 40.8

MAN-00162
Mahindra Special Tool (MST)

0801CAA0001ST Clutch plate aligner tool
0302EAM0001ST Flywheel Lock Tool
Torque in
Nm
BOLT HEX FL - Clutch housing to engine 45 ± 5

M10X1.5X60X8.8X 10
ZN
Clutch Housing +
Transaxle
BOLT HEX FL - Clutch housing to engine 45 ± 5
M10X1.5X75X8.8X 5
ZN
BOLT HEX FL Slave cylinder to clutch housing 10 ± 2

Clutch slave cylin-
M6X1X20X17X8.8 2
der
XZN
Clutch Cover as- BOLT HXFLCBC Clutch cover to flywheel 20 ~ 125

4
sembly M8X1.25X20X8.8
NUT HEX FL - Cutch pedal to BIW 20.0~25.0

Cutch pedal 4
M8X1.25X8X8XZN
DMF Flywheel Bolts 50 + 60°

MAN-00162
Repair Manual Transaxle Nov 2011/ Rev 2
TRANSAXLE
CONTENTS
Description and Operation.............................................................. 1

Transaxle Layout ................................................................................ 3
Clutch Housing FWD .......................................................................... 4
Clutch Housing AWD ......................................................................... 5
Transaxle Housing ............................................................................. 6
Input Shaft 6S - 400 ........................................................................... 7
Gear Train TX 6S - 400...................................................................... 8
Gear Train TX 6S - 400...................................................................... 9
Gear Train TX 6S - 400 .................................................................... 10
Gear Shift Control TX 6S - 400 ........................................................ 11
Shift Tower ....................................................................................... 12
Differential Case TX 6S - 400 - FWD ............................................... 13
Differential Case Sub Assembly TX6S400 A - AWD ........................ 14
Transmission Gear Shift Control RHD ............................................. 15
Incar Repairs ..................................................................................16
Transaxle Oil Replace ...............................................................16
Transaxle..................................................................................... 17
Removal ........................................................................................... 17
Installation ........................................................................................ 24
Gear Shifter Mechanism ............................................................ 25

Removal ........................................................................................... 25
Installation ........................................................................................ 25
Gear Shifter Cable ...................................................................... 26

Removal ........................................................................................... 26
Installation ........................................................................................ 27
Gear Shifter Mounting Bracket ................................................. 29

Removal ........................................................................................... 29
Installation ........................................................................................ 29

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Transaxle Shift Tower................................................................ 29

Removal ........................................................................................... 29
Installation ........................................................................................ 30
Transaxle ................................................................................... 31
Disassembly ................................................................................... 31
Counter Shaft - 1 Disassembly ....................................................... 38
Counter Shaft - 2 Disassembly ....................................................... 40
Input Shaft Disassembly ................................................................. 43
Differential Disassembly................................................................... 44
Assembly ........................................................................................ 46
Input Shaft Assembly ...................................................................... 46
Differential Assembly ...................................................................... 46
Counter Shaft 2 - Assembly ............................................................ 48
Counter Shaft 1 - Assembly ............................................................ 52
Transaxle Assembly ......................................................................... 57
Thrush Washer Thickness Table .................................................... 65
Troubleshooting Chart ................................................................. 66
Mahindra Special Tools (MST) ..................................................... 67

MAN-00162
Transaxle The reverse gear is sliding mesh. The gear

selection is by a direct shift lever operating a 2?rail
system. The accidental operation of two gears is
Description and Operation avoided by an interlocking mechanism. To avoid
vibrations passing on to the shift lever; the shift
This vehicle is fitted with Cougar type manual
lever is two piece with rubber isolation provided on
transmission having six forward and one reverse
to the top half. The transaxle housing is 3 piece
gear. Due to 6 speeds, the vehicle will be operated
aluminum with an intermediate plate. A skid plate
at optimum engine torque and speed resulting
protects the bottom of the gearbox. The transaxle is
better fuel economy and acceleration. This shift
mounted directly on the flywheel through the
pattern is imprinted on the gearshift lever knob. The
integral clutch housing. The transaxle also has a
transmission is fully synchronised in all forward
gear neutral switch (GNS) and reverse gear switch
gears so shifting to either a higher or a lower gear
which give signal to ECU when vehicle is in neutral
is easily accomplished. Cable operated selector
gear position and reverse gear position.
and shifter mechanism is provided.
A few of the unique features are listed below:
Shifting Gear
1. Lowest Drag: All ball & roller bearing used in
main transaxle assembly to reduce frictional
A B losses resulting in higher efficiency and low
drag.
2. Two Final Drive (FD) Ratios:
• First Final drive ratio for 1st /2nd /3rd /4th
gear for better acceleration
• Second FD ratio for 5th/6th gear for better
fuel economy
3. Synchronizers with Carbon lining technol-
ogy:
• Carbon lining exhibits highest coefficient of
friction as compared to other friction
materials leading to compact design for
A. Shifting Lever synchronizers.
B. Shifting Mechanism • Combination of triple, dual and single cone
synchronizers are used to achieve best-in-
class shift feel by achieving minimum shift
R1 3 5 impulse and double bump forces.
4. 3 shaft Design:
2 4 6 • All Drive gear mounted on Input shaft
• 1st /2nd /3rd /4th Driven Gears-
Countershaft I
• 5th/ 6th/ Rev Driven Gears- Countershaft II
5. NVH:
• Gear micro geometry optimized for gear
whine noise reduction. Gear grinding and
honing are being used as finishing process
to achieve better NVH Performance.
The 1st, 2nd gear is having triple cone type
• DMF used to reduce torsion vibration in low
synchronizer, 3rd, 4th gear is having dual cone
rpm to reduce rattle noise.
synchronizer while 5th, 6th and reverse gear is
having single cone synchronizer. • Plastic interface between shift fork and
synchro sleeve to reduce friction and
minimize the noise transfer to shift lever
inside vehicle compartment.

MAN-00162
6. Internal Shift System: Central shift system to

ensure optimized gear shift & select effort.
• Shift system employs Common Detent
technology for gear Shift & Select Effort.
• 3D Ramp profile made to match static shift
effort with synchronization points and
provide Positive drop to assists lever
towards the end of shift.
• Integrated H gate and interlock on shift
tower ensures precise gear selection.
• Plastic pad molded on shift fork to reduce
friction & noise during gear shift.
• Combination of Linear bearing and bush
technology used in transmission to reduce
friction and provide optimum drag during
gear shift and gear selection. Hence
customer feels best gear shift.
7. Cable Shifter: Cable shifter & cable assembly
is designed such that to have best gear shift
precision and higher efficiency.
• Higher shifter stiffness reduces over travel
and gives precise gear shift.
• Cable shifter have less free play in neutral
and gear shifted condition offers better
efficiency.
• Indirect shift through cable dampens the
vibration level and noise transfer to vehicle
compartment.
8. Lift up ring for reverse gear selection is a
unique feature to avoid accidental rev gear
selection.
9. Neutral detection sensor integrated in transaxle
for start stop feature.

MAN-00162

Transaxle Layout
A C
A. Output Shaft D. Input Shaft

B. Counter Shaft I E. Reverse Axle
C. Counter Shaft II

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Clutch Housing FWD
C
G
A. Bracket Cable Shift E. Preload Shim Differential

B. Plug Clutch Housing F. Oil Slinger
C. Oil Seal Differential Case Output G. Oil Seal Input Shaft
D. Drain Plug

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Clutch Housing AWD
C
G
F
H
E
A. Bracket Cable Shift E. Preload Shim Differential

B. Plug Clutch Housing F. Oil Slinger
C. Oil Seal Differential Case Output G. Oil Seal Input Shaft
D. Drain Plug H. Stud

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Transaxle Housing
B
D
A C
N
E
M
J
K H
G
I
A. Transaxle Housing H. Filler Plug

B. Washer Neutral Sensor I. Oil Seal Differential Case Output
C. Linear Bearing Shift Shaft J. Snap Ring Rear Bearing
D. Speed Sensor Vehicle K. Shim Rear Cover
E. Dowel Main Housing L. Plate Bearing Retainer Stamped
F. Transaxle Housing M. Washer Plug
G. Washer Drain /filler Plug N. Reverse Lamp Switch

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Input Shaft 6S - 400
F G
D
C
A. Rear End Main Bearing DGBB E. Input Shaft

B. 6th Fixed Gear F. Front End Main Bearing
C. 4th Fixed Gear G. Snap Ring
D. 3rd / 5th Fixed Gear

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Gear Train TX 6S - 400

I
G
K
E
D T
B J
H
R
F
A
O
C
M S
Q
P
A. Rear End Main Bearing DGBB K. Bush 3rd Gear

B. Speedo Tonner Ring L. 2nd Driven Gear
C. Thrust Washer 4th /6th Gear M. Clutch Body Ring 1/2/3/4 Gear
D. Driven Gear 4th N. NRB 2nd Gear
E. Bush 4th Gear O. Synchro Assembly 1st/2nd
F. Synchro Assembly 3rd/4th DC P. Snap Ring
G. NRB 5th Driven Gear Q. Clutch Body Ring 1/2/3/4 Gear
H. Clutch Body Ring 1/2/3/4 Gear R. NRB 1st / Rev Gear
I. 3rd Driven Gear S. Counter Shaft
J. NRB 3rd Gear T. Front End Main Bearing

MAN-00162

I
G
K
F
B J
A
H
E
C
O
M R
L
Q
P
N
A. Rear End Main Bearing DGBB J. Thrust Washer 5th Gear

B. Thrust Washer 4th/6th Gear K. Snap Ring
C. Nrb 6th Gear L. Synchro Assembly
D. 6th Driven Gear M. Clutch Body Ring Rev Gear
E. Clutch Body Ring 5th/6th N. Reverse Driven Gear
F. Synchro Assembly 5th / 6th SC O. Snap Ring
G. Clutch Body Ring 5th/6th Gear P. Nrb 1st / Rev Gear
H. 5th Driven Gear Q. Counter Shaft 2
I. Nrb 5th Driven Gear R. Front End Main Bearing

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A. Reverse Idler Shaft D. Assembly Reverse Idler Gear

B. Needle Roller Thrust Bearing E. Needle Roller Thrust Bearing
C. Nrb Reverse Idler

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Gear Shift Control TX 6S - 400
A
B
A. Fork Assembly 5th/6th Gear D. Fork Assembly 3rd/4th Gear

B. Rail 5/6/r Gear E. Rail 1/2/3/4 Gear
C. Fork Assembly Reverse Gear F. Fork Assembly 1st/2nd Gear

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Shift Tower
C
A. Linear Bearing Shift Shaft

B. Assembly Shift Tower
C. Breather

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Differential Case TX 6S - 400 - FWD
G D
F
E
A. Sperical Thrust Washer F. Differential Case

B. Bevel Pinion Mate Gear G. Bevel Side Gear
C. Circlip E Type H. Side Thrust Washer
D. Pinion Mate Shaft I. Differential Output Gear Set
E. Differential Case 2WD

MAN-00162
Differential Case Sub Assembly TX6S400 A - AWD
G D
I
H
F
E
A. Sperical Thrust Washer F. Differential Case

B. Bevel Pinion Mate Gear G. Bevel Side Gear
C. Circlip E Type H. Side Thrust Washer
D. Pinion Mate Shaft I. Differential Output Gear Set
E. Differential Case AWD

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Transmission Gear Shift Control RHD
A B
C
D
AF
A. Shifter and Selector Cable Assembly D. Spring - Reverse Lift Ring

B. Knob Gear Shift Manual E. Gear Shifter Assembly
C. Foam Gear Shifter F. Bracket Shift Housing

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Incar Repairs 4. Place a large drain pan below the drain plug.
5. Using a 8 mm allen key, remove the oil

Transaxle Oil Replace draining plug (A) of the transaxle (B) and drain
the oil.
1. Lift the vehicle. For additional informtion
refer to Jacking and Lifting section.
2. Remove all 10 mm mounting bolts (A) of
engine underbody cover (B).
A
A
B
6. Tighten the drain plug to specified torque
value.
7. Refill transaxle oil as per below given

3. Using a 8 mm allen key, remove the transaxle specifications:
oil filling plug (A).
Transaxle oil: MAXMILE SYNTEC 75W-90
Quantity: 3.0 lit
8. Tighten the filler plug to specified torque value.

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Transaxle 3. Remove two 12mm inches mounting bolts (A)

on bonnet LHS. Detach the bonnet assembly.
Removal 4. Remove the battery. For additional informtion

refer to Battery removal and installation
1. Open the bonnet and fix the stay rod (A) in
section.
position to support the bonnet.
5. Loosen 10mm mounting bolts (A) on the
battery tray and detach the battery tray.
A
A
2. Remove the two 12mm inches mounting bolts

(A) on the bonnet RHS.
A 7. Remove the air filter assembly. For additional

informtion refer to Air Filter Housing

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8. Loosen four 10mm degassing tank mounting 11. Press locks (A) and pull out the gear shift
bolts (A), and move the degassing tank with cables (B) connected to top of the transmission
the coolant hose. housing.
A
A
9. Release the clutch slave cylinder lock (A) and 12. Remove the starter motor. For additional
detach the clutch slave cylinder hose (B) from informtion refer to Starter Motor removal
the transmission. and installation section.
13. Remove the 12mm ground connection
mounting bolt (A) from the transmission, and
detach the ground connection.
A
A
10. Pull out two gear shift cables (A) from the
transmission shifting lever.
A A

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14.Press a lock and pull out electrical connectors 18. Detach bottom of the front link rod from the
(A) from the neutral sensor and reverse switch. stabilizer bar on both sides. For additional
informtion refer to Front Stabilizer Bar Link
19. Remove the shock absorber bottom mounting
bolts of the knuckle assemblies. For additional
A informtion refer to Front Strut Assembly
20. Using a screw driver, detach the LHS drive
shaft (A) from the transmission.
15.Press the lock and pull out the electrical

connector (A) of the vehicle speed sensor.
21. Insert a suitable cap (A), to the transmission

LHS to prevent gear oil draining.
A
16. Loosen 36mm drive shaft lock nuts (A), and
remove the 21mm wheel nuts (B) and detach
the both front wheels.
B
A
17.Remove the brake caliper assemblies. For

additional informtion refer to Front Brake
Caliper removal and installation section.

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22. Loosen three 13mm RHS drive shaft mounting 25.Remove the two 10mm power steering hose
bolts (A), and detach the RHS drive shaft. mounting bolts (A) from the cradle.
A
A
23. Insert a suitable cap (A) to the transmission 26.Remove the 12mm intermediate shaft mounting
RHS to prevent oil draining. bolt (A) and remove the intermediate shaft (B)
from the steering gear.
A
B
24. Drain the power steering oil. For additional

informtion refer to Steering Oil Replace 27.Remove the 10mm heat shield mounting bolt (A)
section. from the steering rack.
Notice
While draining rotate the steering wheel
towards LHS and RHS to completely drain
the power steering.
A

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28.Remove the two 10mm mounting bolts (A) of 30. Loosen 15mm mounting nuts (A) from the
power steering suction and return hose brackets catalytic converter bottom pipe.
(B).
B
A
31. Remove a center mounting bolt and nut (A)

29. Remove the 17mm lock nuts of pressure hose from front side of the transmission.
(A) and cooler loop return hose (B), and detach
the hoses from the steering rack.
A
A
32. Remove a center mounting bolt and nut (A)

from rear side of the transmission.
CAUTION
Plug the steering rack assembly inlet and out-
let hose oil passage with dust cap to avoid
any foreign particles entry.

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33. Loosen 10mm mounting bolts (A) from the 36. Support the cradle with a stand.
exhaust gas recirculation (EGR) and VGT
modulators.
37. Using a rope chain (B), hook the engine

carefully at its lifting brackets (A) and lift the
34. Remove a 18mm cradle bracket nut (A) from engine slowly.
both sides of the cradle bracket.
DANGER
A Improper tie-up of the lifting rope chain will
cause damage to the vehicle and the persons
involved.
A A
35. Remove the 13mm and 18mm cradle bracket

cover mounting bolts and nuts (A) from both
sides of the cradle bracket. B
B
A

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38. Remove four 21mm cradle mounting bolts (A) 41. Remove two 14mm transmission top mounting
from the four sides of the chassis. bolts (A) and four 18mm bracket mounting
bolts (B).
A A
39. Separately detach the cradle assembly, and

place it aside by carefully supporting the brake 42. Using hydraulic stand (A) support the
disc. transmission.
40. Loosen the 14mm transmission side mounting 43.Remove other six 14mm mounting bolts (A)
bolts (A) near the flywheel. from the transmission.

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44. Detach the transmission assembly (A) along Installation

with hydraulic stand (B). 1. Correctly match the engine back plate (A) with
a dowel hole pin on the cylinder block.
CAUTION
Maintain a constant gap between the
chassis and water pump to avoid damage to
A/C high and low pressure pipes while
installing the transmission.
2. To install reverse, the removal procedure.

3. Refill transaxle oil if required. For additional
informtion refer to Transaxle Oil Replace
section.

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Gear Shifter Mechanism 3. Press the two cable locks (A) and disconnect
the cables from the shifter mechanism.
Removal 4. Loosen the four 12mm mounting bolts (A) on

1. Remove the floor center console. For the gear shifter mechanism and separately
additional informtion refer to Floor Console room the gear shifter mechanism.
2. Disconnect the two gear shifter cables (A) from

the gear shifter mechanism.
A
A
A Installation

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Gear Shifter Cable 3. Remove the floor center console. For

additional informtion refer to Floor Console
4. Disconnect the gear shifting cables from gear
selector lever end.
Removal
informtion refer to Battery Tray removal and
installation section. 5. Pull out the cable (A) through dash panel
2. Remove the gear shifter cable form mounting cutout.
bracket and disconnect the cable from
Transaxle housing.

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Installation 3. Using gear shifter cable adjustment pin

1. Insert the cable (A) through dash panel cut out (Special Tool Part No : 0703AAK0004ST) lock
as shown in the figure below. the shift tower at 1st -2nd gear neutral gate
position.
Notice
The provision is given in such a way that the
special tool will lock the shift tower only in 1st
-2nd gear neutral gate position.
A
The lever to be locked by

pin at 1&2 gate
2. Tighten and torque the gear shifter cable

grommet (A) to 8 -12 Nm
A 4. Match the profile and press the selector cables

on the cable mounting bracket as shown
below. Ensure the transaxle end connectors
are positively locked in the provisions given on
the bracket. Press and fit the shifter and
selector cables on the ball pins as shown
below.
First match profile than press Press & fit on the ball pin
cable ensure the lock as per image

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5. Match the profile and press the gear shifter 7. Push down the locking pin and release the
lever end connector of shifter and selector gear shifter lever as shown below.
cables on the shifter mechanism as shown
below. Ensure the end connectors are Need to press the pin to release the 1&2 gate lock
positively locked in the provisions on the shifter

mechanism.
Quick adjuster
Match the profile and press & fit it
8. Remove gear shifter cable adjustment pin

(Special Tool Part No : 0703AAK0004ST) from
the shifter tower at the transaxle end.
6. Hold the gear shifter lever in 1st and 2nd gear 1 & 2 gate lock pin
to be removed
gate neutral position and pull the locking pin
towards up to match with the hole of the gear
shifter lever as shown below. Insert the cables
in their respective quick adjuster and release
the quick adjuster lock as shown below.
Pin has to be locked

at 1&2 gate before
fix the cable
9. Shift the gears and check the movement of the

gear shifter lever without any restriction.
Press the cable & release quick

adjuster lock

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Gear Shifter Mounting Bracket Transaxle Shift Tower

Removal
information refer to Battery Tray removal
Notice
Before removing the shift tower, the gear
should be in neutral position.
2. Using a suitable tool, remove the two selector

cables (A) from shift tower.
Removal A A
1. Remove the gear shifter mechanism. For
additional informtion refer to Gear Shifter
Mechanism removal and installation
section.
2. Loosen the four 12mm mounting bolts (A) on
the gear shifter mounting bracket, and
separately remove the bracket (B).
B
3. Press the selector cable locks (A) and remove
the two cables (B) from the bracket.
Installation
1. To install reverse the removal procedure.

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4. Loosen the five 12mm shift tower mounting

bolts (A) and remove the shift tower (B) from
the transaxle.
Notice
While removing the shift tower, slightly tilt and
remove the shift tower from the transaxle.
B
A
Installation
Notice
Tighten the transaxle shift tower mounting
bolts at 25 to 30 Nm.

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Disassembly and Assembly 5. Remove the four 17mm rear transmission

mounting bracket bolts (A) from PTU side.
Transaxle
Disassembly
1. Remove the transaxle assembly from the
vehicle. For additional information refer to
Transaxle removal and installation section.
A
2. Place the transmission assembly on a suitable
work bench.
3. Remove three 10 mm concentric slave cylinder
mounting bolts (A) and detach the Concentric
Slave Cylinder (B) from the transaxle.
6. Remove the three 17 mm front transmission

A mounting bracket bolts (A).
B
4. Remove the four 17 mm transmission top

mounting bracket bolts (A).
7. Remove the 14 mm gear selector lever cable

holding bracket bolts (A) and remove the
bracket (B).
A A
B

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8. Remove the 10 mm vehicle speed sensor

mounting bolts (A) and remove the sensor B
separately.
A
11. Remove the ten 12 mm transmission rear

cover mounting bolts (A) and remove the rear
cover from the housing.
9. Remove the gear neutral switch (A) from the
transmission assembly.
CAUTION
Care should be taken not to distort the side
cover when side cover is removed from the
rear transmission housing.
10. Remove the five 12 mm selector lever

mounting bolts (A) and detach the selector
lever (B).
Notice
Before removing the shift tower, the gear 12. Remove the shims (A) from the rear cover
should be in neutral position. bores and place the shims in their respective
bores.
Notice
Mark the shims while removing to place back
in their respective position.

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15. Using a 10 mm allen key socket (A), remove

all the three shaft end nuts (B) by double
locking the gears.
A
Notice
A
Both counter shafts end nuts must be
removed in clockwise direction. Center shaft
end nut must be removed normally in anti-
clockwise direction.
A
B
13. Using special tool (A), remove the three snap
rings (B) from the transmission input and
counter shafts.
A
B
A
16. Remove the 12 mm reverse idler shaft lock

bolt (A) from outside of transmission housing.
14. Lock the second and third gear selector fork

(A) inside the transmission.
A

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17. Remove the 13 mm reverse idler shaft lock 19. Take out the differential assembly (A) from its
bolt (A) from the transmission housing. position.
18. Remove all the 12 mm clutch housing main 20. Remove the thrust washer (A) from the
joint bolts (A) and pull out the clutch housing reverse idler shaft sub assembly.
(B).
CAUTION
Care should be taken not to distort the clutch
housing and rear housing.
A
B
A
21. Remove the reverse gear (A) from the
transmission housing.

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22. Remove the reverse gear bearing (A) from its 24. Remove the countershaft 1 (A), countershaft 2
position. (B) and input shaft (C) along with fork (D).
Notice
Before removing the countershaft 1,
countershaft 2 and input shaft, the bearing
load need to be released from the bottom side
A of the shafts.
C B
23. Carefully remove the Reverse Idler Shaft (A)

from its position.
D

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25. Using the gear shift roller bearing removing 27. Using the bearing puller (Special Tool No:
tool (Special Tool No: 0703AAK0002ST) (A), 0703AAK0003ST) (A), remove the differential
hold the selector shaft bearing (B). inner bearing outer cone (B) from the transaxle
front housing.
Notice
Insert tool the into the bearing, expand the
tool by tightening the lock nut to hold the
bearing. A
28. Using the bearing puller (Special Tool No:

0703AAK0003ST) (A), remove the differential
outer bearing cone (B) from the transaxle rear
B
housing.
26. Insert the gear shift roller bearing removing

tool (Special Tool No: 0703AAK0002ST) (A),
remove the selector shaft bearing by tightening A
the nut (B).
B B
A
CAUTION
Ensure no damage to housing while using
pullers.

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29. Remove the counter shafts bearing lock bolts 32. Using a suitable tool (A), remove the transaxle
(A) and input shaft bearing lock bolt (B) from drive shaft oil seal (B) from rear housing.
the transaxle front housing.
B A
A
B
33. Using a suitable tool (A), remove the input

30.Remove the counter shafts bearing (A) and shaft oil seal (B).
input shaft bearing (B) from the transaxle front
housing.
B
B
A
31. Using a suitable tool (A), remove the transaxle

drive shaft oil seal (B) from front housing.

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Counter Shaft - 1 Disassembly 4. Remove the fourth driven gear bearing (A).
1. Using a puller for removing ball bearing
(Special Tool No: 0703DAK0006ST) (A),
remove the Rear End Main Bearing DGBB by
supporting on inner race.
A
5. Remove the third and fourth gear synchronizer

hub (A).
Notice
2. Using a suitable tool, remove the speed tonner No specific direction is assigned to each ball
ring (A) and the fourth thrust washer (B). lock but it is assigned as sleeve and hub as-
sembly.
A
3. Remove the fourth driven gear (A).
6. Remove the third driven gear assembly (A).

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7. Remove the third driven gear bearing (A). 9. Remove the second gear (A).
CAUTION
Do not over expand the third driven gear
bearing to avoid the damage of the bearing.
A
10.Using a circlip plier, remove the snap ring (A).
8. Using the 3 leg puller (Special Tool No:

0502CAA0026ST) (A), remove the second gear
lock bush (B).
CAUTION A
To avoid second gear lock bush and gear

being damaged, support it at side of bearing
puller.
11.Remove the first and second gear synchronizer
hub (A).

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12.Remove the first gear (A). Counter Shaft - 2 Disassembly

1. Using a puller for removing ball bearing
(Special Tool No: 0703DAK0006ST) (A),
remove the Rear End Main Bearing DGBB by
supporting on inner race.
13.Remove the first gear bearing (A) from counter

shaft 1.
CAUTION 2. Remove the sixth thrust washer (A).

Do not over expand the first gear bearing to
avoid the damage of the bearing.
3. Remove the sixth driven gear (A).

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4. Remove the sixth driven gear bearing (A). 6. Fix the 3 leg puller (Special Tool No:
0502CAA0026ST) (A) on the flat bearing puller
(Special Tool No: 0502EAA0007ST) (B), and
CAUTION remove the fifth gear along with fifth sixth
synchro assembly.
Do not over expand the sixth driven gear
bearing to avoid the damage of the bearing.
CAUTION
To avoid gear tooth being damaged, support
it at flat side of bearing puller.
A
C
5. Using a circlip plier (A), remove the fifth and B
sixth synchro hub circlip (B).
Notice
7. Remove the fifth gear bearing (A).
• No specific direction is assigned to each
ball lock but it is assigned as sleeve and hub
assembly.
• Size of high speed synchronizer sleeve,
hub and ball locks is between those of fifth
and sixth gears.
A

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8. Using the 3 leg puller (Special Tool No: 10.Remove the reverse gear synchronizer
0502CAA0026ST) (A), remove the fifth gear assembly (A).
thrust bush (B).
CAUTION
To avoid fifth gear thrust bush being
damaged, support it at flat side of bearing
puller. A
11.Remove the reverse driven gear (A).

A
9. Using a circlip plier (A), remove the

synchronizer circlip (B).
12.Remove the reverse driven gear bearing (A).
A B

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13.Using a 10 mm allen key socket, loosen the Input Shaft Disassembly

shaft end lock nut (A), remove the front end 1. Using the puller for removing ball bearing
main bearing (B). (Special Tool No: 0703DAK0006ST) (A),
remove the input shaft inner bearing.
A
B
A
2. Using the 3 leg puller (Special Tool No:

0502CAA0026ST) (A), remove the input shaft
outer bearing (B).

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Differential Disassembly 3. Place the differential assembly in vise, remove

1. Using the adapter for removing differential the 19 mm ring gear mounting bolts (A) and
cage bearing (Special Tool No: detach the ring gear (B).
0703DAK0002ST) (A), remove the differential
outer bearing (B).
CAUTION
Do not damage the ring gear, while removing
the ring gear.
A A
B
B
2. Using the adapter for removing differential

cage bearing (Special Tool No:
0703DAK0002ST) (A), remove the differential
inner bearing (B).
4. Remove the 12 mm bevel pinion shaft lock bolt
(A) from the differential.
A
B

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5. Using the punch (A), tap the hammer to 7. Detach all the bevel gears (A) and thrust
remove the bevel pinion shaft (B) from washer (B).
differential.
Notice
Mark the bevel gears and thrust washer,
while removing the gears and washer.
A
A
B
6. Pull out the bevel gear (A) and thrust washer

(B).

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Assembly Differential Assembly

Input Shaft Assembly Judging from abnormality noted before disassembly
and what is found though visual check of
Notice component parts after disassembly, prepare
replacing parts and proceed to reassembly. Make
Before installation, wash each part and ap- sure that all parts are clean.
ply specified transaxle oil to sliding faces of
bearing and gears. 1. Assemble differential gear and measure thrust
play of differential gear as follows.
Differential gear thrust play
1. Using the adapter for pressing inner bearing
(Special Tool No: 0703DAK0004ST) (A), install x.xx-x.xx mm
the input shaft outer bearing. Left Side
a. Hold differential assembly with soft jawed vise
and apply measuring tip of dial gauge to top
surface of gear.
b. Using two screwdrivers, move gears (A) up
and down and read movement of dial gauge
pointer (B).
B
A 100
10
20
c
30
80
40
70 50
60
2. Using the adapter for pressing inner bearing A A

(Special Tool No: 0703DAK0004ST) (A), install
the input shaft inner bearing (B).
A Right Side
a. Using similar procedure to the left side, set dial
gauge tip to gear shoulder.
b. Move gears (A) up and down by hand and
read dial gauge (B).
B
B
90
80 0
70
10
60
20
50 30
A
40

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2. If thrust play is out of specification, select 3. Install the washer and tighten the 12 mm bevel
suitable thrust washer from among the pinion shaft lock bolt (A) into the differential.
following available size, install it and check
again that specified gear play is obtained.
Available thrust washer thickness. For additional

information refer to Thrust Washer Thickness
Table.
Notice
Before installation, wash each part and ap-
bearing and gears. A
1. Install the bevel gear (A) and thrust washer

(B).
4. Place the differential assembly in vise, install
the ring gear (A) and tighten the 19 mm ring
gear mounting bolts (B).
A
CAUTION
B
Use of any other bolts than specified ones is
prohibited.
B
2. Using center punch (A) and hammer, install the
bevel pinion shaft (B) into the differential. A

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5. Using the dolley for pressing differential cage Counter Shaft 2 - Assembly
bearing (Special Tool No: 0703DAK0001ST)
(A), install the differential inner bearing (B) to Notice
the differential assembly.
A bearing and gears.
B 1. Using a suitable tool (A) install the front end

bearing (B) into the counter shaft.
6. Using the dolley for pressing differential cage

bearing (Special Tool No: 0703DAK0001ST)
(A), install the differential outer bearing (B) to
the differential assembly.
2. Using a 10 mm allen key socket (A), tighten

the shaft end lock nut.
A
A

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3. Install the first and reverse gear bearing (A). 5. Install the reverse driven gear synchronizer
assembly (A).
Notice
assembly.
hub and ball locks is between those of fifth
A and sixth gears.
4. Install the reverse driven gear (A) in the proper

position.
A
6. Using a circlip plier (A) insert the snap ring (B)

into the groove of the counter shaft 2.
A B

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7. Using a dolley for 5th gear bush pressing 9. Install the fifth gear, and sixth and fifth
(Special tool No: 0703DAK0007ST) (A), install synchronizer assembly (A).
the fifth gear thrust washer (B).
Notice
• Support the shaft with specific tool so that
retainer of bearing cone will be free from
compression.
• Make sure that synchronizer ring key slots
A
are aligned with balls while press-fitting
sleeve and hub assembly.
10.Insert the fifth and sixth gear synchronizer ball

A lock (A).
A
A
B
A
8. Install the fifth gear bearing (A).
11.Install the fifth and sixth gear clutch body ring

A (A) into the correct seating position.

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12.Insert the snap ring (A) of the fixth and sixth 14.Insert the sixth gear thrust washer (A).
gear synchronizer hub (B) assembly.
Notice
A
Do not reuse the snap rings. Always replace
the snap rings.
B
A
15.Using the Adapter for Ball bearing pressing
the Rear End Main Bearing DGBB (B).
Notice
For protection of ball bearing, always sup-
13.Install the sixth gear bearing (A) and sixth gear port the bottom of the shaft with wooden
(B) to the countershaft. piece.
B A

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Counter Shaft 1 - Assembly 3. Insert the clutch body inner ring (A) to the first
gear.
Notice
bearing and gears.
1. Insert the first gear bearing (A) into the

countershaft.
4. Insert the clutch body outer ring (A) to the first

gear.
2. Install the first gear (A) into the countershaft.
5. Install the first and second gear synchronizer

assembly (A).
A

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6. Insert the first and second gear synchronizer 9. Insert the outer clutch body ring (A) to the
ball lock (A) to the synchronizer hub. synchronizer.
A
A
7. Insert the snap ring (A) to lock the first and 10.Insert the inner clutch body ring (A) to the
second gear synchronizer assembly. synchronizer.
A
A
8. Insert the first and second gear synchronizer 11.Insert the second gear bearing (A).
selector ring (A).

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12.Install the second gear (A). 15.Install the third driven gear (A).
A
A
13.Using a dolley for 3rd gear bush pressing 16.Install the inner clutch body ring gear (A).
(Special tool No: 0703DAK0007ST) (A), install
the third gear bush (B).
A
A
17.Install the outer clutch body ring (A) to the

gear.
14.Install the third gear driven bearing (A).

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18.Insert the synchronizer selector ring (A). 20.Insert the third and fourth gear synchronizer
hub ball lock (A).
Notice
assembly.
hub and ball locks is between those of third
and fourth gears.
A
21.Insert the third and fourth gear synchronizer
snap ring (A).
19.Install the third and fourth gear synchronizer

hub (A).
Notice
Fix the synchronizer hub between third and
fourth gear.
22.Insert the third and fourth gear synchronizer

selector ring (A).

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23.Insert the outer clutch body ring gear (A). 26.Install the fourth gear (A).
24.Insert the inner clutch body ring gear (A). 27.Install the fourth gear thrust washer (A).
A A
25.Install the fourth gear bearing (A). 28.Install the speedo toner ring (A).
A
A

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29.Using the Adapter for Ball bearing pressing Transaxle Assembly

the Rear End Main Bearing DGBB (B) to the Notice
counter shaft.
Notice ply specified transaxle oil to sliding faces of
bearing and gears.
For protection of ball bearing, always sup-
port the bottom of the shaft with wooden 1. Using the Adapter for pressing differential case
piece. outer cones (Special Tool No:
0703DAK0003ST) (A), install the differential
inner bearing cone (B) to the transaxle front
housing.
Notice
A
Carefully install the bearing cone to avoid
uneven pressing of the bearing cone.
2. Using the Adapter for pressing differential case

outer cones (Special Tool No:
0703DAK0003ST) (A), install the differential
outer bearing cone (B) to the transaxle rear
housing.

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3. Using the Gear Shift roller bearing pressing 6. Install the counter shaft 1 (A) , counter shaft 2
handle (Special Tool No: 0703AAK0001ST) (A), (B) and input shaft (C) along with fork (D) to
install the selector shaft bearing (B). the transaxle front housing.
C B
B
D
4. Install the counter shaft bearing (A) and input 7. Carefully install the reverse gear r shaft (A) to
shaft (B) bearing to the transaxle front housing. its position.
B
A
5. Install the input shaft bearing lock bolt (A) and 8. Install the reverse gear bearing (A) to its
counter shaft bearing lock bolt (B) to the position.
transaxle front housing.
B
A A

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9. Install the reverse gear (A) to the transmission 12. Apply the loctite (A) to the front and rear
housing. transmission housing.
Notice
Apply loctite 5900 to the transmission clutch
housing and rear housing.
10. Install the thrust washer (A) to the reverse

idler shaft sub assembly.
13. Place the transaxle front housing (A) and align

the dowel pin (B) to the transaxle rear housing
(C).
11. Install the differential assembly (A) to its

position.
B
A C

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14. Install all the 12 mm transaxle housing main 16. Tighten the 13 mm reverse idler shaft bolt (A)
joint bolts (A) and tighten to the specified inside the transmission housing.
torque.
17. Install the three snap rings (A) to the

15. Tighten the 12 mm reverse idler shaft bolt (A) Transmission Input shaft and counter shaft.
outside the transmission housing.
A A
18. Lock the second and third gear selector fork

(A) inside the transmission gears.

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19. Using a 10 mm allen key socket, install all 21. Apply the loctite (A) to the transaxle rear
three shaft end nuts (A) by double locking the cover.
gears.
Notice
A Apply loctite 5900 to the transaxle rear cover.
20. Install the shims to the rear cover bores and

place all shims (A) in their respective bores.
22. Install the rear cover (A) to the housing and

A tighten the ten 12 mm transmission rear cover
mounting bolts (B).
A

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23. Set the shifter (A) in neutral position and then 25. Using an adapter for pressing differential case
apply the loctite to the transaxle shift tower oil seal (Special Tool No : 0703GAK0001ST)
mounting location (B). (A), install the transaxle drive shaft oil seal (B)
to the rear housing.
Notice
Apply loctite 5900 to the transaxle selector
lever mounting location.
B
B
26.Using an adapter for pressing clutch housing

oil seal (Special Tool No: 0703BAK0001ST)
(A), install the transaxle drive shaft oil seal (B)
to the front housing.
24.Install the selector lever and tighten the five 12

mm selector lever mounting bolts (A) to the CAUTION
specified torque.
Take care not to damage the oil seal lip by
drive shaft, or oil leakage may take place.
A
A

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27.Using a dolley for pressing input shaft oil seal 30. Install the neutral switch (A) into the
(Special Tool No: 0703BAK0002ST) (A), install transmission assembly.
the transaxle input shaft oil seal to clutch
housing.
31. Install the bracket and tighten the three 17

mm front mounting bracket bolts (A).
28. Install the two brackets (B) and tighten the 14
mm gear selector lever cable holding bracket
bolts (A).
A
A
B
32. Install the rear bracket and tighten the four

17mm rear mounting bracket bolts (A).
29. Install the vehicle speed sensor (A) into the

tranue.

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33. Install the top mounting bracket (A) and

tighten the four 17 mm transmission top
mounting bracket bolts (B).
34. Install the Concentric Slave Cylinder (A) and

tighten the three 10 mm concentric slave
cylinder mounting bolts (B) to the tranaxle.
B
A
35.Install the transaxle assembly to the vehicle.

For additional information refer to
Transaxle removal and installation section.

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Thrust Washer Thickness Table

SIDE WASHER
ITEM DIMENSION ‘G’
THICKNESS
ABOVE BELOW INCLUDING
1 0.100 0.200 0.711
2 0.200 0.300 0.762
3 0.300 0.400 0.813
4 0.400 0.500 0.864
5 0.500 0.600 0.914
6 0.600 0.700 0.965
7 0.700 0.800 1.016
8 0.800 0.900 1.066

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1. Low oil level. 1. Top up oil.
Gear Whine 2. Worn teeth gears. 2. Replace gears.
3. Worn bearings. 3. Replace bearings.
1. Chipped gear teeth. 1. Replace gears.

2. Remove the foreign matter
2. Foreign matter inside and locate how the foreign
Knocking or
transmission. matter came inside e.g. miss-
ticking ing breather and rectify that
also to avoid recurrence.
3. Defective bearings. 3. Replace the bearings.
1. Defective detent 1. Replace the detent springs.

springs.
2. Worn out grooves in 2. Replace the shift rails.

shift rail.
Jumping out of 3. Shaft misalignment. 3. Replace the gears.

gear
4. Worn dog teeth in gear.
5. Worn out fork/fork 4. Replace the forks/pads.

pads.
6. Worn out synchronizer 5. Replace the body.

body.
1. Clutch defective. 1. Rectify the clutch/clutch with-

drawl mechanism.
Unable to select gear
2. Worn out selector 2. Rectify the gear selector
mechanism. mechanism.
1. Clutch defective. 1. Rectify the clutch/clutch with-

drawl mechanism.
Hard gear shifting
2. Improper or contami- 2. Replace the lubricant with
nated lubricants. specified lubricant.

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Gear Shift Roller Bearing Pressing

0703AAK0001ST
Handle
Gear Shift Roller Bearing Removing

0703AAK0002ST
Tool
Bearing Puller (PTU input shaft bear-

ing outer cones, Counter shaft bearing
0703AAK0003ST outer cones, Transaxle input shaft in-
ner bearing, Transaxle C/S inner bear-
ings,Transaxle diff bearing outer cones)
0703AAK0004ST Gear Shifter Cable Adjustment Pin

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Adapter for Pressing Differential Case

0703GAK0001ST
Oil Seal
Adapter for Pressing Clutch Housing

0703BAK0001ST
Oil Seal
Dolley for Pressing Differential Cage

0703DAK0001ST
Bearing on Both Sides TR - 6
Adapter for removing (Transaxle Differ-

0703DAK0002ST ential cage bearings and PTU pinion
bearings)

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Adapter for Pressing Differential Case

0703DAK0003ST
Outer Cones
Adapter for pressing inner bearing on

0703DAK0004ST (COUNTER SHAFT 1 AND 2 AND IN-
PUT SHAFT)
Adapter for Ball bearing pressing -(

0703DAK0005ST COUNTER SHAFT 1 AND 2 AND IN-
PUT SHAFT)
Puller for removing Ball bearing on (

0703DAK0006ST COUNTER SHAFT 1 AND 2 AND IN-
PUT SHAFT)

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0703BAK0002ST Dolley for Pressing Input Shaft Oil Seal
Dolley for 3rd and 5th Gear Bush

0703DAK0007ST
Pressing

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Type 6 speed synchromesh
No of gears 6 forward, 1 reverse
Gear ratio Transaxle ratio Final drive ratio Overall ratio
First 4.15 4.05 16.823
Second 2.14 4.05 8.679
Third 1.24 4.05 5.035
Fourth 0.94 4.05 3.842
Fifth 1.02 3.115 3.2
Sixth 0.87 3.115 2.716
Reverse 4.96 3.115 15.457
Transaxle Oil
Type MAHINDRA "MAXIMILE SYNTEC 75W-90
Qty 3.0 lit
Specs Special Manual Transmission Fluid

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Quan- Torque in
Part Bolt Specification Place of Application
tity Nm
BOLT HEX FL Gear shift housing to floor 20 ~ 125

4
Gear Shift hous- M8X1.25X30X8.8
ing
SCREW HEX FL M8X1.25X15X8.8 Gear shift housing to floor 4 20 ~ 125
Grommet SCREW HEX FL Grommet to dash panel 2 8.0~10.0

M6X1X20X8.8XGR
Transaxle Drain 25 ~ 30
and Filler Plug
FLANGE BOLT M6X1.0X15L HOUSING ( oil reducer & 2 7 ~ 12

speedo sensor )
BEARING RETAINER SCREW BEARING RETAINER 3 7 ~ 12

SCREW
SCREW HEX FL HOUSING ( rear cover ) 10 20 ~ 25

M8X1.25X20X8.8XPH
SCREW HEX FL HOUSING ( shifte tower ) 3 25 ~ 30

M8X1.25X20X8.8XPH
Transaxle
FLANGE BOLT M8X1.25X25L HOUSING ( Rev idler 1 25 ~ 30
locking from side )
FLANGE BOLT M8X1.25X35L HOUSING ( Rev locking 1 25 ~ 30

in front housing )
BOLT HEX FL CLAMING TO HOUSING 17 25 ~ 30

M8X1.25X50X8.8XPH EACH OTHER
FILLER PLUG FILLER PLUG 1 25 ~ 30
REV LAMP SWITCH NGT520 REV LAMP SWITCH 1 25 ~ 30

NGT520
SCREW HEX FL SL BRACKET FOR CABLE 3 35 ~ 40

M10X1.5X20X8.8 SHIFT
STUD BOTH END CLUTCH HOUSING ASS- 1 25 ~ 30

M10X1.5X23X8.8 LY
O/P SHAFT END NUT LH O/P SHAFT END NUT 1 80 ~ 95

M18X1.5X22L
O/P SHAFT END NUT RH O/P SHAFT END NUT 1 80 ~ 95

M18X1.5X22L
O/P SHAFT END NUT RH O/P SHAFT END NUT 1 35 ~ 40

M18X1.5X22L

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Quan- Torque in
Part Bolt Specification Place of Application
tity Nm
FLANGE BOLT M12X1.25X27L DIFF CASE ASSLY 10 80 ~ 95
DRAIN PLUG DRAIN PLUG 1 25 ~ 30
BOLT SHOULDER M8X1.25 HOUSING ( shifte tower ) 2 20 ~ 25

Transaxle
NEUTRAL SENSOR NEUTRAL SENSOR 1 35 ~ 40
PLUG CLUTCH HSG CLUTCH HSG 2 25 ~ 30
PLUG M22X 1.5 NS WITHOUT NUTRAL SEN- 1 25 ~ 30

SOR

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Repair Manual Drive Shaft Nov 2011/ Rev 2
DRIVE SHAFT
CONTENTS

Front Halfshaft LH/RH ........................................................................ 3
Front Halfshaft LH - Exploded View ................................................... 4
Front Halfshaft RH - Exploded View .................................................. 4
Rear Halfshaft LH/RH ........................................................................ 5
Rear Halfshaft LH/RH - Exploded View ............................................. 5
Incar Repairs ....................................................................................7
Front HalfShaft LH ........................................................................7

Removal ............................................................................................. 7
Installation .......................................................................................... 8
Front HalfShaft RH .......................................................................9

Removal ............................................................................................. 9
Installation ........................................................................................ 10
Rear Halfshaft LH (Applicable for All Wheel Drive Vehicle) ..11

Removal ........................................................................................... 11
Installation ........................................................................................ 11
Rear Halfshaft RH (Applicable for All Wheel Drive Vehicle) ..11

Removal ........................................................................................... 11
Installation ........................................................................................ 11
Disassembly and Assembly .........................................................12

Front Halfshaft - RH and LH............................................................. 12
Disassembly..................................................................................... 12
Assembly .......................................................................................... 13

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Drive Shaft
Outboard joint Small seal Inboard joint

retaining clamp
Axle shaft
Large seal retaining Large seal retaining
clamp(CV side) Triglide seal clamp tripot sude
CV boot seal inboard seal
out board seal
Wheel Half Shafts – To protect the internal parts of the inboard

and outboard joint by protecting the grease
Wheel half shaft assemblies are flexible assemblies,
from surrounding detrimental atmospheric
which transmit engine power to independently conditions such as stones, dirt, water, salt,
suspended wheels. They consist of an inner and etc.
outer constant velocity joint connected by an axle
– Facilitate angular and axial movement as
shaft. The inner joint is completely flexible and can
applicable for inboard and outboard joints.
move in and out. The outer joint is also flexible, but
cannot move in and out. Clamps
Seals These are made of stainless steel. The clamps
provide a leak proof connection at housing and axle
• Shaft assemblies use inboard and outboard joint
shaft for the inboard and outboard joints.
seals. The inboard seal is made of Neoprene
rubber and the outboard seal is made of
thermoplastic material. The thermoplastic
Outer Joint (Out Board Joint)
material performs well against normal handling The outer joints use the Constant Velocity (CV) joint
and operational wear conditions. However, it is design, which is the standard outboard joint for front
not strong enough to withstand abusive handling wheel drive cars. It is a fixed centre ball type joint.
or damage due to objects such as sharp tools or The outer housing is made using special steels by
the sharp edges of any other surrounding cold forming process followed by heat treatment. The
component in the vehicle
cold formed surfaces give superior wear resistance
• The functions of the seal are as below: and increased joint life. The main function of the
outboard joint is to allow the vehicle’s wheels to turn
during steering operation or have a steer capability.

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Inner Joint (In Board Joint)

This is a Constant Velocity universal joint radically
self supported and permitting axial movement
consisting of a housing drivably connected to the
axle shaft through three equally spaced transmission
mounted balls. These are made of special steels
through complex forming process followed by heat
treatment. The main function of the inboard joint is to
allow the halfshaft assembly to compensate for
suspension movement in the vehicle by allowing the
shaft to move axially or stroke in the inboard housing.
Axle Shaft
The axle shaft simply connects the inboard joint and
the outboard joint. It is made out of special steel heat
treated to give optimum strength and fatigue
performance. The function of the axle shaft is to
transmit torque and rotation to the wheel from the
transmission.

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Front Halfshaft LH/RH
LH
32 Sz 32 Sz
RH 01 Set
32 Sz 32 Sz

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Front Halfshaft LH - Exploded View

Axle retainer
ring
CV CV
outer ball
CV Inner
CV big
cage race
clamp
CV boot
Axle small
clamp
Axle bar
Outer ball
Needle Trilobe
Inner ball bushing Triglage
Spider housing
Shank ret
Axle small ring
clamp
Triglade
boot Triglade big
clamp
Spider ret
ring
Front Halfshaft RH - Exploded View

Axle retainer
CV ring CV
outer ball
OB-32T
Inner CV big
CV
race clamp
cage CV boot
Axle small
clamp
OB-34T Axle bar Triglade Triglade big

Axle small boot clamp
clamp Spider ret
ring
IB-34T
Spider
Inner ball
Needle
Bearing Outer ball
IB-26T
Trilobe Triglage
bushing housing
Bearing ret
Triglage ring
housing Bearing ret
ring

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Rear Halfshaft LH/RH
X2 01 Set
14 Sz 14 Sz
Rear Halfshaft LH/RH - Exploded View

Spider assembly
Big clamp
Out board tripot

Boot
Trilobe bushing
Small clamp
Axle bar
Small clamp
Boot Trilobe bushing
In board tripot
Big clamp
Slinger
Spider assembly
Shank ret ring

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Service Tips and Precautions Note B

Half shafts must be stored in their original shipping
containers until assembled into vehicle. It is Take all precautions to avoid any contact
important to take all precautions to avoid stacking between the inboard and outboard seals and
half shafts on top of each other. The seals and any surface which may cause a cut, nick or
deflecting rings are extremely delicate and any cut, abrasion. The seals are extremely delicate and
nick, or abrasion may reduce the performance of critical to the performance to the halfshaft. Do
the half shaft and lead to a dissatisfied customer. not allow the seals to contact other halfshafts,
workbenches, the vehicle frame, lower control
arm, or any other chassis component. If
Note A Note E
grease leakage is observed from either seal,
the halfshaft should be removed from the
vehicle, handled with care, and returned to
Note F Delphi for analysis.
Note C
Clamps should be in position and tight. If
clamps are loose, don't install into vehicle.
Note G Return to Delphi for analysis
Note B
Note C Note H
Note D
Note D
To prevent damage to the internal compo-
nents of the inboard joint, take all precautions
to avoid over extending the joints.
Note E
Protect this surface from nicks and scratches.
Damage to this surface may reduce the perfor-
mance of the mating seal.
Note F
Note A Protect deflector ring from impacts, which
could cause dents. A dented/Damaged deflec-
If Out board joint must be angulated to fit the
tor ring may result in an interference condition
half shaft assembly into the vehicle, all pre-
and affect the seal.
cautions should be taken to avoid damaging
the surface of the threads and splines. During
installation.

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Incar Repairs
Note G
Eared clamp must be in position and crimped. Front HalfShaft LH
Take precaution to avoid all contact between
the ear of the clamp and any object, which Removal
may bend/crush, the "ear". Adamaged "ear" 1. Using a suitable tool, release the lock (A) of
will decrease the clamping load, which may the halfshaft locknut.
cause grease leakage and/or intrusion of
water/debris.
Note H
Take the precaution to avoid all contact A
between the inboard seal and the tooling used
to insert the assembly into the transmission.
Contact between the seal and the tooling will
cause a seal peak abrasion which may reduce
the life of the seal and lead to dissatisfied cus-
tomer.
2. Loosen the 36mm halfshaft lock nut without

lifting the vehicle and remove the halfshaft
lock.
3. Lift the vehicle and remove the wheel. For addi-

tional informtion refer to Wheels removal and

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4. Remove the 36mm LHS halfshaft lock nut (A).

Notice
While removing halfshaft, support the lower
control arm using jack to avoid damage of
halfshaft rubber boot and brake disc.
A
8. Detach the halfshaft from the LH knuckle.
9. Remove the LH halfshaft assembly from the
transmission.
Notice
While removing the LHS halfshaft, collect the
oil from the transmission using a container to
avoid oil spilling.
5. Remove the tie rod end. For additional inform-

tion refer to Tie-rod Ends removal and instal- Installation
lation section. 1. To install, reverse the removal procedure.
6. Unclip the wheel speed sensor wire (A) from
the strut assembly.
7. Remove the two 24mm strut mounting bolts (A)

and nuts (B) from bottom of the strut assembly.

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Front HalfShaft RH 4. Remove the 36mm RHS halfshaft lock nut (A).
Removal
1. Using a suitable tool, release the lock (A) of
the halfshaft locknut.

tion refer to Tie-rod Ends removal and instal-
lation section.
6. Unclip the wheel speed sensor wire (A) from
2. Loosen the 36mm halfshaft lock nut without the strut assembly.
lifting the vehicle and remove the halfshaft
lock.

3. Lift the vehicle and remove the wheel. For addi-
tional informtion refer to Wheels removal and

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11.Remove the RH halfshaft (A) from the PTU (B)

Notice (Applicable for All Wheel Drive Vehicle) .
While removing halfshaft, support the lower
control arm using jack to avoid damage of A
halfshaft rubber boot and brake disc. B
8. Remove the halfshaft (A) from the RH knuckle

(B).
B Notice
A
While removing the RHS halfshaft, collect the
oil from the PTU using a container to avoid oil
spilling.
9. Remove the three 14mm halfshaft spiral joint Installation

mounting bolts (A). 1. To install, reverse the removal procedure.
10. Remove the RH halfshaft assembly from the

transmission (Applicable for Two Wheel Drive
Vehicle).
Notice
While removing the RHS halfshaft, collect the
oil from the transmission using a container to
avoid oil spilling.

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Rear Halfshaft LH (Applicable for Rear Halfshaft RH (Applicable for

All Wheel Drive Vehicle) All Wheel Drive Vehicle)
Removal Removal
1. Remove the rear brake disc. For additional 1. Remove the rear brake disc. For additional
informtion refer to Rear Brake Disc removal informtion refer to Rear Brake Disc removal
and installation section. and installation section.
2. Remove the rear wheel hub. For additional 2. Remove the rear wheel hub. For additional
informtion refer to Rear Wheel Hub removal informtion refer to Rear Wheel Hub removal
3. Remove the LHS halfshaft assembly (A) from 3. Remove the RHS halfshaft assembly (A) from
the IRDA. the IRDA.
Notice
While removing the rear LHS halfshaft, collect
the oil from the IRDA using a container to
avoid oil spilling.
Notice
While removing the rear RHS halfshaft, collect
the oil from the IRDA using a container to
avoid oil spilling.
Installation Installation
Notice Notice
Install the rear RHS halfshaft carefully to avoid
Install the rear LHS halfshaft carefully to avoid
damage of oil seal in IRDA.
damage of oil seal in IRDA.

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Disassembly and Assembly 3. Separate the housing assembly from the seal
at large diameter as shown in below image.
Front Halfshaft - RH and LH Slide the seal away from the joint along axle
shaft.
Disassembly
1. Hold the centre of the axle shaft in the vice as
shown in below image and clean the shaft
thoroughly, using cleaning solvent.
4. Remove the spider assembly retainer ring by

using screw-driver as shown in below image
and discard the retaining ring.
Note
Do not damage the sealing surface of outer
housing.
2. Remove the small / Big seal retaining clamp

from the axle shaft with a side cutter or by
tapping the clamp ear junction by screw-driver
with rounded edge as shown in the below
image. Discard the small retaining clamp.
5. Remove the tripot spider assembly from the

axle shaft as shown in below image. If required
tap the spider assembly gently using a nylon
mallet.
Note
The screw-driver should not damage the seal.

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6. Clean the following items thoroughly with 2. Place the tripot spider assembly on to the drive
cleaning solvent. Remove all traces of old axle shaft. Assemble the spider assembly to
grease and any contaminates. the axle shaft and tap gently if required. Insert
• The triglide the new retainer ring using the plier as shown
in the below image. Important: Ensure that the
• Needle rollers ring is fully seated in the groove on the axle.
• Housing
Dry all the parts. Inspect these parts for damage
or wear. (If any of the parts are damaged, the
entire sub-assembly along with the outer
housing needs to be replaced.) After this remove
the seal from the axle shaft
Assembly
1. Install the new small seal retaining clamp on
the neck of the seal. Do not crimp the small
seal retaining clamp. Slide the tripot seal into
the axle shaft, passing over the seal grooves
of the axle shaft towards the CV end of the
axle as shown in below image.
3. Transfer approximately half of the grease from

the service kit into the seal and another half
grease into the tripot housing. Slide the
housing over the spider assembly on the shaft.
Engage the tripot seal with the tripot outer as
shown in the below image.
Note
The end of the tripot seal must be next to the
seal stop on the housing.

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4. Slide the new large seal retaining clamp over

the housing as shown in the below image.
Position the joint assembly at the proper
vehicle dimension for R.H Shaft the distance
should be 759.05 ±1mm and for the L.H. Shaft
488.05 ±1mm (refer fig-13 for details) and
equalise air pressure by lifting the boot seal by
inserting round edged tool.
5. Align the seal bigger dia on the housing and

position the big seal retaining clamp in its
place and crimp the large seal-retaining clamp
(Big clamp) First & small clamp second using
crimping tool as shown in the below image.

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Assembly Requirement
ACTION REASON
DO: Install halfshaft from shipping container directly DO: To prevent cuts and damage to CV boot seal.
to wheel hub on vehicle.or side Gear of Transmis-
sion, and support the Hanger till while side assem-
bly complete.
DO: Keep CV threads free from grease. DO: To prevent improper wheel nut torque and dam-
age to wheel hub bearing.
DO: Perform halfshaft retention checks. DO: To prevent halfshaft disengagement from trans-
mission.
DO NOT: Angulated CV joint by placing it into a DO NOT: To prevent damage to splines and CV joint
shipping bin post or opening on a wire bin. threads.
DO NOT: Stack halfshafts on tables, etc. in the as- DO NOT: To prevent damage to boot seals and
sembly area. clamps, threads and splines.
DO NOT: Over-extend halfshaft assembly by allow- DO NOT: To prevent damage to boots, splines,
ing the halfshaft to hang unsupported. clamps and threads.
DO NOT: To prevent damage to boots, splines, Prevents damage to spider roller bearings, inboard
clamps and threads. boot seals, and tripot housing.
General Guidelines For Testing Drive Shaft Testing for Noise

Noise
Checking for Wheel Side (CV) Joint Noise
• Ensure that the DRIVER is alone in the vehicle
(This noise will appear to emanate closer to the
while conducting the test
wheel, rather than the engine).
• All the windows of the vehicle should be fully
rolled-up to reduce the disturbances caused by 1. Shift to the 2nd gear and maintain a steady
external noises. speed between 20 and 30 kmph.
• Drive on a smooth stretch of road and pay 2. Drive the car to form a figure of “8” as shown
particular attention to various noises emanating in the figure alongside. Identify an audible and
from the front portion of the vehicle. Observe persistent “Cluck” – like noise during either an
the changes in noise levels through speeds extreme left or extreme right turn.
between 10 and 60 kmph 3. The “Clucking” noise on a particular turn can
be confirmed by repeating the turn.
• It should be noted here that the driver may
encounter difficulty in distinguishing between
similar sounding noises resulting from either Extreme
the drive shaft or the under body (for example RIGHT
noise from Strut & Calliper). Turn
• Therefore, it is advised that the car be driven
on uneven and bumpy surfaces as well, to
observe the noises which may then be
attributable to the under-body.
• Focus on that side of the car being considered
for the drive shaft warranty.
• Tests for CV (wheel side) and Inboard (engine Extreme
side) joints are different and need to be LEFT
conducted separately. Turn

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Checking for Engine Side Joint Noise

(This noise will appear closer to the engine, than
the wheel).
1. Shift to the 4th gear and maintain a steady
speed between 40 and 60 kmph.
2. Shift to the 4th gear and maintain a steady
speed between 40 and 60 kmph.
3. Identify an audible ”Dug” sounding noise as the
car decelerates. As the car slows down, it will
be observed that the sound will become louder
and occur after longer intervals.
Other Useful Observation Will Include
SYPTOMS DIAGNOSIS
Noise accompanied A. Vibration could be from

by a vibration of the the calipers and not from
brake pedal the drive shaft.
B. If there is NO vibration
on the pedal, the noise
may be from the drive
shaft
• Ensure the parts are free from External dam-

ages on boot seal or clamps are not tampered
during service.

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Torque in
Nm
SCREW HEX FL
2 40.0 ~ 50.0
M10X1.5X30X8.8XZN
CV Joint Bracket to Engine
Block
Front CV Joints BOLT HEX FL
1 40.0 ~ 50.0
M10X1.5X63X8.8,A
NUT HEX FL - M24x2x21 At Wheel Ends 2 200.0 ~ 260.0
Rear CV Joints NUT HEX FL - 2

At Wheel Ends 200.0 ~ 250.0
M24x2x21

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Repair Manual AWD Nov 2011/ Rev 2
ALL WHEEL DRIVE (AWD) SYSTEM
CONTENTS

AWD Layout ....................................................................................... 1
Components of AWD System ............................................................ 2
Component Location Index - IRDA................................................. 5
Component Location Index - PTU ..................................................6
Incar Repairs .................................................................................... 7
IRDA Oil Replacement .................................................................7
Independent Rear Drive Axle (IRDA) .......................................... 8

Removal ............................................................................................. 8
Installation .......................................................................................... 9
ITM ................................................................................................. 9
Removal ............................................................................................. 9
Installation .......................................................................................... 9
PTU Oil Replacement ................................................................. 10
Power Take Off Unit (PTU) ........................................................11

Removal ........................................................................................... 11
Installation ........................................................................................ 13
Disassembly and Assembly.......................................................... 13
Safety Information ......................................................................13
Safety Precautions .....................................................................14
General Important Safety Notice ...............................................14
Independent Rear Drive Axle (IRDA) ........................................15

Disassembly ..................................................................................... 15
Assembly .......................................................................................... 19

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Power Take Off Unit (PTU) ....................................................... 27

Disassembly..................................................................................... 27
Inspection......................................................................................... 33
Assembly.......................................................................................... 33

IRDA ................................................................................................ 43
PTU .................................................................................................. 49
Technical Specification ................................................................. 53

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All Wheel Drive (AWD) System

AWD Layout
1 8
0 - 42%
7
3 4
2
9 6
5 10
1. Engine ITM system includes electro-magnetically operated

2. Transaxle Clutch which is controlled by an ECU. According to
the driving conditions this system automatically
3. Power Take Off Unit (PTU) delivers torque to rear wheels.
4. Propeller shaft
Distinguishing Characteristics
5. Front axle
• Front and rear axles receive power all the time.
6. Rear axle
• A driver has no way of switching to 2WD.
7. Independent Rear Drive Axle (IRDA)
• Requires a center differential, two drive shafts,
8. Electromagnetic clutch two axle differentials and two powered axles.
9. Data bus Connection • Does not include a transfer case.
10. AWD Electronic Control Unit (ECU) Advantages
All Wheel Drive (AWD) vehicle is equipped with • AWD vehicles tend to offer respectable fuel
Interactive Torque Management (ITM) System economy compared with other types of 4WD
which intelligently transfers torque to all four vehicles.
wheels.
• In AWD vehicles, drivers don't have to activate
It works like a permanent 4WD system by providing the system. They have continuous traction
continuous power to front and rear axles. There is from all four wheels.
no way to turn off the AWD feature, and a driver
doesn't have to do anything to activate it.

MAN-00162
Components of AWD System

1.Power Take Off Unit (PTU)
A
To
B
rqu
e
ou
in
t
e
o rqu
T
A. To Propeller Shaft
B. Helical Gear Pair
C. Hypoid Pair
D. Internal Splines Mate With Transaxle
Differential Case
Function
• Provide Full Time or On Demand torque
distribution between Front and Rear axle.
• PTU components include helical and hypoid
gear set (2 stage torque reduction).

MAN-00162
2.Independent Rear Drive Axle (IRDA)
in
q ue
Tor
A
To
rq
u
eo
ut
To
rq
ue
ou
t
A. IRDA
B. ITM
Function
• To transfer torque and motion to rear wheels.

MAN-00162
3.Interactive Torque Management (ITM) AWD LOCK

A unique feature which works like a permanent All To activate this mode, press "AWD LOCK" switch
Wheel Drive (AWD), the ITM monitors the torque provided on vehicle facia, the LED on the switch
flow to each individual wheel. If a wheel begins to turns "ON". In this mode fixed amount of torque is
slip, torque is automatically directed to the wheels transferred to REAR wheels irrespective of driving
with traction. ITM monitors wheel speed, steering condition. Vehicle can be operated in this mode ON
position and acceleration pedal position and road as well as OFF the road.
distributes torque accordingly:
To turn off the "AWD LOCK" mode press the same
A. Transfers torque to the wheel with better switch once again. The LED on the switch turns
traction without Driver intervention i.e. Torque "OFF".
distribution between front and rear wheels
AWD Indicator
B. Directional Stability: Prevents vehicle's
tendency to Understeer or Oversteer during
cornering
C. Better hill climbing ability i.e. Improvement in
Grade-ability
AWD malfunction indicator turns "ON" when there
D. Enhancement in Acceleration performance is malfunction in the ITM system.
• The four-wheel-drive system communicates via Towing Instruction (Safety instruction)
the high-speed CAN data bus in interaction
with the ESP and EMS. "While towing on two wheels, propeller shaft needs
to disconnected in order to protect the coupling".
• Receives important information like:Wheel
Propeller shaft need not be disconnected while
Speed, Steering angle, Accelerator pedal
towing on all four wheels.
position.
• Evaluates the data on a permanent basis.
• Normally, this is used on straight front-wheel-
drive vehicle, which means that the clutch to
the rear axle is opened. However, if the
electronic system identifies a need to
intervene, it will, within 100 milliseconds,
redistribute the torque between the front and
rear axle.
Using ITM system

ITM system is available in two operating positions
viz., 'AUTO' mode and 'AWD LOCK' mode.
AUTO MODE
Vehicle is by default in 'AUTO' mode. Once the
ignition key is turned ON, ITM system turns into
AUTO mode. In Auto mode, whenever any slippage
is detected in FRONT wheels (slippery surfaces like
icy roads, wet surfaces, etc.) the torque is
transferred to the REAR wheels by ITM system.

MAN-00162
Component Location Index - IRDA
1. Carrier HSG 23.Drain Plug Special

2. Screw Special Bracket Cap 24.Filler Plug Special
3. Hypoid Gear and Pinion Assembly 25.Screw - Flance Head
4. Differential Assembly
5. Pinion Mate Shaft
6. Pin Roller Bearing
7. Thrust Washer
8. Washer Spherical
9. Side Gear
10.Pinion Mate Gear
11.Differential Case
12.Screw Special Drive Gear
13.Nut Special Pinion
14.KIT Bearing Pinion Outer
15.KIT Bearing Pinion Inner
16.Cup Bearing
17.Cone Bearing
18.Shim - ADJ
19.Spacer -Collapsible and Seal - Oil
20.Bracket HSG Assembly - RH and LH
21.HSG Cover Assembly
22.Screw Special HSG

MAN-00162
Component Location Index - PTU
1. Housing Power Takeoff Unit

2. Nipple Breather
3. Hose Breather Rear Axle To Inter
4. Breather Assembly
5. Filler Plug
6. Drain Plug
7. Dowel - Case
8. Cover Power Takeoff Unit
9. Dust Deflector PTU
10.Screw Hex Flange
11.PTU Mounting Bracket
12.Screw Hex Flange
13.Screw Hex Flange
14.Housing Pinion Cartridge PTU
15.Dust Shield - Output
16.Companion Flange
17.O Ring Pinion Housing
18.Screw Hex

MAN-00162
Incar Repairs 5. Refill the oil into the oil filling plug if the oil
level is below the maximum level mark (A).
IRDA Oil Replacement

1. Lift the vehicle. A
2. Using a 8 mm allen key, remove the IRDA oil
filling plug (A) from IRDA (B).
B
value.
7. Refill IRDA oil as per below given
specifications:
IRDA OIL: MAHINDRA "MAXIMILE DO 80W-90
3. Place a large drain pan below the drain plug. EXL"
4. Using a 8 mm allen key, remove the oil QTY: 1.2 LIT
draining plug (A) from IRDA (B) and drain the 8. Tighten the filler plug to specified torque value.
oil.

MAN-00162
Independent Rear Drive Axle 8. Loosen three 17mm mounting bolts (A) from
the yoke and remove rear side of the propeller
(IRDA) shaft from the rear differential.
Removal
additional informtion refer to Battery removal
2. Raise and support the vehicle. For additional
informtion refer to Jacking and Lifting sec- A
tion.
3. Loosen and remove the spare wheel.For addi-
tional informtion refer to Spare Wheel
4. Disconnect the IRDA electrical connectors from
IRDA.
5. Remove the drain plug (A) from IRDA (B) and
drain the oil. 9. Loosen two 13mm center bearing mounting
bolts (A) from the under chassis frame and
detach the propeller shaft from the vehicle.
B A
A
6. Remove the muffler. For additional informtion
refer to Muffler removal and installation sec-
tion.
7. Loosen four 13mm mounting bolts (A) from the
yoke and remove front side of the propeller
shaft from the power transfer unit (PTU).

MAN-00162
10.Remove the Rear drive shaft. For additional

informtion refer to Rear Halfshaft LH
ITM
(Applicable for All Wheel Drive Vehicle) Removal
removal and installation section. For
1. Remove the IRDA assembly. For additional
additional informtion refer to Rear Halfshaft
informtion refer to Independent Rear Drive
RH (Applicable for All Wheel Drive Vehicle)
Axle (IRDA) removal and installation
section.
11. Using hydraulic stand (A) support the IRDA,
2. Remove the two 13 mm mounting bolts (A)
loosen the four 17mm mounting bolts (B) on
from RHS of the ITM assembly (B).
the IRDA and detach the IRDA from the rear
cradle.
A
A
3. Remove the two 13 mm mounting bolts (A)

from LHS of the ITM assembly (B) and detach
Installation ITM from the IRDA.
Installation
1. To install reverse, the removal procedure.
Notice
Never reuse the same IRDA Fluid after
draining. Always use new IRDA fluid.

MAN-00162
PTU Oil Replacement 5. Using a 10mm allen key, remove the PTU oil
filling plug (A) from PTU (B).
1. Lift the vehicle.
2. Remove twelve 10 mm mounting bolts (A) and A
remove engine underbody cover (B) from the
front cradle.
A B
B
value.
7. Refill PTU oil as per below given
specifications:
3. Place a large drain pan below the drain plug. PTU OIL: MAHINDRA "MAXIMILE DO 80W-90
4. Using a 10 mm allen key, remove the oil EXL"
draining plug (A) from the PTU (B) and drain QTY:0.8 LIT
the oil.
8. Tighten the filler plug to specified torque value.

MAN-00162
Power Take Off Unit (PTU) 3. Loosen the 36mm drive shaft lock nut without
lifting the vehicle and remove the drive shaft
lock.
Removal
1. Using a 10 mm allen key, remove the oil 4. Lift the vehicle and remove the wheel. For addi-
draining plug (A) from the PTU (B) and drain tional informtion refer to Wheels removal and
the oil. installation section.
5. Remove the 36mm drive shaft lock nut (A).
B
2. Using a suitable tool, release the lock (A) of

the drive shaft locknut.
tion refer to Tie-rod Ends removal and instal-
lation section.

MAN-00162
7. Unclip the wheel speed sensor wire (A) from 10. Remove the three 14mm drive shaft spiral
the strut assembly. joint mounting bolts (A).
A
A
8. Remove the two 24mm strut mounting bolts (A) 11. Remove the RH drive shaft assembly from the
and nuts (B) from bottom of the strut assembly. PTU.
12. Remove the four 13 mm propeller shaft
mounting bolts (A) from the PTU.
A A
Notice
Support the lower arm to avoid any damage to 13. Remove the two 12mm mounting bolts (A),
the drive shaft rubber boot and the brake disc. two 14mm mounting bolts (B) and remove the
PTU mounting bracket (C) from the PTU.
9. Detach the drive shaft from the RH knuckle.
C
A
B

MAN-00162
14. Remove the four 12mm mounting bolts (A) top Disassembly and Assembly
and bottom side of the PTU (B).
Safety Information
B
WARNING
Failure to follow these instructions could
affect vehicle performance and/or safety and
result in personal injury or death.
A
WARNING
Do not convert or alter axles:
• Improper conversion or alteration of
15. Carefully detach the PTU assembly and place these axles can damage the axles and/or
it in a dust free zone. other vehicle systems.
Do not change axle gear ratios on vehicles
with anti-lock braking systems:
• Vehicle with anti-lock braking systems
may utilize sensors and tone rings within the
axle housings to ensure the functioning of
the anti-lock brakes. Improperly changing the
axle ratios may defeat the anti-lock braking
system.
Do not reuse or substitute Ring Gear Bolts,
OIl Seals:
• If you reuse a ring gear bolt/oil seals or
substitute an inferior quality parts, can cause
severe damage to the axle gears and other
Installation components and possibly resulting in a
1. To install reverse, the removal procedure. sudden “locking up” of the axle and loss of
control of the vehicle.
Notice • Always use AXLE COMPONENTS
Never reuse the same PTU fluid after specifically recommended for the application
draining. Always use new PTU fluid. and install bolts using proper tools and
torquing to the proper specifications.

MAN-00162
Safety Precautions General Important Safety Notice
CAUTION CAUTION
A serious or fatal injury can occur: The use of non-original equipment
replacement a part is not recommended as
• If you lack proper training
their use may cause unit failure and/or
• If you fail to follow proper procedures affect vehicle safety.
• If you do not use proper tools and safety Proper service and repair is important to the
equipments safe, reliable operation. The service
procedures recommended and described in
• If you assemble components improperly this service manual are effective methods
• If you use incompatible components for performing service operations. Some of
these service operations require the use of
• If you use worn-out or damaged tools specially designed for the purpose.
components The special tool should be used when and
• If you use components in a non-approved as recommended.
application.
CAUTION
CAUTION Extreme care should be exercised when
Safety Glasses should be worn at all times working on components utilizing snap rings
when working on vehicle or vehicle or spring loaded retention devices. For
components. personal safety, it is recommended that
industrial strength safety goggles or glasses
be worn whenever repair work is being done
on any vehicle or vehicle components.

MAN-00162
Independent Rear Drive Axle 5. Loosen the 13 mm IRDA bracket mounting

bolts (A) (4 nos) and remove the brackets (B)
(IRDA) from both sides of the IRDA.
Disassembly
1. Drain the IRDA oil.For additional informtion
refer to PTU Oil Replacement section.
2. Remove the IRDA along with ITM.For
additional informtion refer to Independent
Rear Drive Axle (IRDA) removal and A
installation section. B
3. Remove all 13 mm mounting bolts (A) from the
ITM assembly (B) and detach the ITM
assembly from the IRDA.
6. Loosen the 13 mm cover sub assembly

B mounting bolts (A) (10 nos) and remove the
cover sub assembly (B) from the IRDA.
A
A
4. Install the protective face plate (Special Tool

No: 0502BAA0003ST) (A) and tighten the 13
mm bolts (B) (4nos).
7. Install the cover face protective plate (Special

B Tool No: 0502BAA0004ST) (A) and tighten the
13 mm bolts (B) (2 nos).

MAN-00162
8. Install the center piece (Special Tool No:

0502CAA0023ST) (A) into the center of the oil Notice
seal. Do not interchange the bearing cap, bearing
cone and do not use the shims in opposite
direction when installing.
B
A
A
9. Install the 2 leg puller (Special Tool No:

0502CAA0022ST) (A) and remove both sides
of the oil seal (B) from the IRDA.
11.Install the Expander (Special Tool No:
0502BAA0002ST) (A) and remove the
differential case (B) from the IRDA housing.
A
A
B
10.Loosen the 13mm bearing caps mounting bolts
(A) (2 nos) and remove the bearing caps (B)
and shims (C) from the differential case.
12.Remove the needle roller bearing (A) from the
needle roller bearing cone.
A
A
B

MAN-00162
13.Remove the needle roller bearing cone, by

using the needle roller bearing cone removal
tool (Special Tool No: 0502CAA0025ST) (A)
and Universal Handle (Special Tool No:
0502AAA0003ST) (B). A
B
15.Using an adapter (Special Tool No:
A 0502CAA0019ST) (A) and Universal Handle
(Special Tool No: 0502AAA0003ST) (B),
remove the pinion out cup (C) from the IRDA
housing.
14.Using a pinion nut torque removal tool kit
(Special Tool No: 0502EAA0005ST) (A), loosen
the pinion lock nut (B) in anticlockwise
B
direction and remove the pinion.
C
A
Notice
Pinion oil seal can be removed when
removing the pinion outer cone.
Notice
The inner cone and outer cone are removed
from the IRDA assembly by fixing the special
tool (0502CAA0019ST) at its respective sides
to the cones.
B

MAN-00162
16.Using an adapter (Special Tool No: 19. Using a Differential case assembly rework tool
0502CAA0019ST) (A) and Universal Handle kit (4nos) (Special Tool No: 0502EAA0006ST)
(Special Tool No: 0502AAA0003ST) (B), (A), remove the differential pinion shaft pin (B).
remove the pinion inner cup (C) from the IRDA
housing.
A
C B
A
20.Using a Universal Handle (Special Tool No:

17.Fix the center piece (Special Tool No: 0502AAA0003ST) (A), remove the differential
0502CAA0023ST) (A) and flat bearing puller pinion shaft (B).
(Special Tool No: 0502EAA0007ST) (B) as
shown in below image.
A B
B
21.Remove the gears and washers (A) from the

differential case.
18.Fix the 3 leg puller (Special Tool No:
0502CAA0026ST) (A) and remove the
differential cage both sides bearing (B).
A
A

MAN-00162
22.Remove the 13mm ring gear mounting bolts Assembly

(A) (10 nos) and using a mallet hammer 1. Using a Dolly (Special Tool No:
detach the ring gear (B) from the differential 0502CAA0017ST) (A), install the pinion shaft
case. bearing (A).
A
B
B
A
23.Install the Base plate (Special Tool No: 2. Insert the pinion shaft cone (A) into the pinion
0502CAA0024ST) (A), fix the pinion bearing shaft.
removal adapter (Special Tool No:
0703DAK0002ST) (B) and remove the pinion
bearing and cone (C).
3. Place the pinion inner cone (A) into the IRDA

housing.
A
B

MAN-00162
4. Place the dolly (Special Tool No: 6. Place the dolly (Special Tool No:
0502CAA0015ST) (A), fix the Universal Handle 0502CAA0016ST) (A), fix the Universal Handle
(Special Tool No: 0502AAA0003ST) (B) and (Special Tool No: 0502AAA0003ST) (B) and
install the pinion inner cone to the IRDA install the pinion outer cone to the IRDA
housing. housing.
B B
A
A
5. Place the pinion outer cone (A) into the IRDA 7. Place the pinion oil seal (A) into the IRDA
housing. housing
8. Using a dolly (Special Tool No:

0502CAA0020ST) (A), install the pinion oil seal
to the IRDA housing.

MAN-00162
9. Insert the pinion with washer and fix the pinion 11. Using a dolly (Special Tool No:
lock nut (A) into the IRDA. Using a pinion nut 0502CAA0025ST) (A) and Universal Handle
torque removal tool kit (Special Tool No: (Special Tool No: 0502AAA0003ST) (B), install
0502EAA0005ST) (B), tighten the pinion by the needle roller bearing cone.
rotating in clockwise direction.
12. Install the needle roller bearing (A) to the

needle roller bearing cone.
Notice
B The bearing number should be at top
(towards carrier oil seal).
10. Place the needle roller bearing cone (A) to the

IRDA housing.

MAN-00162
13. Place the carrier oil seal (A) to the IRDA 16.Install the pinion shaft and match the pinion
housing. shaft pin hole (A) and differential cage pin hole
(B).
B
A A
14. Using a Dolly (Special Tool No:

0502CAA0021ST) (A), install the carrier oil 17. Using a differential case assembly rework tool
seals to both sides of the IRDA housing. kit (4nos) (Special Tool No: 0502EAA0006ST)
(A), install the pinion shaft pin (B).
A
A
15. Install the gears and washers (A) to the

differential case. 18. Using a pinion height setting gauge (Special
Tool No: 0502EAA0002ST) (A), inspect the
pinion height setting gap.

MAN-00162
19. Install the Dummy bearing (Special Tool No: 21. Fix the indicator with force still applied, set
0502EAA0004ST) (A) to the differential case indicator (A) to 0.00, force differential assembly
assembly, and install the differential case to the extreme end in opposite direction and
assembly to the IRDA housing. check the play.
40
30
50
20
60
A
10
70
0
80
90
A
20. Fix the dial indicator with a magnetic base (A), 22. Repeat above the steps until the same
locate the tip (B) on the surface of case (C) reading is obtained, record reading by referring
and move differential assembly to the extreme the TABLE A and remove the dummy bearings
in the direction towards the indicator. and set aside.
23. Install the ring gear (A) to the case and tighten
ten 14mm ring gear mounting bolts (B).
Notice
B
Tighten the ring gear mounting bolts as per
40
30
50
20
specification.
60
10
70
0
80
90
C B

MAN-00162
24. Using a dolly (Special Tool No: 26.Force differential case assembly to the dial
0502CAA0018ST) (A), install the differential gauge locate tip (A) and ring gear to mesh with
case bearings (B). pinion gear and record reading by referring the
TABLE B.
40
30
50
B
20
60
10
70
0
80
90
A
Notice
A
Repeat the procedure for installation of
shims/bearing cone on opposite side of
differential case.
Install spreader and dial indicator. Spread the
B carrier not over 0.14mm.
27. Install the expander/stretcher (Special Tool No:

0502BAA0002ST) (A) and place the differential
case (B) with adding shims to the IRDA
housing.
25.Place the differential case into the IRDA

housing and install the dial gauge (A) and
locate the tip of indicator on the surface of ring
gear and force till applied set indicator at 0.
A
40
30
50
20
60
10
70
0
80
90
B
A

MAN-00162
28.Install the bearing caps (A) and tighten the two 30. Install the brackets (A) from both sides of the
13mm bearing caps mounting bolts (B). IRDA and tighten the 13 mm bracket mounting
bolts (B) (4 nos).
Notice
Do not interchange the bearing caps when
installing. Tighten the caps as per
specification.
B
A
31. Remove the 13 mm bolts (A) (4 nos) and

remove the protective plate (B) from the
carrier.
29.Install the cover sub assembly (A) and tighten

the ten 13 mm cover sub assembly mounting A
bolts (B).
A
B
B
32. Install the ITM assembly (A) and tighten the

13 mm ITM mounting bolts (B).

MAN-00162
TABLE A
New pinion Marking (English) (Value in Inches)
Old Pinion
Marking -4 -3 -2 -1 0 +1 +2 +3 +4
(English)
+4 +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0
+3 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001
+2 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002
+1 +0.005 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003
0 +0.004 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004
-1 +0.003 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005
-2 +0.002 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006
-3 +0.001 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007
-4 0 -0.001 -0.002 -0.003 -0.004 -0.005 -0.006 -0.007 -0.008
TABLE B
New pinion Marking (Metric) (Value in mm)
Old Pinion
Marking -10 -8 -5 -3 0 +3 +5 +8 +10
(Metric)
+10 +.20 +.18 +.15 +.13 +.10 +.07 +.05 +.02 0
+8 +.18 +.16 +.13 +.11 +.08 +.05 +.03 0 -.02
+5 +.15 +.13 +.10 +.08 +.05 +.02 0 -.03 -.05
+3 +.13 +.11 +.08 +.06 +.03 0 -.02 -.05 -.07
0 +.10 +.08 +.05 +.03 0 -.03 -.05 -.08 -.10
-3 +.07 +.05 +.02 0 -.03 -.06 -.08 -.11 -.13
-5 +.05 +.03 0 -.02 -.05 -.08 -.10 -.13 -.15
-8 +.02 0 -.03 -.05 -.08 -.11 -.13 -.16 -.18
-10 0 -.02 -.05 -.07 -.10 -.13 -.15 -.18 -.20

MAN-00162
Power Take Off Unit (PTU) 5. Detach the housing pinion catridge (A) from its
position.
Disassembly
1. Drain the PTU oil. For additional informtion
A
2. Remove the PTU assembly. For additional
informtion refer to Power Take Off Unit
(PTU) removal and installation section.
3. Using a suitable tool (A), hold the companion
flange and loosen the 28 mm PTU pinion nut
(B).
A B
6. Remove the nine 12 mm PTU housing side

cover bolts (A), and separate the cover.
4. Remove the all 12 mm housing pinion catridge

mounting bolts (A).
7. Pull out the input shaft (A) and counter shaft

(B) simultaneously.
A
B
A
Notice
Place the shafts carefully and gears should
not get damaged while handling.

MAN-00162
8. Using the suitable tool, remove the counter 11. Remove the ‘O’ ring (A) from housing pinion
shaft oil seal (A) from the PTU unit. catridge.
9. Using a mallet hammer, detach the companion 12.Detach the collapsible spacer (A) from the
flange (A) from housing pinion catridge. pinion shaft.
A A
10. Using a mallet hammer (A), carefully detach 13. Using a suitable tool (A), carefully pull out the
the pinion assembly (B) from the housing Pinion oil seal (B) from pinion cartridge.
pinion catridge.
B A
A

MAN-00162
14. Remove the oil slinger (A) from the housing 17. Using the Adapter for removing bearing outer
pinion catridge. cone (Special Tool No: 0708AAK0008ST) (A),
remove the pinion head bearing cone (B) from
the pinion shaft outer in cartridge.
A
A B
15. Remove the pinion tail bearing (A) from the

housing pinion catridge.
18. Using a suitable tool (A), remove the PTU
dust deflector (B).
A
B
A
16. Using the Adapter for removing bearing outer

cone (Special Tool No: 0708AAK0009ST) (A),
remove the pinion tail bearing cone (B) from 19. Using a suitable tool (A), pull the input shaft
the pinion shaft inner in cartridge. oil seal (B) from PTU side cover.
B
A A

MAN-00162
20. Using the bearing puller (Special Tool No: 22. Remove the input shaft bearing cone (A) and
0703AAK0003ST), lock the PTU counter shaft shims (B) from PTU side cover.
outer bearing cones (A), support the centre
piece (B), rotate the puller stud (C) in
clockwise direction and detach the bearing
cone and shims.
A B
C
B 23. Using the bearing puller (Special Tool No:

A 0703AAK0003ST), lock the PTU counter shaft
outer bearing cones (A), support the centre
piece (B), rotate the puller stud (C) in
21. Using the bearing puller (Special Tool No: clockwise direction and detach the bearing
0703AAK0003ST), lock the PTU input shaft cone and shims from PTU housing.
bearing cones (A) and shims, support the
centre piece (B), rotate the puller stud (C) in
C
clockwise direction and detach the bearing
cone and shims from the PTU side cover.
B
B

MAN-00162
24. Using the bearing puller (Special Tool No: 27.Place the center piece (Special Tool No:
0703AAK0003ST), lock the PTU input shaft 0502CAA0023ST) (A) on input shaft, and using
bearing cones (A), support the centre piece the input shaft bearing tool (Special Tool No:
(B), rotate the puller stud (C) in clockwise 0708AAK0002ST) (B), remove the input shaft
direction and detach the bearing cones from bearing.
the PTU housing.
A B A
28. Place the center piece (Special Tool No:

25. Remove the PTU breather nipple (A) from 0502CAA0023ST) (A) on input shaft, and using
PTU housing. the input shaft bearing tool (Special Tool No:
0708AAK0002ST) (B), remove the input shaft
bearing.
26. Using a suitable tool (A), remove the CVJ oil

seal on Input shaft (B).

MAN-00162
29. Place the center piece (Special Tool No: 31. Fix the flat bearing puller (Special Tool No:
0502CAA0023ST) (A) on counter shaft, and 0502EAA0007ST) (A) on the pinion shaft
using the counter shaft bearing Tool (Special bearing, and using the 3 leg puller (Special
Tool No: 0708AAK0005ST) (B), remove the Tool No: 0502CAA0026ST) (B), remove the
counter shaft bearing. pinion shaft bearing.
B B
A
30. Place the center piece (Special Tool No: 32. Remove the pinion bearing shims (A).
0502CAA0023ST) (A) on counter shaft, and
using the counter shaft bearing Tool (Special
Tool No: 0708AAK0005ST) (B), remove the
counter shaft bearing.
B
A

MAN-00162
Inspection Assembly
1. Visually check all the parts for any damage 1. Using a dolley for pressing input shaft bearing
and distortion. (Special Tool No: 0708AAK0001ST) (A), install
2. Referring to normal gear tooth face, specifically the inner bearing to the input shaft.
inspect the uneven wear, chips of gear tooth.
and bearings. Replace the parts if necessary.
Notice A
Do not reuse the seals and O-rings.
Ring Gear and Pinion Inspection

Ring gear and pinion is supplied as a set. They are
matched with each other during manufacture.
Matching numbers on both pinion and ring gear are
etched for verification.
2. Using a dolley for pressing input shaft bearing

(Special Tool No: 0708AAK0001ST) (A), install
the outer bearing to the input shaft.
If a new gear set is used, verify numbers on pinion

and ring for matching before proceeding with
assembly.

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3. Using an adapter for pressing counter shaft 6. Using a dolley for pressing pinion shaft bearing
bearing (Special Tool No: 0708AAK0004ST) (Special Tool No:0708AAK0010ST) (A), install
(A), install the inner bearing to the counter the pinion bearing into the pinion shaft till the
shaft. bearing touches the seating position.
A
A
4. Using an adapter for pressing counter shaft 7. Insert the spacer collapsible (A) into the pinion
bearing (Special Tool No: 0708AAK0004ST) shaft.
(A), install the outer bearing to the counter
shaft.
8. Using an adapter for pressing bearing outer

cone of pinion shaft inner in catridge (Special
5. Properly insert the shim (A) into the pinion. Tool No: 0708AAK0007ST) (A), install the inner
pinion bearing cone to the pinion catridge.
A
A

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9. Using an adapter for pressing bearing outer 12. Using a dolley for pressing pinion shaft
cone of pinion shaft outer in catridge (Special bearing in catridge (Special Tool No:
Tool No: 0708AAK0006ST) (A), install the outer 0708AAK0010ST) (A), tap the outer bearing to
pinion bearing cone to the pinion catridge. the housing pinion catridge.
A A
10. Insert the outer bearing (A) to the housing 13. Insert the oil slinger (A) into the housing pinion
pinion catridge. catridge.
A
A
11. Insert the pinion shaft (A) to the housing 14. Insert the oil seal (A) into the housing pinion
pinion catridge. catridge.
A
A

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15. Using an adapter for pressing oil seal in 17. Insert the ‘O’ ring (A) into the housing pinion
catridge (Special Tool No: 0708AAK0011ST) catridge.
(A), tap the housing pinion catridge.
CAUTION A
Take care not to damage pinion oil seal lip.
Failure may cause leakage of the oil.
18. Using an adapter for pressing bearing outer

cone of PTU counter shaft (Special Tool No:
0708AAK0015ST) (A), install the shims and
inner cone to the PTU side cover.
CAUTION
16. Insert the companion flange (A) into the Do not heavily press the bearing cone into
housing pinion catridge. the PTU side cover, to avoid the damage of
PTU side cover and housing.

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19. Using an adapter for pressing bearing outer 21. Using an adapter for pressing bearing outer
cone of PTU input shaft (Special Tool No: cone of PTU input shaft (Special Tool No:
0708AAK0014ST) (A), insert the outer cone 0708AAK0014ST) (A), insert the countershaft
and shim to the PTU side cover. cone to the PTU housing. For adding shims
refer to Counter Shaft Bearing Shims Table.
A
A
20. Using an adapter for pressing oil seal in PTU

Main housing ( Sp e c i a l To o l No: 22. Using an adapter for pressing bearing outer
0708AAK0013ST) (A), insert the oil seal into cone of PTU Counter shaft (Special Tool No:
PTU side cover. 0708AAK0015ST) (A), install the shims and
input shaft bearing cone to the PTU housing.For
adding shims refer to Input Shaft Bearing
Shims Table.

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23. Install the PTU breather nipple (A) to the PTU 26. Install the both PTU input shaft (A) and
housing, and tighten to the specified torque. countershaft (B) to the PTU housing.
B
A
A
24. Install the counter shaft oil seal (A) into the
PTU unit. Notice
Apply loctite 5900 to the PTU housing side
cover.
A
27. Apply the loctite (A) on the PTU housing side
cover.
25. Using an adapter for pressing oil seal in PTU

cover (Special Tool No: 0708AAK0012ST) (A),
install the counter shaft oil seal into the PTU
unit.

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28. Install and tighten the nine 12mm PTU 31. Tighten the all 12 mm housing pinion catridge
housing side cover bolts (A). mounting bolts (A) to the specified torque.
29. Install the dust cap to the PTU housing side 32. Using a suitable tool (A), hold the companion
cover (A). flange and tighten the 28mm PTU pinion nut
(B).
A B
30. Install the housing pinion catridge (A) to the

PTU housing by matching the dowell pin. 33. Using an adapter for pressing input shaft oil
seal in housing (Special Tool No:
0708AAK0003ST) (A), install the CVJ oil seal
to the PTU input shaft.
A

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34. Install the PTU assembly. For additional

informtion refer to Power Take Off Unit
(PTU) removal and installation section.
35.Refill the PTU oil. For additional informtion

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Counter Shaft Bearing Shims Table
COUNTERSHAFT BEARING SHIM
mm
0.0508 0.0762 0.1016 0.127 0.1778 0.2286 0.254 0.381 1.4224 ACIEVED
DIMENSION
THOU 2 3 4 5 7 9 10 15 56 THOU mm
1 1 2 1 99 2.515
3 1 101 2.565
1 3 1 103 2.616
1 3 1 105 2.667
1 1 3 1 107 2.718
1 1 3 1 109 2.769
1 3 1 111 2.819
1 1 3 1 113 2.870
1 2 115 2.921
1 2 117 2.972
1 2 119 3.023
1 2 121 3.073
1 1 2 120 3.048
2 1 100 2.540

MAN-00162
Input Shaft Bearing Shims Table
INPUT SHAFT BEARING SHIM
mm 0.0508 0.0762 0.1016 0.127 0.1778 0.2286 0.254 0.381 0.635 0.762 0.889 2.489 ACIEVED
DIMENSION
THOU 2 3 4 5 7 9 10 15 25 30 35 98 THOU mm
1 1 2 6 0.152
1 1 2 5 0.127
1 1 2 4 0.102
2 2 4 0.102
1 1 1 2 0.051
1 3 1 0.025
1 3 - -
1 1 1 2 5 0.127
1 - -
1 1 100 2.540
1 1 - -
2 1 - -
2 1 - -
1 1 1 0.025
1 1 1 2 0.051
2 1 - -
1 1 1 - -
2 1 - -
2 1 2 0.051
1 1 1 - -
1 1 1 - -
1 1 1 1 1 0.025

MAN-00162

IRDA
Universal Handle (FOR

0502AAA0003ST
ALL Adapters)
0502BAA0002ST Expander / Stretcher
Pinion height setting

0502EAA0002ST
gauge
PINION height Master

0502EAA0003ST
block

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Dummy bearing - Differ-

0502EAA0004ST
ential case
Dolly-pressing pinion inn

0502CAA0015ST
cup
Dolly-pressing pinion out

0502CAA0016ST
cup
Dolly-pressing pinion inn

0502CAA0017ST
cone

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Dolly-pressing differential
0502CAA0018ST
case bearings
Adapter-remove pinion
0502CAA0019ST out cup and Pinion Inner
cup
Dolly-pressing pinion oil

0502CAA0020ST
seal
Dolly-pressing carrier oil

0502CAA0021ST
seal

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2 leg puller for carrier oil

0502CAA0022ST seal removal standard 3
inch
Center piece for carrier

0502CAA0023ST
oil seal removal
Base plate for bearing re-

0502CAA0024ST
moval
Protective plate for TBU

0502BAA0003ST
face

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Protective plate for Cov-

0502BAA0004ST
er face
Pinion nut torque remov-

0502EAA0005ST
al tool kit
Dolly R&R needle roller

0502CAA0025ST
bearing

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Differential case assem-

0502EAA0006ST
bly rework tool kit (4nos)
Flat bearing puller for dif-

0502EAA0007ST
ferential cage bearing
3 leg puller standard 8

inch (C/s shaft on Tran-
0502CAA0026ST saxle, Pinion Bearing on
Catridge, Pinion Bearing
on IRDA)

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PTU
0708AAK0001ST Dolley for pressing input shaft bearing
Adapter for removing input shaft bear-

0708AAK0002ST
ings
Adapter for pressing input shaft oil seal

0708AAK0003ST
in housing
Adapter for pressing (counter shaft

0708AAK0004ST
bearing and IRDA Sleeve R&R)

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Adapter for removing counter shaft

0708AAK0005ST
bearings
Adapter for pressing bearing outer

0708AAK0006ST
cone of pinion shaft outer in catridge

0708AAK0007ST
cone of pinion shaft inner in catridge
0708AAK0008ST Adapter for removing bearing outer

cone of pinion shaft outer in catridge

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Adapter for removing bearing outer

0708AAK0009ST
cone of pinion shaft inner in catridge
PTU - 10
Dolley for pressing pinion shaft bear-
0708AAK0010ST
ings in catridge
0708AAK0011ST Adapter for pressing oil seal in catridge
Adapter for pressing oil seal in PTU

0708AAK0012ST
cover S/A

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Adapter for pressing oil seal in PTU

0708AAK0013ST
Main housing

0708AAK0014ST
cone of PTU input shaft

0708AAK0015ST
cone of PTU Counter shaft
Bearing Puller (PTU input shaft bear-

ing outer cones, Counter shaft bearing
outer cones, Transaxle input shaft in-
0703AAK0003ST
ner bearing, Transaxle C/S inner bear-
ings, Transaxle differential bearing
outer cones)

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Three leg puller standard 8 inch (C/s

0502CAA0026ST shaft on Transaxle, Pinion Bearing on
Catridge, Pinion Bearing on IRDA)
Part Specification
PTU Ratio 3.27
Torque in
Nm
BOLT HEX FL -
4 40.0 ~ 50.0
M10X1.5X55X8.8XZN
STUD BOTH END -

2 40.0 ~ 50.0
M10X1.5X18X8.8,A
PTU
NUT HEX FL -
PTU Mounting 1 40.0 ~ 50.0
M10X1.5X10X8XZN
SCREW HEX FL - 2
20.0 ~ 25.0
M8X1.25X20X8.8
HEX FL - 2
20.0 ~ 25.0
M10X1.5X25X10.9
PTU Oil Filler 1

28.0 ~ 32.0
Cap

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Torque in
Nm
M8 X 1.25 X25 X8.8 PTU Mounting Bracket 2 12 ~ 20
Breather Hose 1 12 ~ 20
M12 X 1.5 X 30 Hex Flange Bolt 4 25 ~ 35
M10 X 1.5 X 30 Hex Flange Bolt 3 25 ~ 35

PTU
Filler Plug 2 24 ~ 34
PTU Housing Side

9 12 ~ 20
Cover Bolts
Drain Plug 1 24 ~ 34
BOLT HEX FL -
IRDA IRDA Mounting 4 100.0~120.0
M12X1.5X80X8.8XPH,A
IRDA Filler Cap 1 28.0 ~ 32.1
Ring Gear Bolt Torque 86 ~ 95
Pinion Nut Torque 220 ~ 595
Pinion Torque To Rotate (PT-

2.133 ~ 3.074
TR)
Bearing Cap Bolt Torque 52 ~ 57
IRDA PT-
Total Torque To Rotate (TTTR) TR+(0.502 ~
0.805)
BackLash 0.076 ~ 0.152
Drain Plug Torque 27 ~ 41
Cover Plate Bolt Torque 19 ~ 26
Filler Plug Torque 27 ~ 41
Bracket Mounting Bolt Torque 80 ~ 90

MAN-00162
Repair Manual Suspension Nov 2011/ Rev 2
SUSPENSION
CONTENTS
Front Suspension ....................................................................................1

Description and Operation ................................................................. 1
Incar Repairs ...................................................................................4

Component Test ................................................................................. 4
Front Strut Assembly................................................................... 5

Removal ............................................................................................. 5
Installation .......................................................................................... 5
Lower Control Arm (LCA) ............................................................6

Removal ............................................................................................. 6
Installation .......................................................................................... 6
Lower Control Arm Front Bush ...................................................7

Removal ............................................................................................. 7
Installation .......................................................................................... 8
Lower Control Arm Ball Joint ....................................................10

Removal ........................................................................................... 10
Installation ........................................................................................ 10
Anti Roll Bar ................................................................................10

Removal ........................................................................................... 10
Installation ........................................................................................ 11
Anti roll bar Bush ....................................................................... 11

Removal ........................................................................................... 11
Installation ........................................................................................ 12
Front Stabilizer Bar Link............................................................ 12

Removal ........................................................................................... 12
Installation ........................................................................................ 12

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Front Knuckle Assembly ........................................................... 13

Removal ........................................................................................... 13
Installation ........................................................................................ 15
Wheel Bearing Hub .................................................................... 15

Removal ........................................................................................... 15
Installation ........................................................................................ 16
Front Cradle Assembly.............................................................. 17

Removal ........................................................................................... 17
Installation ........................................................................................ 18

Assembly Front Strut ........................................................................ 18
Disassembly ..................................................................................... 18
Assembly.......................................................................................... 19

Torque Chart .................................................................................. 26
Rear Suspension ................................................................................... 27

Description and Operation ............................................................... 27
Component Location Index .......................................................... 29
Service Tips and Precautions ...................................................... 30

General Precautions ........................................................................ 30
Incar Repairs.................................................................................. 31
Component Test............................................................................... 31
Rear Shock Absorber ................................................................ 32

Removal ........................................................................................... 32
Installation ........................................................................................ 33

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Rear Stabilizer Bar .....................................................................33

Removal ........................................................................................... 33
Installation ........................................................................................ 34
Rear Stabilizer Bar Link ............................................................34

Removal ........................................................................................... 34
Installation ........................................................................................ 35
Rear Stabilizer Bar Bush ........................................................... 35

Removal ........................................................................................... 35
Installation ........................................................................................ 35
Link Rod Mounting Bracket on Knuckle Side ..........................36

Removal ........................................................................................... 36
Installation ........................................................................................ 36
Front Lower Tubular Link .......................................................... 37

Removal ........................................................................................... 37
Installation ........................................................................................ 37
Front Lower Tubular Link Bush - Knuckle Side ...................... 38

Removal ........................................................................................... 38
Installation ........................................................................................ 39
Front Lower Tubular Link Bush - Frame Side ......................... 40

Removal ........................................................................................... 40
Installation ........................................................................................ 41
Rear upper rod link ....................................................................42

Removal ........................................................................................... 42
Installation ........................................................................................ 42
Rear Upper Rod link Bush - Frame Side .................................. 43

Removal ........................................................................................... 43
Installation ........................................................................................ 44
Rear Upper Rod link Bush - Knuckle Side ............................... 45

Removal ........................................................................................... 45
Installation ........................................................................................ 47

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Front Upper Link ........................................................................ 48

Removal ........................................................................................... 48
Installation ........................................................................................ 48
Front Upper Link Bush .............................................................. 49

Removal ........................................................................................... 49
Installation ........................................................................................ 50
Rear Lower Control Link ........................................................... 51

Removal ........................................................................................... 51
Installation ........................................................................................ 52
Rear Lower Link Bush ................................................................ 52

Removal ........................................................................................... 52
Installation ........................................................................................ 53
Toe Bar ........................................................................................ 54

Removal ........................................................................................... 54
Installation ........................................................................................ 54
Toe Bar Bush .............................................................................. 55

Removal ........................................................................................... 55
Installation ........................................................................................ 56
Toe Bar Ball Joint End............................................................... 57

Removal ........................................................................................... 57
Installation ........................................................................................ 57
Rear Knuckle .............................................................................. 58

Removal ........................................................................................... 58
Installation ........................................................................................ 58
Rear Knuckle Bush .................................................................... 59

Removal ........................................................................................... 59
Installation ........................................................................................ 59
Rear Cradle................................................................................. 60
Removal ........................................................................................... 60
Installation ........................................................................................ 61

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Rear Wheel Hub.......................................................................... 61

Removal ........................................................................................... 61
Installation ........................................................................................ 62
Assembly and Disassembly ..........................................................62

Rear Shock Absorber ...................................................................... 62
Disassembly ..................................................................................... 62
Assembly .......................................................................................... 64
Toe Bar ........................................................................................... 64
Disassembly ..................................................................................... 64
Assembly .......................................................................................... 65

Visual Inspection .............................................................................. 65
Mahindra Special Tool (MST)........................................................ 68
Torque Chart ..................................................................................72
Wheel Alignment ...................................................................................73

Camber ............................................................................................ 73
Caster ............................................................................................... 73
Toe In and Toe Out .......................................................................... 73
Wander ............................................................................................. 74
Drift/Pull ............................................................................................ 74
Ride Height ...................................................................................... 74
Wheel Alignment Specifications ....................................................... 75
Wheel Alignment and Sequence of operation .................................. 76

MAN-00162
Suspension
Front Suspension
The Front suspension system is independent McPherson strut suspension. It consists of a strut which
combines the coil spring over dual tube hydraulic shock absorber in a single unit. The top of the strut is
mounted to body with nuts, and bottom is mounted to knuckle with fasteners. Strut Assembly also includes
PU bump stopper, bearing and integrated rebound stopper.
A. Front Strut C. Stabilizer bar or Antiroll bar

B. Stabilizer Link D. Lower Control Arm
It also includes a Lower Control Arm (LCA) with ball joint on outer end, which in turn is mounted with knuckle us-
ing fasteners. The inner two ends of LCA are mounted on engine cradle using fasteners. This link takes all the fr-
ont longitudinal loads generated due to braking & acceleration; and transverse load due to cornering.
The front also includes antiroll bar with ball joint link assembly. It transfers loads from outer to inner tyre during
cornering and in case of uneven tyre vertical movement.

MAN-00162
B
D
A. Strut Assembly D. Stabilizer Bar Link

B. Lower Control Arm E. Stabilizer bar or Antiroll bar
C. Cradle Assembly

MAN-00162

Observe the following precautions when servicing CAUTION
the front suspension components.
Oil may reduce life of the rubber bushings,
• Ensure a dust free environment before starting wipe off any oil on rubber parts immediately.
the work.
• Before disassembling or servicing, clean the • When installing the rubber bushings, the final
outer surface of the components. tightening should be done without load and with
• Ensure that the component parts are free from the tires on level ground.
foreign objects during disassembly and assem- • After installing suspension components, check
bly of the component parts. the wheel alignment for correct specification.
the correct order. If work is interrupted, the dis-
assembled parts must be covered with clean DANGER
cover/paper cloth. Care should be taken while working with
heavy parts, failure to follow this instruction
will lead to personal injury and damage to the
parts.
LCA Rear mounting bolt to be tightened

from head side at this location on RH and
Vehicle Front
LH.
Do’s and Don’ts 2. Stabilizer bars Front have to be fitted in the cor-
1. Do not jack the vehicle by putting the jack below rect orientation with RH marking located on RH
any of the front suspension link assembly or fr- of the vehicle. Any assembly deviation on this
ont LCA or Frame mounting location. Jacking on results in the fouling of stabilizer bar with sur-
suspension link assembly will damage the Link. rounding parts
For additional information refer to Jacking 3. All rubber bushings should be free from oil and
and Lifting section. do not require any lubrication. Grease or mineral
oil base lubricants will deteriorate the bushings.

MAN-00162
4. Only flanged Bolts and Nuts as per specifica- Incar Repairs

tions should be used. Use of spring washer and
plain washer to be prevented. Component Test
5. The top center nut for front strut should be prop- Ball Joint Checking
erly torqued to the specifications.
1. Prior to testing inspect the ball joint for wear, in-
6. Both front and rear suspension should be tight- spect the wheel bearings for any play.
ened in design condition (4 passengers weights)
2. Raise and support the vehicle.
and not in rebound.
3. Inspect the ball joint and ball joint boot for dam-
7. The equivalent of 4 passenger weight in terms
age.
of ride height are Front – 460 mm, Rear - 485
mm. 4. If the ball joint or ball joint boot is found dam-
aged, renew the ball joint.
8. All silent block with voided and flange bushes
should be mounted as per the specified 5. Inspect the ball joint for relative movement by
orientation. alternatively pulling the wheel downward and
pushing upward. Observe any relative move-
ment between the wheel knuckle and lower arm
of the ball joint.
6. If relative movement is not observed the ball jo-
int is in good condition.
7. Check the ball joints.
8. Check the looseness of ball joints in LCA.

MAN-00162
Front Strut Assembly Notice

Support the lower arm to avoid any damage to
the drive shaft rubber boot and the brake
disc.
4. Remove three 14mm mounting nuts (A) from

upper part of the strut assembly and detach the
strut.
Removal
1. Remove the wheel from the vehicle. For addi-
tional information refer to Wheels removal A
2. Unclip the wheel speed sensor wire (A) from the
strut assembly.
Installation


MAN-00162
Lower Control Arm (LCA) 3. Remove 21mm front and rear bolts and nuts (A)
from the lower control arm, and separately
detach the lower control arm from the cradle.
Removal
1. Remove a front wheel from the vehicle. For Installation
additional information refer to Wheels
2. Loosen the 17mm pinch bolt (A) and 18mm Notice
mounting nut (B) from the lower control arm ball
joint. LCA rear mounting bolt to be tightened from
head side on RH and LH.
Notice
Check for the alignment of ball joint position
inside the knuckle. If it is not positioned prop-
erly, it creates noise after tightening.
B A
CAUTION
The LCA bushings do not require any kind of
lubrication. Grease or mineral oil base lubri-
cants will deteriorate the bushings perfor-
mance & life.

MAN-00162
Lower Control Arm Front Bush 4. Fix the adapter pin (A) (sub part of
0401BAA0027ST) into the cavity bush remov-
Removal ing adapter (B) (Special Tool Part
1. Remove the lower control arm. For additional No:0401BAA0028ST).
information refer to Lower Control Arm (LCA)
Notice
To remove the LHS and RHS front lower con-
trol arm front bush, follow the same proce- B
dure.
2. Place the base block (A) (Special Tool Part

No:0401BAA0027ST) on the hydraulic press.
A
5. Insert the cavity bush removing adapter (A) into

the front lower control arm front bush.
A
Notice
Use the base block as shown in the picture
above, while removing and installing the lower
control arm bush.
6. Using a hydraulic press (A), remove the front
3. Place the lower control arm (A) on the base lower arm front bush from the front lower control
block (B) in a proper position. arm.
A
B

MAN-00162
Installation LHS Front Lower Control Arm Bush

1. Fix the front lower control arm front bush (A) into 3. Using a locking tool (A) locking tool (A) (Special
the front lower arm (B) in a proper position. Tool Part No:0401BAA0029ST / 2), lock the front
lower control arm (B) along with the cavity bush
fixing adapter (C) (Special Tool Part
No:0401BAA0029ST / 1 ).
A
C
A
B
2. Place cavity bush fixing adapter (A) (Special

Tool Part No:0401BAA0029ST/1) into the cut
section (B) of the front lower control arm front
bush. 4. Using a hydraulic press (A), insert the front lower
control arm front bush (C) into the front lower
control arm until the locking tool (B) is removed.
A
B
C
B
Notice
Inserting the lower control arm front bush, the
bush must be in straight position to the hy-
draulic press for avoid the bush damage.

MAN-00162
5. Using a hydraulic press (A), fix the front lower 7. Using a hydraulic press (A), insert the front
control arm front bush (B) into the front lower lower control arm front bush (C) into the front
control arm in proper position. lower control arm until the locking tool (B) is
removed.
A
A
B
RHS Front Lower Arm Bush

6. Using a locking tool (A) (Special Tool Part No: Notice
0401BAA0029ST / 2), lock the front lower con-
trol arm (B) along with cavity bush fixing adapter While inserting the lower control arm front
(C) (Special Tool Part No:0401BAA0029ST/1). bush, the bush must be in straight position to
the hydraulic press to avoid the bush damage.
LH
A
RH
8. Using a hydraulic press (A), fix the front lower

control arm front bush (B) into the front lower
control arm (C) in proper position.
B
C
A
B
C

MAN-00162
Lower Control Arm Ball Joint Anti Roll Bar

Removal
1. Remove the front lower arm. For additional
information refer to Lower Control Arm (LCA)
2. Using a circlip plier remove the front lower con-
trol arm ball joint mounting circlip (A) from the lo-
wer control arm.
Removal
1. Remove the front wheel. For additional infor-
mation refer to Wheels removal and installa-
tion section.
A 2. Remove the two exhaust rubber mounts (A), two
15mm exhaust intermediate pipe mounting nuts
(B) and remove the exhaust middle pipe.
3. Using a suitable tool, remove the front lower
control arm ball joint from the lower control arm.
Notice
Carefully remove the ball joint, without damag- A
ing the front lower Control arm.
B
Installation
3. Using a 5mm Allen key (A) and special ring sp-

anner (B), lock the link rod stud and loosen the
two 18mm mounting link rod nuts from both
sides of the anti roll bar end.

MAN-00162
Anti roll bar Bush
4. Separately detach the anti roll bar. Remove the

anti roll bar bushes from the stabilizer bar.
Removal
Installation
1. To install, reverse the removal procedure. mation refer to Wheels removal and installa-
tion section.
Notice
2. Remove two 14mm anti roll bar bush mounting
While installing the anti roll bar, make sure clamp bolts (A) and separately detach the bush
that lengthened side of the stopper should be (B) from the anti roll bar clamp.
fixed in RHS and shortest side of the stopper
should be fixed in LHS.
Notice
Using a 14mm deep socket (A), tighten the anti
roll bar bush mounting clamp bolt to a speci-
fied torque.
A
Notice
Mounting link rod nuts to be tightened to the
specified torque. While giving torque usage of B
suitable tool is necessary for holding.

MAN-00162
Installation Front Stabilizer Bar Link

Notice
Using a 14mm deep socket (A), tighten the anti
roll bar bush mounting clamp bolt to a speci-
fied torque.
Removal
A 1. Remove a front wheel from the vehicle. For
2. Using a 5mm Allen key and special ring spanner,
lock the link rod stud and loosen the two 18mm
lock nuts (A) of the link rod and separately
detach the front link rod.
Installation

MAN-00162
Front Knuckle Assembly 2. Loosen the 36mm drive shaft lock nut without
lifting the vehicle and remove the drive shaft lock
nut.
The front knuckle holds the suspension components

in place. The front lower arms and the drive shaft are 3. Lift the vehicle and remove the wheel. For addi-
mounted on front knuckle. It is one of the critical co- tional information refer to Wheels removal
mponents of the wheel alignment. and installation section.
4. Remove the brake disc. For additional infor-
mation refer to Front Brake Disc removal and
CAUTION installation section.
• Do not use hammer for removing the ball
5. Loosen the 10mm mounting bolts (A) and detach
joint Front : Steering OBJ from the respective
the wheel speed sensor.
knuckles. It damages the knuckle and the ball
joint boot.
Removal
1. Using a suitable tool, release the lock (A) of the
drive shaft locknut.
A
Notice
Disconnect the battery negative terminal be-
fore removing the wheel speed sensor.

MAN-00162
6. Remove the lock pin (A), loosen the 17mm nut 10.Loosen a 17mm bolt (A) and a 18mm nut (B)
(B) and detach the steering ball joint. from the knuckle, and detach the front lower co-
ntrol arm ball joint. Separately detach the front
knuckle assembly.
A
A
B
B
7. Remove three 10mm mounting bolts (A) on the

brake disc carrier plate and detach the carrier
plate. 11.Unclip the wheel speed sensor wire (A) from the
strut assembly.
8. Loosen two 18mm wheel bearing hub mounting

bolts (A) and two 17mm wheel bearing mounting 12.Loosen the 24mm shock absorber mounting
bolts (B) from the wheel knuckle. bolts (A) and nuts (B) from the front knuckle, and
remove the knuckle assembly.
B
9. Remove the wheel bearing hub separately from
the front knuckle.

MAN-00162
Installation Wheel Bearing Hub

Notice
Tighten the drive shaft lock nut to precise
torque and lock the nut.
CAUTION
• ABS seal (Inboard side) should not be dam-
aged. Hence it is recommended to keep away
any sharp objects while servicing areas in and
around bearing.
• If damaged, bearing with hub should be
replaced.
• Steel Hammer should not be used for push-
ing bearing assembly out of knuckle. Use of
plastic mallet is advisable and recommended.
• The bearing should not be dropped.
Removal
1. Using a suitable tool, release the lock (A) of the
drive shaft locknut.

MAN-00162
2. Loosen the 36mm drive shaft lock nut without 6. Loosen two 18mm wheel bearing mounting bolts
lifting the vehicle and remove the drive shaft (A) and two 17mm wheel bearing mounting bolts
lock. (B) from the wheel knuckle.
Notice
The wheel bearing should not be replaced
alone, it should be replaced along with the
hub.
3. Lift the vehicle and remove the wheel. For addi- A

tional information refer to Wheels removal
4. Remove the front brake disc. For additional
information refer to Front Brake Disc
Installation
plate. 1. To install, reverse the removal procedure.
Notice
Tighten the drive shaft lock nut to precise
torque and lock the nut.
A

MAN-00162
Front Cradle Assembly 5. Remove the both lower control arm (LCA). For
additional information refer to Lower Control
Arm (LCA) removal and installation section.
6. Remove the two 13mm rear mounting bolts (A)
and 18mm nut (B) from both sides of the cradle
bracket.
A
B
Removal
DANGER
Dropping of heavy object may result in serious 7. Loosen the 18mm front mounting nuts (A) from
personal injury. Extreme care should be taken both sides of the cradle bracket and remove the
while handling heavy objects. mounting plate.
1. Remove twelve 10 mm mounting bolts (A) and

front cradle. A
2. Remove the steering rack assembly. For

additional information refer to Power
Steering Rack removal and installation
section.
3. Remove the anti roll bar. For additional infor-
mation refer to Anti Roll Bar removal and
4. Remove the front and rear engine mountings.
For additional information refer to Engine
Mounting removal and installation section.

MAN-00162
8. Using a suitable jack support the front cradle Disassembly and Assembly
assembly.
9. Remove the four 21mm cradle mounting bolts Assembly Front Strut
(A) from the chassis.
Disassembly
1. Fix and tighten the spring compressor (A) with
the front shock absorber assembly.
WARNING
A
Ensure that the spring compressor is tight-
ened with the spring, else expansion of the
spring cause damage to humans.
10. Remove the front cradle from the vehicle.
2. Using a 19mm special ring spanner (A) and a

6mm Allen key (B), loosen the shock absorber
mounting lock nut.
Installation
DANGER
Dropping of heavy object may result in serious B
personal injury. Extreme care should be taken A
while handling heavy objects.
3. Pull out the shock absorber top mounting (A),

bearing (B) and the spring stopper (C) along with
spring seating rubber (D).

MAN-00162
C D
A
4. Detach the dust boot (A) and the spring (B)

along with the spring compressor from the shock
absorber.
5. Detach the shock absorber (A), bump stop (B)

and spring seating rubber (C).
B A
Assembly
1. To assemble, reverse the disassembling proce-
dure.

MAN-00162

1. Front strut top mounting nut 1. Check & tighten the nuts as per
on body loosened torque specified in spec sheet.
2. Front strut top center nut on 2. Check & tighten the hardware
Piston rod loosened. using Allen Key and special tool.
Thud Noise from the front 3. Play in front LCA ball joint. 3. Replace the Ball joint assembly
from LCA.
4. Play / permanent set on Sta- 4. Replace mounting bushes.
bilizer bar mounting bushes
on cradle.
Front Ride height low 1. Coil spring breakage 1. Replace coil spring
2. Strut lower spring seat dam- 2. Replace front shock absorber (use
aged / deformed same peripheral parts if not dam-
aged)
1. Oil leakage from front shock 1. Replace shock absorber.

absorber.
2. High tyre pressure. 2. Correct the tyre pressure as per
Front ride too bouncy specifications.
3. Bump stopper damage. 3. Replace bump stopper.
1. Torque loose of Strut bottom 1. Check & ensure proper torques as

bolt / front LCA mounting per specification of hardware.
hardware/ Stab bar & stab
links.
2. Front bump stopper dam- 2. Replace bump stopper.
aged.
Metallic Noise 3. Spring seat top / bottom 3. Replace the spring seat.
worn out.
4. LCA rubber bush failure. 4. Replace LCA bush.
And LCA bush sleeve is
touching to cradle.

MAN-00162
1. Unevenly loaded or over 1. Notify the customer about correct

loaded vehicle. vehicle loading.
2. Incorrect tire pressure. 2. Reset the tire pressure or else re-
place the tire, if damaged. Replace
the tire valve, if found leaking.
3. Wheel alignment is out of 3. Adjust the alignment as per the
specification. specification.
4. Brake drag. 4. Inspect and correct the brake. Re-
Vehicle drifts or pulls to one side.
fer brake system.
5. Damage of steering compo- 5. Inspect the steering components

nents. and replace if necessary.
6. Front strut is weak on one 6. Check the leakage or damage of

side. strut, replace if damaged.
1. Worn out front wheel bear- 1. Replace the front wheel bearing, if
ings. damaged.
2. Damage or bent front wheel 2. Replace the front wheel knuckle, if
knuckle. damaged.
3. Damage or bent front lower 3. Replace the front lower control
control arm. arm, if necessary.
Front tires incorrect or abnormal
4. Damage or bent steering 4. Replace the steering inner ball
tire wear inner ball joint. joint, if necessary adjust wheel
alignment.
5. Incorrect wheel alignment. 5. Adjust the wheel alignment to the
specification. For additional infor-
mation refer to Wheel Alignment
1. Loose wheel nuts. 1. Tighten the wheel nuts to required

specification.
2. Leakage in front strut 2. Inspect the strut. Renew strut if
assembly. necessary.
Sway or roll
3. Loose or worn stabilizer bar 3. Inspect the stabilizer bar assem-
links or bushings. blies. Tighten to specification or
renew stabilizer bar components if
necessary.
1. Anti roll bar bush crack or 1. Replace the anti roll bar bush if
worn out. necessary.
2. Worn or damaged lower arm 2. Replace the lower arm bush if nec-
bush. essary.
Squeak noise from the front sus- 3. Front shock absorber defor- 3. Replace the defective shock ab-
pension. mation or deflection. sorber, if damaged
4. Improper installation or 4. Check and adjust specified torque

loose suspension parts. if necessary.

MAN-00162
1. Stabilizer bar link is loose 1. Tighten the mounting bolts and

from one end of in shock ab- nuts to the specified torque.
sorber assembly to other
end of the stabilizer bar.
2. Damaged threads in stabiliz- 2. Replace the stabilizer bar link rod,
er bar link rod. if damaged
Rattling, knocking noise from the

3. Damaged in stabilizer bar 3. Replace the stabilizer bar stopper,
front side stopper. if damaged
4. Loose suspension mount- 4. Tighten the suspension mounting

ings. to the specified torque.
5. Lower arm ball joint worn 5. Replace lower arm ball joint, if
out. worn out.
Rough/Harsh ride 1. Defective front shock ab- 1. Replace the shock absorbers if
sorbers. necessary.
2. Over inflated tires 2. Check and rectify the tire pressure.
1. Loose wheel nuts. 1. Tighten the nuts to specification.

2. Loose front suspension fas- 2. Tighten the fasteners to the specifi-
teners. cation.
3. Loose or worn front wheel 3. Inspect and replace the front wheel
bearings. bearings, if necessary.
Wheel wobble 4. Tires worn or wheels out of 4. Replace the tires or balance the
balance. wheels.
5. Incorrect wheel alignment. 5. Adjust the wheel alignment to the

specification.
6. Brake disc run out. 6. Replace the disc.

MAN-00162

1. Check the control arm ball joint 1. Replace the control arm.
stud for any damage or wear.
2. Check the control arm ball joint
jam. 2. Replace the control arm.
3. Check the control arm ball joint
play in axial directions or if end 3. Replace the control arm.
pl-ay is excessive.
Lower Control Arm 4. Check the control arm ball joint
dust cover for any damage. 4. Replace the control arm.
5. Check the control arm bushes
for wear.
6. Check the lower control arm 5. Replace the bush/ lower con-
for any bend, twist or damage. trol arm assembly.
6. Replace the lower control arm

assembly.
1. Check the anti roll bar for twist 1. Replace anti roll bar.
or deformation. Replace if nec-
essary.
Anti roll Bar
2. Check the rubber bushing for 2. Replace anti roll bar bushes.
cracks, wear or deterioration.
Replace if necessary.
1. Check the strut for oil leakage, 1. Replace the strut.

damage and deformation.
2. Press and leave the strut, ch-
eck for return duration. 2. Replace the strut if the dura-
Front strut
3. Check the eye bush for dam- tion is long or erratic.
age.
3. Replace the strut if damaged
or hard.
1. Check for any damage and 1. Replace the knuckle assem-

Knuckle Assembly
deformation. bly.
1. Check the hub for any damage 1. Replace the hub.

and deformation.
Wheel Hub
2. Check wheel hub play. 2. Check and replace the hub as-
sembly.

MAN-00162
Type Independent front - McPherson Strut
Spring Coil Spring
Shock absorbers Hydraulic with gas filled

Base block for assy and disassy for

0401BAA0027ST all suspension bushes (1 no)
Adapter for removing Cavity Bush

LCA Front (1 no)
0401BAA0028ST
Adapter Pin (4 nos)

MAN-00162
LH
Adapter for Fixing Cavity bush LCA RH
0401BAA0029ST/1
front (1 no)
0401BAA0029ST/2 Locking tool (1 no)

MAN-00162
Torque Chart
Tool description Bolt Size Torque in Nm
Lower Control Arm Front M14 160 ± 10
Lower Control Arm Rear M14 150 ± 20
LCA Knuckle Ball joint M12 100 ± 10
Bracket Stabilizer bar mounting Front M10 53 ± 07
Stabilizer bar Link mounting Front M12 95 ± 15
Front Shock absorber Bottom M14 150 ± 20
Front Shock absorber Top M10 53 ± 07
Front LCA front mounting 80 ± 05
Front craddle to BIW 180.0~200.0
Rear fixation member to floor M10 45.0~60.0
Washer Cradle Body Mount (Front side) M12 80.0±10.0
Rear Fixation Member (Rear Side) M12 80.0±10.0

MAN-00162
Rear Suspension
B
E
F
A. Rear Upper Rod Link • Front upper link made from hydro forming has
B. Rear Shock Absorber & Coil Spring Assembly bush at frame side & cross axis ball joint at
knuckle side. It takes lateral load.
C. Rear Lower Control Link
• Toe Bar has bush at frame end & ball joint at the
D. Front Upper Link knuckle end. It also takes care of transverse
E. Stabilizer Bar / Antiroll Bar load & helps in adjusting wheel Toe angle.
F. Toe Bar This suspension consists of rear shock absorber
G. Front Lower Tubular Link assembly which comprises coil spring over dual tube
hydraulic shock absorber in a single unit. The top of
H. Rear Stabilizer Bar Ball Joint Link
the shock assembly is mounted to body with 2 nuts,
The Rear suspension system is independent multi- and bottom is mounted to Rear lower control link
link suspension with 5 control links. using fastener. Shock absorber assembly also
• Rear Lower control link is a sheet metal forming includes PU bump stopper, and integrated rebound
part with bushes at both the ends. It majorly stopper.
takes care of transverse load and also supports
shock absorber assembly. On this link at frame
end camber adjustment provision is provided.
• Front Lower tubular link is with rubber bushes at
both ends. This link take care of longitudinal load
during braking & acceleration.
• Rear upper rod link is having rubber bushes at
both the end. One end is connected to body and
other to the knuckle. it also takes longitudinal
loads during braking and acceleration.

MAN-00162
Rear suspension links are mounted on Rear frame. There are two variants of rear frame. One for FWD and other
for AWD with differential mounting provision as shown in the below figures.
Assembly Rear Frame FWD Assembly Rear Frame AWD

Rear suspension includes antiroll bar with ball joint link assembly as shown in Assembly Rear Frame AWD figure.
It transfers loads from outer to inner tyre during cornering and in case of uneven tyre vertical movement.

MAN-00162
A D
H
E
G
F
A. Front Upper Link E. Toe Bar
B. Rear Upper Link Rod F. Front Lower Tubular Link
C. Rear Lower Control Link G. Stabilizer Bar / Antiroll Bar
D. Rear Shock Absorber & Coil Spring Assembly H. Rear Stabilizer Bar Link

MAN-00162
Service Tips and Precautions • Disassembled parts (except for rubber parts)
should be cleaned by pressurized air or wiping
General Precautions with paper cloth.
Observe the following precautions when disas-
sembling and servicing the rear suspension
• Ensure a dust free environment before starting
DANGER
the work. Slippage/dropping of heavy/large objects dur-
ing the suspension work will cause personal
• Before disassembling and servicing, clean the
injury.
outer side of the parts.
• Ensure that the component parts are free from
foreign objects during disassembly and assem-
bly of the component parts. DANGER
Care to be taken while working with heavy
correct order. If work is interrupted, the disas-
parts, failure to follow this instruction will
sembled parts must be covered with clean
lead to personal injury and damage to the
cover/paper cloth.
parts.
Upper link Front

and Toe bar
Frame side to be
tightened from
Bolt head side
Lower link Rear

knuckle side to be Vehicle Front
tightened from
Bolt head side
Do’s and Don’ts 2. Stabilizer bars Rear have to be fitted in the cor-
1. Do not jack the vehicle by putting the jack below rect orientation with RH marking located on RH
any of the Rear suspension link assembly or Re- of the vehicle. Any assembly deviation on this
ar Frame cross member.location. There is provi- results in the fouling of stabilizer bar with sur-
sion provided on the BIW long member for Jack- rounding parts.
ing in rear side. Jacking on suspension link 3. After dismantling & during assembling don’t
assembly will damage the Link. For additional swap LH & RH parts.
information refer to Jacking and Lifting sec- 4. Always put permanent painting marking after
tion. torquing the fasteners.

MAN-00162
5. Don’t use sharp edged tools like Spanner near Incar Repairs
ball joint boot,as it may damage the rubber
boot. Component Test
6. Use hand gloves during working. 1. Prior to testing, inspect the ball joint for wear and
7. Check for bolt & nut thread damage before inspect the wheel bearings for any play.
assembling. 2. Raise and support the vehicle.
8. Rear shock absorber to be fitted in correct orien- 3. Inspect the ball joint and ball joint boot for dam-
tation as shown below. age. If any damage is found, replace the same.
9. The top center nut for both front strut and rear
shock absorber (as shown below) should be pr-
operly torqued to the specifications. CAUTION
Do not use any tools or equipment for check-
ing the relative movement of wheels or sus-
A pension components. It may lead to
suspension damage. The use of tools or
equipment will also create relative movement
that may not exist while using hand force.
Relative movement must be measured using
hand force only.
4. If relative movement is not observed the ball

joint is in good condition.
B
A. Top centre nut (rear shock).

B. Coil spring bottom start point to be outside of the
vehicle for both RH & LH.
10.Only flanged bolts and nuts should be used. Use
of spring washer and plain washer to be pre-
vented.
11.Both front and rear suspension should be tight-
ened in design condition (4 passengers weights)
and not in rebound.
12.The equivalent of 4 passenger weight in terms of
ride height are Front – 460 mm, Rear - 485
mm.
13. All rubber bushings should be free from oil.
14. All silent block with voided and flange bushes
should be mounted as per the specified
orientation.

MAN-00162
Rear Shock Absorber 3. Remove the 21mm shock absorber mounting

bolt and nut (A) from the rear lower link.
The shock-absorber is also called as a damper. The 4. Remove the four 14mm mounting bolts (A) and
shock-absorber smoothens out or damps the shock remove the suspension tower cover plate.
impulses or vibrations induced due to the wheel tr-
avel over the uneven road surfaces.
Removal
1. Remove the rear wheel from the vehicle. For
A
DANGER
Slippage/dropping of heavy/large objects
could cause damage. This may also cause
injury to the person involved.
2. Remove the 21mm rear lower link bolt and nut

(A). 5. Remove the two 14mm top mounting nuts (A) fr-
om the shock absorber.
A
A

MAN-00162
6. Remove the shock absorber assembly. Rear Stabilizer Bar

Notice
Slowly press the rear lower control link in the
downward direction to remove the shock ab-
sorber. Care should be taken not be distrubed
Rear brake hose while removing shock ab-
sorber.
Installation
2. After installation camber bolt torque to be
checked by holding on the bolt head side & tight-
ing on the nut side.
The stabilizer bar transmits part of the torsional force

to the opposite wheel, pulling into its wheel housing.
This causes the inner wheel suspension to be com-
pressed and thereby reducing the body roll. The sta-
bilizer bars are connected to the stabilizer bar links.
Removal
1. Remove the silencer muffler. For additional
information refer to Muffler removal and
2. Remove the stabilizer bar link bottom mounting
nut. For additional information refer to Rear
section.
3. Using a frame removal and refit tool (Special
Tool Part No:0402EAA0001ST), remove the two
16mm bolts (A) and bracket from RH side of the
stabilizer bar.

MAN-00162
4. Using Rear Stab bar bolt (mounting on frame)

removal and refit tool (Special Tool Part
Rear Stabilizer Bar Link
No:0402EAA0001ST), remove the two 16mm
bolts (A) and bracket from LH side of the stabi-
lizer bar.
A stabilizer bar link rod is included to control suspen-

sion lean/sway during turns.
5. Remove the stabilizer bar.

Removal
Installation additional information refer to Wheels
1. To install, reverse the removal procedure. removal and installation section.
2. Using a 5mm Allen key (A), lock the stabilizer
link stud, and remove the 18mm top mounting
nut (B) from the stabilizer link.
B
A

MAN-00162
3. Using a 5mm Allen key (A), lock the stabilizer Rear Stabilizer Bar Bush
link stud, and remove the 18mm bottom mount-
ing nut (B) from the stabilizer bar. Removal
1. Remove the stabilizer bar bracket. For addi-
tional information refer to Rear Stabilizer Bar
B 2. Remove the stabilizer bar bush.
4. Remove the stabilizer link.
Notice
Check the rubber for cracks, wear, or deterio-
ration, and also check for the stabilizer link
bend. Notice
The bush has cut sections to facilitate the re-
Installation moval and installation of the bush.
Installation
Notice 1. To install, reverse the removal procedure.
Mounting link rod nuts to be tightened to the
specified torque. While giving torque usage of
suitable tool is necessary for holding.

MAN-00162
Link Rod Mounting Bracket on 5. Separately remove the link rod mounting
bracket.
Knuckle Side
Removal
2. Detach the wheel speed sensor wiring (A) from
the link rod top mounting bracket.
Installation
CAUTION
Avoid the damage of wheel speed sensor wir-
ing while removing.
3. Remove the link rod top mounting nut. For addi-

tional information refer to Rear Stabilizer Bar
Link removal and installation section.
4. Loosen and remove the two 19mm link rod
mounting bracket bolts (A) and nuts (B).

MAN-00162
Front Lower Tubular Link 3. Remove the 21mm front lower tubular link
mounting bolt (A) from the chassis side and
detach the front lower tubular link.
Removal
1. Remove the rear wheel. For additional infor-
Notice
tion section. Check the rubber bushes for cracks, wear, or
2. Remove the 21mm link lower tubular link mount- deterioration and also check for the front low-
ing nut (A) from the knuckle side. er tubular link bend.
Installation

MAN-00162
Front Lower Tubular Link Bush - 4. Place the front lower tubular link (A) on the base
block.
Knuckle Side
Removal
1. Remove the front lower tubular link. For addi-
tional information refer to Front Lower Tubu-
lar Link removal and installation section.
A
5. Place the lower link bush adapter (A) (Special

Tool Part No:0401BAA0030ST/2) into the lower
link (B).
3. Insert the dolly pressing tool (A) (Special Tool

Part No:0401BAA0030ST/1) into the base block. A B
6. Using a hydraulic press (A), remove the lower

link bush from the front lower tubular link .

MAN-00162
Installation 3. Insert the lower link bush adapter (A) (Special

1. Insert the bush (A) into the front lower tubular Tool Part No:0401BAA0030ST/2) into the lower
link (B). link (B).
Notice Notice
To avoid the bush damage, install the bush in To avoid the bush damage, install the bush in
straight position into the lower link front. straight position into the lower link front.
A
B A
B
2. Fix the pin (A) (sub part of 0401BAA0027ST) 4. Using a hydraulic press (A), install the bush
into the lower link bush adapter (B) (Special Tool into the front lower tubular link.
Part No:0401BAA0030ST/2).
A A

MAN-00162
Front Lower Tubular Link Bush - 4. Place the lower link frame side (A) on the base
block.
Frame Side
Removal
1. Remove the front lower tubular link. For addi-
tional information refer to Front Lower Tubu-
lar Link removal and installation section.
A
5. Place the lower link bush adapter (A) (Special

Tool Part No:0401BAA0031ST/2) into the lower
link (B).

Part No:0401BAA0031ST/1) into the base block. A B
6. Using a hydraulic press (A), remove the lower

link bush from the lower link frame side.

MAN-00162
Installation 3. Insert the lower link bush adapter (A) (Special

1. Insert the bush (A) into the lower link frame side Tool Part No:0401BAA0031ST/2) into the lower
(B). link (B).
Notice Notice
To avoid the bush damage, install the bush in To avoid the bush damage, install the bush in
straight position into the lower link frame side. straight position into the lower link frame side.
A
B A
B
2. Fix the pin (A) (sub part of 0401BAA0027ST) 4. Using a hydraulic press (A), install the bush
into the lower link bush adapter (B) (Special Tool into the lower link frame side.
Part No:0401BAA0031ST).
A A

MAN-00162
Rear upper rod link 3. Remove the 24mm rear upper rod link mounting
bolt (A) from the chassis side and separately
remove the rear upper rod link.
Removal
Notice
tion section. Check the rubber bushes for cracks, wear, or
2. Remove the 18mm rear upper rod link mounting deterioration, and also check for the rear up-
nut (A) from the knuckle side. per rod link bend.
Installation

MAN-00162
Rear Upper Rod link Bush - 4. Place the rear upper rod link (A) on the base
block.
Frame Side
Removal
1. Remove the rear upper rod link. For additional
information refer to Rear upper rod link
A
Notice
below, while removing and installing the
bush.
5. Fix the adapter pin (A) (sub part of

0401BAA0027ST) into the rear upper rod link
bush adapter (B) (Special Tool Part
No:0402BAA0017ST/2).
3. Insert the dolly pressing tool (A) (Special Tool A

Part No:0402BAA0017ST/1) into the base block.

MAN-00162
6. Insert the rear upper rod link bush adapter (A) Installation
(Special Tool Part No:0402BAA0017ST/2) into 1. Insert the bush (A) into the rear upper rod link
the rear upper link (B) . (B).
Notice
To avoid the bush damage, install the bush in
straight position into the rear upper rod link.
A B
A
B
7. Using a hydraulic press (A), remove the rear

upper link bush from the rear upper rod link.

No:0402BAA0017ST/2).

MAN-00162
3. Insert the rear upper rod link bush adapter (A) Rear Upper Rod link Bush -
(Special Tool Part No:0402BAA0017ST/2) into
the rear upper link (B). Knuckle Side
Removal
1. Remove the rear upper rod link. For additional
A 2. Place the base block (A) (Special Tool Part
B No:0401BAA0027ST) on the hydraulic press.
Notice
below, while removing and installing the
bush.
4. Using a hydraulic press (A), install the bush into

the rear upper rod link.


MAN-00162
4. Place the rear upper rod link knuckle side (A) on 6. Insert the rear upper link bush adapter (A) (Spe-
the base block. cial Tool Part No:0402BAA0016ST) into the rear
upper rod link knuckle side (B) .
A A B

0401BAA0027ST) into the rear upper rod link 7. Using a hydraulic press (A), remove the rear
bush adapter (B) (Special Tool Part upper rod link bush from the knuckle side.
No:0402BAA0016ST).
A

MAN-00162
Installation 3. Insert the rear upper rod link bush adapter (A)
1. Insert the bush (A) into the rear upper rod link (Special Tool Part No:0402BAA0016ST) into the
knuckle side(B). rear upper rod link (B).
Notice
straight position into the rear upper link.
A
B
A
B
4. Using a hydraulic press (A), install the bush into

the rear upper rod link knuckle side.
A
No:0402BAA0016ST).

MAN-00162
Front Upper Link 3. Remove the 21mm front upper link bolt (A) and
nut (B).
A
B
Removal 4. Remove the 21mm front upper link mounting

1. Remove the rear wheel from the vehicle. For bolt (A) and nut (B) and separately remove the
additional information refer to Wheels front upper link.
B A
2. Detach the wheel speed sensor wire (A) from
the front upper link.
Installation
Notice
Upper link front frame side to be tightened
from bolt head side.

MAN-00162
Front Upper Link Bush 4. Fix the adapter pin (A) (sub part of
0401BAA0027ST) into the front upper link bush
Removal adapter (B) (Special Tool Part
No:0402BAA0020ST/2).
1. Remove the front upper link. For additional
information refer to Front Upper Link
Notice B
Use the base block as shown in the picture be-
low, while removing the bush.
5. Insert the upper link frame bush adapter (A)

(Special Tool Part No:0402BAA0020ST/2 into
A the front upper link.
3. Insert the dolly pressing tool (B) (Special Tool

Part No:0402BAA0020ST/1) into the base
block(A)(Special Tool Part No:0401BAA0027ST).
A 6. Using a hydraulic press (A), remove the front

upper link frame bush.

MAN-00162
Installation 3. Place the front upper link (A) on the base block.
No:0401BAA0027ST) on the hydraulic press. Notice
To avoid the bush damage, install the bush
Notice in straight position into the lower link front.
below, while installing the bush.
A A
4. Insert the front upper link bush adapter (A) (Spe-

cial Tool Part No:0402BAA0020ST/2) in the front
2. Insert the dolly pressing tool (A) (Special Tool upper link.

MAN-00162
5. Using a hydraulic press (A), install the front up- Rear Lower Control Link
per link bush.
Removal
2. Remove the 21mm rear lower control link bolt
and nut (A) from knuckle side.
3. Remove the 21mm shock absorber mounting

bolt and nut (A).

MAN-00162
4. Remove the 21mm rear lower control link cradle Rear Lower Link Bush
side mounting bolt (B) with locking washer (A)
and nut. Removal
1. Remove the rear lower control link. For addi-
tional information refer to Rear Lower Con-
trol Link removal and installation section.
A
Notice
B
Use the base block as shown in the picture be-
low, while removing the bush.
5. Remove the rear lower control link assembly.
Notice
A
Wheel alignment is required after removing or
replacing the rear lower link.
Installation
Notice
Lower link rear knuckle side to be tightened 3. Insert the dolly pressing tool (B) (special tool
from bolt head side. part no 0402BAA0019ST/1) into the base
block(A)(SpecialTool Part No:0401BAA0027ST).

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4. Place the rear lower link (A) on the base block. 7. Using a hydraulic press (A), remove the rear
lower link bush.
A A

0401BAA0027ST) into the rear lower link bush Installation
adapter (B) (Special Tool Part
1. Place the rear lower link bush (A) in the rear
No:0402BAA0019ST/2).
lower link.
Notice
straight position into the rear lower link.
A
6. Insert the rear lower link bush adapter (A) (Spe-
cial Tool Part No:0402BAA0019ST/2) into the
rear lower link.

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2. Insert the rear lower link bush adapter (A) (Spe- Toe Bar
cial Tool Part No:0402BAA0019ST/2) into the
rear lower link.
Removal
3. Using a hydraulic press (A), install the rear lower 1. Remove the toe bar end. For additional infor-
link bush. mation refer to Toe Bar Ball Joint End
2. Remove the 21mm toe bar mounting nut and bo-
lt (A) from the cradle side.
A
A
3. Remove the toe bar assembly from the cradle.
Notice
While removing or replacing the toe bar or
the ball joint, ensure wheel alignment is
done.
Installation
Notice
Toe bar frame side to be tightened from bolt
head side.

MAN-00162
Toe Bar Bush 4. Place the toe bar (A) on the base block.
Removal
1. Remove the toe bar. For additional informa-
tion refer to Toe Bar removal and installation
section. A

0401BAA0027ST) into the toe bar bush adapter
(B) (Special Tool Part No:0402BAA0018ST/2).

No:0401BAA0027ST) on the hydraulic press, B
and insert the dolly pressing tool (B) (Special
Tool Part No:0402BAA0018ST/1) into the base
block.
B A
6. Insert the toe bar bush adapter (A) (Special Tool

Part No:0402BAA0018ST/2) into the toe bar.
A
A

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7. Using a hydraulic press (A), remove the toe bar 2. Insert the toe bar bush adapter (A) (Special Tool
bush from the toe bar. Part No:0402BAA0018ST/2) into the toe bar
bush.
Installation
3. Using a hydraulic press (A), install the toe bar
1. Place the toe bar bush into the toe bar (A).
bush into the toe bar.
Notice
To avoid the bush damage, install the bush in A
straight position into the toe bar.

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Toe Bar Ball Joint End 4. Separately remove the toe bar end by rotating it
anticlockwise from the toe bar.
Removal
2. Loosen a 24mm toe bar adjustment lock nut (A)
by rotating the nut clockwise.
A
Notice
While removing or replacing the toe bar end,
ensure wheel alignment if required.
3. Remove a toe bar end cotter pin (A) and a

22mm lock nut (B). CAUTION
Check the rubber boot cut or wear, and also
check the ball joint worn out.
Installation

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Rear Knuckle 6. Remove the link upper front knuckle side. For
additional information refer to Front Upper
Link removal and installation section.
G 7. Remove the rear lower link knuckle side. For
A
F additional information refer to Rear Lower
Control Link removal and installation sec-
tion.
B 8. Separately remove the rear knuckle assembly.
Installation
Notice
E C Wheel alignment is required after remove or
D replacing the wheel rear knuckle.
A. Upper Rear
B. Caliper Mounting
C. Lower Rear
D. Lower Front
E. Toe Bar
F. Upper Front
G. Stabilizer Bar Mounting Bracket
The rear knuckle holds the suspension components.
Removal
1. Remove the rear wheel hub assembly. For addi-
tional information refer to Rear Wheel Hub
2. Remove the stabilizer link knuckle side mounting
nut. For additional information refer to Rear
section.
3. Remove the toe bar knuckle end. For additional
information refer to Toe Bar Ball Joint End
CAUTION
Do not use hammer for removing the ball joint
(Rear : Toe Bar) from the respective knuckles.
It damages the knuckle and the ball joint boot.
4. Remove the link lower front knuckle side. For

additional information refer to Front Lower
Tubular Link removal and installation sec-
tion.
5. Remove the rear upper link. For additional

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Rear Knuckle Bush 4. Using a hydraulic press (A), remove the knuckle
bush (B) from the rear knuckle.
Removal
1. Remove the rear knuckle assembly. For addi- A
tional information refer to Rear Knuckle
Notice B
To remove the LHS and RHS rear knuckle
bush, follow the same procedure.
2. Place the rear knuckle (A) into the hydraulic

press.
A Installation
1. Insert the bush (A) into the rear knuckle.
3. Fix the rear knuckle bush adapter (A) (Special

Tool Part No:0402BAA0018ST/2) into the rear
knuckle in proper position.
2. Insert the rear knuckle bush adapter (A) (Special

A Tool Part No:0402BAA0018ST/2) into the rear
knuckle bush (B).

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3. Using a hydraulic press (A), fix the knuckle bush Rear Cradle
(B) into the rear knuckle.
Removal
A 1. Remove the silencer muffler. For additional
information refer to Muffler removal and
2. Remove the propeller shaft.
B
3. Remove the link upper rear. For additional
4. Remove the link lower front. For additional
information refer to Front Lower Tubular Link
5. Remove the stabilizer bar link. For additional
information refer to Rear Stabilizer Bar Link
Notice 6. Remove the toe bar. For additional informa-
Inserting the knuckle bush, the bush must be tion refer to Toe Bar removal and installation
in straight position to the hydraulic press to section.
avoid the bush damage. 7. Remove the link upper front. For additional
information refer to Front Upper Link
8. Remove the rear lower link. For additional
information refer to Rear Lower Control Link
9. Remove the rear knuckle assembly. For addi-
tional information refer to Rear Knuckle
10. Remove the stabilizer bar. For additional infor-
mation refer to Rear Stabilizer Bar removal
11.Remove the rear drive shaft.(Only for AWD vehi-
cle) For additional information refer to Rear
Halfshaft LH (Applicable for All Wheel Drive
Vehicle) removal and installation section. For
additional information refer to Rear Halfshaft
RH (Applicable for All Wheel Drive Vehicle)
12. Remove the IRDA assembly. (Only for AWD
vehicle) For additional information refer to
Independent Rear Drive Axle (IRDA) removal
13. Remove the rear parking brake cable assembly.
For additional information refer to Parking
Brake Cable - Rear removal and installation
section.

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Rear Wheel Hub

DANGER Removal
Slippage/dropping of heavy/large objects 1. Loosen the 36mm axle nut (A) and the five
could cause damage. This may also cause 21mm wheel nuts (B) without lifting the vehicle.
injury to the person involved.
Notice
While removing or replacing the cradle assem-
A B
bly, ensure wheel alignment is done.
14. Remove the 24mm two bolts (A) and two nuts
(B) from the cradle assembly.
2. Lift the vehicle and remove the wheel, and re-

move the 36mm axle nut.
A
A 3. Remove the 10mm bolt (A) on the wheel speed
sensor and remove the wheel speed sensor.
B
B
A
Installation
Notice
While removing or replacing the cradle
assembly, ensure wheel alignment if required.
4. Remove the rear brake disc. For additional

information refer to Rear Brake Disc removal

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5. Loosen the four 18mm mounting bolts (A) on the Assembly and Disassembly
wheel hub.
Rear Shock Absorber
6. Remove the hub along with wheel bearing from

the knuckle.
Disassembly
1. Using a special tool (A), compress the shock
absorber spring.
Notice
Wheel bearing is not serviceable. It is replaced
along with the hub. A
Installation

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2. Using a 5mm Allen key (A), lock the shock 5. Remove the shock absorber spring stopper plate
absorber stud, and loosen a 16mm lock nut (B) (A).
of the shock absorber.
A
A
B
6. Separately remove the shock absorber spring

3. Remove the 16mm shock absorber stud lock nut stopper plate rubber (A).
with washer (A).
A
A
7. Remove the plate washer (A) from the shock

4. Separately remove the upper rubber bush (B) absorber.
and the top mounting plate (A).
A
B

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8. Using a special tool (B), separately remove the Toe Bar

spring (A).
Disassembly
9. Separately remove the bump stopper (A) from
1. Loosen the 24mm toe bar end side lock nut (A)
the shock absorber.
by rotating the nut clockwise.
A
A
Assembly 2. Remove the toe bar end (A) by rotating it anti-

1. To assemble, reverse the disassembly proce- clockwise.
dure.
CAUTION A
• Ensure the spring compressor special tool
is mounted properly to avoid any personnel
injury and/or damage to the tool.
• Care to be taken not to drop the spring with

clamp suddenly to avoid any injury.

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Assembly Diagnosis and Testing

1. To assemble, reverse the disassembly pr-
ocedure. Inspection and Verification
1. Visually inspect the rear suspension compo-
nents for any noticeable signs of mechanical
damage.
2. If an obvious cause is found, correct the same
before proceeding to the next step.
3. Perform a road test
• For any suspension alignment or ride height
concerns, refer to the troubleshooting chart.
• Verify the complaint by performing a road
test on a good conditioned road. If any abnormal
noise is observed refer to the troubleshooting
chart
4. Inspect tires.
• Check the tire pressure with normal vehicle
Notice loads and also in cold condition. Ensure that the
After removing or replacing the toe bar, wheel tire pressure is as per specification.
alignment is required. • Verify that all the tires are of specified size.
• Inspect the tires for uneven wear or dam-
age.
5. Inspect the chassis and the under body.
• Remove dirt or road deposits from the chas-
sis and the underbody.
Visual Inspection
Mechanical
• Check the suspension fasteners for looseness
or damage.
• Check the shock absorber for damage or leak.
• Check the stabilizer bar, bushes and the link
rods for wear, bend or damage.
• Inspect the drive shaft for any damage.

MAN-00162
1. Coil spring breakage. 1. Replace coil spring.

2. Rear Shock absorber lower 2. Replace rear shock absorber. (use
spring seat damaged / defo- same peripheral parts if not dam-
Rear Ride height low rmed. aged)
3. Leakage in shock absorber. 3. Replace the shock absorber.
4. Low tire pressure. 4. Check and adjust tire pressure.
1. Oil leakage from rear shock 1. Replace shock absorber.

absorber. 2. Correct the tyre pressure as per
Rear ride too bouncy 2. High tyre pressure. specifications
3. Bump stopper damage 3. Replace bump stopper
1. Weak or defective shock ab- 1. Check and replace the shock ab-
sorber. sorber.
2. Excessive wheel play. 2. Check and replace wheel bearing if
Incorrect or abnormal tire wear required.
3. Incorrect tire size or pres- 3. Adjust tire pressure and proceed
sure. further repairs with recommended
tire size.
1. Unevenly loaded vehicle. 1. Notify the customer about incorrect

vehicle loading.
2. Leakage or weak shock ab- 2. Replace the shock absorber ass-
Vehicle leans to one side sorber. embly.
3. Low Camber height. 3. Check the camber height and do
the wheel alignment.
1. Over, unevenly or incorrectly 1. Notify the customer of incorrect

loaded vehicle. vehicle loading.
2. Damaged shock-absorber. 2. Inspect the shock absorber. Re-

Sway or roll place the shock-absorber if neces-
sary.
3. Loose or worn out stabilizer 3. Inspect the stabilizer bar and the
bar links or bushes. bush. Replace the stabilizer bar co-
mponents if necessary.
Thud Noise from the Rear 1. Play / permanent set on Sta- 1. Replace mounting bushes.
bilizer bar mounting bushes
on cradle.
2. Shock absorber mounting 2. Tighten the shock absorber mount-
bolts loose. ing bolts.
3. Failed shock absorber mak- 3. Replace the shockabsorber.
ing thud noise.

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1. Torque loose of hardwares 1. Check & ensure proper torques as

of shock absorber, control per specification of hardware.
links, stabilizer bar & stabi-
lizer bar links.
2. Rear bump stopper dam- 2. Replace bump stopper.
Metallic Noise aged.
3. Rubber spring seat top & bo- 3. Replace the same.
ttom coil sleeve worn out.
4. Control links rubber bush fa-
ilure. 4. Replace the damaged bush
Clunk - noise occurs from the 1. Loose or damaged rear sus- 1. Inspect for loose or damaged rear
rear Suspension when shifting pension components. suspension components. Repair or
the gear from reverse to drive replace the components if neces-
sary.
1. Loose or bent shock absorb- 1. Inspect the shock absorber for

er. loose or bend and tighten or re-
place it if necessary.
Rear suspension noise - squeak,
2. Damaged or worn stabilizer 2. Inspect the stabilizer bushes, re-
creak or rattle noise.
bushes. place if necessary.
3. Worn or damaged stabilizer 3. Inspect the stabilizer bar and link
bar or link rod. rod, replace if necessary.
1. Leak or bend in shock ab- 1. Replace the shock absorber.

Rough or Harsh ride.
sorber.

1. Check the shock absorber for

smooth operation by full
stroke, compression and ex-
Shock absorber tension. 1. Replace if necessary.
2. Check the shock absorber for
fluid leakage, damage or
deformation.
1. Check the stabilizer bar for 1. Replace if necessary.

Rear stabilizer bar
twist or deformation.
1. Check the rubber bushes for 1. Replace the rubber bushes.

Rubber bushes
cracks, wear or deterioration.

MAN-00162
Type Multilink suspension
Spring Coil Spring
Anti-roll bar At rear
Shock absorbers Hydraulic with gas filled

Base block for assy and disassy

for all suspension bushes (1 no)
0401BAA0027ST
Adapter Pin (4 nos)
Rear upper rod link bush (knuckle

0402BAA0016ST side) removal and refit adapter (1
no)

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0402BAA0017ST/1 Dolley (1 no)
Rear upper rod link bush (frame

0402BAA0017ST/2 side) removal and refit adapter (1
no)
Toe bar bush removal and refit

0402BAA0018ST/2
adapter (1 no)

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Rear lower link bush removal and

0402BAA0019ST/2
refit adapter (1 no)
Front Upper Link bush removal

0402BAA0020ST/2
and refit adapter (1 no)

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Front lower tubular link bush

0401BAA0030ST/2 (Knuckle side) removal and refit
adapter (1 no)
Front lower tubular link bush

0401BAA0031ST/2 (frame side) removal and refit
adapter (1 no)

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Rear Stab bar bolt mounting on

0402EAA0001ST
frame removal and refit tool (1 no)
Torque Chart
Tool description Bolt Size Torque in Nm
Upper Control Link Front Knuckle M14 150 ± 20
Upper Control Link Front Frame M14 95 ± 15
Upper Control Link Rear Knuckle M12 150 ± 20
Upper Control Link Rear Frame M16 150 ± 20
Lower Control Link Front Knuckle M14 150 ± 20
Lower Control Link Front Frame M14 150 ± 20
Lower Control Link Rear Knuckle M14 150 ± 20
Lower Control Link Rear Frame -Camber bolt M14 160 ± 10
Toe bar Frame M14 150 ± 20
Toe bar ball joint Knuckle M14 150 ± 20
Rear Toe bar center Nut - 2 numbers M16 90 ± 10
Bracket Stabilizer bar mounting Rear M10 53 ± 7
Stabilizer bar Link mounting Rear M12 95 ± 15
Rear Frame - Front and rear mounting M16 210 ± 30
Rear Shock absorber Bottom M14 150 ± 20
Rear Shock absorber Top M10 53 ± 7
Rear craddle (FWD) to BIW M16 170.0~240.0
Rear craddle (AWD) to BIW M16 170.0~240.0

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Wheel Alignment
Wheel alignment involves correct positioning of the Caster is the forward or backward tilt of the steering
wheels in the vehicle. The positioning is accom- knuckle from vertical position. Tilting the top of the
plished by suspension and steering linkage adjust- knuckle forward provides negative caster. Tilting the
ments. Wheel alignment is essential for efficient top of the knuckle backward provides positive caster.
steering, good directional stability and to minimize Positive caster promotes directional stability. This
tire wear. The most important measurements of an angle enables the front wheels to return to a straight
alignment are caster, camber, toe-in and toe-out. ahead position after turns. The caster on the vehicle
is fixed and cannot be changed at any point.
Camber
Toe In and Toe Out
Toe is a measurement of how much the front wheels
Camber angle are turned in or out from a straight-ahead position
viewed from the top. When the wheels are turned in,
toe is positive (+). When the wheels are turned out,
toe is negative (-). The actual amount of toe is nor-
mally only a fraction of a degree. Improper toe
adjustment will cause premature tire wear and cause
steering instability and vehicle pulling too.
Toe In (Positive Toe)
A
Camber is the inward or outward tilt of the wheel rela-
tive to the center line of the wheel, when viewed from
the front. Tilting the top of the wheel inward provides
negative camber. Tilting the top of the wheel outward
provides positive camber. Incorrect camber will
cause uneven wear on the inside or outside edge of
the tires.
Caster
B
Caster angle

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Toe Out (Negative Toe) Ride Height

Ride height is to be measured from wheel center to
the wheel arc for both front and rear in unladen con-
dition.
A
Rear Ride Height
Rear Wheel Arch
Rear
Ride
Height
Wander
• Wander is the tendency of the vehicle to move
randomly left & right, which requires frequent
Ground
steering corrections to maintain straight ahead
position.
Front Ride Height
Drift/Pull
• Drift/Pull is a tugging sensation felt by the hands
on the steering wheel that must be overcome to
Front Fender
keep the vehicle going straight.
• A vehicle-related drift/pull on a flat road will
cause a consistent deviation from the straight-
ahead path and require constant steering input Front Ride Height
in the opposite direction to counteract the effect.

• Drift/ Pull may be induced by conditions which
are external (wind, Road Chamber); and within
the vehicle (like incorrect wheel alignment, dam-
age in suspension & steering linkages &
bushes). Ground

MAN-00162
Wheel Alignment Specifications

Front Suspension
Parameter Specification Max difference between LH and RH side
Caster 2º 30´ to 4º 30´
Camber -0º 30´ to 0º 30´ 0º 30´
Toe RH 0 to 0º10´ or ( 0 to 1 mm)
Toe LH 0 to 0º10´ or ( 0 to 1 mm)
Toe Total 0 to 0º20´ or ( 0 to 2 mm) 0º10´ or 1 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 0 to 0º10´ or ( 0 to 1 mm)
Toe LH 0 to 0º10´ or ( 0 to 1 mm)
Toe Total 0 to 0º20´ or ( 0 to 2 mm) 0º 10´ or 1 mm
Tyre Pressure 30 psi
Ride height 516 mm ±10mm

MAN-00162
Wheel Alignment and Sequence of operation

2. Before doing wheel alignment, ensure front and
Notice rear tyre pressure are as per specifications.
Vehicle to be run for some distance before start-
Wheel Alignment and Ride height ing the wheel alignment. This will settle the load
measurement is to be done in Unladen on each tyre.
condition.
Wheel alignment for Rear Suspension to be 3. Put the vehicle on wheel alignment machine and
done first and then Front Suspension to be do the wheel mapping w.r.t. Machine.
carried out. 4. Do the setting of Front steering wheel for
Straight ahead Position (SAP) and lock the
1. Refer the wheel alignment specification for the steering column rotation.
Front and Rear Suspension. 5. Wheel alignment for Rear Suspension to be
STEP 1:
Toe adjustment
Rear Toe
ajustment STEP 2:
Camber Adjustment
(2 Places LH and
RH)
STEP 3:
Toe and
camber setting
7. STEP 1: On Rear RH side, first adjust the RH

toe by shifting the Hex Nut and bring to specified
band.
STEP 2: Then adjust the RH Camber by rotating
the Camber bolt and bring to specified values.
Full Torque to be applied on Camber Nut by
ensuring the specified camber value of 160±10
Nm.
STEP 3: Then RH toe to be adjusted if gone out
of specs and full torque to be applied on RH toe
bar.
8. 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.

MAN-00162
9. Front wheel alignment includes adjustment of • Camber: There is no provision given for front
Front Toe angle & camber angle (if required). camber adjustment. If camber value is found out
• Toe: First loose the lock nut on Toe rod assy by of specification range, then use following hard-
holding the OBJ housing and then adjust the toe ware in place of existing M16 strut mounting bot-
by rotating the IBJ shank. After setting the toe, tom hardwares..
torque the lock nut by holding the OBJ housing Bolt Hex Fl. M14 X 1.5X 80 X 8.8
as shown in figure-6 Nut Hex Fl.M14 X 1.5 X14
Front toe
adjustment
(for both LH & RH)
10.After assembling above hardwares, required

camber specs is to be ensured by puling/push-
ing the wheel end assy. as required. Torque
value of 150±10 Nm to be ensured on these
hardwares
CAUTION
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.

MAN-00162
Tool Part No Description Image
Rear Toe Bar center Nut Torque

0402BAA0021ST
tightening tool
Steering Toe Bar Nut torque tighten-

0401BAA0032ST
ing tool

MAN-00162
Repair Manual Wheels and Tyres Nov 2011/ Rev 2
WHEELS AND TYRES
CONTENTS
Incar Repairs .................................................................................... 2

Tyre Inspection and Rotation ............................................................. 3
General Procedure ............................................................................. 3
Wheels........................................................................................... 5
Removal ............................................................................................. 5
Installation .......................................................................................... 5
Spare Wheel ..................................................................................6

Removal ............................................................................................. 6
Installation .......................................................................................... 6
Winch Mechanism ........................................................................ 7

Removal ............................................................................................. 7
Installation .......................................................................................... 7
Tyre Changing ..............................................................................8

Removal ............................................................................................. 8
Inspection........................................................................................... 9
Installation .......................................................................................... 9
TPMS ..........................................................................................11
Removal ........................................................................................... 11
Inspection......................................................................................... 11
Installation ........................................................................................ 12
Wheel Balance ............................................................................12

Types of imbalance .......................................................................... 12
Tyres should always be balanced when .......................................... 13
Tyres should always be balanced when .......................................... 13
Diagnostics and Testing ...............................................................14


MAN-00162

MAN-00162
Wheels and Tyres 5. Two-digit number (17): This number is the

wheel or rim diameter in inches.
6. Two or three digit number (104): This
Description and Operation number is the tyre's load index. It is a
The tyres fitted in this vehicle are radial tubeless measurement of how much weight each tyre
tyres mounted on 17 inch diameter wheels. can support.
The radial tubeless tyres play an important role in 7. (S): The “S” stands for speed rating. It denotes
vehicle handling and riding characteristic of the the speed at which a tyre is designed to be
vehicle, and a change of tyre should be as per driven for extended periods of time.
specification.
The air pressure maintained in the tyres has direct

influence on the obtained fuel average, braking and
on riding characteristic, so it is essential to maintain
tyre pressure as per specification.
The tubeless tyres are comparatively less
vulnerable to heat and friction generated between
the tyres and the road surface which helps to
increase the life of the tyres. It also improves
acceleration and fuel efficiency because these are
lighter and have lower rolling resistance than the
the tubed tyres. In case of tyre puncture you can
safely drive with the tubeless tyres to certain
distance before the tyre loses the air completely.
Tyre Rating
Tyre rating P 235 / 65 R 17 104 S is explained as
follows:
P 235 65 R 17 104 S
1 2 3 4 5 6 7
1. P: The “P” indicates the tyre is designed for

passenger vehicles
2. Three-digit number (235): This number gives
the width in millimeters of the tyre from
sidewall edge to sidewall edge.
3. Two-digit number (65): This number, known
as the aspect ratio, gives the tyre's ratio of
height to width 65% of width in this case.
4. R: The “R” stands for radial.

MAN-00162

Observe the following precautions when The tubeless tyres fitted in this vehicle is 235/65/
disassembling or servicing the wheels and tyres. R17 104H rated.
• Before attempting to balance the wheels and "235" is the width of the tyre in millimeters
tyres assembly, clean both inner & outer sides between sidewall edges at designated air pressure
of the rims. Also remove any existing balance and load.
weights.
"65" is the aspect ratio that is ratio between height
• Repair punctures only in the tread area. and width section of the tyre, where height of the
• Avoid repairing of a tyre with bulges or blisters, tyre is equal to 65 percentages of its width.
ply separation, broken and cracked beads.If
any of these symptoms exist, replace the tyres. A
• Clean the wheel rim bead seats by using a

non-abrasive cleaner to remove the mounting C
lubricants and old rubber.
• Lubricate bead area with suitable tyre lubricant,
before mounting or demounting the tyre.
• Use an accurate tyre gauge to check tyre D B
pressure.
• Mounting and demounting of the tyre must be
done only from the narrow ledge side of the
wheel. Care must be taken to avoid damaging
the tyre beads.
• Non-flammable rubber lubricant must be
Fig: 2
applied to bead and wheel mating surfaces
before assembling the rim wheels. H. Tyre Width
I. Outer diameter
DANGER J. Section height

K. Rim diameter
Improper Jacking will lead to falling of vehicle
and vehicle parts which cause personal injury. "R" indicates that the tyre is made by using radial
construction code.
"17" is the diameter of the rim in inches.
"104" is the load index of the tyres that supports
900Kg (1984 lb) weight.
"S" is the speed rating or speed symbol of the tyre.
The speed rating denotes the speed at which the
tyre is designed to be driven for extended periods
of time under a standard condition of load and
inflation pressure.
Notice
High performance tyres have a lower aspect
ratio than other tyres. This is because tyres
with a lower aspect ratio provide better later-
al stability.

MAN-00162
When the vehicle goes around a turn lateral forces Worn out Tyre
are generated and the tyre must resist these
forces. Tyres with a lower profile have shorter,
stiffer sidewalls so they resist cornering forces in Tread wear indicator
better manner.
Tyre Inspection and Rotation

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 New tread Worn tread
mud, snow, and wet traction levels, and contribute
to a smooth, quite ride. Follow the recommended
tyre rotation.
Because your vehicle's tyres may wear unevenly,
It is recommended to rotate the tyres as per the you may need to replace them before a wear band
Maintenance Schedule. appears across the entire tread. Some spots wear
Recommended Tyre Rotation Method: more heavily than others.
• Spare wheel should go to Rear Left wheel. General Procedure
• Rear Left wheel should go to Front Right. Procedure for TPMS Learning
• Rear Right wheel should go to Front Left. 1. Press the TPMS switch in the cluster and turn igni-
• Front Right wheel should go to Rear Right. tion ON along with the switch pressed, infotainment
• Front Left wheel should go to Spare wheel. will be displayed as below and TPMS warning lamp
in the cluster will start blinking.
Front Side of Vehicle
2 5
1
1
3 4
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 below.

MAN-00162
5. Start removing air from rear left tyre. Once the tyre
as below.
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 below.
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 below to
indicate all tyres were learnt successfully.
4. Start removing air from rear right tyre. Once the

tyre get learnt, vehicle alarm and hazard lamp will
change as below.
7. If there were any problem in learning, system will

alert through alarm and hazard lamp 5 times to
indicate the tyre learning is not complete.

MAN-00162
Wheels Installation
Removal
1. Position the vehicle in a two post lift. Notice
Notice Tighten the wheel nuts to the specified
torque.
While removing the wheel nuts apply park-
ing brake.
2. Open the tool box (A) and remove the 21mm

wheel spanner from the cargo area.
3. Loosen the five 21mm wheel nuts using a

wheel spanner (A) by rotating anti-clockwise.

information refer to Jacking and Lifting
5. Remove the wheel nuts and the wheel from
the vehicle.

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Spare Wheel 3. Loosen the spare wheel using a winch access

tool (A) by rotating anti-clockwise.
Removal
1. Open the tool box (A) and remove the winch Notice
access tool from the cargo area. Loosen the spare wheel till the spare wheel
reaches the ground.
4. Remove the spare wheel from the winch rope.

A Installation
Notice
Fix the spare wheel in proper position.
2. Using a suitable tool, remove the spare winch

loosening nut cap (A).

MAN-00162
Winch Mechanism Installation

Notice
Tighten the wheel nuts to the specified
torque.
Removal
1. Remove the spare wheel. For additional
information refer to Spare Wheel removal
2 Remove the two 13mm winch mechanism
mounting bracket bolts (A), and three 13mm
winch mechanism mounting nuts (B), from the
under body.
B
A
3. Remove the winch mechanism separately.

MAN-00162
Tyre Changing
Removal
1. Using a tyre valve tool, release air in the tyre
and remove the valve core from the stem to
completely deflate the tyre.
Notice
Do not use the bead breaker (A) to valve side
as shown below. Failure to follow this in-
struction will lead to damage the sensor.
2. Break down the tyre (A) preferably by using a

bead breaker with Nylon Roller (B), on the tyre
changing machine (C).
A
C
4. Using a tyre tool (A), lift outer tyre bead (B)
over the rim.
3. Using a bead breaker (A), deflate the tyre.

A
Notice
The valve must be positioned opposite to the B
bead breaker to avoid the possible sensor
damage.

MAN-00162
Installation
Notice 1. Place the wheel rim (A) on the rotating table
• The valve must be positioned opposite to the (B) and clamp the rim by activating jaw clamp
bead breaker to avoid the possible sensor and paddle.
damage.
• Do not allow the tyre tool to touch the
sensor.
5. Using a tyre tool (A), lift inner tyre bead (B) A

over the rim.
B B
2. Apply jelly soap solution to top and bottom of

the tyre beadings.
Notice
• Valve must be positioned just left of the start
position to avoid sensor damage.
• Do not allow the tyre tool to touch the
sensor.
6. Separately remove the tyre from the rim.
Inspection 3. Fit the bottom bead of the tyre by fixing the

1. Check the tyre inner surface for cuts and TPMS at 3’o clock position as shown in the
punctures. figure below, which protects the TPMS when
the beading seats.

MAN-00162
4. Place the tyre on the wheel rim. 7. Fit the top beading of the tyre by rotating the
5. Fix the lower beading (A) by rotating the wheel wheel clockwise, and pushing down the bead
rim (B) clockwise and push down on the lower as shown below, so that it does not hit the
beading as the position shown in the figure sensor when the bead fixes.
below, which protects the TPMS when the
beading seats.
B
A
8. Match the yellow point of the tyre with the

valve hole or valve sensor.
9. Fix the lower beading on to the wheel.
Notice
10. Fit the valve core to the valve stem.
Ensure that the valve core is not fitted as this
may cause debris to get in to the valve stem.
6. Reposition the wheel such that the TPMS is at

9’o clock position and then fit the lower
beading.
Notice
Ensure matching of the yellow point on the
tyre with the valve.

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11. Inflate the tyre until it passes the bead humps TPMS
and maintain the pressure as per the
specification. Removal
1. Remove the tyre. For additional information
refer to Tyre Changing removal and
2. Using a tyre tool (A), lift the inner tyre bead (B)
over the rim.
A
B
3. Using the tool, remove the sensor (A) from the

wheel rim.
Notice
The TPMS and Valve cannot be replaced sepa-
rately. These can be replaceable as assembly.
Inspection
1. Ensure that the TPMS is not damaged while
removing the tyre.
2. Check the tyre inner surface for cuts and
punctures.

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Installation Wheel Balance

A balanced tyre is one where mass of the tyre -
when mounted on its wheel and the vehicle's axle -
Notice is uniformly distributed around the axle (its center
Tighten the sensor at proper position, with- of rotation)
out damage.
Types of imbalance
1. Static Imbalance: Vertical movement resulting
from heavy or light spots in a tyre in such cases
tyre won't roll evenly and the tyre/wheel assem-
bly undergoes an up-and-down movement.
2. Dynamic Imbalance: Lateral movement (wob-
ble or shimmy) resulting from unequal weight on
both sides of the tyre and wheel/rim assembly’s
circumferential centerline.
Heavy Spots
Static Imbalance Dynamic Imbalance
The wheel should always be balanced and aligned

in order to provide:
• Enhanced tyre life
• Driving safety and steering control
• Better performance of the car
Unbalanced tyre may lead to premature tyre wear
and driver fatigue due to vibration.

MAN-00162
Tyres should always be balanced

when Notice
• They are mounted on wheels for the first time For balancing a wheel, follow the manufactur-
• When they are remounted after repair or er’s (of balancing machine) manual for balanc-
• When there are signs of shimmy or vibrations ing instructions, recommendations and any
other additional information.
A vehicle is said to be properly aligned when all
suspension and steering components are sound
and when tyre and wheel assemblies are running
straight and true. Proper alignment is necessary for
even tread wear and precise steering. Uneven front
or rear tyre wear can lead to misalignment.
Tyres should always be balanced

when
1. Deposits of mud, dust etc.must be cleaned
from inside of the rim.
2. Remove stones from tread, clean the tyre and
rim before balancing to achieve better results.
3. Each tyre should be inspected for any damage.
4. The type of balance weights, when used, must
be in accordance with the profile of the rim
flange.Refer below recommendations for usage
of balance weights.
Alloy Wheel Rim Balance Wt
A 55
Steel Rim Balance Wt
A for Alloy Wheel Rim
S 55
S for Steel Wheel Rim
Gap 3.2±0.2 Gap 5.5±0.3
Steel Rims Alloy Rims

MAN-00162
Diagnostics and Testing 3. Frequently check the condition of the wheels,

and replace any wheel that is bent, cracked,
Inspection and Verification dented or has excessive runout.
1. Inspect the tyres for incorrect inflation and 4. Frequent inspections are recommended when
uneven wear which indicates a need for rapid or extreme temperature changes occur,
balancing, rotation or suspension alignment. when road surfaces are rough or littered with
2. Tyres should be frequently checked for cuts, foreign material.
stone bruises, abrasions, blisters and for 5. Check the tyre tread depth, if the depth is
objects that are embedded in the tread. reduced to 1.6mm or less, replace the tyres.
Symptom Symptom Image Possible Causes Cause image Remedy
Rapid wear at 1. Over inflation 1. Adjust correct tyre

centre of the tyres. pressure.
1. Camber to be
1. Excessive checked and ad-
camber. just to the specifi-
One edge wear cation.
2. Excessive
cornering. 2. Check and adjust
hub end play.
1. Check and cor-

1. Incorrect toe rect Toe In.
in. 2. Do a tyre rotation.
Feathered edge
wear 2. Improper tyre 3. Check for chas-
rotation inter- sis bend.
vals.
1. Lack of tyre 1. Carryout tyre ro-

rotation. tation.
2. Worn or mis-
Wavy or Scal-
aligned sus- 2. Check and re-
loped wear
pension parts. place the suspen-
sion components.

MAN-00162
1. Unbalanced 1. Balance the tyres.

tyre.
2. Check the disc
2. Rear disc brake roundness.
brake round-
ness. 3. Check the
jammed wheel
Bald spots 3. Faulty wheel cylinder/calipers.
bearings.
4. Check the wheel
4. Sudden brak- bearings.
ing.
5. Avoid driving with
sudden brake
locking.
Side wall circum- 1. Run Flat (It is more obvious from in- 1. Replace the tyre.
ferential tyre bulg- side).
ing
Side tyre wall 1. Kerb damage.

crack radially/di- 2. Stone hit. 1. Replace the tyre.
agonal
1. Tyre pressure is high or low. 1. Adjust the tyre pressure.

2. Wheel or tyre imbalance. 2. Balance the wheel & tyre assemblies.
Vehicle vibration 3. Bent wheel rim. 3. Install a new wheel rim.
from wheels 4. The tyre bead is not fixed properly in 4. Remove and refit the tyre on the rim.
the wheel rim.
5. Uneven tyre wear. 5. Replace both tyre and rim.

MAN-00162
1. Loosen wheel bolts. 1. Check and tighten the wheel bolts to the
specified torque.
2. Damaged and unbalanced wheel. 2. Inspect the wheel rim and tyre. Balance
the wheel. If necessary replace the tyre
and rim.
3. Worn out bearing. 3. Check and replace the front wheel bear-
Wheel wobbling
ing, For additional information refer to
4. Uneven worn brake disc. Wheel Hub removal and installation
section..
5. Brake grabbing.
4. Check and replace Brake disc.
5. Check the brake caliper assembly and
replace the necessary parts.
1. Under 1. Maintain the cor-

Cracked treads
inflation. rect tyre pressure.
1. Under 1. Adjust correct tyre

inflation of the pressure.
tyre.
Rapid wear at
2. Lack of 2. Do the tyre rota-
Shoulder rotation tion.
Excessive
cornering.

MAN-00162
Make BRIDGESTONE & JK
Wheel rim size 7J X 17 Regular (Alloy & Steel)
Tyre size designation including ply rating Tyre Size:P235/65R17
Tyre Type Radial - Tubeless
Laden Tyre pressure (front and rear), kg/cm2 Front: 2.2 kg/cm2
Rear: 2.0 kg/cm2
Bolt Torque in
Specification Nm
Wheel Nut
95.0±10.0
M14X1.5
Wheels Wheels Fitment 20
Nut Wheel Alloy 120.0±10.0
Hub BOLT HEX FL Front and Rear Hub mounting

M12X1.5X55X8.8 16 95.0±5.0
XGR
Spare wheel NUT HEX FL - Winch to underbody

winch M10X1.5X10X8.8 5 45.0±5.0
XZN

MAN-00162
Repair Manual Brake System Nov 2011/ Rev 2
BRAKE SYSTEM
CONTENTS
Brakes................................................................................................... 1

Non ABS Hydraulic Schematic........................................................... 2
Component Location Index (all variants) ......................................3

Brake System ..................................................................................... 4
Brake Fluid ......................................................................................... 5
Inspecting Brake Fluid Level .............................................................. 5
In Car Repairs................................................................................... 6
Preliminary Brake Check.................................................................... 6
Troubleshooting of Vacuum Booster Assembly ................................. 7
Bleeding Procedure Using Diagnostic Tool ...................................... 10
Brake Pipes And Hose Check .......................................................... 10
Brake switch adjustment .................................................................. 11
Front Brake Pad ..........................................................................11

Removal ........................................................................................... 11
Inspection ......................................................................................... 12
Installation ........................................................................................ 14
Front Brake Caliper ....................................................................14

Removal ........................................................................................... 14
Installation ........................................................................................ 15
Front Brake Caliper Hose ..........................................................15

Removal ........................................................................................... 15
Inspection ......................................................................................... 16
Installation ........................................................................................ 16
Front Brake Disc......................................................................... 17

Removal ........................................................................................... 17
Inspection......................................................................................... 17
Installation ........................................................................................ 17

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Front Brake Disc Carrier Plate .................................................. 18

Removal ........................................................................................... 18
Installation ........................................................................................ 18
Rear Brake Pad .......................................................................... 18

Removal ........................................................................................... 18
Inspection......................................................................................... 19
Installation ........................................................................................ 20
Rear Brake Caliper ..................................................................... 21

Removal ........................................................................................... 21
Installation ......................................................................................... 22
Rear Brake Caliper Hose ........................................................... 22

Removal ........................................................................................... 22
Inspection......................................................................................... 23
Installation ........................................................................................ 23
Rear Brake Disc ......................................................................... 23

Removal ........................................................................................... 23
Inspection......................................................................................... 24
Installation ........................................................................................ 24
Brake Fluid Reservoir ................................................................ 24

Removal ........................................................................................... 24
Inspection ......................................................................................... 25
Installation ........................................................................................ 25
Brake Master Cylinder .............................................................. 26

Removal ........................................................................................... 26
Inspection ......................................................................................... 26
Installation ........................................................................................ 26
Brake Booster ............................................................................ 27

Removal ........................................................................................... 27
Installation ........................................................................................ 28
Brake Pedal Assembly .............................................................. 29

Removal ........................................................................................... 29
Installation ........................................................................................ 30

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Brake Pedal Tension Spring ......................................................30

Removal ........................................................................................... 30
Installation ........................................................................................ 30
Brake Pedal Nylon Bush............................................................ 31

Removal ........................................................................................... 31
Installation ........................................................................................ 31
Brake Switch ...............................................................................31

Removal ........................................................................................... 31
Installation ........................................................................................ 32
Front RHS Wheel Brake Bundy Pipe (Black Color)................. 32

Removal ........................................................................................... 32
Installation ........................................................................................ 33
Front LHS Wheel Brake Bundy Pipe (Green Color) ................ 33

Removal ........................................................................................... 33
Installation ........................................................................................ 34
Rear LHS Wheel Brake Bundy Pipe (Yellow Color)................. 34

Removal ........................................................................................... 34
Installation ........................................................................................ 35
Rear RHS Wheel Brake Bundy Pipe (Blue Color) ....................36

Removal ........................................................................................... 36
Installation ........................................................................................ 37
Master Cylinder Outlet Brake Bundy Pipe ...............................37

Removal ........................................................................................... 37
Installation ........................................................................................ 37
Brake Booster Vacuum Reservoir ............................................38

Removal ........................................................................................... 38
Installation ........................................................................................ 38
Brake Vacuum Hose .................................................................. 39

Removal ........................................................................................... 39
Installation ........................................................................................ 39

MAN-00162

Front Brake Caliper ........................................................................ 40
Exploded View ................................................................................. 40
Disassembly ..................................................................................... 41
Inspection ......................................................................................... 42
Assembly .......................................................................................... 42
Rear Brake Caliper ......................................................................... 44
Exploded View ................................................................................. 44
Guide Pin Identification and Orientation........................................... 44
Troubleshooting Chart .................................................................. 45
Special Tools ................................................................................. 48
ABS ..................................................................................................... 51
Working of Anti-Lock Braking System (ABS) ................................... 51
Hydraulic Schematics - ABS ........................................................ 54
Service Tips and Precautions ...................................................... 55
Incar Repairs.................................................................................. 55
Front Wheel Speed Sensor ....................................................... 55

Removal ........................................................................................... 55
Inspection......................................................................................... 56
Installation ........................................................................................ 56
Rear Wheel Speed Sensor ........................................................ 56

Removal ........................................................................................... 56
Inspection ......................................................................................... 57
Installation ........................................................................................ 57
ABS ELECTRONIC HYDRAULIC CONTROL UNIT (EHCU) ..... 57

Removal ........................................................................................... 58
Installation ........................................................................................ 59
Technical Specification................................................................. 60

MAN-00162
Electronic Stability Program (ESP) .................................................. 61

Description and operation ................................................................ 61
Hydraulic Schematics - ESP ......................................................... 61
In Car Repairs................................................................................. 61
ESP ECU and Hydraulic Unit ....................................................61
Yaw Rate Sensor (YRS) .............................................................62

Removal ........................................................................................... 62
Inspection......................................................................................... 62
Installation ........................................................................................ 62
Steering Angle Sensor (SAS) .................................................... 63
ESP Specifications .......................................................................64
Parking Brakes .................................................................................. 65
Integral Parking Brake Mechanism .............................................. 65
Parking Brake Mechanism ............................................................66
Component Location Index ...........................................................67
In Car Repairs .................................................................................68

Parking brake cable adjustment....................................................... 68
Parking Brake Cable - Front ......................................................69

Removal ........................................................................................... 69
Installation ........................................................................................ 70
Parking Brake Cable - Rear .......................................................70

Removal ........................................................................................... 70
Installation ........................................................................................ 71
Parking Brake Lever Assembly ................................................ 72

Removal ........................................................................................... 72
Installation ........................................................................................ 72

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Parking Brake Switch ................................................................ 72

Removal ........................................................................................... 72
Installation ........................................................................................ 73
Troubleshooting Chart .................................................................. 74


MAN-00162
Brakes
Brake system of XUV500 consists of front ventilated
disc brakes with twin pot caliper and rear disc brakes
with single pot caliper. These are hydraulically oper-
ated and diagonally split with primary circuit con-
nected to front left and rear right calipers whereas
secondary circuit is connected to front right and rear
left calipers. Integral park brake mechanism is pro-
vided on the rear calipers
To reduce pedal effort, a twin diaphragm vacuum
booster is fitted between brake pedal and tandem
master cylinder. Should the servo unit fail, the push
rod still acts mechanically to provide non-assisted
braking. The vacuum in the system is generated by
camshaft driven vacuum pump
The parking brake is console mounted cable oper-
ated acting on rear wheels.
The braking system includes a Load sensing Propor-
tioning Valve (LSPV) (for Non ABS only ). It controls
the brake fluid pressure going to the rear depending
on the load on the vehicle.
ABS system is fitted on to XUV500 to allow efficient
braking without wheel locking, thereby allowing the
driver to retain steer-ability and control of the vehicle.
Should one circuit fail the other remains unaffected
and the vehicle can be brought to a halt. The hydrau-
lic pressure is applied from the tandem master cylin-
der to the front and rear wheel calipers through
suitable bundy tubes/flexible hoses.
ABS with Electronic Stability Programmer ensures
great stability and steer-ability while braking and also
avoids wheel locking, skidding of wheels during
panic braking. Electronic Brake Force Distribution
ensures proper brake pressure distribution on all
wheels.
Hill Descent Control (HDC) system assists the driver
to descend a steep hill (maximum 50% inclination)
by means of brake intervention so that the vehicle
speed is limited without driver's support. During HDC
control if the wheel slip becomes excessive, ABS will
be activated automatically.
To prevent vehicle from rolling back on steep hill, Hill
Hold Control (HHC) system is provided .Hill Hold
Control with acceleration sensor identifies gradients
and holds the vehicle for about three to four seconds
after the brakes have been released in order to pre-
vent the vehicle from accidentally rolling backwards
during a hill start.

MAN-00162
Non ABS Hydraulic Schematic
Front RH Rear RH
Caliper & Disc Caliper & Disc
Rear RH hose
Front RH hose
Booster - TMC
System Split: Diagonal
TWIN - LSPV
Front LH Rear LH
Caliper & Disc Caliper & Disc
Front LH hose Rear LH hose

Primary Circuit
Secondary Circuit

MAN-00162
Component Location Index (all variants)
Q
P
R B A
O
I N
J K
H M
G C
F
D
E
A. Rear Caliper J. Brake Pedal

B. Rear Disc K. Vaccum Hose
C. Bundy Tube L. Vaccum Reservoir
D. Front Disc M. Yaw Rate Sensor
E. Front Caliper N. Parking Brake Cable
F. Dust Shield O. Park Brake Lever
G. ABS EHCU P. Steering Angle Sensor
H. Front Wheel Speed Sensor Q. LSPV
I. Booster TMC

MAN-00162
Service Tips and Precautions Brake System

Do’s
1. Inspect brake fluid level regularly and top up if CAUTION
necessary Use only recommended fluids and lubricants.
2. Change Front brake pad along with Electric pad Use only fresh brake fluid to clean or wash
wear indicator. brake system components.
3. For Rear brake Pad change, use special tool to

rotate the piston and fix new pad.
4. Use only genuine Dot 4 brake fluid. CAUTION

5. Immediately change the pads once found the Never use gasoline, kerosene, alcohol, motor
indicator on. oil, transmission fluid, or any fluid containing
mineral oil to clean the brake system compo-
6. Extreme cleanliness is required when dealing nents. These fluids may damage the rubber
with hydraulic system. caps and seals.
7. Do use only fresh brake fluid or alcohol for

cleaning internal parts of the hydraulic system.
8. ESP switch should be always ON. DANGER

Don’ts Aftermarket linings may contain asbestos
1. Don’t try to use the old brake pad wear sensor fibers. Breathing high concentrations of
asbestos fibers can cause personal injury,
2. Don’t use the disc with thickness below permis- care should be taken while servicing the brake
sible limits. parts. Avoid using aftermarket lining.
3. Don’t over torque and under torque any joints
including hydraulic joints. • Disconnect the negative terminal of the battery
before performing any work on the brake system
4. Don’t reuse the brake oil, always use fresh oil especially ABS/ESP system.
from sealed container.
• Tighten the brake lines to specific torque while
5. Do not allow the brake fluid to come below min installing.
level in reservoir. • Clean the brake pads and shoes with waste
cloth.
6. Do not use kerosene / petrol / diesel for cleaning
• Always check the brake fluid for dirt, discolora-
the cylinders. tion or separation into distinct layers. Also check
7. Do not apply grease on anti rattle clips for front the reservoir cap seal for distortion.
as well as rear brakes. • Always replace the brake fluid with fresh brake
fluid from a sealed container.
Notice
Do not sand or grind the brake lining unless
the equipment contains the dust residue. Dis-
pose all residue in sealed bags or containers
to reduce the exposure.

MAN-00162
Brake Fluid Inspecting Brake Fluid Level

Inspect the fluid level in the reservoir regularly. It
should be kept at MAX. The level normally drops with
DANGER accumulated distance and condition associated with
Do not allow the brake fluid to come in contact wear of brake linings.
with eyes or skin. If it happens by accident,
thoroughly wash the affected area with water Notice
and get medical help.
The brake and clutch fluid is drawn from the
same reservoir.
CAUTION • Park the vehicle on level ground.

• Check whether the fluid level is between ’MIN’
Brake fluid can damage paintwork, hence
and ’MAX’ marks on the reservoir. Top up if
wash the spilled brake fluid immediately with required with recommended grade of brake fluid.
plenty of clean water.
CAUTION
Thoroughly clean all brake calipers, pipes
and fittings with brake fluid before commenc-
ing work on any part of the brake system. X-
- A
-XM
-MA
Failure to do so may cause foreign matter to
enter the system and cause damage to seals
N-
and pistons which may seriously impair the -MI
efficiency of the brake system. N-

-MI
Notice
Notice
Use only recommended brake fluid to flush the
brake system. Do not use mineral oils such as Do not fill the reservoir above the maximum
engine oil, any petroleum based cleaning flu- line.
ids or any proprietary fluids.
CAUTION
CAUTION Brake System should be drained and flushed
Do not reuse the brake fluid. Always use at recommended service interval.
fresh brake fluid from a sealed container.
The brake system should be drained and flushed at

recommended service intervals.
When filling the brake fluid, the electrical terminals
should be carefully covered to avoid entry of fluid into
the terminals and plugs.

MAN-00162
In Car Repairs
Notice
Preliminary Brake Check
Before starting the road test ensure proper
• It should be doubly ensured that brake is in
inflation of tires as per specification.
good condition throughout. The only way to do
so is to inspect the brakes every time the
vehicle visits the workshop. • Road test for the brakes should be taken by a
A. Front Brake And Rear Brake skilled driver with sufficient experience.
• Check the pads for wear, if excessive wear is • Brakes shall be tested on dry, clean smooth
observed or suspected, remove them from the and reasonably level road which is not
caliper assembly and inspect them. For crowded.
additional information refer to Front Brake • Drive the vehicle at low speeds in a safe area.
Pad removal and installation section. For
• Test the brakes by making brake applications
additional information refer to Rear Brake
with both light and heavy pedal forces at
Pad removal and installation section.
various speeds to determine if the vehicle
• Check the disc for any scores, grooves or any stops evenly and effectively.
uneven wear. For additional information
• If complaint is based on noise when braking,
refer to Front Brake Disc removal and
check the suspension components. Bounce
installation section. For additional
front and rear of the vehicle and listen for
information refer to Rear Brake Disc
noise that might be caused by loose, worn or
damaged suspension or steering components.
• Wipe the disc with a clean dry cloth.
Test carried out after wheel balancing and wheel
B. Parking Brake alignment will give a better clarity and help in
• Pull the parking brake and count the notches better, specific identification of a brake related
engaged, the travel should not be more than 2 defect.
notches. For additional information refer to
Parking brake cable adjustment section.
C. Brake Hoses/lines And Brake Fluids
• Any traces or evidences of brake fluid leakage
should be inspected and the cause found and
rectified immediately.
• All brake hoses and line should be replaced as
per recommended interval.
• The brake hoses should be checked for any
damage, cracks, leakage etc. Proper routing,
clamping and mounting should be ensured.
• Inspect brake fluid level and condition. Note
that the brake reservoir fluid level will reduce in
proportion to normal lining wear. This is normal
and should not be mistaken for contamination.
• If fluid level is abnormally low, look for
evidence of leaks at calipers, brake lines, and
master cylinder.
• If fluid appears contaminated, drain out a
sample to examine. System should be flushed
if the fluid is separated into layers. Replace
components affected by this contamination if
required.
D. Road Test Note

MAN-00162
Troubleshooting of Vacuum Booster Assembly
BASIC TEST
ENGINE OFF. Depress and release brake pedal

several times to remove vacuum from Booster
Assembly. After this the peda l application will feel
hard to press.
Depress the brake pedal and hold with light pressure of @ 10kgs. and
start the engine
If the booster is functioning satisfactory,

the pedal will fall slig htly and then hold.
Here less pressure will be needed to hold the
pedal dawn.
If the booster is not operating, If the booster is

disconnect the vacuum hose from the NRV. operating pl.
Then with engine running , turn over and do the
check vacuum supply with a vacuum gauge. vacuum leak test.
There should be at least 600 mm of Hg vacuum
for diesel and 500 mm of hg for petrol vehicle.
If vacuum supply is If vacuum supply is

below 600 mm of hg for 600 mm of Hg for or
diesel and 500 mm of Hg more for diesel or 500
for petrol veh. replace or mm of Hg or more for
repair vacuum hose and petrol vehicle, then the
vacuum source . booster is faulty and
should be replaced.
When adequate vacuum

supply is obtained,
repeat basic test.

MAN-00162
VACUUM LEAK TEST
Run engine to medium speed. Release accelerator

and turn engine off. This builds up vacuum.
Wait for 90 seconds and apply brakes. Two or more

applications should be vacuum assisted.
If applications are not vacuum If applications are

assisted disconnect vacuum hose vacuum assisted there
from vacuum source or NRV is no vacuum leak.
whichever is easier. If disconnected do the hydraulic leak
from NRV , attach short length of test.
hose to valve.
Blow into hose attached to NRV. If air

passes through, valve is defective.
If NRV or check valve is If NRV or check valve

defective install new NRV is ok, vacuum booster is
and repeat vacuum leak leaking and should be
test. replaced.
HYDRAULIC LEAK TEST Depress and release brake pedal

several times.Then hold pedal
depressed with medium pressure.
If pedal falls away hydraulic system is If pedal does

leaking. Check for external leakage at wheel not fall
cylinders, calipers , brake pipes , hoses and away
joints. hydraulic
If there is no external leak, there may be an system is not
internal leak ( master cylinder seals ) . Repair leaking.
or replace parts needed to correct leak.

MAN-00162
Brake System Bleeding
Notice CAUTION
Before bleeding the brake system refer to gen- At all times during the bleeding process, it
eral brake service practice and brake fluid pre- has to be ensured that the fluid level in the
cautions. reservoir does not drop below minimum.
3. Connect the bleed tube to the Rear Right

caliper bleed screw and place the other end
CAUTION submerged in a transparent container
containing sufficient brake fluid.
• Do not spill brake fluid on the vehicle, it
4. Depress the brake foot pedal and hold it down.
may damage the paint, if the brake fluid does
contact the paint, wash it off immediately with 5. Open the bleed screw (A). The fluid will flow
water. into the transparent container (B).
• Make sure no dirt or other foreign matter is

A
allowed to contaminate the brake fluid.
A
Notice
• Always use the brake fluid recommended
in the specification list.
• Do not reuse the drained fluid.
• Entire bleeding operation should be done B
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 6. Tighten the bleed screw and release the pedal.
bleeding procedure and should be checked 7. After the pedal returns, allow an interval of 3 to
after bleeding each brake caliper and same 4 seconds before making the next stroke.
has to be topped up as required. Steps 4 to 6 should be repeated until there are
no more air bubbles at the end of the bleed
tube.
1. Open the bonnet.
2. Open the reservoir cap and pour brake fluid
(A) till the lower edge of the filler neck.

MAN-00162
8. Now follow the same procedure at the other Brake Pipes And Hose Check
wheels as per the sequence given below. • All hoses and pipes (tubes) must be free from
A.Rear right excessive bending, twisting and pulling.
B.Front left • Make sure there is no interference with other
parts when turning steering both clockwise and
C.Front right counter clockwise.
D.Rear left • The brake pipe is an important safety part. If the
brake fluid leak is detected, always disassemble
C A the parts. Replace the applicable part with a new
one, if necessary.
• Do not bend or twist brake hose sharply, or
strongly pull it.
• While removing components, cover the connec-
tions so that no dirt, dust or other foreign matter
enters the piping and hose.
• Refill with new brake fluid.
B D • Do not reuse drained brake fluid.
B D
5. After the bleeding sequence is completed

remove the bleed tube and place the dust cap
on the bleed screw.
6. Ensure that the bleed screw is tightened to the
specified torque.
Notice
• If the bleeding of any cylinder or caliper
continues without success for a considerable
time, then tighten the bleed screw after each
downward stroke of the pedal, allowing the
pedal to return back.
• After the bleeding is done check for any
leaks in the bleed screw by applying the brake
pedal hard.
Bleeding Procedure Using Diagnostic

Tool
Bleeding through diagnostic tool has to be done
only for ABS vehicles and for the below mentioned
specific case:
a. If the brake pedal becomes spongy after ABS
intervention/operation.
For bleeding procedure refer to "ABS / ESP
Diagnostic manual".

MAN-00162
Brake switch adjustment Front Brake Pad

1. Press the lock (A) and disconnect the electrical
connector from the brake switch. Removal
Battery removal and installation section.
2. Remove the front wheels. For additional infor-
tion section.
A 3. Press the lock and pull out the electrical connec-
tors from the brake pad sensor.
4. Connect a transparent plastic pipe to the brake
bleeding nipple (A) and dip the other end of the
pipe into a container (B) filled with brake fluid.
2. Place the brake pedal in release position.
Notice
Make sure weld nut (A) is not disturbed during
brake pedal switch adjustment.
B
3. Loosen the lock nut.
4. Adjust the brake switch till the gap between the
switch and the stopper on the brake pedal is
2mm.
5. Loosen the brake bleeding nipple (A). By using a
suitable tool (B), compress the caliper piston and
Lock nut
drain brake fluid from the caliper. Then tighten
the brake bleeding nipple.
Weld nut
A
2mm
• Connect the pedal with the booster clevis

B
• Keep 2mm thick spacer on the stopper
• Tight the switch till it touches the spacer.
• Lock the switch position by tightening the
lock nut.
5. After confirming the gap tighten the lock nut.

MAN-00162
6. Loosen the 16mm front caliper lower retaining 8. Remove the anti rattle clips from the caliper
bolt (A) from the caliper assembly and carefully bracket.
move the caliper upwards without disconnecting
the caliper hose.
Inspection
Measure the pad lining thickness if it is found to be
Notice 10mm or less it has to be replaced.
Before removing the sliding pin bolt, ensure The inboard pads of front brakes are provided with
that the pedal is fully depressed i.e. caliper is the wear indicator and pads are to be replaced
fully returned at zero condition. along with wear indicator.
Inboard PAD Assembly

WARNING
Make sure that flexible hose is not twisted
when tightening joint bolt. If it is twisted,
reconnect it using care not to twist it.
7. Separately remove the brake pads (A) attached Wear Indicator

with the antirattle clips.
PAD Thickness 11mm
Useful PAD Thickness 10mm

A
CAUTION
Never polish pad lining with sandpaper.

MAN-00162
Notice
OFF
mm
mm
in
ON
• While inserting the pads between the
5.21
ORIGIN
ABS/O
carrier and disc care should be taken that
the friction material should be towards the
70
80
disc.
90
100
110
• Rotate the disc and make sure it is free

120
130
to rotate. If it is not free to rotate, inspect

140
150
and make sure that the pads are sitting

mm
square with the disc without any tilt.

• Before inserting the pads ensure that
caliper is returned fully to its position. (Push
mm
5.21
the caliper inside if necessary.)

1. Measure the thickness at the thinnest and worn • Never polish pad lining with sandpaper.
area of the pad. Replace pad assembly when If lining is polished with sandpaper, hard par-
pad thickness is less than the limit value. ticles of sandpaper will be deposited in lin-
2. Check for the oil leakage from Calipers/piston ing and may damage disc. When pad lining
seals. requires correction, replace it with a new
one.
• While fitting the guide pin ensure that
CAUTION the straight portion of the pin matches with
The inboard pads are provided with wear the ear of the calliper body.
indicator assembly. Hence the brake pads • The Pads in the Pad kit should be re-
are not inter-changeable place on the respective caliper i.e. assemble
< RH > marked pads on RH Caliper and < LH
> marked pads on LH Caliper.
• Always ensure that the anti rattle pad
clips are replaced whenever the pads are re-
placed
• Because the bleed screw is loosened to
push the pistons of the caliper back, it is re-
quired to bleed the vehicle to retain the origi-
nal brake performance of the vehicle.
• If the pads are to be reused make sure
they are assembled back in the same posi-
tion as they were when removed i.e., in-
board pad on to the piston side and
outboard pad to the wheel side. This is pos-
sible only when at the time of removal these
pads are marked for their positions and kept
aside. Never lubricate the pad seating areas
as it may lead to jamming.
• Do not apply grease on anti rattle clips.

MAN-00162
Front Brake Caliper

Removal
Projection on Pad
Spring 1. Remove the brake pads. For additional infor-
mation refer to Front Brake Pad removal and
2. Loosen the 14mm front disc caliper hose banjo
bolt (A) and remove the hose. Collect the brake
fluid from caliper in a clean container. Block the
brake hose using a dust cap to prevent loss of
brake fluid and prevent contamination and keep
the pipe in the vertically up-straight position.
CAUTION
The pad springs which fits on the carrier has a
Be careful not to twist flexible hose while-
projection on one side. Care must be taken while
loosening the bolt.
assembling the pad spring such that this projection
will never point towards the brake disc but always
towards the opposite side of the brake disc.
Installation
• Replace and lubricate anti-rattle clips with
brake grease.
• Tighten the 16mm bolt to the specified
torque. A
Notice
After fitting the pads, apply brake pedal 5 to
6 times in static condition in order to make
the pads align properly.
2. Bleed the brake system. For additional infor- 3. Loosen the two 17mm mounting bolts (A) on the
mation refer to Brake System Bleeding sec- brake caliper.
tion.

MAN-00162
4. Separately detach the brake caliper. Front Brake Caliper Hose

Removal
1. Loosen the 11mm front brake caliper hose lock
nut (A) from the Wheel arch.
Installation
1. Tighten the caliper mounting bolts to the speci-
fied torque.
2. Install the brake pad. For additional informa- 2. Pull out the caliper hose lock plate (A) from the
tion refer to Front Brake Pad removal and Wheel arch.
3. Connect the caliper hose and tighten to the
specified torque.
A
WARNING
4. After completing installation, fill reservoir with

brake fluid and bleed air from brake system. For
additional information refer to Brake System
Bleeding section.
5. Check each installed part for fluid leakage.
6. Perform brake test and check fluid leakage. CAUTION
Be careful not to twist flexible hose while loos-
ening the bolt.

MAN-00162
3. Loosen the 14mm caliper hose mounting banjo Installation

bolt (A). 1. To install, reverse the removal procedure.
CAUTION
To avoid brake fluid leakage, replace the
banjo bolt washers with new one while
installing the caliper hose.
A
Bleeding section.
WARNING
Notice Make sure that flexible hose is not twisted
Collect the brake fluid from caliper in a clean reconnect it using care not to twist it.
container. Do not reuse the drained fluid.
4. Separately detach the caliper hose.
Inspection
1. Check for wear, cracks, and damage. If damage
or deformation is present, replace with new one.
2. All hoses and pipes (tubes) must be free from
excessive bending, twisting and pulling.
3. Check the brake lines (tubes and hoses), and
connections for fluid leaks, damage, twist, defor-
mation, and loose connections. Replace any of
the damaged parts.

MAN-00162
Front Brake Disc 4. Check the surface of the disc rotor for uneven
wear, cracks, and serious damage. If any non-
Removal standard condition is detected, replace with new
1. Remove the brake calliper. For For additional one.
information refer to Front Brake Caliper 5. The disc should be free from score marks. If
removal and installation section. scored, it should be replaced with new one.
6. The disc should be cleaned with dry cloth, oil
Notice traces to be wiped out completely.
Support the removed caliper with a wire hook
so as to prevent brake hose from bending and Notice
twisting excessively or being pulled. Don’t Before assembly clean the mating faces of the
operate brake pedal with brake pads removed. hub and brake disc.
2. Loosen the two brake disc mounting screws (A)

and separately detach the brake disc (B). Installation
Inspection
1. Inspect the disc thickness before assembling the
caliper back to the carrier.
a. Actual thickness of front disc = 30 mm
b. Minimum thickness of front disc = 28 mm
mm in ORIGIN
mm
70 80 90 100 110
29.91 120 130 140 150 mm
OFF ON ABS/O
2. Inspect the thickness of the pad.

3. Replace the pad assembly if the pad thickness is
less than the limit value.

MAN-00162
Front Brake Disc Carrier Plate Rear Brake Pad

Removal
tion section.
3. Release the hand brake lever, such that the
wheels rotate freely.
4. Remove two 12mm caliper mounting bolts (A)
from the caliper bracket.
It's a dust and stone guard mounted on front knuckle

behind the brake disc to protect the braking surface
of front brake disc.
Removal
1. Remove the front brake disc. For additional
information refer to Front Brake Disc
A
plate.
Notice
A Support the removed caliper with a wire hook
so as to prevent brake hose from bending
and twisting excessively or being pulled.
Don’t operate brake pedal with brake pads re-
moved.
Installation

MAN-00162
5. Remove the brake pads (A) from the caliper Inspection

bracket.
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

A
OFF
mm
mm
in
ON
5.21
ORIGIN
ABS/O
70
80
90
100
110
120
130
140
150
6. Detach the antirattle clips (A) from the caliper br-
mm
acket.
mm
5.21
CAUTION
The inboard pads are provided with wear indi-
cator assembly. Hence the brake pads are not
A
inter-changeable.

MAN-00162
Notice
• While inserting the pads between the car-
Projection on Pad
rier and disc care should be taken that the Spring
friction material should be towards the
disc.
• Rotate the disc and make sure it is free to
rotate. If it is not free to rotate, inspect and
make sure that the pads are sitting square
with the disc without any tilt.
• Before inserting the pads ensure that cali-
per is returned fully to its position. (Push the
caliper inside if necessary.)
• Never polish pad lining with sandpaper. If The pad springs which fits on the carrier has a
lining is polished with sandpaper, hard parti- projection on one side. Care must be taken while
cles of sandpaper will be deposited in lining assembling the pad spring such that this projection
and may damage disc. When pad lining re- will never point towards the brake disc but always
quires correction, replace it with a new one. towards the opposite side of the brake disc.
• While fitting the guide pin ensure that the Installation
straight portion of the pin matches with the 1. Using a special tool (0604BAA0001ST) (A),
ear of the calliper body. compress the rear caliper piston (B) by rotating
• The Pads in the Pad kit should be re- clockwise.
place on the respective caliper i.e. assemble
< RH > marked pads on RH Caliper and < LH
> marked pads on LH Caliper. CAUTION
• Always ensure that the anti rattle pad While using the special tool, always rotate the
clips are replaced whenever the pads are re- tool such that the direction of rotation is
placed. towards the front of the vehicle i.e. for rear
right caliper, rotation of tool is in clockwise
• If the pads are to be reused make sure direction where as for rear left caliper, rotation
they are assembled back in the same posi- of tool is in anti-clockwise direction.
tion as they were when removed i.e., in-
board pad on to the piston side and
outboard pad to the wheel side. This is pos-
sible only when at the time of removal these
pads are marked for their positions and kept
aside. Never lubricate the pad seating areas
as it may lead to jamming.
• Do not apply grease on anti rattle clips.
Towards Front
of the vehicle

MAN-00162
2. To install, reverse the removal procedure. Rear Brake Caliper

• Tighten a 12mm bolt to the specified torque. Removal
Notice 1. Remove the rear wheel. For additional infor-
While installing, the brake pads should not be tion section.
interchanged.
2. Release the parking brake handle, such that the
wheels rotate freely.
3. Lift the parking brake lever (A), and detach the
parking brake cable from the caliper.
4. Loosen the 13mm caliper hose lock nut (A) from

the caliper.
CAUTION
Be careful not to twist flexible hose while
loosening the bolt. Collect the brake fluid
from caliper in a clean container.

MAN-00162
5. Remove two 13mm caliper bracket mounting Rear Brake Caliper Hose
bolts (A).
Removal
1. Loosen a 10mm rear brake caliper hose lock nut
(A) from the Wheel arch.
6. Separately detach the rear brake caliper.
2. Pull out the caliper hose lock plate (A) from the
Wheel arch. Collect the brake fluid in fresh con-
tainer
Installation
WARNING 3. Loosen a 13mm caliper hose lock nut (A) from

the caliper.
2. Bleed the brake system. For additional infor-

mation refer to Brake System Bleeding sec-
tion. A
Notice
Rear brake caliper is not serviceable. It is to be
replaced as a unit only.

MAN-00162
Rear Brake Disc

CAUTION Removal
Be careful not to twist flexible hose while loos- 1. Remove the rear brake calliper. For additional
ening the bolt. information refer to Rear Brake Caliper
4. Separately detach the caliper hose. Notice
Support the removed caliper with a wire hook
as to prevent brake hose from bending and
twisting excessively or being pulled. Don’t
operate brake pedal with brake pads removed.
2. Loosen the two brake disc mounting screws (A).
Inspection
2. All hoses and piping (tubes) must be free from
excessive bending, twisting and pulling.
3. Check the brake lines (tubes and hoses), and
connections for fluid leaks, damage, twist, defor-
mation, and loose connections. Replace any
3. Separately detach the brake disc from the
damaged parts.
knuckle.
Installation
CAUTION
To avoid brake fluid leakage, replace the
banjo bolt washers with new one while
installing the caliper hose.

Bleeding section.
WARNING

MAN-00162
Inspection Brake Fluid Reservoir

1. Inspect the disc thickness before assembling the
caliper back to the carrier.
a. Actual thickness of rear disc = 10 mm
b. Minimum thickness of rear disc = 8 mm
10.50
Removal
CAUTION
2. Inspect the disc thickness before assembling
If brake fluid is spilt on the paint work, the
3. Inspect the thickness of the pad affected area must be immediately washed
4. Replace the pad assembly if the pad thickness with cold water.
is less than the specified limit value.
5. Check the surface of the disc rotor for uneven 1. Disconnect and isolate the negative terminal of
wear, cracks, and serious damage. If any non- the battery. For additional information refer to
standard condition is detected, replace with new Battery removal and installation section.
one.
6. The disc should be free from score marks. If mation refer to Intercooler removal and
scored, replace the disc with new one installation section.
3. Take out fluid with syringe or such.
Notice
4. Press the lock (A) and pull out the electrical
Before assembly clean the mating faces of the connector from the brake fluid reservoir.
hub and brake disc.
Installation

MAN-00162
5. Disconnect the clutch master cylinder input hose Inspection

(A) from the brake fluid reservoir. 1. Check for improper assembly, damage and
deterioration.
Installation
A mation refer to Brake System Bleeding sec-
tion.
6. Remove the brake fluid reservoir mounting lock

pin (A) from the master cylinder.
7. Pull out the brake fluid reservoir (A) from the

master cylinder.

MAN-00162
Brake Master Cylinder
Inspection
Removal 1. Check for wear, cracks, and damage. If damage
1. Disconnect and isolate the negative terminal of or deformation is present, replace the affected
the battery. For additional information refer to part.
Installation
mation refer to Intercooler removal and 1. Fix new O-rings with the master cylinder.
3. Remove the brake fluid reservoir. For additional
information refer to Brake Fluid Reservoir
CAUTION
removal and installation section. Properly install the brake bundy pipes back
4. Remove 13mm primary and secondary brake to master cylinder. If misaligned, it will cause
bundy pipe lock nuts (A) and detach the brake damage to the threads leading to master cyl-
bundy pipes (B). Plug the ports with suitable inder failure.
grommet / cap.
Notice
Make sure that lines are fitted correctly.

A 3. Tighten 12mm master cylinder mounting nuts to
4. Bleed the brake system. For additional
information refer to Brake System Bleeding
B
section.
5. Loosen two 12mm master cylinder mounting

nuts (A) and detach the master cylinder. Plug the
ports with suitable grommet / cap.

MAN-00162
Brake Booster Removal

2. Remove two 12mm bolts (A) from the engine
tow hook.
The brake booster converts mechanical force applied

by driver into hydraulic force through master cylinder.
The booster is installed on the firewall/dash panel
with brake pedal. It consists of servo (tandem dia-
phragm), master cylinder, brake fluid reservoir and
low brake fluid warning sensor (FLWI). The servo
consists of 8"+9" diameter diaphragms in tandem 3. Press the clip (A) and pull out the outlet hose (B)
with push rod connected to brake pedal. from the oil separator.
When the push rod is pressed by brake pedal, air
enters through filter in vacuum servo. Power assist is
generated by utilizing the pressure differential
between atmospheric pressure and vacuum. The
force gets multiplied based on boost ratio and
applied to the output rod going inside master cylin-
A
der. The output road strokes the master cylinder pis-
tons and it generates hydraulic pressure in hydraulic
brake lines going to front and rear braking system.
B
4. Remove the ABS unit. For additional

information refer to ABS ELECTRONIC
HYDRAULIC CONTROL UNIT (EHCU)
5. Remove the brake fluid reservoir. For
additional information refer to Brake Fluid
Reservoir removal and installation section.

MAN-00162
6. Remove the brake booster push rod lock pin (A) Installation
in the brake pedal. 1. To install, reverse the removal procedure.
A
Bleeding section.
3. Tighten the four 12 mm booster mounting nuts to
4. Check pedal height and play.
7. Remove four 12mm mounting nuts (A) from the

brake booster from the brake pedal and detach
the brake booster.

MAN-00162
Brake Pedal Assembly 3. Press the lock and pull out the electrical
connector (A) from the brake pedal switch.
It is connected to brakes booster push rod through

clevis pin. Brake pedal switch is mounted on the
brake pedal. When the brake pedal is depressed by 4. Remove the brake booster push rod lock pin (A)
the driver based on brake pedal travel, brake pedal from the brake pedal.
ratio and vacuum assist booster ratio, hydraulic pres-
sure is generated in the master cylinder. Also brake
switch gets released to activate brake lamps/stop
lamps and High mount stop lamp at the rear of the A
vehicle.
Removal
2. Using a screwdriver, remove the steering
column lower shroud mounting screws (A) and
detach the shroud assembly (B).
5. Remove two 13mm brake pedal top mounting

nuts (A).
B
A

MAN-00162
6. Remove four brake pedal bottom mounting nuts Brake Pedal Tension Spring
(A) and separately detach the brake pedal
assembly. Removal
A 2. Remove the brake pedal.For additional infor-
mation refer to Brake Pedal Assembly
3. Remove the 13mm brake pedal mounting nut
(A) from the brake pedal box.
A
Installation
2. Tighten the four 12 mm booster mounting nuts to
4. Release the brake pedal tension spring (A) and

pull out mounting bolt (B).
A
B
5. Separately remove the brake pedal tension

spring.
Installation
2. Check the operation of the brake/ brake switch
post installation.

MAN-00162
Brake Pedal Nylon Bush Brake Switch

Removal
2. Remove the brake pedal assembly. For addi-
tional information refer to Brake Pedal
Assembly removal and installation section..
3. Remove the brake pedal tension spring. For
additional information refer to Brake Pedal
Tension Spring removal and installation sec-
tion.
4. Push the brake pedal pin and pull out the brake
pedal bush (A) from the brake pedal.
Removal
1. Using a screwdriver, remove the steering col-
umn lower shroud mounting screws (A) and
A detach the shroud assembly (B).
Installation
2. Check the operation of the brake and brake
A
pedal.
2. Press the lock and disconnect the electrical con-

nector (A) from the brake pedal switch.

MAN-00162
3. Loosen a 14mm brake pedal switch lock nut (A), Front RHS Wheel Brake Bundy
rotate the brake pedal switch in anticlockwise
direction and detach the brake pedal switch (B). Pipe (Black Color)
Removal
B 1. Disconnect and isolate the negative terminal of
2. Using a suitable spanner, loosen the 12 mm
brake bundy pipe lock nut (A) from the ABS unit.
A
Installation A
Notice
At ignition ON condition, adjust the brake
pedal switch till it reaches the brake stop light 3. Pull out the front RHS wheel brake bundy pipe
off condition. (A) from the routing clips (B).
2. Adjust the brake switch. For additional

information refer to Brake switch
adjustment section.
A

MAN-00162
4. Using a suitable spanner, loosen the 11 mm Front LHS Wheel Brake Bundy
lock nut (A) from Front RH wheel detach the
brake bundy pipe (B).
Pipe (Green Color)
Removal
brake bundy pipe lock nut (A) from the ABS
B units.
A
A
Installation
tion.
3. Pull out the front LHS wheel brake bundy pipe

(A) from the routing clips (B) on the firewall.
B A

MAN-00162
4. Pull out the front RHS wheel brake bundy pipe Rear LHS Wheel Brake Bundy
(A) from the routing clips (B).
Pipe (Yellow Color)
Removal
B Battery removal and installation section.
brake bundy pipe lock nut (A) from the ABS
units.
5. Using a suitable spanner, loosen the 11 mm lock

nut (A) from front LHS wheel and detach the br-
ake bundy pipe (B).
A
3. Using a suitable spanner, loosen the 11 mm (A)
and 14 mm (B) pipe lock nuts.
B
B
Installation A
tion.

MAN-00162
4. Pull out the rear LHS wheel brake bundy pipe 7. Pull out the rear LHS wheel brake bundy pipe
(A) from the routing clips (B). (A) from the routing clips (B) near the upper arm.
A B
B
A
5. Pull out the rear LHS wheel brake bundy pipe 8. Using a suitable spanner, loosen the 11 mm lock
(B) from the routing clips (A) near the fuel tank. nut (A) from rear LHS wheel and detach the br-
ake bundy pipe (B).
B
A
B
6. Pull out the rear LHS wheel brake bundy pipe

(B) from the routing clips (A) near the fuel tank.
Installation
A mation refer to Brake System Bleeding sec-
tion.

MAN-00162
Rear RHS Wheel Brake Bundy 4. Pull out the rear RHS wheel brake bundy pipe
(A) from the routing clips (B).
Pipe (Blue Color)
Removal
brake bundy pipe lock nut (A) from the ABS unit.
B
A
5. Pull out the rear RHS wheel brake bundy pipe

A (B) from the routing clips (A) near the fuel tank.
A
B
3. Using a suitable spanner, loosen the 11 mm (B)

and 14 mm (A) pipe lock nuts.
6. Pull out the rear RHS wheel brake bundy pipe

(A) from the routing clips (B) near the upper
A
arm.
B
A B

MAN-00162
7. Pull out the rear RHS wheel brake bundy pipe Master Cylinder Outlet Brake
(A) from the routing clips (B) near the spare
wheels. Bundy Pipe
Removal
B Battery removal and installation section.
A
2. Using a 0.55”(14mm) spanner, remove the brake
bundy pipe lock nuts and detach the bundy pipe
(A) from the master cylinder.
8. Using a suitable spanner, loosen the 11 mm lock

nut (B) from rear RHS wheel and detach the br-
ake bundy pipe (A).
A
B
3. Using a 0.55”(14mm) spanner, remove the brake

bundy pipe lock nuts and detach brake bundy
pipe (A) from the ABS unit.
Installation
mation refer to Brake System Bleeding sec- A
tion.
Installation
tion.

MAN-00162
Brake Booster Vacuum 3. Remove the fuel filter assembly. For additional
Reservoir installation section.
4. Disconnect the brake booster vacuum hose (B)
from the vacuum reservoir and remove two
10mm vacuum reservoir mounting bolts and
nuts (A) and (C) from the chassis.
Removal
1. Press the lock and pull out the electrical connec-
tor (A) of the Heated Mass Airflow (HFM) sensor.
5. Press the clip (A) and disconnect the EGR vac-
uum hose from bottom of the brake booster vac-
uum reservoir and detach the brake booster
vacuum reservoir.
A
2. Loosen two air filter outlet hose clamp (A) and

remove the air filter outlet hose from the air filter
housing.
Installation
A

MAN-00162
Brake Vacuum Hose 4. Press the clip (A) and disconnect the vacuum
hose (B) from the vacuum pump.
Removal
1. Press the routing clip (B) and disconnect the
vacuum hose (A) from the brake booster.
B
5. Remove the booster vacuum hose and vacuum

pump hose separately.
2. Press the routing clip (A) and disconnect the Installation

vacuum hose (B). 1. To install, reverse the removal procedure.
Notice
A
Fix the vacuum hoses properly to avoid leak-
age and poor braking.
3. Press the clip (A) and disconnect the non return

valve vacuum hose (B) from the vacuum reser-
voir.
B A

MAN-00162
Disassembly and Assembly

Front Brake Caliper
Exploded View
F C
G H
DISC BRAKE ASSEMBLY - LH SIDE DISC BRAKE ASSEMBLY - RH SIDE
A. Caliper Assembly E. Guide Pin
B. Outer Brake Pad F. Inner Brake Pad
C. Caliper Bracket G. Brake Hose Assembly
D. Locking Pin H. Caliper Pin Bolt

MAN-00162
Disassembly 4. Keep the wooden piece (A) between the plunger

and the caliper housing, and blow dry com-
Notice pressed air into the caliper gradually through the
inlet port connected to banjo bolt, to gradually
To overhaul caliper assembly, the carrier move the piston (B) out of the caliper.
assembly with pads need not be removed from
the vehicle. A
1. Remove the front Caliper assembly from the

vehicle. For additional information refer to
Front Brake Caliper removal and installation
section.
2. Remove the sliding pin boot (A) along with the
sliding pin (B) from the carrier and separate
the sliding pin boot and the sliding pin
5. Remove the piston (A) from the caliper housing.
3. Pull out the anti rattle clip (A) from the carrier.
6. Remove the piston boot (A) from the caliper

A housing.

MAN-00162
7. Follow the same procedure for the other piston 2. Caliper Housing
also.
Bores should be free from score, pitting, and
8. Remove the sealing rings (A) from the grooves corrosion. The seal grooves in the bore should be
in the caliper housing one after the other. thoroughly cleaned and no nicks should be there at
the edges. If the above conditions are satisfactory
then replacement with appropriate kit will give
satisfactory performance. If not the caliper
A assembly should be replaced
3. Carrier
Remove the grease from sliding pin bores and
clean the bores thoroughly. The carrier-machined
surface should be free from any damages, hit
marks etc., and the sliding pin bores should be free
from ovality and damages. Check for the carrier
mounting bolts.
4. Sliding Pins
Should be free from rust, bends and step formation
9. Remove the bleed screw (A) from the caliper due to wear. In necessary replace the sliding pin
housing. with new one.
Assembly
Notice
Discard all the rubber parts and the anti-rattle
clips and use new one at the time of assembly.
A
1. Dip the sealing rings in fresh brake fluid and fit

it on to the groove in the caliper pot and work
around with fingers until properly seated.
2. Smear fresh brake fluid to the pistons surface,
assemble piston boot on to the piston by revers-
ing the dust cover.
3. Smear brake fluid liberally into the bores. Now
locate the piston squarely and push gradually
Inspection into the bore until it reaches the bottom.
Clean all the internal parts thoroughly with fresh
brake fluid or alcohol. Do not use mineral oil like Notice
kerosene, petrol, diesel etc. After thoroughly
cleaning, examine all parts for damages and If the piston does not move smoothly, remove
corrosion. it and examine the sealing ring for correct
seating in its groove. Fit the other end of the
Check the various parts for the following: piston boot on to the caliper housing. Fit the
1. Piston other piston by the same method.
Outer surface should be free from nicks, score or
rust and should feel smooth to touch. Do not use
emery paper on piston surface.

MAN-00162
4. Smear sliding pins with the grease (A) provided

in the kit.
5. Fit the sliding pin rubber boot on to the sliding

pin.
CAUTION
Do not use mineral base grease for lubricat-
ing sliding pin. Using mineral base causes
swelling of sliding pin rubber bush.
6. Insert the sliding pin (A) into the carrier bores

and fit the sliding pin boots (B) on to the carrier
(thick collar end of the boot).
7. Now fit the caliper housing to the carrier in the

reverse order of removal.
Notice
Adjust the sliding pin such that the flat end
should match caliper housing slot.
8. Tighten the caliper pin bolt.

MAN-00162
Rear Brake Caliper

Exploded View
BLEEDER KIT
CARRIER SUB ASSEMBLY KIT
CALIPER SUB ASSEMBLY KIT
PINS KIT PAD ASSEMBLY KIT
Guide Pin Identification and Orientation
Disc direction of
rotation
Rubber bush
Identification
slots
Guide pin Locking pin

assembly
How to identify guide pin and lock pin? 3. Guide pin is having 2 identification slot on its
1. Guide pin is always assembled at leading side head while locking pin is without these slots.
while locking pin is at trailing side.
2. Guide pin is without bush while locking pin is
with rubber bush.

MAN-00162
1. Leakage in the hydraulic sys- 1. Repair the leakage by check-

tem. ing the hydraulic system. Fill
and bleed the system.
2. Air in the system. 2. Bleed the Brake System.
3. Brake pads or disc are worn 3. Install the new brake pads.
out.
4. Master cylinder piston scored 4. Install the new master cylinder.
Brake pedal soft/ spongy or piston bore is worn out.
5. Replace the hoses, and bleed
5. Soft or weak hoses. the system.
6. Replace the disc and pads,
6. Brake pads or discs worn out. bleed the system.
7. Flush the system and refill with
7. Poor quality brake fluid. recommended grade of brake
fluid.
1. Brake pad worn below recom- 1. Replace the brake pads with
mended thickness. new one.
2. Brake booster not working. 2. Perform the brake booster
functional test.
3. Vacuum leakage to the brake 3. Check and rectify the vacu-
booster. um connections.
4. Kinked, dented or clogged bu- 4. Identify and replace.
ndy pipes, hoses or 'T' con-
Brake pedal hard nections.
5. Binding pedal linkage. 5. Lubricate and free up the sys-
tem.
6. Fading brake due to non rec- 6. Replace with recommended

ommended grade of brake pa- grade of brake pads.
ds.
7. Brake lining soiled with brake 7. Replace the brake pads.

fluid, oil or grease.

MAN-00162
1. Air in the system. 1. Bleed the system.
2. Incorrect pedal play. 2. Adjust the pedal play.
3. Air in dual circuit or in master 3. Bleed and top up with recom-

cylinder. mended brake fluid.
Excessive pedal travel 4. Soft or bulging hoses. 4. Replace the hoses. Bleed the
brake system.
5. Leakage of caliper. 5. Adjust or replace the faulty
parts if necessary.
6. Partial brake system failure 6. Identify and repair by replacing
either in dual circuit or in Mas- necessary parts.
ter cylinder.
1. Incorrect tire pressure. 1. Inflate all the tires to the rec-

ommended pressure.
2. Wrong wheel alignment. 2. Check and adjust the wheel
alignment as per specification.
3. Loose suspension parts. 3. Tighten suspension mountings
Grabbing or Pulling brakes to the specified torque.
4. Loose caliper mountings and 4. Tighten the caliper and disc

disc. mounting bolts to the specified
torque.
5. One side brake pad soiled with 5. Replace the brake pads and
brake fluid, oil or grease. necessary parts.
1. Excessive lateral face out in 1. Check and replace the brake

disc or parallelism not within disc.
the specification.
Brake Chatter or Brake roughness 2. Broken anti-rattle clip. 2. Replace the anti-rattle clip.
3. Incorrect parking brake adjust- 3. Check and adjust the parking

ment. brake as per specification.
1. Worn out brake disc or pad. 1. Check and replace the brake
disc and pad.
2. Glazed brake pad lining. 2. With sand paper, clean the
3. Seized master cylinder or brake pad lining surface.
Poor braking efficiency plunger.
4. Vacuum leak in the hose to 3. Replace the master cylinder.
servo.
4. Check and replace the vac-
uum hose.

MAN-00162
1. Bent or warped backing plate 1. Replace or realign the backing

causing interference with disc. plate.
Squealing noise when brakes are 2. Loose parts in the brake sys- 2. Check and adjust the loose
not applied tem. parts.
3. Improper positioning of pads 3. Correct the position of pads in
in caliper. caliper.

MAN-00162
Parameter Non ABS ABS ESP
Front Brake Type/Size Twin pot C45+45 Twin pot C45+45 Twin pot C45+45
Front Pad R808 R808 R808
Front Disc Dia x thick 330 x 30 330 x 30 330 x 30
Rear Brake Type/Size BIR III / C38 BIR III / C38 BIR III / C38
Front pad R808 R808 R808
Rear Disc Dia x thick 294 x 10 294 x 10 294 x 10
Booster Type Tandem 8”+9” Tandem 8”+9” Tandem 8”+9”

(5.5 Ratio) (5.5 Ratio) (5.5 Ratio)
TMC Type/Size Fixed seal - Fixed seal - Fixed seal -

23.81mm 23.81mm 23.81mm
M10 Port M12 Port M12 Port
Pressure Modulation Twin LSPV ABS 8 ESP 8
Pedal Ratio 3.5 3.5 3.5
Brake System Split x x x
Special Tools
Rear Brake Caliper Re-

0604BAA0001ST
tractor

MAN-00162
Bolt Torque in
Specification Nm
LOCK SPRING For locking hose at caliper 4
All Bundy tubes 16.0±2.0

Bundy Tubes
NUT HEX FL
" T " connector mounting 8.0±2.0
M6X1X6X8 GR
BOLT HEX FL -
M12X1.25X40X8. Caliper to knuckle 4 95.0±5.0
8XZN
SCREW HEX FL
M8X1X12X8.8XG Dust shield 6
R 10.0 ± 2.0
Front Brakes sys-
tem SCREW FTCS
CR Disc mounting 4
M6X1X16X6.6,A
Banjo Bolt Front caliper banjo mounting 2 25.0~28.0
Copper washer
4
banjo
BOLT HEX FL -
M10X1.25X45X8. Caliper to knuckle 4 45.0~48.0
8XZN
Rear brake sys-
tem
SCREW FTCS
CR Disc mounting 4 10.0 ± 2.0
M6X1X16X6.6,A

MAN-00162
Bolt Torque in
Specification Nm
SCREW HEX FL
Park brake lever M8X1.25X15X8.8 Park brake lever to floor 3
XZN
BOLT COMBI LP -
Park brake cable M8X1.25X25X8.8 Park brake cable to underbody 4 25.0~28.0
XZN
SCREW HEX FL
M8X1.25X25X8.8 EHCU bracket mounting 2
XZN
EHCU
NUT HEX FL
EHCU grommet mounting 1
M6X1X6X8 GR
8.0± 2.0
BOLT HEX FL
Wheel Speed
M6X1X25X8.8XZ WSS mounting 4
Sensor
N
Brake pedal NUT HEX FL -

M8X1.25X8X8XZ Pedal with booster to BIW panel mtg. 5 20.0~25.0
N

MAN-00162
ABS The ABS and EBD warning lamps will illuminate for
a system check when the ignition is switched on.
Working of Anti-Lock Braking System Both lamps will then extinguish to indicate the
(ABS) system is healthy. If a fault occurs with the system
or any of its constituent components the relevant
warning lamp in the instrument cluster will
CAUTION illuminate to inform the driver for the respective
fault.
1. ABS is an aid to retain steering control and
stability while braking. A. Braking without ABS in operation:
In case of normal braking operation when no wheel
2. ABS will not prevent accidents resulting
speed differences are detected and neither ABS
from excessive cornering speeds, following
nor EBD are active, when the driver presses the
another vehicle too closely.
brake pedal, brake pressure developed in tandem
master cylinder (TMC) reaches to each wheel
3. ABS will not improve braking performance
through hydraulic control unit (HCU). During this
or stopping distance beyond that which is
phase, both inlet and outlet solenoid valves are
physically possible in relation to road condi-
switched OFF (or not excited) by the ECU. Hence
tions and the vehicles tyres or brakes.
the inlet valve is open and outlet valve remains
closed allowing the brake fluid to flow freely
4. The additional control provided by ABS
through the inlet valve and to the relevant wheel.
must never be exploited in a dangerous man-
ner which could jeopardize the safety of driver When the driver releases brake pedal, the brake
or other road users. fluid flows back from the wheel, through the
respective one way valve towards TMC.
The ABS ECU takes wheel speed information from
sensors, and monitors the relative deceleration/
acceleration of each wheel at all times. These
signals are used to calculate the rotational
deceleration (negative acceleration) rates for each Re-circulation inlet Valve
wheel during braking operation. In the event of a Pump (Open)
One way
wheel slip condition (i.e. rotational deceleration Accumulator
Valve
being outside of allowable limits) the hydraulic

system will control the brake line pressure by
Outlet Valve
operating the appropriate solenoid valves within the (Closed)
hydraulic modulator and thus releasing the brake

pressure from that particular wheel.
Once the wheel deceleration has recovered to
within allowable limits the modulator then allows
pressure to be re-applied to the particular brake
caliper from which the brake pressure was Solenoid Electric- Valve Open-close
released. valve ity status open- channel
When ABS intervention is necessary the warning close
lamp will not illuminate but the driver will feel the
INLET OFF OPEN Master cylin-
brake pedal pulsating and may experience audible
der - Wheel
feedback from the modulator indicating that ABS
cylinder
control is taking place.
OUTLET OFF CLOSE Wheel cylin-
der -reservoir

MAN-00162
B. Braking with EBD into Operation

In case of a braking where the ABS ECU detects a
slip difference between the front and rear wheels,
EBD comes into operation. If the difference in
Inlet Valve
wheel slip between the front and rear wheels Re-circulation (Open)
Pump
exceeds a predetermined threshold, the ABS One way
Valve
activates the pressure inlet valves for the rear Accumulator
wheels, closing the valves and preventing further

pressure build up at that rear wheels.
Outlet Valve
(Closed)
If during the braking event, this slip ratio between
the front and rear axle reduces below the threshold
level the inlet valves will be de-activated and switch
back to their normally open state allowing further
pressure increase at the rear axle.
If the driver reduces the brake pedal effort during Solenoid Electric- Valve Open-close
EBD control, brake fluid can return to the TMC valve ity status open- channel
through the one way valve located within the close
modulator in parallel to the Inlet valve.
INLET ON CLOSE Master cylin-
If the driver releases the brake, the inlet valves will
der - Wheel
be deactivated and fluid can return to the TMC via
cylinder
the inlet valve and the one way valve.
EBD control only acts upon the rear axle and can OUTLET OFF CLOSE Wheel cylin-
only limit pressure being applied to a wheel, it der -reservoir
cannot perform pressure reductions.
2. Pressure Reduction Phase
C. Braking with ABS in Operation
If the ECU detects that the % Slip relative to the
In case of braking where the ABS ECU detects a other wheels and vehicle reference speed is still
significant difference in the wheel speed information increasing during the pressure hold phase and the
from an individual wheel. The electronic control unit wheel is tending further towards lock, it will start the
instructs the hydraulic modulator to vary the brake pressure reduction phase, as the existing brake
pressure being applied at the affected wheel(s). pressure in the wheel brake is too high. It will
There are three stages to this control. activate the relevant outlet valve within the
1. Pressure Maintaining (Hold) Phase: hydraulic modulator, switching it from its normally
closed position to open. This will allow fluid to pass
When the braking forces being applied are higher from the wheel brake into the accumulator chamber
than the forces that can be transmitted to the road within the modulator. At the same time the ECU will
surface for a specific wheel, the ECU will detect activate the return pump integrated into the
that the wheel is tending towards lock. It will then modulator to draw fluid from the accumulator and
activates the relevant inlet valve within the wheel brake and return it to the TMC. This fluid
hydraulic modulator, switching it from its normally being returned to the TMC is what is felt as the
open position to closed, hence preventing further pulsations at the pedal, and the amplitude of the
pressure being transmitted from the TMC to the pulsations is relative to the amount of fluid that
affected wheel brake. As the outlet valve is closed needs to be reduced. Pressure reduction will
in this phase the pressure at the wheel is continue until the controlled wheel speed returns to
maintained. the vehicle reference speed.
If the driver reduces the brake pedal effort during
ABS control, brake fluid can return to the TMC
through the one way valve located within the
modulator in parallel to the Inlet valve.

MAN-00162
Solenoid Electric- Valve Open-close

valve ity status open- channel
close
Inlet Valve
Re-circulation
Pump
(Open) INLET OFF OPEN Master cylin-
One way
Valve der - Wheel
Accumulator
cylinder
OUTLET OFF CLOSE Wheel cylin-

Outlet Valve der -reservoir
(Closed)
D. Fail-safe Function
If the ABS system detects any fault that may
adversely affect its performance it will switch to a
fail safe shut down mode. When this happens the
Solenoid Electric- Valve Open-close electricity supply to the solenoid valves is
valve ity status open- channel deactivated, stopping control signal output, this
close causes the valves to switch to their default state.
(Open for inlet valves / Closed for Outlet valves)
INLET ON CLOSE Master cylin-
The System will light the relevant warning lamp at
der - Wheel
the same time to inform the driver the vehicle has
cylinder
either an ABS or an ABS and EBD failure.
OUTLET ON OPEN Wheel cylin- In this condition, the conventional hydraulic brake
der -reservoir circuit will still function, allowing brake pressure to
reach all wheels. It should be d that with an ABS
3. Pressure Increase Phase fault it will be possible to lock the wheels and in
As the ECU detects that the speed of the controlled case of an EBD failure the brake force
wheel has increased to the vehicle reference speed proportioning between front and rear will no longer
and hence the % slip reduced. It will sequentially function and hence rear wheel lock is possible
deactivate the outlet and inlet valves switching before front.
them to their normal positions. With the outlet valve
closed further pressure reduction is prevented and
the inlet valve can be opened to allow brake fluid
from the TMC to enter the wheel brake increasing
the brake pressure once again. If the driver
releases the brake at any time during ABS control
the inlet valves will be deactivated and fluid can
return to the TMC via the inlet valve and the one
way valve.
Inlet Valve
Re-circulation (Open)
Pump
One way
Valve
Accumulator
Outlet Valve
(Closed)

MAN-00162
Hydraulic Schematics - ABS

Rear Right (RR) Caliper
Brake Hydraulic circuit - ABS
Front Right (FR) Caliper
Rear RH hose
Front RH hose
TMC Secondary
To ABS EHCU MC 2
ABS EHCU To Front RH
ABS EHCU To Rear RH

To ABS EHCU MC 1
MC 2 RF LR
TMC Primary
EHCU
Rear LH hose
Front LH hose MC 1 LF RR
ABS EHCU To Rear LH
ABS EHCU To Front LH
Front Left (LF) Caliper Rear Left (LR) Caliper
The Anti lock braking system consists of a Hydraulic modulator with integrated Electronic control unit, four
wheel speed sensors (one located at each wheel) and warning lamps in the instrument cluster. The brake
pipes are connected to the brakes through the ABS EHCU. They make two independent circuits which are
diagonally split. The primary circuit connects the Front Left and the Rear Right brake while the secondary
connects Front Right and Rear Left brake through connectors. Internal to the Hydraulic modulator each brake
has a pair of solenoid valves, one inlet and one outlet; these are activated by the ECU to control the brake
pressure of individual wheels.

MAN-00162

• Before undertaking any electric arc welding
work, disconnect the ABS EHCU's wiring har-
Front Wheel Speed Sensor
ness connector.
Removal
• During paintwork operations or major repair 1. Disconnect and isolate the negative terminal of
work, which are likely to subjected to higher tem- the battery. For additional information refer to
perature (above 85° C), the EHCU must be Battery removal and installation section.
removed.
• Do not expose any part of the ABS control sys- mation refer to Wheels removal and installa-
tem to excessive heat or flame. tion section.
• Do not use any ABS component if it has signs of 3. Release the lock and pull out the wheel speed
being dropped or damaged. sensor electrical connector (A) and separately
• Do not repair any ABS component including wir- detach the wiring connector.
ing harness and connectors. Replace them,
entirely, with new components.
Notice
Wiring routing issues and loose connections
are common causes of ABS service calls. En-
A
sure proper electrical connections are made at
wheel speed sensors and EHCU assembly.
• Avoid free fall of the wheel speed sensor.

• The wheel speed sensor tip should not be
scratched.
• The wheel speed sensor should not be exposed
to strong magnetic field.
4. Disconnect the wheel speed sensor wiring
• Do not push the wheel speed sensor in with any
harness (A) from the routing clamp (B).
hard material.
• Do not leave the wheel speed sensor loose. It
will lead to vibration issues and lead to malfunc-
tion of the ABS system. A
• Do not leave the wheel speed sensor cable B
loose. If loose, it may foul with other vehicle
parts during vehicle running condition or during a
turn.

MAN-00162
5. Remove the 10mm sensor mounting bolt (A) Rear Wheel Speed Sensor
from the knuckle and detach the front wheel
speed sensor (B). Removal
CAUTION Battery removal and installation section.
Do not pull wire harness when removing 2. Remove the rear wheel. For additional infor-
front wheel speed sensor. mation refer to Wheels removal and installa-
Do not cause damage to surface of front tion section.
wheel speed sensor and do not allow dust, 3. Release the lock and pull out the wheel speed
etc. to enter its installation hole. sensor electrical connector (A) and separately
detach the wiring connector.
4. Disconnect the wheel speed sensor wiring

Inspection harness (B) from the routing clamp (A).
1. Check the sensor for damage.
2. Check the sensor connectors and harness for
damage.
Installation
1. Check that no foreign material is attached to B
sensor.
A
CAUTION
Do not pull or twist wire harness more than
necessary when installing front wheel speed
sensor.
3. Check that there is no clearance between

sensor and knuckle.

MAN-00162
5. Remove the 10mm sensor mounting bolt (A) ABS ELECTRONIC HYDRAULIC
from the knuckle and detach the rear wheel
speed sensor (B). CONTROL UNIT (EHCU)
CAUTION
Do not pull wire harness when removing
rear wheel speed sensor. RL RR
050
Do not cause damage to surface of rear FR 0 265 B4E 709/01

090702/006
FL
CC-014990
wheel speed sensor and do not allow dust,
MC1 MC2
etc. to enter its installation hole.
B This is an Electro-hydraulic device for reducing,

holding and restoring pressure to one or more
wheel brake, independent of the brake pedal effort
applied by the driver.
A
Electronic Hydraulic Control Unit (EHCU) consists
of
• Electronic Control Unit (ECU) and
• Hydraulic Control Unit (HCU)
When the brake is applied, hydraulic fluid is routed
Inspection from the Master cylinder to the Front and Rear
1. Check the sensor for damage. Brakes through the ABS-EHCU. The Primary and
2. Check the sensor connectors and harness for Secondary outlet of the Master Cylinder is
damage. connected to the EHCU inlet. The EHCU outlet is
connected to the Front Left, Front Right, Rear left
Installation and the Rear right brake circuit. The Electronic
1. Check that no foreign material is attached to Control Unit (ECU) monitors the Wheel Speed
sensor. through wheel Speed Sensors. If a wheel is about
2. To install reverse the removal procedure. to lock-up, the ECU signals the concerned Valve in
the EHCU. The valve modulates the hydraulic
brake pressure to the respective wheels to prevent
CAUTION wheel lock-up.
Do not pull or twist wire harness more than During the ABS operation, a slight pulsation may
necessary when installing rear wheel speed be felt in the brake pedal to indicate ABS is active
sensor. and can hear motor noise from engine
compartment. It is recommended to hold the brake
pedal firmly when ABS is active rather than
3. Check that there is no clearance between pumping of brake pedal. Depressing the brake
sensor and knuckle. pedal on slippery road surfaces as on a manhole
cover, a steel plate at a construction site, joint in a
bridge, etc. on a rainy day tend to activate the anti-
lock brake system

MAN-00162
Removal 4. Loosen four 12mm lock nuts (A) of the ABS unit
1. Disconnect and isolate the negative terminal of outlet brake bundy pipes, and detach the outlet
the battery. For additional information refer to brake bundy pipes. Plug the ports with suitable
grommet / cap.
CAUTION
Carefully detach the bundy pipe without any
3. Press the lock and pull up the ABS module elec- bending. Constant pressure is not maintained
trical connector lock lever (A) and disconnect the in the brake fluid flowing through the bended
electrical connector.
bundy pipe.
A B C
CH
CAUTION
BOSCH
BOSCH
PRESS
If brake fluid splits on the paintwork, the

affected area must be immediately washed
with cold water.
A . Lever release lock

B . Lever pull up to disconnect
C . Lever pull down to connect
A
A
CH
Press
5. Loosen two 13mm lock nuts (A) of the ABS unit

inlet brake bundy pipes, and detach the inlet
brake bundy pipes. Plug the ports with suitable
grommet / cap.

MAN-00162
6. Loosen two 12mm ABS unit mounting bracket 3. Ensure proper torque to all bundy pipes
bolts (A), and separately detach the ABS unit. attached to ABS ECU.
4. Clear all faults using diagnostic tool.
5. Road test the vehicle to ensure proper
operation of the conventional brakes and ABS
system.
Installation
Notice
• Identify the brake pipes going into and out
of the Hydraulic Unit (HCU) with tags so that
reinstallation of the brake lines becomes easy.
• Proper care should be taken before discon-
necting the brake pipes from HCU and the HCU
must be thoroughly cleaned on the outside to
prevent any dirt particles from falling into the
ports of HCU or entering the brake pipes.
CAUTION
Do not give an impact to hydraulic unit.
Use care not to allow dust to enter hydraulic
unit.
Do not place hydraulic unit on its side or
upside down. Handling it in inappropriate way
will affect its original performance.

tion.
Notice
• ABS ECU and is not serviceabl
• If the ECU is being replaced with a new
ECU, it must be reprogrammed with the use of
a scan tool.

MAN-00162
System Description Specifications
System ABS 8
General
Type 4 channel, 4 wheel speed sensor integrated ABS
Type Diagonal Split

Hydraulic Control Unit
(HCU) Hydraulic control method 3 modes - Pressure Maintain /Reduction /In-
crease
Operating voltage 12 V
Electronic Control Unit
(ECU)
Operating temperature - 40° C to + 120° C
Type Active hall effect
ABS sensors Operating temperature - 40° C to + 115° C
Supply Voltage 4.5V

MAN-00162
Electronic Stability Program In Car Repairs

(ESP)
ESP ECU and Hydraulic Unit
Description and operation
ThThis system enhances directional control and
stability of the vehicle under various driving
conditions. The ESP corrects for oversteering and
understeering behavior of the vehicle by applying RL RR
the brake of the appropriate wheel automatically. FR
050
0 265 B4E 709/01 FL

Engine power may also be reduced to assist in 090702/006
CC-014990
counteracting the condition of oversteer or MC1 MC2
understeer and help the vehicle maintain the

desired path. ESP uses steering angle sensors and
YAW rate sensor to determine the path that the
driver intends to steer the vehicle and compares it
to the actual path of the vehicle. When the actual
path does not match the intended path, the ESP
applies the brake of the appropriate wheel to assist
in counteracting the condition of oversteer or The ESP ECU and hydraulic control unit consist of
understeer. a hydraulic modulator with integrated pressure
• Oversteer - when the vehicle is turning more sensor and electronic control unit. In addition to the
than appropriate for the steering wheel position individual wheel valves present for the ABS, the
ESP hydraulic modulator has a pair of internal
• Understeer - when the vehicle is turning less switching valves on the primary and secondary
than appropriate for the steering wheel position brake circuits from the master cylinder. These are
Whenever the vehicle is started, the ESP system used when brake pressure has to be increased at
will be in active mode. This mode should be used individual wheels.
for most driving conditions. Removal and installation procedure OF ESP
EHCU is same as ABS EHCU. For additional
Hydraulic Schematics - ESP information refer to ABS ELECTRONIC
HYDRAULIC CONTROL UNIT (EHCU) removal
The hydraulic circuit layout of the ESP system and installation section..
similar to ABS, i.e., diagonally split. For details
refer the Hydraulic System Layout in ABS
Section.
The ESP system consists of a hydraulic modulator
with integrated pressure sensor; electronic control
unit and four wheel speed sensors which it shares
with the ABS system. In addition to the individual
wheel valves present for the ABS, the ESP
hydraulic modulator has a pair of internal switching
valves on the primary and secondary brake circuits
from the master cylinder. These are used when
brake pressure has to be increased at individual
wheels. It has a yaw rate sensor and steering
angle sensor connected via the high speed CAN.
There is information lamp in the instrument cluster
which is used to identify when the system is
operating and when a fault has been detected.

MAN-00162
Yaw Rate Sensor (YRS) 3. Unlock the lock (A), press the lock and
disconnect the electrical connector (B) from the
A yaw rate sensor is a gyroscopic device that yaw rate sensor.
measures a vehicle's angular velocity around its
vertical axis. The output is usually in degrees per
second or radians per second. The angle between
the vehicle's heading and vehicle actual movement
direction is called slip angle, which is related to the B
yaw rate.
This Sensor is used to measure the physical effects
of yawing, lateral and longitudinal acceleration. In BO
SC
H
order to achieve this, the Sensor features both a

sensor element for yaw rate and one or two sensor A
elements for acceleration. The communication
between Sensor and the ECU is done by a CAN-
Interface.
4. Remove the two 12mm yaw rate sensor

BO
SC mounting nuts (A), and separately detach the
H
yaw rate sensor (B).
H
SC
BO
Removal A
2. Remove the floor console. For additional Inspection
information refer to Floor Console removal
Physical Inspection: Inspect the yaw rate sensor
and replace if the following is found
• If the connecter is damaged, scratched or
cracked.
• If the sensor has been dropped.
• If surface of the sensor is cracked, dented or
chipped off.
Installation
Notice
Check the operation of yaw rate sensor after
installation. For more information refer to the
Diagnostic Manual.

MAN-00162
Steering Angle Sensor (SAS)
The steering angle sensor is fitted on the combi-

switch. When the steering rotates, the SAS inner
part also rotates as it is locked to the clock spring.
Thus it detects the angle through which the driver
is rotating the steering.
For additional information refer to Steering
Angle Sensor (SAS) removal and installation
section.

MAN-00162
ESP Specifications
System Description Specifications
2General System ESP 8
4 channel, 4 wheel speed sensor integrated with

Type
Yaw rate sensor and Steering angle sensor
Hydraulic Control Unit Type Diagnal Split, with integrated pressure sensor
(HCU)
Hydraulic control
3 modes - Pressure Maintain /Reduction / Increase
method
Electronic Control Unit Operating voltage 12 V

(ECU)
Type Active hall effect

Wheel Speed sensors
Supply Voltage 4.5V
Type Non Contact, Absolute Angle sensor

Steering Angle sensor
Interface CAN
Operating temperature - 400C to + 850C
Yaw rate,
Type
Yaw rate sensor Lateral and Longitudinal Acceleration
Interface CAN
Operating temperature - 400C to + 850C

MAN-00162
Parking Brakes
Integral Parking Brake Mechanism
Park brake lever
Parking brake-when cable pulls hand brake lever

pulling force is converted into input torque. BIR
mechanism convert this input torque into axial clamp
force. This force is transmitted to piston to pads and
parking brake function is achieved.
Notice
Replace the rear caliber assembly, due to inte-
gral parking brake mechanism failure.

MAN-00162
Parking Brake Mechanism
D A
C
E F
When cable pulls hand brake lever, rotating plate (A)

starts to rotate by input torque.Three balls (B) moves
tangentially between ramps on the rotating plate and
the mobile plate (C).Mobile plate is prevented from
rotating by the three tabs engaged in bushing (D)
slots, transmits an axial load to the piston by the
means of the adjustment screw (E) by compressing
limit spring (F).

MAN-00162
Rear disc
Park brake lever Rear caliper
Equalizer Parking Brake cable
Parking Brake cable

MAN-00162
In Car Repairs
Parking brake cable adjustment
1. Switch off the engine and keep transmission in
neutral position. A
2. Fully release the parking brake lever by pressing
2 4 6
R 1 3
2V
the release button.And lift the vehicle on suitable
position.
3. Pull and remove the center console top cover
(A).
35
6
R1
24
7. In case wheels are not able to rotate freely,

A reverse the last incremental adjustments till both
the rear wheels are able to rotate freely.
8. After the adjustment, drive the vehicle up a gra-
dient and verify that the parking brake's opera-
tion is satisfactory.
CAUTION
The brake pad should not be allowed to wear
4. Tighten the 10mm hand brake cable adjusting below minimum value 10 mm of thickness of
nut (A). the disc.
A
5
2 4 6
R 1 3
2V
5. Confirm that both the rear wheels are still rotat-

ing freely.
6. If still no brake binding is taking place, cable nut
(A) can be further tightened a little.

MAN-00162
Parking Brake Cable - Front 5. Remove the clip (A) and remove the locking pin
(B) from the parking brake cable equalizer.
Removal 6. Detach the parking brake cable (A) from the

1. Loosen the parking brake cable. For additional bracket mounting.
information refer to Parking Brake Cable -
Front removal and installation section.
2. Remove the center console. For additional
information refer to Floor Console removal A
3. Pull the parking brake cable lock (A) from the
parking brake cable.
4. Lift the vehicle. For additional information

refer to Jacking and Lifting section.

MAN-00162
7. Remove the parking brake cable seating rubber Parking Brake Cable - Rear
(A) from the under chassis.
8. Detach the parking brake cable (A) from the Removal

parking brake lever assembly. 1. Remove the rear wheels. For additional infor-
Installation mation refer to Wheels removal and installa-
tion section.
2. Adjust the parking brake cable. For additional 2. Loosen the parking brake cable. For additional
information refer to Parking brake cable information refer to Parking brake cable
adjustment section. adjustment section.
3. Lift the parking brake lever (A) and detach the
parking brake cable (B) from both sides of the
brake calipers.

MAN-00162
4. Remove the 12mm parking brake cable mount- 7. Remove the clip (A), and remove the locking pin
ing bracket bolts (A) located above both sides of (B) from the parking brake cable equalizer.
the rear toe bar.
A
A
8. Detach the parking brake cables from the under

5. Remove the two 12mm cable mounting bracket chassis bracket mounting (A).
bolts (A) from center of the under chassis.
Installation
6. Remove the parking brake cable mounting
screw (A) from the heat shield.
2. Adjust the parking brake cable. For additional
information refer to Parking brake cable
adjustment section.

MAN-00162
Parking Brake Lever Assembly Parking Brake Switch
Removal Removal
1. Remove the parking brake cable - For addi- 1. Remove the center console. For additional
tional information refer to Parking Brake information refer to Floor Console removal
Cable - Front removal and installation sec- and installation section.
tion. 2. Pull and disconnect the parking brake switch
1. Remove the three 12mm parking brake cable electrical connector (A) from the parking brake
lever mounting nuts (A) and detach the parking assembly.
brake lever assembly.
Installation
2. Adjust the parking brake cable. For additional
information refer to Parking brake cable
adjustment section.

MAN-00162
3. Remove the 8mm parking brake switch mount-

ing bolt and nut (A) from the parking brake ass-
embly, and separately detach the parking brake
switch.
Installation
2. Tighten the parking brake lever mounting bolt to
3. Check the parking brake switch operation.
Notice
Do not overtighten the parking brake switch,
failure to follow will lead to parking bake
switch damage.

MAN-00162
Symptom Troubleshooting Remedy

Possible Causes Chart
1. Parking brake cables im- 1. Adjust the parking brake cables.
proper adjustment. For additional information refer
to Parking brake cable adjust-
ment section.
2. Brake pad or disc wear. 2. Check the brake pads or disc. If
worn out, replace the pads or
disc.For additional information
Parking brake will not engage refer to Preliminary Brake Check
section.
3. Check the parking brake cables. If
3. Parking brake cables break- broken, replace the parking brake
age. cables.
4. Replace the parking brake equaliz-
4. Parking brake equalizer er.
damage.
1. Caliper parking brake lever 1. Replace the caliper assembly.

internal defect.
2. Oil and dirty condition of 2. Clean the parking brake pads. If
Parking brake dragging brake pads. necessary, replace the brake pads.
3. Replace the parking brake cable.
3. Binding of parking brake
cable.
1. Parking brake switch dam- 1. Replace the parking brake switch.

age.
2. Loose connection of parking 2. Replace the parking brake switch
Parking brake warning light will
brake switch connector. connector, if damaged.
not illuminate
3. Breakage of parking brake 3. Check the parking brake switch
switch wiring harness. wiring harness, replace if dam-
aged.

MAN-00162
1. Check the parking brake lever 1. Replace the parking brake

assembly for bends, damage lever.
and cracks
Parking Brake Lever and Housing 2. Check the cable for wear and 2. Replace the parking brake
Assembly damage cable assembly.
3. Replace the parking brake

3. Check parking brake warning
lever switch.
lamp switch for malfunction.
1. Check the parking brake cable 1. If the parking brake cable

assembly for damages assembly is damaged then
replace it.
Parking Brake cable assembly
2. Check the parking brake cable 2. Remove and check the park-
for ease of operation (sticki- ing brake cable assembly if
ness, hard to operate,etc.) required replace it.
1. Check the parking brake 1. Replace the parking brake

switch for damage switch if found to be damaged.
Parking Brake Switch 2. If the electrical connections
2. Check the electrical connec- are damaged then replace the
tion for damage. affected component.

MAN-00162
Repair Manual Steering System Nov 2011/ Rev 2
STEERING SYSTEM
CONTENTS

Supplemental Restraint System (SRS) .............................................. 3
Incar Repairs ....................................................................................4

Component Test ................................................................................. 4
General Procedure............................................................................. 5
Steering Wheel ............................................................................. 6

Removal ............................................................................................. 6
Installation .......................................................................................... 8
Steering Angle Sensor (SAS) ...................................................... 9

Removal ............................................................................................. 9
Inspection......................................................................................... 11
Installation ........................................................................................ 11
Combination Switch ...................................................................12

Removal ........................................................................................... 12
Installation ........................................................................................ 12
Steering Column Assembly .......................................................13

Tilt & Telescopic Adjustable Steering Column ................................. 13
Removal ........................................................................................... 14
Inspection......................................................................................... 15
Installation ........................................................................................ 15
Steering Oil Replace .................................................................. 15
Power Steering Reservoir ..........................................................16

Removal ........................................................................................... 16
Installation ........................................................................................ 17

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Intermediate Shaft ...................................................................... 17

Intermediate Shaft Upper with Universal Joint ................................. 18
Removal ........................................................................................... 18
Installation ........................................................................................ 18
Connector Intermediate Shaft .......................................................... 19
Removal ........................................................................................... 19
Installation ........................................................................................ 19
Tie-rod Ends ............................................................................... 20

Removal ........................................................................................... 20
Inspection ......................................................................................... 21
Installation ........................................................................................ 21
Power Steering Rack ................................................................. 21

Removal ........................................................................................... 21
Inspection......................................................................................... 23
Installation ........................................................................................ 23
Power Steering Suction Hose .................................................. 24

Removal ........................................................................................... 24
Installation ........................................................................................ 24
Power Steering Pressure Hose................................................. 25

Removal ........................................................................................... 25
Installation ........................................................................................ 26
Power Steering Return Hose .................................................... 26

Removal ........................................................................................... 26
Installation ........................................................................................ 27
Cooler Loop Assembly ............................................................. 27

Removal ........................................................................................... 27
Installation ........................................................................................ 29
Power Steering Pump................................................................ 29

Removal ........................................................................................... 29
Inspection ......................................................................................... 30
Installation ........................................................................................ 30

MAN-00162

Visual Inspection .............................................................................. 30
Component Inspection and Remedy Action .................................... 34
Mahindra Special Tool (MST) ........................................................37

MAN-00162
Steering System
The vehicle is fitted with hydraulic power steering for
lighter steering effort and easy maneuverability. The
system has the below mentioned features:
• Rack and pinion steering gear type.
• Steering column (collapsible type - if equipped)
and intermediate shaft
• Steering column - tilt and telescopic type (if
equipped)
• Internal incorporated bush in the steering
column to provide vibration damping.
Power assistance is available during normal
operating conditions. in case of any failure in
hydraulic system, the steering can still be operated
mechanically but with increased steering effort.
Power steering system consists of a collapsible ste-
ering column with intermediate shaft, rack and pinion
steering gear assembly, belt driven hydraulic steering
pump and steering fluid supply and return hoses with
reservoir.
The tilt and telescopic steering column assembly
consists of three shafts interconnected via the
universal joint. While one end of the steering column
is connected to the steering wheel, the other end is
bo-lted to the pinion on the rack. The rack assembly
provides upward/do-wnward and forward/backward
movement via the locking system provided in the
steering column bracket.
The rotation of the pinion moves the gear rack
sideways. This lateral action of the rack pushes and
pulls the tie rods to change the direction of the front
wheels. Power assist is provided by an engine driven
hydraulic pump. The pump supplies hydraulic fluid
under pressure to the steering gear through the
pressure hoses. As steering wheel is rotated, the
steering fluid is allowed to pass through the steering
gear valve depending on the rotational direction of
the steering wheel. The fluid moves the piston, which
forms a part of the steering gear, giving power
assistance to rotate the steering wheel.

MAN-00162
A
B
C
H D
A. Steering column assembly F. Assembly steering gear (steering rack and pin-
B. Power steering reservoir with mounting bracket ion assembly)
C. Power steering pump G. Suction hose
D. Steering grommet H. Cooler loop assembly
E. Return hose I. Pressure hose

MAN-00162
Service Tips and Precautions Supplemental Restraint System (SRS)

1. Always work in a dust free environment.
2. Before reinstalling the old parts, clean them thor- WARNING
oughly. Improper or incorrect removal & installation of
3. Use only genuine Mahindra recommended SRS components may unintentionally activate
spare parts only. the system, which can lead to personal injury.
4. Use only Mahindra recommended steering fluids
from a sealed container. Ensure steering fluid
does not contaminated, during filling in reservoir.
5. Ensure that recommended tightening torque val-
WARNING
ues are maintained during assembly. The service operations should be followed in
correct sequence. Failure to do so may cause
6. Steering Hoses to be checked for open ends clo-
the SRS to unexpectedly deploy during service
sure with the caps on it before assembly, if not
leading to a serious accident.
found then needs to be replaced. (This is to
avoid, entry of any foreign particle inside.)
7. Steering Pump to be checked before assembly
for proper closure of fluid inlet and pressure DANGER
hose port with cap to avoid, entry of any foreign
particle inside. Do not use electrical test equipment on cir-
cuits related to the SRS, unless instructed to
8. Used Steering Oil not to be used at any condi- do so.
tion, to eliminated any foreign contamination.
9. Do not spill the steering fluid on the vehicle, as it The supplemental restraint system includes airbag
may damage the paint. To keep fluid from spray- and seat belt pre-tensioner. They work along with the
ing or running out of lines and hoses, drain it in a front seat belts in reducing the severity of injury to the
suitable collector. driver during collision. The deployment depends on
10.Perform functional tests wherever required. the impact or severity of collision.
11.All preventive and schedule maintenance must
be performed only by an authorized Mahindra
dealer.
Notice
Some service operations affect the Supple-
mental Restraint System (SRS). Be sure to
read the precautionary notices for SRS before
commencing the service.
WARNING
Do not start the engine while working on steer-
ing system, this may lead to personal injury
and/or component damage.

MAN-00162
Incar Repairs Universal Joint
Component Test
Steering Linkage
WARNING
1. Hold the steering wheel firmly move it up and Replace the steering column shaft mounting
down and to the left and right and check for bolt at the steering gear end. Failure to follow
steering column universal joint free play, steer- this instruction may lead to loss of steering
ing wheel or steering column looseness. control and accident.
2. With the road wheels in straight ahead position,
gently turn the steering wheel to the left and the 1. Detach the steering column shaft from the steer-
right to check free play in the steering linkage. ing gear pinion.
2. Hold the steering shaft universal joint yoke (A)
Steering Inner Ball Joint
and rotate the free yoke (B) as shown in below
1. Raise and support the vehicle. image.
2. Firmly hold the road wheel and apply twisting
motion (as shown in arrows) to check for any
free play in the wheel bearing or suspension
A
components.
3. If the movement is not smooth or jerky, replace

the steering column intermediate shaft.
4. Hold both the universal joint and yokes, twist
them clockwise and counter clockwise.
3. With the aid of another technician turn the steer- 5. If excessive play is found, replace the steering
ing wheel and hold it firmly. column intermediate shaft.
4. Firmly hold the right-hand road wheel and apply
horizontal rocking motion to check for any free
play in the tie-rod end.
5. Repeat the same test for the other side as well.
6. If excessive play exist, replace the steering gear
ball joint assembly.

MAN-00162
General Procedure
Check for Power Steering Fluid Leaks CAUTION
1. Lower the vehicle.
Do not operate the steering system without
2. Run the engine at idle and slowly turn the steer-
power steering fluid. Failure to follow this
ing wheel to the left-hand steering lock position.
Hold the steering wheel in this position for about instruction will lead to the damage of the steer-
5 seconds. ing system components.
3. Slowly turn the steering wheel to the right-hand
steering lock position. Hold the steering wheel in 4. Pull out the power steering return hose from the
this position for about 5 seconds. reservoir and plug the reservoir with dust cap.
4. Turn the steering wheel away from the right- 5. Crank the engine for about 7 seconds. Stop the
hand steering lock and stop for about 3 seconds. engine immediately if the engine starts.
5. Check the power steering fluid leaks at steering 6. Slowly turn the steering wheel from lock to lock
gear housing, power steering hoses and con- position three to four times and add power steer-
nections. If there is a power steering fluid leak at ing fluid until the air in the system exits out.
any of these parts, replace as necessary. 7. Connect the power steering return hose and fill
Power Steering System Bleeding the power steering fluid reservoir to the MAX
mark with the recommended power steering
Whenever air enters the power steering hydraulic fluid.
system, the system must be bled to ensure free of
air. Filling and bleeding the power steering system 8. Start the engine and gently turn the steering
helps to ensure trouble-free operation as well as pre- wheel left and right to full-lock (each side) for
vents the damage of the power steering system com- three to four times.
ponents. 9. With the engine running at idle, check that the
1. Raise and support the vehicle. Make sure that fluid in the reservoir is not foaming or contain
the road wheels are off the floor. bubbles.
2. Inspect the fluid pressure hoses and clips for 10.Switch OFF the engine and examine the power
proper connections. steering hose connections, steering gear boots,
power steering valve body and power steering
3. Fill the power steering fluid reservoir to the pump for external leaks.
'MAX' mark. Make sure that the power steering
fluid in the power steering fluid reservoir does 11. Lower the vehicle.
not fall below the MIN mark, as air could enter
into the system.
MAX
MIN

MAN-00162
Power Steering System Flushing Steering Wheel

CAUTION
A
Do not mix or use any unspecified fluids. 80
100 120
140 2 3
km/h
160
x1000 rpm
4
Doing so may lead to seal deterioration and 60
40
R
E
F
ODO
km
180
200
220
1
0
H
C
5
6
20
leaks. A leak ultimately causes loss of fluid, 0

7
which results in loss of power steering assis- SOURCE

RES
CRUISE
OFF
+
+ SET
tance.
-
-
D C
1. Pull out the power steering return hose and plug
the reservoir opening. B
2. Attach an extension hose between the power
steering hose and an empty container.
3. Raise the front wheels off the ground if required.
4. Top up the power steering fluid in the reservoir. A. Steering Wheel
5. Crank the engine for about 15 seconds. While B. Driver Airbag
cranking, slowly turn the steering wheel from C. Cruise Control Switches
lock to lock position.
D. Audio Control Switches
The steering wheel houses the driver airbag, cruise
CAUTION and audio controls along with the usual dual tone
horn pad. It is attached to the collapsible steering col-
Do not crank the engine continuously for more umn.
than 15 seconds, it may damage the starter
motor. Removal
1. Remove the Driver Airbag assembly. For addi-
6. Lower the vehicle. tional information refer to Driver Airbag
7. Remove the extension hose and connect the removal and installation section.
power steering return hose to the power steering 2. Position the steering wheel (A) at the center
pump reservoir. position.
8. Remove the plug and connect the power steer-
ing return hose.
9. Install the clamps into place. 80
100 120
140 3 4
60
160 2
10.Top up the power steering fluid reservoir to app-

5
A
40 H
180
20 1
200 6
c
0
propriate level and bleed the system if

220
7
necessary.
11.Start the engine and turn the steering wheel from
lock to lock position to ensure the fluid circula-
tion in the system.
Notice
Use only Mahindra recommended power
steering fluid.

MAN-00162
3. Press the lock and pull out the audio and cruise 5. Insert the steering wheel puller (A) (Special Tool
control electrical connectors (A) from the clock Part No:0604BAA0001ST) into the driver airbag
springs. lugs and tighten the center long bolt (B) of the
tool. Using a 22mm socket and wrench set,
remove the steering wheel from the steering col-
umn shaft.
100 120
80 140 3 4
60
160 2 5
40 H
180
20 1
200 6
c
0 220
7
A 60
80
100 120
140
160 2
3 4
5
40 H
180
20 1
200 6
c
0 220
7
A
B
4. Remove the 18mm steering wheel lock nut (A)
from the steering column.
CAUTION
The position of the clock spring should not
be disturbed. The clock spring can turn 2.5
turns from its home position on either side.
A

MAN-00162
Installation 4. Install the driver airbag in its position on the

steering wheel. For additional information
1. Install the steering wheel (A), on the steering
refer to Driver Airbag removal and installa-
column shaft (B) by keeping the steering in
tion section.
straight ahead position as shown in the figure.
DANGER
Improper or incorrect removal and installation
A of the SRS components will cause uninten-
tional activation of the system leading to per-
sonal injury.
B
CAUTION
The service operations should be followed in
the correct sequence. Failure to do so may
cause the SRS to unexpectedly deploy during
service leading to a serious accident.
2. Using a 18mm socket and wrench set, tighten
the lock nut (A) of the steering column to the
specified torque.
information refer to Wheel Alignment sec-
tion.
6. Check the steering wheel buttons for operation.
CAUTION
Do not use excessive force to the steering wh-
A eel for removal. This may cause steering wh-
eel bend. Gently tap if needed. While installing
steering wheel ensure the splines are aligned
properly and the steering wheel slides easily
on the column shaft.
3. Install the audio and cruise control electrical con-

nector (A) to the clock springs.
100 120
80 140 3 4
60
160 2 5
40 H
180
20 1
200 6
c
0 220
7

MAN-00162
Steering Angle Sensor (SAS) 2. Using a screwdriver, remove the steering col-
umn lower cover mounting screws (A) and
remove the shroud assembly (B).
A
The SAS is mounted on the steering column behind
the clock spring. The sensor has a sensor unit for de- 3. Remove the mounting screws (A) of the steering
tecting the steering angle position of the steering wh- column upper shroud.
eel.
Notice
Calibrate the SAS once refitted. For calibration 60
80
100 120
140
160
2
3
x1000rpm
4
5
H
procedure, refer ESP diagnostic manual. 40
20
180
200
1
c
6
22 0 7
0
Removal FRO
PUL
NT
L
REA
R OFF
MI
OFST
INT F
ON
LO
S W
HIG
H
Notice
Before removing the clock spring, turn the
steering and position the front wheels to a
straight ahead direction. A
1. Remove the Steering Wheel. For additional

information refer to Steering Wheel removal

MAN-00162
4. Remove the three steering column lower 7. Disconnect the airbag electrical connector (A)
shroud mounting screws (A) and remove the from the clock spring (B).
lower shroud (B).
A
8. Using a suitable tool (A), pull the top side of the
5. Remove the steering column upper shroud (A) clock spring lock (B).
and detach the shroud assembly.
B
3 4
100 120 x1000rpm
80 100 120 140
80 140 2 5 MIST
60 160 H OFF
60 160 F
INT
40 180 6 LOW
40 180 1 HIGH
200 c
20
20 200
0
0 22
220
0 7
A A
FRO
NT
REA
R OFF
M
PUL OFIST
L INT F
ON
LO
S HIG
W
H
9. Using a suitable tool (A), press the RHS clock

6. Disconnect the clock spring electrical connector spring locks (B) and carefully unlock.
(A) from the clock spring (B).
MIST
F OFF
B INT
LOW
HIGH
A B

MAN-00162
10.Using a suitable tool (A), press the LHS clock Installation

spring locks (B) and carefully pull out the clock
spring assembly from the combination switch.
CAUTION
The clock spring can rotate from its centre
FRONT
OF
F
OF
F
position after installation. To locate the clock
spring at the central position, rotate the clock
RERR
OFF
PULL ON F OF
F
INT
LOW
spring from end to end and note the number of

HIGH
turns. Now divide the number of turns by 2.

Rotate the clock spring from its current posi-
tion by exactly the same amount of turns as
calculated above. This will bring the clock
B
spring to its central position. Any deviation in
this procedure may lead to errors in the ESP
A
system.
11.To remove the SAS, pull the clock spring locks

and detach the SAS as shown in the image
CAUTION
below. The steering angle sensor should be calibrated
when it is removed and refitted. If this is not
done the system may malfunction. Refer to
ESP Diagnostic manual.

2. Calibrate the SAS once refitted. For calibration
procedure, refer ESP diagnostic manual.
Inspection
Inspect the steering angle sensor and replace
found in following conditions
1. If the connecter is damaged, scratched or
cracked.
2. If the sensor has been dropped.
3. If surface of the sensor is cracked, dented or
chipped off.

MAN-00162
Combination Switch 3. Loosen the combination switch 6mm allen key

mounting screw (A) and remove the
combination switch (B) from the steering
coloum.
F RO NT
REAR OFF
MIS
PULL OFFT
B
ON
INT
LOW
HIGH
Removal
1. Remove the clock spring assembly. For
additional information refer to Clock Spring Installation
2. Unlock the lock (A) and disconnect the
electrical connector from the combination Notice
switch.
Tighten the combination switch allen key
mounting screw as per specification over
tighten will lead to damage of the switch.

MAN-00162
Steering Column Assembly

Tilt & Telescopic Adjustable Steering intermediate shaft connects the steering column to
Column the power-assisted steering gear. For reasons of
safety, the steering column assembly incorporates a
collapsible steel cage and an intermediate shaft with
a deformation zone designed to crumple
progressively in the event of a head-on collision.
A. Steering Column Tilt

The steering column is bolted to the bulk head. It is a
tiltable and dual stage collapsible column. The
steering column shaft is mounted on two needle
B. Steering Column Tilt & Telescopic
bearings internally at the ends suspended by rubber
mountings in the steering column assembly. An
A B
A. Before Collapse
B. After Collapse
C. Steering Column mounting bolts

MAN-00162
Removal 4. Remove the instrument lower panel mounting

1. Remove the Steering Wheel. For additional screws (A) and remove the lower shroud (B).
2. Using a screwdriver, remove the steering col-
umn lower cover mounting screws (A) and de- B
tach the shroud assembly (B).
B
A
5. Remove the combination switch.

6. Disconnect all the ignition key barrel electrical
connectors (A).
A
3. Remove the two mounting screws (A) of the A

steering column upper shroud (B) and remove
the shroud assembly.
3 4
100 120 x1000rpm
80 140
2 5
60 160 H
40
20
180
200
1
c
6
A
22 0 7
0
A
FRO
NT
REA
R OFF
MI
PUL OFST
L INT F
ON
LO
S W
HIG
H
7. Remove the 12mm bolt (A) from the joint con-

nected to the steering column and the intermedi-
ate shaft (B).
A
8. Remove the two 12mm steering column mount-

ing bracket bolt and nuts (A).

MAN-00162
Steering Oil Replace

A A
2. Raise and support the vehicle. Make sure that
the road wheels are off the floor. For additional
information refer to Jacking and Lifting sec-
tion.
front cradle.
9. Remove the 12mm bolt (A) from the steering col-

umn mounted on the cross beam.
A A
B
740-12-1C-1SCB
COIL 85
O/E/N
1006
4. Press the clip (A), pull out cooler loop return

hose (B). Finally drain the power steering fluid.
A
Notice
Steering column bolt (rivet type) is to be
chiseled out and new bolt to be fixed.
B
10.Separately remove the steering column from the
cross beam.
Inspection
1. Check the steering column for cracks, damages
or deformation. Replace the steering column if
necessary.
Installation Notice
During the power steering fluid draining, ro-
2. Tighten all bolts to the specified torque. tate the steering wheel towards LHS and RHS
3. Check the wheel alignment. For additional to completely drain the power steering fluid.
section.

MAN-00162
Power Steering Reservoir

CAUTION Removal
Do not allow steering fluid level in the reser- 1. Disconnect and isolate the negative terminal of
voir to go below the MIN level as this will lead the battery. For additional information refer to
to air entering into the system. Battery removal and installation section.
2. Remove the 10mm front wiper reservoir neck
mounting bolt (A).
Notice
When replacing the power steering fluid reser-
voir, make sure that the power steering fluid is
clean and not mixed prior to use. The power
steering fluid should be poured slowly into the EN C
LOSE
OP
reservoir to minimize the possibility of aera- POWER
G
tion. STEERIN RE
EN WASHING F
LU
FLUID
C ID
DS
IN
W
5. Connect the cooler loop return hose (B) and A
press clip (A).
3. Drain the power steering fluid from the reservoir.

4. Press the clip (A) and disconnect the inlet hoses
B (B) from the steering fluid reservoir.
MAX
MIN
A
Notice
Ensure that, the cooler loop return hose clip is
locked in proper position.
B
6. Lower the vehicle and fill the power steering fluid
into the reservoir at maximum level.
7. Start the engine, slowly turn the steering wheel
from lock to lock position for 4 to 5 times. This is
to ensure the proper circulation of steering fluid
in the system.
8. Check the maximum steering fluid level. Fill the
fluid into the reservoir, if maximum fluid level is
not reached.

MAN-00162
5. Press the clip (A) and disconnect the power Intermediate Shaft
steering suction & return hose (B) from the
steering fluid reservoir.
MAX
MIN
A
A. Intermediate Shaft Upper with Universal Joint

6. Pull out the power steering reservoir (A) from the B. Connector Intermediate Shaft
power steering reservoir bracket.
The intermediate shaft is mounted between the col-
lapsible steering column and the steering gear. It
consists of an universal joint with a splined joint con-
A
nection which is firmly fastened to the steering gear
and steering column. The main function of the inter-
mediate shaft is to enable the change in the shaft
length when the column is tilted and also to absorb
vibrations which may be generated by the wheels
MAX
MIN and suspension up to the steering wheel, as well as

acting as a safety measure and collapse in the event
of an accident.
The intermediate shaft transfers the rotational move-
ment of the steering column to the power steering
gear input shaft.
Installation
CAUTION
To avoid damage of the reservoir, correctly
match the reservoir with the bracket.
Notice
Refill the power steering reservoir with new
power steering fluid. Avoid using old power
steering fluid.

MAN-00162
Intermediate Shaft Upper with Univer- 3. Remove the 12 mm intermediate shaft upper
sal Joint universal joint mounting bolt (A) from the
steering column.
Removal
Notice
While attempting to remove the intermediate
shaft, lock the steering wheel at center posi- A
tion.
740-12-1C-1SCB
1. Remove the two 12 mm intermediate shaft
COIL 85
O/E/N
1006
upper Universal Joint mounting bolt (A)
connecting upper and lower intermediate
shafts.
4. Separately remove the intermediate shaft upper

with universal joint.
Installation
A
2. Push the upper intermediate shaft mounting

bracket (A) towards the steering column side.

MAN-00162
Connector Intermediate Shaft 3. Remove twelve 10 mm mounting bolts (A) and

Removal front cradle.
Notice
While attempting to remove the intermediate
shaft, lock the steering wheel at center posi-
tion.
A
1. Remove the two 12 mm connector inter-
mediate shaft mounting bolt (A) connecting
upper and lower intermediate shafts.
4. Remove the 12mm intermediate shaft mounting

bolt (A) and remove the intermediate shaft (B)
from the steering gear.
A B
2. Push the upper intermediate shaft mounting

bracket (A) towards the steering column side. A
5. Separately remove the connector intermediate

shaft from the steering gear.
A Installation

MAN-00162
Tie-rod Ends 4. Loosen the 19mm tie-rod end lock nut (A) and
remove the tie-rod end (B).
Removal
tion section.
2. Loosen the 22mm tie-rod end lock nut (A) from
the steering ball joint (B).
A B
5. Rotate the tie-rod end (A) in anticlockwise direc-

B tion, and separately remove the tie-rod end.
CAUTION
Improper installation may damage the rubber
3. Remove the tie-rod end lock pin (A) from the boot of the tie-rod end.
knuckle assembly (B).

MAN-00162
Inspection Power Steering Rack

1. Check the tie-rod end for any bend or damage.
Replace it, if necessary.
2. Check the ball joint thread for damage. A
B
3. Check the ball joint for excessive wear.
4. Check for ball joint dust cover for damage. C
Installation D
2. Tighten all bolts to the specified torque. E
3. Check the wheel alignment. For additional F
section. G
A. Tie Rod End

B. Pinion (Connecting Point to Intermediate Shaft)
C. Hydraulic Lines
D. Dust Boot
E. Mounting Bushes
F. Steering Rack Assembly
G. Tie Rod
The power steering rack comprises of a rack and pi-
nion type steering gear and a hydraulic cylinder.
Hydraulic pressure is controlled by the built-in pr-
essure relief valve. Fluid flow is regulated by the high
pressure input line and low pressure return line. As
the power steering rack assembly is exposed to
dusty and severe operating conditions, the seals and
all inner hydraulic components are protected ad-
equality by expandable rubber bellows.
Removal
Notice
The wheels should be in straight ahead posi-
tion before disconnecting the steering rack as-
sembly from the vehicle.
1. Remove the front tyres. For additional informa-

tion refer to Wheels removal and installation
section.

MAN-00162
2. Remove twelve 10 mm mounting bolts (A) and 8. Remove the two 10mm mounting bolts (A) of
remove engine underbody cover (B) from the power steering suction and return hose brackets
front cradle. (B).
B
A
3. Drain the power steering fluid. For additional 9. Remove the 17mm lock nuts of pressure hose
information refer to Steering Oil Replace (A) and cooler loop return hose (B), and detach
removal and installation section. the hoses from the steering rack.
4. Remove the Tie-rod End. For additional infor-
mation refer to Tie-rod Ends removal and
5. Remove the intermediate shaft. For additional A
information refer to Intermediate Shaft
B
6. Remove the front link rod from the stabilizer bar.
For additional information refer to Front Sta-
bilizer Bar Link removal and installation sec-
tion.
7. Remove the 10mm heat shield mounting bolt (A)
from the steering rack.
CAUTION
A let hose oil passage with dust cap to avoid

MAN-00162
10. Remove the 17mm center mounting bolt & nut

(A) and the 18mm bottom mounting bolt (B),
separately remove the transmission rear mount-
ing.
A
A
13. Separately remove the power steering rack

from the cradle.
B
Inspection
11. Remove the four 17mm mounting bolts (A) and 1. Check steering rack assembly for cracks, dam-
separately remove the mounting bracket from ages or leakages. Replace the steering rack
the rear side of the transmission. assembly if required.
2. Check the steering inner ball joint for any dam-
Notice age. Replace the steering rack assembly if
required.
Detach the rear side of transmission mounting
bracket only for the AWD vehicles where as it 3. Check steering rack dust boot for any wear or
not required for 2WD vehicles. deterioration. Replace if necessary.
Installation
Notice
Refill the power steering reservoir with new
A power steering fluid. Avoid using old power
steering fluid.

section.
12. Remove the 18mm mounting bolts (A) from both

sides of the power steering rack.
Notice
Remove four 18mm mounting bolts from both
sides of the power steering rack of the AWD,
and three 18mm mounting bolts in the 2WD.

MAN-00162
Power Steering Suction Hose Installation

Removal
2. Fill and bleed the power steering system. For
1. Remove the NVH cover.
additional information refer to Steering Oil
2. Drain the power steering fluid. For additional Replace section.
information refer to Steering Oil Replace sec-
tion.
3. Using a suitable plier, remove the hose clip (A)
and release the power steering suction hose (B)
from the power steering fluid reservoir.
MAX
MIN
4. Using a suitable plier, remove the hose clip (A)

and release the power steering suction hose (B)
from the pump assembly.
A
B
5. Detach the pump to reservoir suction hose.

MAN-00162
Power Steering Pressure Hose 6. Remove the 17mm power steering pressure
hose lock nut (A) from the power steering pump.
Removal
1. Drain the power steering fluid. For additional
tion.
4. Remove the radiator assembly. For additional A
information refer to Radiator removal and
5. Remove the 10mm power steering pressure 7. Remove the 10mm power steering pressure
hose mounting bracket bolt (A) from the power hose mounting bracket bolt (A) from the cradle.
steering pump.
8. Remove the 10mm heat shield mounting bolt (A)


MAN-00162
9. Remove the two 10mm mounting bolts (A) of Power Steering Return Hose
power steering pressure and cooler loop return
hose bracket (B) and detach the brackets. Removal
A information refer to Steering Oil Replace sec-
tion..
B 2. Remove the 10mm heat shield mounting bolt (A)
A
10. Remove the 17mm lock nuts (A) of power steer-
ing pressure hose (B), and detach the pump
connected to the rack hose.
B
A 3. Remove the two 10mm mounting bolts (A) of
power steering pressure and cooler loop return
hose bracket (B) and detach the brackets.
CAUTION
Plug the steering rack assembly inlet and ou-
tlet hose oil passage with dust cap to avoid
Installation
Replace section.

MAN-00162
4. Remove the 17mm lock nuts (A) of cooler loop Cooler Loop Assembly
return hose, and detach the cooler loop return
hose (B) from the steering rack. Removal
B
tion.
2. Remove the front bumper.
A
3. Press the clip (A), pull out the power steering co-
oler loop return hose (B) from the cradle.
CAUTION
let hose oil passage with dust cap to avoid
5. Remove the 10mm cooler loop return hose 4. Press the lock (A) and pull out the cooler loop
mounting bracket bolt (A) from the cradle. Press hose (B) from the power steering reservoir joint.
the clip and pull out the cooler loop joint hose
(B).
MAX
MIN
B A
A
B
Installation
Replace section.

MAN-00162
5. Remove the two 10mm front bumper top deflec- 8. Press the clip (A) and pull out the cooler loop
tor mounting bolts (A) and detach the front hose (B) connected to the steering rack joint.
bumper top deflector (B).
B A
9. Press the clip (A) and pull out the cooler loop
6. Remove the two 10mm front bumper RHS de- hose (B) connected to the power steering fluid
flector mounting bolts (A) and detach the front reservoir.
bumper RHS deflector (B).
B
A
B
A
10.Remove the two 10mm cooler loop bracket

7. Remove the two 10mm cooler loop bracket mo- mounting bolts (A) and detach the cooler loop
unting bolts (A) from the radiator cross bar and bracket (B).
detach the cooler loop assembly (B).
A
A
B B
B

MAN-00162
Installation Power Steering Pump

Replace section.
Removal
tion.
CAUTION
Avoid spillage of power steering fluid on
other components. Wipe off immediately, if
any spillage is noticed. Adequately cover the
power steering reservoir and hoses from any
foreign material/dust.

4. Remove the radiator. For additional informa-
tion refer to Radiator removal and installa-
tion section.
5. Remove the radiator fan shroud. For additional
information refer to Cooling Fan Shroud with
Flaps removal and installation section.
6. Remove the power steering pressure hose. For
additional information refer to Power Steer-
ing Pressure Hose removal and installation
section.

MAN-00162
7. Remove the two 12mm power steering pump Diagnosis and Testing
mounting bolts (A) and detach the power steer-
ing pump separately. Inspection and Verification
1. Visually inspect the steering components for any
A noticeable signs of mechanical damage.
Visual Inspection
• Check the tire pressure.
A • Check the accessory drive belt for any damage.
• Check the Tie-rod ends for bend or damage.
• Check the steering inner ball joints for any bend
or external damage.
• Check ball joint rubber boots for signs of crack-
ing or deterioration.
• Check inner and outer ball joints for excessive
wear.
8. Separately remove the power steering pump
from the bracket. • Inspect all the steering bushes for signs of wear
and deterioration.
Inspection
1. Check steering pump for any damage or cracks. • Check the steering oil level in the reservoir. If the
Replace the pump if necessary. level is below “MIN” mark, top up steering fluid.
2. Check the power steering fluid for any • Check the steering gear assembly for any exter-
contamination. Do not reuse the fluid if it is nal damage or steering fluid leakage.
contaminated.
• Check the power steering pressure lines for fluid
Installation leakage and deterioration.
1. To install, reverse the removal procedure. • Check the power steering pump and the reser-
voir for fluid leakage.
2. Tighten all nuts and bolts to the specified torque.
• Check the steering gear rubber bellows for cuts,
cracks, deterioration and oil traces.
Replace section. If the cause is not visually evident, verify the symp-
tom and refer to the Troubleshooting Chart.

MAN-00162
1. Loose steering rack 1. Tighten the mounting bolts to the

assembly mounting bolts. specification.
2. Loose steering linkage. 2. Check the steering linkage

mounting bolts for correct torque.
Replace the linkage if necessary.
Rattle or Chuckle noise in the steer- 3. Pressure hose fouling 3. Adjust the hose position as nec-
ing gear with other parts of the essary.
vehicle.
4. Worn out inner ball joint. 4. Replace the inner ball joint.
5. Replace the outer ball joint.
5. Loose outer ball joint.
6. Replace the intermediate shaft
6. Play in universal joint.
assembly.
1. Air in the steering sys- 1. Top up the power steering reser-

tem. voir with steering fluid and bleed
the system.
2. Loose steering rack 2. Tighten the mounting bolts to the
assembly mounting bolts. correct torque.
3. Improperly adjusted or 3. Adjust the wheel bearings or

Excessive steering wheel play worn out front wheel replace with new one if neces-
bearings. sary.
4. Damaged or worn steer- 4. Replace the steering rack assem-

ing rack assembly. bly.
5. Worn or damaged rub- 5. Replace the rubber bushings.
ber bushing on steering
gear mounting.
1. Steering ball joint dam- 1. Check and replace the steering

age. ball joints.
2. Improper tire pressure 2. Inflate the tire pressure to the
Vehicle pulls to one side while driving
specification.
3. Incorrect wheel align- 3. Adjust the wheel alignment as per
ment. specifications.
1. Low fluid level in the res- 1. Fill the fluid to the correct level.
ervoir.
2. Reservoir cap not 2. Install the reservoir cap properly.
Hissing noise
installed properly.
3. Air leak between pump 3. Check and repair as necessary.
and reservoir.

MAN-00162
1. Uneven tire pressure. 1. Inflate the tires to the specifica-

tion.
2. Steering wheel rubbing 2. Adjust the steering wheel and
against directional signal steering column.
housing.
3. Tight or seized steering 3. Replace the steering column
column bushing or bear- bushing or bearings.
ings.
4. Steering joint or linkage 4. Lubricate or renew the joints.
Poor steering wheel return binding.
5. Steering inner ball joint 5. Check and replace the steering
damage. inner ball joint.
6. Kink in return hose. 6. Replace the hose.
7. Incorrect wheel align- 7. Adjust the wheel alignment to the

ment. specification.
8. Damaged front suspen- 8. Check the suspension parts,
sion parts. replace as necessary.
1. Low tire pressure. 1. Adjust the tire pressure.

2. Low steering fluid level in 2. Fill the reservoir to the correct
the reservoir. level.
3. Steering pump belt slip- 3. Replace the belt.
page.
4. Replace the steering gear assem-
4. Leakage in steering gear
bly.
assembly.
5. Internal leakage in steer- 5. Replace the steering pump.
ing pump.
6. Lower coupling flange 6. Loosen the retain bolt and adjust
rubbing against the steer- as necessary.
Steering hard
ing gear.
7. Leakage in the steering 7. Check and replace the pressure
pressure lines. lines.
8. External damage in 8. Replace the steering rack assem-
steering rack assembly. bly.
9. Damaged or worn out 9. Check and replace necessary
front suspension compo- components.
nents.
10. Low fluid pressure in the 10. Air in the fluid and loss of fluid
system. due to internal leakage in the
pump.
1. Slippage in steering 1. Replace the belt.

Chirp noise in the steering gear.
pump drive belt.

MAN-00162
1. Scored pressure plate, 1. Replace the pump.

thrust plate or rotor in the
pump.
2. Extreme wear of cam 2. Replace the pump.
Growl noise in steering pump. ring.
3. Low steering fluid level. 3. Fill the steering fluid to the correct
level.
4. Air in the steering sys- 4. Bleed the steering fluid system.
tem.
1. Pump vanes sticking in 1. Replace the pump and flush the

Rattle or knock noise in the steering rotor slot. system.
pump. 2. Pressure hose fouling on 2. Adjust the hose position as nec-
other parts of the vehicle. essary.
1. Excessive total toe-in or 1. Check the front toe settings and

out. adjust if necessary.
2. Unevenly loaded or over- 2. Educate the customer about cor-
loaded vehicle.
rect vehicle loading.
3. Worn out steering inner 3. Inspect the steering ball joint.

ball joints. Replace the steering rack assem-
bly if necessary.
Vehicle Wander
4. Loose, worn or damaged 4. Inspect the front wheel bearings.
front wheel bearings. Replace wheel bearings if neces-
sary.
5. Worn or damaged front 5. Check and replace necessary
suspension components. components.
6. Loose suspension fasten- 6. Tighten the fasteners to the

ers. required specification.
1. Loose wheel nuts. 1. Tighten the nuts to the specifica-

tion.
2. Loose front suspension 2. Tighten the fasteners and mount-
fasteners and mountings. ings to the specification.
3. Loose front wheel bear- 3. Inspect the front wheel bearings.

ings. Replace the bearings if neces-
sary.
Steering wheel shimmy
4. Problem in Front shock 4. Replace the shock absorbers if
absorbers, necessary.
5. Damaged wheel. 5. Inspect the wheel rims for dam-

age and balance the wheel & tire
assemblies.
6. Worn out or loose UJ 6. Tighten the bolts or replace the

and/or coupling. shaft assembly.

MAN-00162
1. Loose wheel nuts. 1. Tighten the wheel nuts to the

specification.
2. Loose front suspension 2. Tighten the fasteners and mount-
fasteners and mountings. ings to the specification.
3. Loose front wheel bear- 3. Inspect the front wheel bearings.

ings. Replace the bearings if neces-
sary.
Steering wheel wobble
4. Tires worn or wheels out 4. Balance the wheels. Replace the
of balance. rims and tires if necessary.
5. Incorrect wheel align- 5. Adjust the wheel alignment to the
ment. specification.
6. Worn out steering inner 6. Replace the steering rack assem-
ball joints. bly.
Component Inspection and Remedy Action

Steering Wheel 1. Check steering wheel for 1. Replace steering wheel.

physical damage and/or dis-
tortion.
Steering Column 1. Check steering column for 1. Tighten the bolts as per torque
loose mounting bolts. specification.
2. After tightening check for axial 2. Replace steering column.
play.
3. Check for splines wear and 3. Replace steering column.
tear.
4. Check for looseness of steer- 4. Replace steering column.
ing column pre-torqued bolts.
Intermediate Shaft 1. Check for axial play in the 1. If play is excessive, replace
shaft. shaft.
2. Check for physical damage. 2. Replace the shaft if damaged.
3. Replace the shaft if wear and

3. Check for wear and tear. tear is found.
4. Replace the shaft assembly if
4. Check if column is collapsed. shaft is collapsed.

MAN-00162
Steering Rack 1. Check for physical damage. 1. Replace steering rack.
2. Check for abnormal noise dur- 2. Replace steering rack if noise

ing steering action. is found.
3. Check for oil leakage from bel- 3. Replace steering rack if leak-
lows or spool valve. age is found.
4. Check inner ball joint play. 4. Replace steering rack if play is

found.
Tie rod end 1. Check ball joint play. 1. Replace the tie rod end if play
is excessive.
2. Check for bellows damage. 2. Replace the tie rod end if dam-
age is found.
Power steering fluid reservoir. 1. Check for cracks or distortion. 1. Replace the reservoir.
2. Check for fluid leakage from 2. Replace the reservoir.
cap or reservoir.
Power steering pump. 1. Check for leakage from pump 1. Replace the pump.
body.
2. Check for physical damage to 2. Replace the pump.
pump body or pulley bend or
distortion.
3. Check for pumping pressure. 3. Conduct power steering pump
pressure test.
Power steering lines. 1. Check lines for cracks, distor- 1. Replace the concerned hose.
tions, damages or flaring es-
pecially at joints.
2. Check for material deteriora- 2. Replace the concerned hose.
tion.

MAN-00162
POWER STEERING SYSTEM:
Steering system - type Hydraulic power steering with

Rack and pinion steering gear
and collapsible steering column
Steering column collapsible stroke 80 mm
Ratio of Steering wheel angle to road wheel angle 15.4:1
Steering wheel diameter 380 mm
No. of steering wheel turns (Lock to Lock) 3.1
Vehicle turning circle diameter 11.2 meters
Lubrication Details:
Location Grease type Grease Quanti-

ty
At Rack, Pinion, Bearing and at Rack bush CALTEX 20g (Approx.)

MARFAK
At Bellow lip for Inner Ball Joint Silicon grease Smear
POWER STEERING RACK AND PINION ASSEMBLY:
Type End take-off and pinion steering

gear
Rack Travel 147mm
No.of steering wheel turns (lock to lock) 3.1
Steering gear specification 47.43 per revolution
Max.operating pressure 90bar
POWER STEERING PUMP:
Type Vane Type, drooping flow charac-

teristics
Cartridge capacity 9.6 cc/rev
Controlled Flow 7.5 lpm to 5 lpm
Relief Pressure 100 bar
Operating Speed 600 - 8500 RPM
Operating temperature -40° C to + 120° C
POWER STEERING RESERVOIR:

MAN-00162
Type Transparent Plastic Reservoir
At Max. level: 290 ml

Capacity
At Min. level: 230 ml

0604BAA0001ST Steering Wheel Puller

MAN-00162
Bolt Torque in
Specification Nm
Bolt Combi Plain

M12 X 1.5 X 65 X Stg.gear to craddle 4 85.0±5.0
8.8
OBJ -SLOTTED
2 80.0±5.0
Steering Gear NUT
OBJ - Tie rod end
PIN COTTER
2 NA
3.2X30 ZN
Steering gear toe rod nut for alignment 2 65.0±5.0
BOLT COMBI L
1 No for Lower UJ to Gear Yoke & 1
M8X1.25X30X8.8 2 25.0±3.0
No for Column joining with I Shaft
XZN
NUT HEX FL
M8X1.25X8X8 Column Upper Bracket to CCBr 1 20.0±1.0
GR
Bolt Hex Flange -

M8 X 1.25 X 30 X Column Upper Bracket to CCB 1 20.0±1.0
Column 8.8 Gr
Bolt Hex Flange -

M8 X 1.25 X 70 X Column Lower Bracket to CCB 1 25.0±1.0
8.8 Gr
11.0±2.0
SCREW HEX FL
M6X1X20X8.8XZ Rubber Boot mounting on Firewall 4
N
SCREW HEX FL
Strg Hose & Res-
M6X1X15X8.8XG Reservoir bracket to BIWr 3
ervoir
R
Screw Hex Flange

- M6 X 1 X 12 X For Cooler Loop hose bracket mtg 2
8.8 X ZN
Nut Hex Flange - For fixing return hose to cradle & cool- 11.0±2.0
3
M6 X 1 X 8.8 Gr er loop hose to Cooler loop bracket
Oil Line - RH
Bolt Combi - M6 X
For fixing hose clamp on stg gear 1
1 X 12
Screw Hex Flange

- M6 X 1 X 20 X For fixing top clamp 1
8.8 Gr

MAN-00162
Bolt Torque in
Specification Nm
Pr.hose And Re-

For pressure hose NUT mounting 1 22.0±2.0
turn Hose
Screw Hex Flange

- M6 X 1 X 12 X For Cooler Loop hose bracket mtg 2
8.8 X ZN
Screw Hex Flange

For fixing top clamps on cradle brack-
Oil Line - LH - M6 X 1 X 20 X 2 11.0±2.0
ets
8.8 X ZN
For fixing return hose to cradle, cooler

Nut Hex Flange -
loop hose to Cooler loop bracket & top 5
M6 X 1 X 8.8 Gr
clamps on cradle brackets
NUTHEX FL
For steering wheel mounting with col-
Steering Wheel M12X1.25X11.2X 1 38.0~41.0
umn
8
Combination
M6 allen bolt 1 9±0.5
Switch

MAN-00162
Repair Manual Instrument Cluster Nov 2011/ Rev 2
INSTRUMENT CLUSTER
CONTENTS

Instrument Cluster Overview .................................................................. 2
Instrument Cluster and Warning Indicators ............................................ 2
Warnings and Indicators ........................................................................ 5
Check Engine Indicator ......................................................................... 6
Charging System Warning .................................................................... 6
Low Engine Oil Pressure Warning ......................................................... 6
Water in Fuel Indicator ........................................................................... 6
Parking Brake System / Brake Fluid Level Warning .............................. 6
Tire Pressure Monitoring System (TPMS) Warning ............................... 7
Turn Signal Indicator .............................................................................. 7
Immobilizer System Warning ................................................................. 7
Headlamp High Beam Indicator ............................................................. 7
Open Door Warning ............................................................................... 7
Driver Seat Belt Reminder ..................................................................... 7
OBD Indicator (Applicable for BSIV vehicles) ........................................ 7
Glow Plug Indicator ................................................................................ 7
Rear Fog Lamp Indicator ....................................................................... 7
Front Fog Lamp Indicator ...................................................................... 7
SRS Airbag Warning .............................................................................. 8
Anti-lock Brake System (ABS) Warning ............................................... 8
Cruise Control Indicator ......................................................................... 8
Interactive Torque Management (ITM) Warning .................................... 8
Hill Decent Control (HDC) Warning ........................................................ 8
Hill Hold Control (HHC) Warning ........................................................... 8
ESP OFF Indicator ................................................................................ 8
ESP Malfunction Indicator ...................................................................... 8
Start / Stop Indicator .............................................................................. 8
Engine Temperature Warning ............................................................... 8
Over Speed Warning ............................................................................. 8
Key in Warning ...................................................................................... 8
Instrument Panel Illumination ................................................................ 9

MAN-00162
Incar Repairs ................................................................................... 9
Instrument Cluster ....................................................................... 9

Removal ............................................................................................. 9
Installation ........................................................................................ 11

Inspection and Verification ................................................................... 12

MAN-00162
Instrument Cluster
The electronic instrument cluster is located in the instrument panel above the steering column.
B
80 10
60 0
km 12
/h 0
40
14
F 0
20
R
ODO 16
0
0 E km
18
0
3
2
1
x1
20 00
2 0 0
rp 4
m
CL
K
3 22
0
BA
ND
7 H
VOL
5
POW
8 SELER 4
EXIT
5
RDM SOURCE C
6
RPT +
6
9
EQ
V
ME -
7
NU 0 TA V
#
LIS
T
SO
UR
CE
INF
O
MU
TE
ECO
N
A/C
OFF
REA RES
AU A/C R
TO
M CRU
ISE
OFF
+
SET
AWD
LOC
K PASS
ENGE
R
STAR
T
A
STOP
ES
OF P
F
A. Instrument cluster B. Instrument cluster hood.

The Instrument Cluster has following features:
• Analogue Gauge : Speedometer, Tachometer
and Fuel gauge
• Bar graph: Engine Temperature
• Odometer and Trip meter
• Tell tales
• TPMS Switch
• Gear Information

MAN-00162
Instrument Cluster Overview
77
55
44
88
66
1
33 9
1 9
2
2
1. TPMS learning switch 2. Speedometer 3. Odo and Trip meter 4. Fuel level 5. Gear information
6. Tell tale zone 7. Tachometer 8. Engine temperature 9. Trip switch
Instrument Cluster and Warning Indicators

Speedometer Tachometer
The speedometer indicates the speed of the vehicle. The tachometer shows engine speed in thousands of
The speedometer is calibrated in kilometers per hour. revolutions per minute (RPM).
Notice
If the vehicle speed is more than 150 kmph,
CAUTION
over speed buzzer in the cluster will trigger Do not continuously operate the engine in
warning alarm. high RPM. This may cause severe engine
damage.

MAN-00162
Trip Switch Odometer
Trip switch is located on right hand side of instrument When this mode is selected, ODO will be displayed.
cluster. The odometer records the total distance the vehicle
has been driven.
During ignition ON, the display mode can be
switched between odometer and tripmeter by Tripmeter
pressing the trip switch.
TPMS Switch
The tripmeter records the total distance of two trips.

One is recorded in tripmeter A, and the other is
TPMS switch is located to the left hand side of the recorded in tripmeter B.
instrument cluster. For instance, tripmeter A can record the distance
from the point of origin, and tripmeter B can record
For additional information refer to Procedure for the distance from where the fuel tank is filled.
TPMS Learning section.
Trip A mode
• Short press of Trip switch in Trip A will change
to Trip B
• Long press of Trip switch in Trip A will reset
Trip A
Trip B mode
• Short press of Trip switch in Trip B will change
to ODO
• Long press of Trip switch in Trip B will reset
Trip B

MAN-00162
Fuel Level Temperature Bar Graph
The fuel level indicates the approximate amount of Engine temperature bar graph will illuminate in blue
fuel in the fuel tank. when the coolant temperature is low. Engine
temperature bar graph will start blinking in red when
Reserve: Last 2 bar in the fuel bar graph indicates
the coolant temperature is high.
the reserve.
Low level: Last bar in the fuel bar graph blinks when
the fuel tank reaches the low level (approximately 5 WARNING
liters).
Never remove the radiator cap when the
At curves and inclinations, the fuel bar graph may engine is hot. The engine coolant is under
fluctuate or the low fuel warning light may come on pressure and could cause severe burns. Wait
earlier than usual due to the movement of fuel in the until the engine is cool before adding coolant
tank. to the reservoir.
Notice
When all bars on the fuel level are blinking,
contact the nearest Authorised Mahindra
CAUTION
Dealer. Driving with an overheated engine can
cause serious engine damage.
Gear Information
Notice
Gear information will display the current gear position
The direction of the arrow shows that the fuel in the vehicle while running.
filler lid is on the left side of the vehicle.

MAN-00162
Warnings and Indicators
Indicator Description
Check Engine Indicator
Charging System Warning
Low Engine Oil Pressure Warning
Water in Fuel Indicator
Parking Brake System / Brake Fluid Level Warning
Tyre Pressure Monitoring System (TPMS) Warning
Turn Signal Indicator
Immobilizer System Warning
Headlamp High Beam Indicator
Open Door Warning
Driver Seat Belt Reminder
OBD Indicator (Applicable for BSIV vehicles)
Glow Plug Indicator
Rear Fog Lamp Indicator
Front Fog Lamp Indicator
SRS Airbag Warning
Anti-lock Brake System Warning
Cruise Control Indicator
Interactive Torque Management (ITM) Warning
Hill Descent Control (HDC) Warning
Hill Hold Control (HHC) Warning
ESP OFF Indicator
ESP Malfunction Indicator
Start / Stop Indicator
Engine Temperature Warning

MAN-00162
Check Engine Indicator

This warning light comes ON when
the ignition switch is turned to the ON CAUTION
position and goes OFF after few
If the engine is not stopped immediately
seconds. Illumination at any other
after the low engine oil pressure warning
time indicates an engine fault. If the indicator
light is illuminated, it could lead to severe
illuminates continuously or blinks while driving, the
engine damage.
performance of the engine management system is
impaired. Contact the Mahindra Authorised Dealer
for further assistance. Water in Fuel Indicator
Charging System Warning This warning light illuminates when
the water level in the fuel filter has
This warning light comes ON when reached the maximum permissible
the ignition switch is turned to the ON limit. Water in the fuel filter should be
position and goes OFF when the drained immediately to avoid fuel
engine is started. If the warning light system damage. Drain the water from the fuel filter
comes ON while driving, the battery and restart the engine. The indicator should turn
is not being charged when the engine is running. OFF automatically. If not, contact an Authorised
Try not to use other electrically operated controls Mahindra Dealer.
such as the power windows, audio system and AC.
Keep the engine running. Stopping and starting of
the engine will discharge the battery rapidly. CAUTION
Immediately take the vehicle to the nearest Failure to drain water from the fuel filter will
Authorised Mahindra Dealer. damage the vehicle’s fuel injection system
and engine.
CAUTION Parking Brake System / Brake Fluid

Don’t continue driving when the charging Level Warning
system warning light is illuminated because
the engine can stop unexpectedly. The brake system warning lamp
illuminates when:
Low Engine Oil Pressure Warning 1. The parking brake is not released
fully
This warning light comes ON when
2. The brake fluid level in the reservoir is low
the ignition switch is turned to the ON
position and goes OFF when the 3. Front brake pad is worn out
engine is started. If it continues to If the fluid level is low, add brake fluid as required.
illuminate with a buzzer sound twice,
it means the oil pressure has dropped very low. Turn ON the ignition and check for the warning
light. If the warning light remains ON after adding
1. Drive safely to the side of the road and stop
fluid, have your brake system inspected for leaks or
2. Turn OFF the engine and wait for 5 minutes for worn out brake pads as soon as possible by the
the oil to drain back into the engine oil sump nearest Mahindra Authorised Dealer.
3. Check the engine oil level. If the level is low,
add oil as required. Notice
4. Start the engine and check the warning light. If If the warning light remains ON, or if the
the warning light is still ON, turn OFF the brakes do not operate properly, do not drive
engine and contact the nearest Authorised the vehicle.
Mahindra Dealer

MAN-00162
Open Door Warning

WARNING When any of the doors including
Driving the vehicle with a warning light ON is tailgate and bonnet are not closed
dangerous. If the brake warning light remains properly, open door tell tale illuminates
ON, have the brakes checked immediately by and the buzzer rings 3 times once
an Authorised Mahindra Dealer. ignition is turned ON.
Driver Seat Belt Reminder

Tire Pressure Monitoring System
(TPMS) Warning • Once the ignition is turned ON, driver
seat belt reminder warning lamp will
• If the TPMS warning indicator flash till the driver seat belt is
comes ON without blinking, check the engaged.
tyre pressure or temperature
• Once the engine is turned ON, buzzer will sound
immediately
for 30 seconds if the driver seat belt is not
• If the TPMS warning indicator will blink for 75 engaged.
seconds and remain ON, it means there is some
malfunction in TPMS system. Contact an OBD Indicator (Applicable for BSIV ve-
Authorised Mahindra Dealer. hicles)
Turn Signal Indicator
OBD is a part of the emission control,
which monitors various emission
Left arrow indicator will flash when left
control system components. OBD
turn indicator is turned ON and right
indicator illuminates when the ignition
arrow indicator will flash when right
switch is turned to the ON position, and will go out
turn indicator is turned ON in the
in a few seconds after the engine is started. If OBD
combination switch. Both left and right arrow
indicator remains ON or does not illuminate when
indicators will flash simultaneously along with click-
the ignition key is turned to the ON position take
clack sound, if the hazard warning indicator switch
the vehicle to the nearest Authorised Mahindra
is ON. A sudden increase in the rate of flashing
Dealer.
indicates failure of one or more of the indicator
bulbs. Glow Plug Indicator
Immobilizer System Warning
Glow plug indicator illuminates when
When the key is in the ignition switch, the ignition is turned ON. It
this light serves as the immobilizer automatically goes OFF when the glow
system warning light. Tell tale will blink plug reaches the required temperature.
when the vehicle is locked / ignition Rear Fog Lamp Indicator
OFF. The light will go OFF when confirmation by
the immobilizer system is completed. If the indicator The rear fog lamp indicator illuminates
flashes rapidly or fails to turn ON, or remains ON when the rear fog lamps are turned
continuously, it indicates a system malfunction. If ON.
any of these occur, contact an Authorised Mahindra
Dealer as soon as possible.
Front Fog Lamp Indicator
Headlamp High Beam Indicator
The front fog lamp indicator illuminates
High beam tell tale will illuminate when
when the front fog lamps are turned
the headlamp high beam is turned ON.
ON.
It will flash when the headlamp flasher
is used.

MAN-00162
SRS Airbag Warning ESP OFF Indicator

This indicator illuminates when ESP
With Ignition ON, this indicator comes switch is in OFF position.
ON and goes OFF automatically after
few seconds. If the SRS airbag
warning light illuminates while driving,
this indicates a malfunction in the airbag system. ESP Malfunction Indicator
Have the system checked by an Authorised
Mahindra Dealer as soon as possible. While driving, if this tell tale blinks, it
indicates that ESP has taken control of
Anti-lock Brake System (ABS) Warn- the vehicle stability. If the tell tale
ing remains ON, it indicates the
malfunction in the ESP System.
The warning light stays ON for a few Contact the nearest Authorised Mahindra Dealer.
seconds when the ignition switch is
turned to the ON position. Start / Stop Indicator
If the ABS warning light stays ON • Tell tale blinks when the vehicle is
while driving, the ABS control unit has detected a about to stop and comes ON
system malfunction. If this occurs, normal braking continuously when the vehicle is
will function. Contact nearest Authorised Mahindra completely stopped
Dealer as soon as possible. • On restarting the vehicle again using
clutch / key, the indicator goes OFF
Cruise Control Indicator
The indicator illuminates when the
Engine Temperature Warning
cruise control is ON. The indicator Engine temperature warning indicator
goes OFF when the cruise control is will start blinking once the coolant
OFF. temperature reaches 1050 C. It will
start blinking at double rate when the
Interactive Torque Management (ITM) temperature reaches 1100C and it will
Warning continuously remain ON with buzzer alert once the
temperature reaches 1140 C. In this case, contact
The indicator illuminates when the ITM nearest Authorised Mahindra Dealer.
system malfunction occurs. Contact
nearest Authorised Mahindra Dealer. Over Speed Warning
Buzzer will sound for 5 seconds when the vehicle
speed exceeds 150 kmph in the cluster.
Hill Decent Control (HDC) Warning
Key in Warning
This indicator illuminates when HDC
Buzzer will sound from instrument cluster when the
malfunction occurs. Contact nearest
remote key is left in the ignition OFF position and
Authorised Mahindra Dealer.
the driver door is open for 60 seconds.
Hill Hold Control (HHC) Warning

This indicator illuminates when HHC
malfunction occurs. Contact nearest

MAN-00162
Instrument Panel Illumination Incar Repairs

Instrument Cluster
The instrument panel illumination comes ON when

1. Ignition is ON
2. Position lamp / Parking lamp or Headlamp is Removal
ON 1. For any fault or malfunction related to
Roll the control knob up or down for brighter or instrument cluster, refer Instrument cluster
dimmer intensity of illumination for following: diagnostic manual.
• Instrument cluster 2. Push the lever (A) down and move the steering
column downwards.
• Ambient lamp
• Interior switches Notice
• Infotainment screen / display
The tilting steering coloum can be moved in
upward,downward,inward and outward direc-
tions.
RES
CRUISE SET
OFF
-
SOURCE
V
+
V

MAN-00162
3. Pull out the instrument cluster bottom cover (A) 5. Slide the cluster upper hood forward (A) and
from the instrument panel. pull out slowly the cluster upper hood from the
instrument cluster.
4. Unlock the cluster upper hood (A) from the

instrument cluster. 6. Remove the three mounting screws (A) of the
instrument cluster lower hood and remove the
Notice cluster lower hood.
Carefully unlock the cluster hood as shown

below to avoid the damage.
A A
7. Remove the cluster front mounting screw (A).

MAN-00162
8. Remove the two instrument cluster top Installation

mounting screws (A) and Pull the instrument
cluster (B) slightly in the forward direction. Notice
Follow the instructions from diagnostic man-
ual after installation of the instrument cluster.
2 4
6
1. Insert the instrument cluster two locators (A)

R 1
3 5
and two rib locks (B) properly into the

FRO
NT
REA
R OFF
LO
INTW
OF
MISTF
instrument panel.
B
9. Press the lock and disconnect the instrument

cluster electrical connector (A) and remove the
instrument cluster.
B
A

MAN-00162

Inspection and Verification Electrical damage
1. Verify the customer‘s concern. • Check the wiring harness for any short circuit.
2. Visually inspect the instrument cluster for any • Check for the loose electrical connector.
noticeable signs of mechanical or electrical • Check the instrument cluster for any
damage. malfunction.
3. If an obvious cause found during the If the cause is not found visually during the
inspection, correct the same before proceeding inspection. For additional information refer
to the next step. to Instrument Cluster Diagnostic manual.

MAN-00162
Repair Manual Instrument Panel Nov 2011/ Rev 2
INSTRUMENT PANEL
CONTENTS
Description and Operation .............................................................1

IP, Duct , Vent and OB Vent Bezel ................................................... 3
CCB and Wiring Harness .................................................................. 4
LH Top Cover, PAB and Upper Glove Box ....................................... 5
RH Top Cover, Instrument Cluster and Cluster Hood........................ 5
Lower Glove Box and BIN Seperator ................................................. 5
Incar Repairs ...................................................................................6
Floor Console Top Tray ...............................................................6

Removal ............................................................................................. 6
Installation .......................................................................................... 8
Floor Console ...............................................................................8

Removal ............................................................................................. 8
Installation .......................................................................................... 9
Bezel Upper to Carrier ................................................................. 9

Removal ............................................................................................. 9
Installation ........................................................................................ 10
Sunload sensor ..........................................................................10

Removal ........................................................................................... 10
Installation ........................................................................................ 10
Central Bezel ...............................................................................11

Removal ........................................................................................... 11
Installation ........................................................................................ 11
Audio Unit ...................................................................................12

Removal ........................................................................................... 12
Installation ........................................................................................ 12

MAN-00162
Lower Glove Box ........................................................................ 13

Removal ........................................................................................... 13
Installation ........................................................................................ 13
Upper Glove Box ........................................................................ 14

Removal ........................................................................................... 14
Installation ........................................................................................ 14
Defrost Grill RHS ........................................................................ 15

Removal ........................................................................................... 15
Installation ........................................................................................ 15
Demist Grill RHS ........................................................................ 15

Removal ........................................................................................... 15
Installation ........................................................................................ 15
Top Cover RHS........................................................................... 16

Removal ........................................................................................... 16
Installation ........................................................................................ 17
Tweeter RHS............................................................................... 17
Removal ........................................................................................... 17
Installation ........................................................................................ 17
OB Air Vent Bezel RHS .............................................................. 18

Removal ........................................................................................... 18
Installation ........................................................................................ 18
Defrost Grill LHS ........................................................................ 19

Removal ........................................................................................... 19
Installation ........................................................................................ 19
Demist Grill LHS ......................................................................... 19

Removal ........................................................................................... 19
Installation ........................................................................................ 19
Top Cover LHS ........................................................................... 20

Removal ........................................................................................... 20
Installation ........................................................................................ 21

MAN-00162
Tweeter LHS................................................................................ 22
Removal ........................................................................................... 22
Installation ........................................................................................ 22
Passenger Air Bag .....................................................................22

Removal ........................................................................................... 22
Installation ........................................................................................ 23
Bin Separator ..............................................................................23

Removal ........................................................................................... 23
Installation ........................................................................................ 24
OB Air Vent Bezel LHS ...............................................................24

Removal ........................................................................................... 24
Installation ........................................................................................ 24
IB Vent Center Left .....................................................................25

Removal ........................................................................................... 25
Installation ........................................................................................ 25
IB Vent Center Right .................................................................. 25

Removal ........................................................................................... 25
Installation ........................................................................................ 25
HVAC Control Unit .................................................................... 26

Removal ........................................................................................... 26
Installation ........................................................................................ 26
Central bezel switch bank .........................................................26

Removal ........................................................................................... 26
Installation ........................................................................................ 26
Infotainment Display Unit ..........................................................27

Removal ........................................................................................... 27
Installation ........................................................................................ 27
Audio Control Unit .................................................................... 27

Removal ........................................................................................... 27
Installation ........................................................................................ 27

MAN-00162
MBFM ......................................................................................... 28
Removal ........................................................................................... 28
Installation ........................................................................................ 29
ITM ECU ...................................................................................... 29

Removal ........................................................................................... 29
Installation ........................................................................................ 29
Fuel Flap Release Switch .......................................................... 30

Removal ........................................................................................... 30
Installation ........................................................................................ 30
Head Lamp Leveling .................................................................. 31

Removal ........................................................................................... 31
Installation ........................................................................................ 31
Cluster Intensity Switch ............................................................ 32

Removal ........................................................................................... 32
Installation ........................................................................................ 32
Instrument Panel ........................................................................ 33

Removal ........................................................................................... 33
Installation ........................................................................................ 36
Cross Car Beam (CCB) .............................................................. 36

Removal ........................................................................................... 36
Inspection ......................................................................................... 39
Installation ........................................................................................ 39
CCB wiring harness with fuse box ........................................... 40

Removal ........................................................................................... 40
Installation ........................................................................................ 40

Floor Console Top Tray ................................................................... 41
Disassembly..................................................................................... 41
Assembly .......................................................................................... 42


MAN-00162
Instrument Panel
The instrument panel is mounted in A-pillar channel located near the front doors with corner mounting bolts
and fixed in the cross car beam with center mounting bolts. The instrument panel not only offers utility but
also enhances the visual appeal of the interiors. The front console located at the center of the instrument
panel, houses the in-car entertainment system, HVAC controls and other switch functions like ESP, AWD. The
instrument panel also forms a housing for the wiring looms, diagnostic connector, Body control module
(MBFM), fuse box, HVAC components like evaporator unit and heater core along with the blower and the vent
system. The cluster is mounted at the RHS of the instrument panel. The glove boxes (upper and lower) are
provided at the LHS of the instrument panel.

MAN-00162
D B
Q
C
P 40
60
80 10
0
km 12
/h 0
14
A
F 0
20
R
ODO 16
0
0 E km
18
0
3
2
1
x1
20 00
2 0 0
rp 4
m
CL
K
3 22
0
BA
ND
O
7 H
VOL
5
POW
8 SELER 4
EXIT
5
RDM C
6
RPT
6
9
EQ
ME
7
NU 0 TA
#
LIS
T
SO
UR
CE
INF
O
MU
TE
ECO
N
N OFF
AU
A/C
TO
M
REA
A/C R
E
M AWD
LOC
STAR
K PASS
ENGE
R
T
A
STOP
ES
OF P
F
F
R
G
J I H
K
L
A. Instrument Panel Assembly J. Central Bezel Switch Bank

B. Bezel Upper to Carrier K. Hand Brake Lever
C. Central Bezel Bin L. Floor Console
D. LH Top Cover and Passenger Air Bag M. HVAC Control Unit
E. Instrument Cluster N. Infotainment and Audio Unit
F. A/C Vent O. Infotainment Display Unit
G. Instrument Panel End Cover P. Lower Glove Box
H. Steering Wheel Q. Upper Glove Box
I. Floor Console Trim R. Gear Shifter Lever

MAN-00162
IP, Duct , Vent and OB Vent Bezel
D
C
F
A
A. Carrier
B. IB & OB Vent
C. Side Air Duct
D. Defrost Duct Upper & Lower
E. Demist Duct
F. Manifold Duct
G. OB Vent Bezel

MAN-00162
CCB and Wiring Harness
A. Airbag Wiring Harness

B. CCB
C. Electrical Wiring Harness

MAN-00162
LH Top Cover, PAB and Upper Glove Lower Glove Box and BIN Seperator
Box
A
C B
F A
B
E
A. Bin Seperator
A. Defrost Grille B. Lower Glove Box Assembly
B. Tweeter Adaptor
C. PAB
D. Demist Grille
E. Upper Glove Box
F. Top Cover LH
RH Top Cover, Instrument Cluster and

Cluster Hood
A. Instrument Cluster Hood

B. Top Cover RH
C. Instrument Cluster

MAN-00162

To protect the instrument panel and adjacent
areas: Floor Console Top Tray
• Ensure the availability of sufficient work space
before removing or installing the instrument
Removal
panel. 1. Pull out the floor console top cover (A) from
the floor console.
• Care should be taken not to damage and
scratch the instrument panel when removing
and installing fasteners within the vehicle.
A
CAUTION
2 4 6
While removing or installing the instrument
R 1 3
12
V
panel, protect the seats and carpets from
damage.
Notice
• Disconnect battery before carrying out any
work on instrument panel.
2. Press the lock (A) and open the floor console
• Protect the modules, connectors, and wiring
box (B).
from dirt, heat, static electricity and moisture.
CAUTION B
While removing or installing the instrument A
panel, ensure that the instrument panel is not
scratched or damaged.

MAN-00162
3. Rotate the gear lever knob (A) in anti- 5. Pull out the top tray (A) from the floor console.
clockwise, and remove the knob from the gear
lever.
A
5
2 4 6
R 1 3
12
V
Notice
4. Open the gear lever cover zip (A) from the Apply the handbrake during removing the
gear lever. top tray from the floor console and slowly
remove the top tray.
A
CAUTION
While attempting to remove the top tray,
ensure that the tray lock is not damaged.
6. Press the lock (A) and disconnect the power

output socket electrical connector. Pull out the
audio USB electrical connector (B) from the
floor console top tray.
7. Remove the top tray from the floor console.

MAN-00162
Installation Floor Console

Notice
Install the floor console properly into the in-
strument panel. Carefully install without
scratching the driver and co-driver seats, in-
strument panel.
Removal
2. Remove the floor console top tray. For
additional information refer to Floor
Console Top Tray removal and installation
section.
3. Pull out the side trims (A) from both the sides
of the floor console.
Notice
Carefully remove the side trims without
damaging the trim locks.

MAN-00162
4. Remove the two 10mm top mounting bolts (A) Bezel Upper to Carrier
from the floor console.
5. Open the floor console mounting bolt cover Removal

(A) and remove the two 10mm mounting 1. Disconnect and isolate the negative cable of
bolts (B) from both the LHS and the RHS the battery. For additional information refer
sides of the floor console. to Battery removal and installation section.
2. Lift the bezel upper to carrier (A) from the
instrument panel.
A A
Bye from
w201
20 : 33 pm
11 22 33 44 55 66
EXIT
EXIT RDM
RDM RPT
RPT
VOL
VOL
CLK
CLK BAND
BAND POWER
POWER EQ
EQ TA
TA
77 SEL
SEL ##
88 99 00
6. Remove the floor console from the instrument MENU

MENU LIST
LIST SOURCE
SOURCE INFO
INFO MUTE
MUTE
panel.
Notice
Carefully detach the floor console without
any scratches or damage.
Installation
Notice
Install the floor console properly into the in-
strument panel. Carefully install without
scratching the driver and co-driver seats, in-
strument panel.

MAN-00162
3. Press the lock and disconnect the sunload Sunload sensor

sensor electric connector (A) and remove the
bezel upper to carrier from the instrument
panel.
Removal
1. Remove the bezel upper to carrier. For
4. Remove the sunload sensor. For additional additional information refer to Bezel Upper
information refer to Sunload sensor to Carrier removal and installation section.
2. Press the lock and remove the sunload sensor
Installation (A) from the bezel upper to carrier.
CAUTION
A
While installing the bezel to upper carrier,
ensure that the sunload sensor wiring
harness is routed properly and the clips are
fixed into the bezel to upper carrier.
Notice
Remove the sunload sensor carefully avoid
to damaging the sensor locks.
Installation
1. Press and fix the sunload sensor into the bezel
upper to carrier.
CAUTION
While installing the bezel to upper carrier,
ensure that the sunload sensor wiring
harness is routed properly and the clips are
fixed into the bezel upper to carrier.

MAN-00162
Central Bezel
4. Disconnect the five electrical connectors (A)
from the central bezel and remove the central
bezel from the instrument panel.
1 2 3 4 5 6
EXIT RDM RPT
VOL
CLK BAND POWER EQ TA
7 8 SEL 0 #
9
MENU LIST SOURCE INFO MUTE
ECON A/C REAR

A/C
OFF AUTO MODE
AWD
LOCK
PASSENGER
A
START
A
ESP
STOP OFF
Removal
1. Remove the bezel upper to carrier. For
additional information refer to Bezel Upper
to Carrier removal and installation section. Installation
2. Remove the floor console top tray. For 1. To install, reverse the removal procedure.
section. CAUTION
3. Carefully pull out the central bezel from the While installing the central bezel, ensure that
instrument panel. the wiring harness is routed properly. Always
install the central bezel from bezel upper to
carrier side.
1 2 3 4 5 6
VOL EXIT RDM RPT
POWER
CLK BAND SEL
EQ TA
7 8 0 #
9
ECON A/C REAR

A/C
OFF AUTO MODE
PASSENGER
AWD
LOCK
START ESP
A
STOP
OFF
Notice
Always pull the central bezel carefully from
the bottom side to avoid the damage of
central bezel and the central bezel locks.

MAN-00162
Audio Unit 3. Unscrew four 20mm mounting screws (A) on

the audio unit.
Removal 4. Pull the audio unit slightly in the forward

direction and disconnect the electrical
connectors (A, B) and antenna connector (C)
CAUTION of the audio unit.
Store the removed audio unit in a dust free
environment. Avoid direct sunlight,
excessive heat or humidity. C
B
Notice
Press the Power ON/OFF button on the face
plate to Turn ON/OFF the audio system. A
Notice
If the steering mounted audio controls are not
functioning, the controls on the face plate can
be used. 5. Remove the audio unit from the instrument
panel.
1. Disconnect the negative terminal of the battery. Installation
2. Remove the center bezel. For additional Notice
information refer to Central Bezel removal
and installation section. Properly route the audio unit wiring harness to
avoid the short circuit and malfunction.
2. Check the audio unit operation after

installation.

MAN-00162
Lower Glove Box 3. Slowly remove the lower glove box from the
instrument panel.
4. Disconnect the lower glove box lamp electrical
connector (A) and glove box lamp switch
electrical connectors (B) from the lower glove
box.
Removal
1. Remove the three screws (A) from the bottom
side of the glove box.
5. Remove the lower glove box from the

instrument panel.
Installation
CAUTION
While installing the lower glove box, ensure
that the glove box is fixed properly.
A 2. Check the glove box operation after

installation.
2. Remove the two lower glove box mounting
screws (A) from inside of the glove box.

MAN-00162
Upper Glove Box 4. Remove the four 20mm mounting flower

screws (A) from the inner side of the upper
glove box.
Removal
1. Remove the lower glove box. For additional 5. Remove the upper glove box from the
information refer to Lower Glove Box instrument panel.
Installation
2. Open the upper glove box using the glove box 1. To install, reverse the removal procedure.
outer lid.
3. Remove the two upper glove box mounting
screw covers (A) from inside of the glove box. CAUTION
While installing the upper glove box, ensure
that the glove box is fixed properly.
A 2. Check the glove box operation after

installation.

MAN-00162
Defrost Grill RHS Demist Grill RHS
Removal Removal
1. Unlock and remove the defrost grill (A) from 1. Unlock and remove the demist grill (A) from
the RHS top cover. the RHS top cover.
Notice Notice
Carefully remove the RHS top cover defrost Carefully remove the RHS top cover demist
grill without damaging the locks. grill without damaging the locks.
1. Press and install the defrost grill (A) into RHS 1. Press and install the demist grill (A) into RHS
top cover. top cover.

MAN-00162
Top Cover RHS 4. Remove the three steering column cover

mounting screws (A) and detach the cover (B)
from the instrument panel.
A
Removal
1. Remove the defrost grill RHS. For additional 5. Remove the two RHS top cover mounting
information refer to Defrost Grill RHS screws (A) from the instrument panel.
2. Remove the center bezel. For additional A
3. Pull out the instrument panel end cover RHS
(A) from the instrument panel.
6. Remove the eight 20mm RHS top cover flower

screws (A) and remove the RHS top cover (B)
slowly from the instrument panel.

MAN-00162
Notice Tweeter RHS

Carefully remove the RHS top cover without Removal
damaging the locks. 1. Remove the top cover RHS. For additional
information refer to Top Cover RHS removal
7. Disconnect the electrical connector and and installation section.
unscrew the two 20mm flower mounting 2. Disconnect the electrical connector and
screws (A), remove the tweeter (B) from the unscrew the two 20mm flower mounting
RHS top cover. screws (A), remove the tweeter (B) from the
RHS top cover.
B
B
A
A
Notice
Notice
Disconnect the tweeter carefully avoid to
damaging the tweeter. Disconnect the tweeter carefully avoid to
damaging the tweeter.
8. Remove the RHS top cover from the
instrument panel. Installation
Installation 1. To install, reverse the removal procedure.

MAN-00162
OB Air Vent Bezel RHS Installation

Removal
1. Remove the top cover RHS. For additional
2. Remove the fuel flap release switch. For
additional information refer to Fuel Flap
Release Switch removal and installation
section.
3. Remove the cluster intensity switch. For
additional information refer to Cluster
Intensity Switch removal and installation
section.
4. Remove the headlamp levelling switch. For
additional information refer to Head Lamp
Leveling Switch removal and installation
section.
5. Unscrew the five 20mm mounting flower
screws (A) of the OB RHS air vent bezel (B)
and remove the OB vent bezel from the
instrument panel.

MAN-00162
Defrost Grill LHS Demist Grill LHS
Removal Removal
2. Pull and remove the defrost grille (A) from the 1. Unlock and remove the demist grill (A) from
LHS top cover. the LHS top cover.
Notice Notice
Carefully remove the LHS top cover defrost Carefully remove the LHS top cover demist
grille without damaging the locks. grill without damaging the locks.
1. Press and install the defrost grill (A) into LHS 1. Press and install the demist grill (A) into LHS
top cover. top cover.

MAN-00162
Top Cover LHS 5. Remove the two LHS top cover mounting
screws (A) from the instrument panel.
Removal 6. Remove the six 20mm flower screws (A) from

1. Remove the defrost grill LHS. For additional the LHS top cover (B) and remove the LHS top
information refer to Defrost Grill LHS cover slowly from the instrument panel.
2. Remove the center bezel. For additional
and installation section. B
3. Remove the upper glove box. For additional A
information refer to Upper Glove Box
4. Pull out the instrument panel end cover LHS
(A) from the instrument panel. A
A
Notice
Carefully remove the top cover, to avoid
damaging the top cover locks.

MAN-00162
7. Remove the two 12mm passenger airbag

mounting bolts (A) from the instrument panel. Notice
Disconnect the tweeter carefully avoid to
10. Remove the LHS top cover from the

instrument panel.
Installation
8. Press the lock and disconnect the passenger

airbag electrical connector (A) from the
passenger airbag.
9. Disconnect the electrical connector and

unscrew the two 20mm flower mounting
screws (A), remove the tweeter (B) from the
LHS top cover.

MAN-00162
Tweeter LHS Passenger Air Bag

Removal
1. Remove the top cover LHS. For additional
information refer to Top Cover LHS removal
2. Disconnect the electrical connector and
unscrew the two 20mm flower mounting
screws (A), remove the tweeter (B) from the
LHS top cover.
A
Removal
information refer to Top Cover LHS removal
B
2. Unlock the passenger air bag locks (A) and
remove the passenger air bag (B) from the
LHS top cover.
Notice
Disconnect the tweeter carefully avoid to A
Installation

MAN-00162
Notice Bin Separator

Place the passenger air bag carefully in
proper position as shown below.
Removal
1. Remove the lower glove box. For additional
information refer to Lower Glove Box
2. Pull out the instrument panel end cover LHS
(A) from the instrument panel.
Installation

MAN-00162
3. Unscrew the two 20mm bin separator flower OB Air Vent Bezel LHS
mounting screws (A) and remove the bin
separator carrier (B) from LHS of the
instrument panel.
Removal
Installation information refer to Top Cover LHS removal
1. To install, reverse the removal procedure. and installation section.
2. Remove the bin separator. For additional
information refer to Bin Separator removal
3. Unscrew the five 20mm mounting flower
screws (A) of the OB LHS air vent bezel (B)
and remove the OB vent bezel from the
instrument panel.
Installation

MAN-00162
IB Vent Center Left IB Vent Center Right
Removal Removal
1. Remove the top cover LHS. For additional 1. Remove the top cover RHS. For additional
information refer to Top Cover LHS removal information refer to Top Cover RHS removal
2. Unscrew the four 20mm flower mounting 2. Unscrew the four 20mm flower mounting
screws (A) and remove the IB air vent LHS (B) screws (A) and remove the IB air vent RHS (B)
from the instrument panel. from the instrument panel.
A A
B B

MAN-00162
HVAC Control Unit Central bezel switch bank
PASSENGER START
@
STOP
1 2 3
EXIT
4 5
RDM
6
RPT
ESP
CLK BAND
7 8
VOL
POWER
SEL
9
EQ
0
TA
#
OFF
ECON A/C REAR

A/C
OFF AUTO MODE
PASSENGER
AWD
LOCK
START
A
ESP
STOP OFF
Removal Removal
1. Remove the central bezel. For additional 1. Remove the central bezel. For additional
information refer to Central Bezel removal information refer to Central Bezel removal
2. Remove the four 20mm flower screws (A) and 2. Remove the four 20mm flower screws (A) and
detach the HVAC control unit (B) from the detach the control panel (B) from the central
central bezel. bezel.
B
A
A
Notice Notice
Replace the HVAC control unit incase of Replace the control panel incase of failure.
failure. HVAC control unit is not serviceable. Control panel is not serviceable.
2. Check the HVAC control unit operation after 2. Check the control panel operation after
installation. installation.

MAN-00162
Infotainment Display Unit Audio Control Unit
1 2 3 4 5 6 1 2 3 4 5 6
EXIT RDM RPT EXIT RDM RPT
VOL VOL
CLK BAND POWER EQ TA CLK BAND POWER EQ TA
7 8 SEL 0 # 7 8 SEL 0 #
9 9
MENU LIST SOURCE INFO MENU LIST SOURCE INFO

MUTE MUTE
ECON A/C REAR ECON A/C REAR

A/C A/C
OFF AUTO MODE OFF AUTO MODE
PASSENGER PASSENGER
AWD AWD
LOCK LOCK
START START
A
ESP A
ESP
STOP OFF STOP OFF
Removal Removal
1. Remove the central bezel. For additional 1. Remove the central bezel. For additional
information refer to Central Bezel removal information refer to Central Bezel removal
2. Remove the four 20mm flower screws (A) and 2. Remove the four 20mm flower screws (A) and
detach the infotainment display unit (B) from detach the audio unit (B) from the central
the central bezel. bezel.
A B
B
A
Installation Notice
Replace the audio unit incase of failure. The
2. Check the infotainment display unit operation
audio unit is not serviceable.
after installation.
Installation
2. Check the audio unit operation after
installation.

MAN-00162
MBFM 3. Press the lock (A) and disconnect the two

electrical connectors from the MBFM.
Notice
The MBFM mounting bolts can be removed
e a s i l y, w h i l e d i s c o n n e c t i n g t h e M B F M
connectors.
A
Removal
1. Disconnect the battery negative cable. For
2. Remove the three steering column cover
from the instrument panel. 4. Unlock and disconnect the two MBFM
electrical connectors (A) from the MBFM and
remove the 10mm mounting bolt (B) from the
top side of the MBFM.
Notice
The MBFM mounting bolts can be removed
B e a s i l y, w h i l e d i s c o n n e c t i n g t h e M B F M
connectors.
A
B
Notice
Don't bent or twist the MBFM mounting
bracket when removing to avoid misalignment
when installing the MBFM.

MAN-00162
5. Remove the two 10mm mounting bolts (A) ITM ECU

middle and bottom side of the MBFM.
6. Remove the MBFM from the cross beam Removal

(CCB). 1. Remove the negative terminal of the battery.
Installation removal and installation section.
2. VIN & Variant Flashing procedure should be information refer to Lower Glove Box
done once MBFM is replaced. For additional removal and installation section.
information refer to MBFM diagnostic
manual. 3. Disconnect the ITM ECU electrical connector
(A), remove the two 10mm ITM ECU mounting
Notice nuts (B) and detach the ITM ECU (C).
• Properly route the wiring harness before

installing the MBFM.
C
• Do not over Tighten the MBFM mounting
bolts over tighten will lead to damage B
the MBFM mountings.
Installation
2. VIN & Variant Flashing procedure should be
done once ITM ECU is replaced. For
additional information refer to ITM
diagnostic manual.

MAN-00162
Fuel Flap Release Switch
Installation
1. Press and install the fuel flap release switch
Removal and connect the electrical connector.
2. Disconnect the fuel flap release switch

electrical connector (A), unlock the lock (B)
and remove the swtich (C) from the instrument
panel.

MAN-00162
Head Lamp Leveling Switch
Installation
1. Press and install the headlamp leveling switch
2. Disconnect the headlamp leveling switch

electrical connector (A), unlock the lock and
remove the swtich (B) from the instrument
panel.

MAN-00162
Cluster Intensity Switch
Installation
1. Press and install the cluster intensity switch
2. Disconnect the cluster intensity switch electrical

connector (A), unlock the lock and remove the
swtich (B) from the instrument panel.

MAN-00162
Instrument Panel
10.Remove the A-pillar lower trims. For
additional information refer to A-Pillar
Lower Trim removal and installation
section.
11. Remove the fuel flap release switch. For
additional information refer to Fuel Flap
Release Switch removal and installation
section.
12. Remove the headlamp leveling switch. For
additional information refer to Head Lamp
Leveling Switch removal and installation
section.
13. Remove the cluster intensity switch. For
additional information refer to Cluster
Removal Intensity Switch removal and installation
section.
14. Remove the IB vent center left. For additional
CAUTION information refer to IB Vent Center Left
While removing or installing the instrument removal and installation section.
panel, ensure that the instrument panel is not 15. Remove the IB vent center right. For
scratched or damaged. additional information refer to IB Vent
Center Right removal and installation
1. Remove the floor console. For additional section.
information refer to Floor Console removal 16. Press the lock and disconnect the foot well
and installation section. lamp electrical connector (A) located below the
2. Remove the steering column. For additional lower glow box.
information refer to Steering Column
3. Remove the instrument cluster. For additional
information refer to Instrument Cluster A
4. Remove the central bezel. For additional
5. Remove the audio unit. For additional
information refer to Audio Unit removal and
6. Remove the OB vent bezel LHS. For
additional information refer to OB Air Vent
Bezel LHS removal and installation section.
7. Remove the OB vent bezel RHS. For
additional information refer to OB Air Vent
Bezel RHS removal and installation section.
8. Remove the bonnet opening cable. For
additional information refer to Bonnet Cable
9. Remove the A-pillar upper trims. For
additional information refer to A-Pillar
Upper Trim removal and installation section.

MAN-00162
17. Remove the two 20mm Diagnostic connector 20. Remove the seventeen 10mm instrument
flower mounting screws (A) and disconnect the panel mounting bolts and remove the
diagnostic connector (B) from the instrument instrument panel from the cross beam (CCB).
panel located at the driver side.
21. Unscrew the two 20mm center manifold duct

18. Press the lock and disconnect the foot well flower mounting screws (A) and detach the
lamp electrical connector (A) located near MDS center manifold (B) from the instrument panel.
connector.
A
A
22. Unscrew the three 20mm flower mounting

19. Detach the sunload sensor electrical wiring screws (A) of the RHS side air duct and detach
harness from the instrument panel. the side air duct (B) from the instrument panel.

MAN-00162
23. Unscrew the two 20mm flower mounting 26. Unscrew the five 20mm flower mounting
screws (A) of the LHS side air duct and detach screws (A) of the defrost duct, unlock the
the side air duct (B) from the instrument. locator (B) and remove the defrost duct (C)
A
B
C
A
24.Unscrew the two 20mm flower mounting
screws (A) of the demist ducts both LHS, RHS
and remove the side ducts (B) from the
instrument panel. C
Notice
• Carefully remove the wiring harness from
25. Unscrew the four 20mm flower mounting the instrument panel during removing
screws of the OB air vent (A) both LHS, RHS the instrument panel.
and remove the OB air vents (B) from the • Carefully remove the mounting bolts or
instrument panel. else the windshield may be damaged due
to mishandling of the socket and wrench
set.
A

MAN-00162
Installation Cross Car Beam (CCB)

Notice
• Properly route the wiring harness into
the instrument panel.
• Tighten the instrument panel mounting
bolts as per torque specification.
Notice
Fix all the parts properly and do not over
tighten the parts screws, over tighten will
lead to damage the threads.
Removal
1. Remove the instrument panel assembly. For
additional information refer to Instrument
Panel removal and installation section.
Notice
While attempting to remove the cross beam,
pull out the wiring harness and disconnect
the electrical connectors from the cross
beam.
CAUTION
• Do not pull out the wiring harness, use a
proper cutter/tool to remove the lock ties.
• Carefully remove and install the cross

beam, failure to follow this instruction may
lead to personal injury.
2. Remove the MBFM. For additional

information refer to MBFM removal and

MAN-00162
3. Unlock the lock and disconnect the two SRS 6. Unlock and disconnect the passenger side of
module electrical connectors (A) from the SRS the CCB wiring harness electrical connectors
module which is located below the RHS HVAC (A) and 10mm nut earth connection (B).
unit.
A B
7. Disconnect the antenna electrical connector (A)

4. Remove the 10mm SRS module earth unlock and disconnect the electrical connector
mounting nut (A) and disconnect the earth (B) and front LHS door electrical connector (C).
connection which is located below the LHS
HVAC unit.
C
B
A
A
8. Disconnect the two electrical connectors (A)

from RHS of the evaporator.
5. Unlock and disconnect the seven electrical
connectors (A) from driver side of the cross
beam (CCB).

MAN-00162
9. Remove the two 12mm cross beam mounting 11.Remove the two 12mm mounting bolts (A)
bolts (A) from the HVAC unit. from the bottom of the LHS of the cross beam.
10.Remove the two 12mm cross beam mounting 12.Remove the two 12mm mounting bolts (A)
nuts (A) from LHS,RHS of the HVAC unit. from the bottom of the RHS of the cross beam.
A
A
13.Remove the four 12mm mounting bolts (A)

from the RHS of the cross beam mounted in A-
pillar channel.
A
A

MAN-00162
14.Remove the four 12mm mounting bolts (A) 17. Unclip the wiring harness locks, remove the
from the LHS of the cross beam mounted in A- 10mm earth mounting and disconnect the
pillar channel. cross beam (CCB) wiring harness along with
fuse box and wiring harness from the CCB.
15.Remove the cross beam (CCB) along with fuse

box and wiring harness from the vehicle.
Notice
16.Remove the three 12mm fuse box mounting
bolts and detach the fuse box from the CCB. CCB wiring harness comes along with the
fuse box.
A Inspection
1. Check the cross beam (CCB) for any bend or
damage.
740-12-1C-1SCB
COIL 85
0/E/N
0932
30
15
10
25
15
5
2. Check for any compression scars or fractures.

25
25
25
515
15
15
5
Installation
20
15
15
15
20
30
25
15
20
5
0938
75
15
75
5
15
A CAUTION
740-12-1C-1SCB
COIL 85
0/E/N
0932
30
25
20
Do not overtighten the CCB mounting bolts

740-12-1C-1SCB
740-12-1C-1SCB
COIL 85
0/E/N
0932
COIL 85
0/E/N
0932
when installing. This may lead to the damage

of the threads and mounting bolts.
CAUTION
While installing the CCB ensure that the
wiring harness is routed properly.
Notice
Install the cross beam (CCB) into the
mounting holes provided in the vehicle.

MAN-00162
CCB wiring harness with fuse 3. Remove the three 12mm fuse box mounting
bolts (A) and detach the fuse box from the
box CCB.
740-12-1C-1SCB
COIL 85
0/E/N
0932
30
15
10
25
15
525
25
25
515
15
15
5
5
20
15
15
15
20
30
25
15
20
5
5
0938
75
15
75
5
15
5
A
740-12-1C-1SCB
COIL 85
0/E/N
0932
30
25
20
740-12-1C-1SCB
740-12-1C-1SCB
COIL 85
0/E/N
0932
COIL 85
0/E/N
0932
Removal Notice
Notice • Remove the fuse box along with the wir-
ing harness.
Fuse box is not replaceable separately. Fuse
• Do not cut the wiring harness cable ties
box comes along with CCB wiring harness.
use the suitable tool to disconnect the
wiring harness.
1. Remove the cross beam (CCB). For
additional information refer to Cross Car
Beam (CCB) removal and installation Installation
section. 1. To install, reverse the removal procedure.
2. Unclip the wiring harness locks and disconnect
the cross beam (CCB) wiring harness along
Notice
with fuse box and wiring harness from the • Properly route the wiring harness before
CCB. installing the cross beam.
• Fix the fuse box properly.

MAN-00162
Disassembly and Assembly

Floor Console Top Tray
Disassembly
C
VD
12
12
V
3. Unscrew the three 20mm USB unit flower

mounting screws (A) and remove the USB unit
(B) from the power outlet box.
1. Remove the floor console top tray. For
section.
2. Unscrew the four 20mm power outlet box
flower mounting screws (A) and remove the
power outlet box (B) from the floor console top
tray. B
A
B B

MAN-00162
4. Unscrew the six 20mm cup holder flower

mounting screws (A) and detach the cup
holder (B) from the floor console top tray. B
B
Assembly
1. To install, reverse the disassembly procedure.
Notice
B
Do not over tighten the mounting screws,
over tighten will lead to damage the threads
and parts.
5. Unscrew the four 20mm gear lever cover

flower mounting screws (A) and remove the
gear lever cover (B) from the floor console top
tray.

MAN-00162

• Check for any visible damage in the instrument
panel and trims caused by an accident or fire.
• Check for any damaged mounting locations or
fasteners.
• Check for any dents or cracks on the dash
board.
• Check for any damaged reinforcements or
braces.
Notice
While inspecting the reinforcement and panel
braces, remove the instrument panel.
After installation or repair, inspect the

instrument panel for these conditions:
• Proper positioning.
• Proper finishing in terms of appearance and
texturing.
• Proper installation of trims and fasteners.
• Proper routing of electrical wiring.
• Proper operation of electrical circuits.
• Proper operation of all instruments, gauges
and warning lamps.
• Proper illumination and control of
instrumentation.
• Proper operation of all switches and other
electrical component controls.

MAN-00162
Bolt Torque in
Specification Nm
SCREW HCC P
Floor console To BIW 6 4.0±0.5
M6X1X20X4.6,A
BOLT HEX FL
M8X1.25X30X8.8 6
XZN
IP/CCB ASSY IP/CCB assy to BIW 30.0~35.0
BOLT HEX FL
M8X1.25X55X8.8 4
XZN
SCREW PHCR
Driver Side Panel M6X1X16X8.8X8 Driver side panel to carrier 3
K
SCREW PHCR 4.0±1.0

Driver side panel Driver side panel reinforcement to car-
M6X1X16X8.8X8 4
reinforcement rier
K
SCREW PHCR
Shroud assembly to combi and str col-
Shroud assembly M6X1X16X8.8X8 5
umn
K
CCB Wiring har- M6 Eyelet ring ter- Ground(Near Interconenction with

1 6±0.5
ness minal Floor LH)
SELF TAPPING
Audio Unit SCREWS M4 X 8 3±0.5
1.46 X 14
Centre Console SELF TAPPING

Control Switch- SCREWS M4 X 5 3±0.5
bank 1.46 X 14
SCREW
FLANGED SELF
Speakers TAPPING 20 4±0.5
4.8X1.6X18XC
ZN
SCREW HEX FL
MBFM M6X1X12X8.8XG 3 4±0.5
R
NUT HEX FL
ITM ECU ECU to dash panel 2 8.0~10.0
M6X1X6X8

MAN-00162
Repair Manual HVAC Nov 2011/ Rev 2
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)

CONTENTS
Description and Operation-HVAC System .................................... 1

Air Circulation ..................................................................................... 1
Air Conditioning .................................................................................. 1
Heating ............................................................................................... 2
HVAC Controls ................................................................................... 3

HVAC Layout ..................................................................................... 8
Front HVAC ....................................................................................... 9
Floor A/C Duct .................................................................................. 10
Rear A/C Duct ................................................................................. 11
Service Tips and Precautions .......................................................12

Refrigerant Oil Replacement ............................................................ 14
Refrigerant Recovery Recycling and Recharging ......................15

Discharging the system .................................................................... 15
Evacuation of the system ................................................................. 16
Purging – if required ......................................................................... 16
Preliminary Charging and High Pressure Leak Test ........................ 17
Charging the System........................................................................ 17
Contaminated Refrigerant Handling ................................................. 18
Do’s & Dont’s ................................................................................... 19
Incar Repairs ..................................................................................20
Fresh/Recirculation Actuator ....................................................20

Removal ........................................................................................... 20
Inspection ......................................................................................... 20
Installation ........................................................................................ 20
Temperature (Hot/Cool) Actuator .............................................21

Removal ........................................................................................... 21
Inspection ......................................................................................... 21
Installation ........................................................................................ 21
Thermistor / Thermosensor .......................................................22

Removal ........................................................................................... 22
Installation ........................................................................................ 23

MAN-00162
Particle Filter .............................................................................. 24

Removal ........................................................................................... 24
Inspection ......................................................................................... 25
Installation ........................................................................................ 25
Mode Actuator ............................................................................ 25

Removal ........................................................................................... 26
Inspection ......................................................................................... 26
Installation ........................................................................................ 26
Blower Motor .............................................................................. 26

Removal ........................................................................................... 26
Inspection......................................................................................... 27
Installation ........................................................................................ 27
Blower Resistor .......................................................................... 28

Removal ........................................................................................... 28
Inspection ......................................................................................... 28
Installation ........................................................................................ 28
HVAC Water Drain Hose ............................................................ 29

Removal ........................................................................................... 29
Inspection ......................................................................................... 29
Installation ........................................................................................ 29
Expansion Valve ........................................................................ 30

Removal ........................................................................................... 30
Installation ........................................................................................ 31
A/C Pressure Switch.................................................................. 31

Removal ........................................................................................... 31
Installation ........................................................................................ 31
Front HVAC Unit......................................................................... 32

Removal ........................................................................................... 32
Installation ........................................................................................ 33
Floor Foot Duct LH .................................................................... 33

Removal ........................................................................................... 33
Inspection......................................................................................... 33
Installation ........................................................................................ 34

MAN-00162
Floor Foot Duct RH ....................................................................34

Removal ........................................................................................... 34
Inspection ......................................................................................... 34
Installation ........................................................................................ 35
B Pillar Floor Duct LH ................................................................35

Removal ........................................................................................... 35
Inspection ......................................................................................... 35
Installation ........................................................................................ 36
B Pillar Floor Duct RH ................................................................36

Removal ........................................................................................... 36
Inspection ......................................................................................... 36
Installation ........................................................................................ 37
B-Pillar Floor Duct Middle .........................................................37

Removal ........................................................................................... 37
Inspection ......................................................................................... 37
Installation ........................................................................................ 37
B-Pillar Duct IP HVAC End ........................................................38

Removal ........................................................................................... 38
Inspection ......................................................................................... 38
Installation ........................................................................................ 38
Rear RHS Quarter Trims (Upper and Lower) ...........................39

Removal ........................................................................................... 39
Installation ........................................................................................ 41
Rear LHS Quarter Trims (Upper and Lower) ............................42

Removal ........................................................................................... 42
Installation ........................................................................................ 44
Rear Blower Motor ..................................................................... 45

Removal ........................................................................................... 45
Inspection......................................................................................... 45
Installation ........................................................................................ 45

MAN-00162
Rear Blower Resistor................................................................. 46

Removal ........................................................................................... 46
Inspection ......................................................................................... 46
Installation ........................................................................................ 46
Rear HVAC Water Drain Hose ................................................... 47

Removal ........................................................................................... 47
Inspection ......................................................................................... 47
Installation ........................................................................................ 47
Rear HVAC Unit .......................................................................... 47

Removal ........................................................................................... 47
Installation ........................................................................................ 49
Rear Duct LH Top....................................................................... 49

Removal ........................................................................................... 49
Installation ........................................................................................ 49
Rear Duct LH Middle.................................................................. 50

Removal ........................................................................................... 50
Installation ........................................................................................ 50
Rear Duct LH Bottom ................................................................. 50

Removal ........................................................................................... 50
Installation ........................................................................................ 50
Rear Duct Middle ........................................................................ 51

Removal ........................................................................................... 51
Installation ........................................................................................ 51
Rear Duct HVAC End ................................................................. 52

Removal ........................................................................................... 52
Installation ........................................................................................ 52
Rear Duct RH Top ...................................................................... 52

Removal ........................................................................................... 52
Installation ........................................................................................ 52
Compressor................................................................................ 53
Removal ........................................................................................... 53
Installation ........................................................................................ 54

MAN-00162
A/C Condenser ........................................................................... 54

Removal ........................................................................................... 54
Installation ........................................................................................ 56
Condenser Cartridge (desiccant) ..............................................57

Removal ........................................................................................... 57
Installation ........................................................................................ 58
Front A/C Hoses ........................................................................58

Removal ........................................................................................... 58
Installation ........................................................................................ 62
A/C High Pressure Hose (compressor to condensor) ............62

Removal ........................................................................................... 62
Installation ........................................................................................ 63
Rear A/C Hoses (evaporator to underbody) ............................64

Removal ........................................................................................... 64
Installation ........................................................................................ 65
Rear A/C Hoses (under body to front A/C joint) ...................... 66

Removal ........................................................................................... 66
Installation ........................................................................................ 67
Disassembly and Assembly.......................................................... 68
Front HVAC Unit .........................................................................68

Disassembly ..................................................................................... 68
Assembly .......................................................................................... 71
Rear HVAC Unit ..........................................................................72

Disassembly..................................................................................... 72
Assembly .......................................................................................... 73

MAN-00162
Heating, Ventilation and Air Conditioning (HVAC)

Description and Operation-HVAC System
The Heater, Ventilation and Air conditioning Depending upon fresh or recirculation mode
combines air conditioning, heating and ventilating selected at HVAC control panel, a flap located on
functions. blower housing is operated air is sucked by the
blower either from outside or inside the cabin. At
The system comprises of:
fresh air inlet there is a wire mesh. Before air is
1. Blower & Air Inlet system sucked inside the system, it is filtered first by HVAC
2. Heater core, and Air distribution assembly filter.
3. Air Conditioning system Filtered air is then forced towards the main
distribution hosing where multiple flaps are
The HVAC system of XUV500 has front as well as
provided. By selecting a particular distribution mode
rear AC unit.
at HVAC control panel, different flaps get operated
Foot ducts are provided for better comfort for driver in pre-defined way thereby air flow is distributed
and co-driver. All the flaps are controlled electrically among different vents.
by actuators. HVAC system also helps in defrosting
Air flow volume or speed is controlled via a blower
and defogging the windshield. Fresh air and
resistor and can be adjusted by adjusting blower
recirculation mode can also be selected.
speed knob on the HVAC control panel. Flow
For second and third row passengers ducts are direction of air flow coming out of vents can be
provided on B & C pillar respectively. controlled by manually adjusting the vents.
The front HVAC unit caters to the first and second Depending upon selected temperature knob
row occupants and also aids in front windshield position on HVAC control panel, amount of air
defrost function. passing through evaporator and heater is
controlled. Finally both cold and hot air streams are
The blower control is provided in near third row
mixed together and are distributed further.
seats in order to control the blower fan speed for
third row passengers. Air Conditioning
Full Automatic Temperature Control (FATC) is The Air conditioning function is carried out using
provided for automatic control of cabin air closed circuit configuration based on Vapor
temperature. FATC also controls the circulation and Compression Refrigeration Cycle. The system uses
humidity of the air inside the vehicle. With FATC, R134a as refrigerant and suitable lubricating oil.
the driver selects the temperature and the FATC Refrigerant gets circulated through a closed loop as
maintains the user selected temperature, regardless long as air conditioner is in operation.
of outside temperature changes. The FATC control
The primary components are:
module controls air conditioning, ventilating,
heating, and defrosting systems. The FATC • Suction hose
automatically adjust doors, blower speeds, and • Compressor, compressor clutch
compressor cycling to maintain a given
• Discharge hose
temperature.
• Condenser, receiver/drier, condenser fan
Air Circulation • Liquid pipe
The primary components are:
• Trinary pressure switch
• Pollen filter
• Thermostatic expansion valve
• Front and rear blower motor assemblies
• Evaporator
• Front and rear blower resistors
• Evaporator inlet and outlet pipes
• Air distribution housings
• Thermosensor
• Flaps
• Refrigerant and refrigerant oil
• Air ducts and vents

MAN-00162
The compressor used in system is of swash plate superheated state. The cabin air while passing
type, fixed displacement Compressor. In this through the evaporator core, gets cooler and gets
compressor a fixed angle swash plate, attached to dehumidified. The condensate water gets drained
the drive shaft, rotates to reciprocate double acting off to atmosphere through drain hose, located
pistons. The axially reciprocating pistons suck below the evaporator housing.
refrigerant from suction side and deliver
Finally this low-pressure and low-temperature
compressed refrigerant to discharge side.
refrigerant vapor gets sucked by compressor and
The compressor pulley is driven by the engine belt. the cycle repeats itself.
If electromagnetic clutch is not engaged, drive shaft
A trinary pressure switch is located on the liquid
does not rotate even as pulley keeps on rotating
pipe connecting condenser to thermostatic
with engine through drive belt. Once electrically
expansion valve. To prevent system failure,
energized, electromagnetic clutch engages and the
depending upon actual refrigerant pressure, the
rotary motion of the compressor pulley is
trinary pressure switch makes compressor clutch
transferred to drive shaft which in turn start
get engaged or disengaged. Pressure switch shuts-
reciprocating the pistons.
off compressor when refrigerant pressure either
The compressor is lubricated by refrigerant oil exceed a specified limit or if it falls below specified
which circulates throughout the refrigerant system limit. It allows/restarts the compressor if refrigerant
along with the refrigerant. pressure is within normal operating range.
Additionally the pressure switch starts condenser
When in operation, compressor draws in low-
fan once refrigerant pressure exceed a specified
pressure and low-temperature refrigerant vapor
limit and shuts it off when refrigerant pressure falls
from the evaporator and compresses it to a high-
below a specified limit.
pressure and high-temperature refrigerant vapor,
which is then pumped to the condenser. A thermosensor is provided, which depending upon
the air temperature just besides the coolest portion
The condenser is basically a heat exchanger where
of evaporator core, makes compressor clutch get
atmospheric air flowing across it's core is used to
engaged or disengaged, in order to prevent ice
cool the refrigerant flowing inside tubes. Inside
formation near evaporator. If cabin air temp just
condenser, high-pressure and high-temperature
beside the evaporator falls below certain limit,
refrigerant vapor gets converted into high-pressure
thermosensor shuts the compressor off and restarts
and moderate-temperature liquid in sub cooled
it again once air temperature rises back above
state. Condenser also has an integrated receiver/
certain limit.
drier which removes impurities and moisture from
circulating refrigeration by using strainer and For recovering/recharging refrigerant and refrigerant
desiccant inside it. Then the refrigerant flow toward oil, a high pressure side port located on liquid pipe
thermostatic expansion valve through liquid pipe. and a low pressure side charging port located on
suction hose has been provided.
The system uses box or block type of thermostatic
expansion valve. While passing through metering
orifice of the thermostatic expansion valve, high
Heating
pressure and moderate-temperature refrigerant The primary comoponents are:
liquid get throttled to low-pressure and low- • Cabin Heater
temperature liquid. The refrigerant then flows to the
• Heater inlet and outlet pipes
evaporator. Based upon pressure and temperature
of refrigerant vapor coming out of evaporator, Cabin Heater is essentially a heat exchanger where
thermostatic expansion valve regulates the amount hot engine coolant is passed through the heater
of liquid refrigerant flowing towards evaporator tubes which heats-up the cabin air flowing across
the heater core. Engine coolant keeps flowing
Evaporator is also a heat exchanger where
through the heater as long as engine and hence
refrigerant flowing inside tubes is used to cool the
water pump is in operation.
cabin air flowing across the evaporator core. While
flowing through condenser low-pressure and low-
temperature liquid refrigerant gets converted into
low-pressure and low-temperature vapor in

MAN-00162
HVAC Controls
1. Temperature control dial

2. Economic mode
3. A/C On switch 2 3 4 5
4. Recirculation mode selector ECONECON A/C A/C REAR REAR 6
A/C A/C
5. Rear air condition main switch
6. Fan speed control dial
8 9 10 11 - - +
1 7 OFF OFF
AUTO AUTO MODEMODE 12
7. Rear window defroster switch
8. ECON OFF mode selector
9. AUTO mode selector
10. Fresh air mode selector
11. Air distribution mode selector
12. Front windshield defroster selector
Blower Fan Speed Control Dial Temperature Control Dial
Cool Hot
- +
You can select blower fan speed from low to high

position. To increase the blower fan speed, turn the This control is used to set the degree of cooling or
dial in clockwise direction.To decrease the blower fan heating desired.
speed, turn the dial in anti-clockwise direction.
Cool: Turning the dial in anti-clockwise (Blue)
Blower Fan OFF Switch direction.
Hot: Turning the dial in clockwise (Red) direction.
Turn the dial to set the desired temperature. The
OFF temperature will increase to the maximum 32°C
(90°F) by turning the dial clockwise. The temperature
will decrease to the minimum 17°C (62°F) by turning
Press this switch to turn OFF the blower fan which the dial anti-clockwise.
will subsequently stop the operation of the heating
and cooling system.
Air Conditioning Switch
A/C
Press this switch to turn ON or OFF the AC. The

switch will illuminate when the blower fan is turned
ON. Push the switch once again to turn OFF the AC.

MAN-00162
Economy (ECON) Switch Manual Operation

All the functions of air conditioning and heating
system can be manually controlled by pressing
ECON
individual push switches except AUTO switch.
By selecting fresh air / recirculation and then
Press ECON switch to turn economy mode on.
choosing AUTO mode will set all the functions
During ECON AC operation the system automatically
automatically.
cuts OFF at a higher temperature than normal AC.
The operation can be used during mild weather
Air Distribution Mode Switch
conditions for better fuel efficiency. Comfort level
may be compromised during this operation. Repress
the ECON switch again to turn economy mode OFF.
MODE
Fresh Air Mode Switch
To adjust air distribution, press the MODE switch.

Each pressing of mode switch will change the flow
pattern accordingly.
Air distribution mode switch allows you to select the
With the fresh air mode selected, air enters the below air flow pattern.
vehicle from outside and is heated or cooled
according to the other functions selected. 1. Face mode
Air will be discharged through face and the second
Air Recirculation Mode Switch row seat vents. Corresponding information will
appear on the infotainment display.
This is used to select recirculation of inside air. With 02:01 am RADIO

the recirculation mode selected, air from within the 5410KHz
passenger compartment is drawn through the AM2-CH1
heating system and heated or cooled according to 0
17. 0 C
the other functions selected. Set temp
AUTO Mode Switch

40 0 C AC on Econ
Outside
AUTO
The air conditioning system is controlled

automatically in the AUTO mode. Press the AUTO
switch to turn ON the AUTO mode. The modes,
blower fan speeds, air intake (fresh/recirculation) and
air conditioning will be controlled automatically based
on temperature setting.

MAN-00162
2. Face and Floor mode 4. Floor Defrost mode

Air will be discharged through face, floor and the Air will be discharged through the windshield
second row seat vents. Corresponding information defroster vents, floor vents and side defroster
will appear on the infotainment display. vents.Corresponding information will appear on the
infotainment display.
02:01 am RADIO
8010KH 02:01 am MENU
AN1-CH3
0
17. 0 C
Set temp
38 0 C AC on Econ
Outside
AC on Econ
3. Floor mode
Air will be discharged through floor vents. 5. Defrost mode
Corresponding information will appear on the Air will be discharged through the windshield
infotainment display. defroster vents, side defroster vents and side vents.
Corresponding information will appear on the
infotainment display. During this, the fresh mode will
be activated automatically to improve windshield
defrosting.
02:01 am RADIO
02:01 am MENU
AC on Econ
AC on Econ

MAN-00162
Front Windshield Defroster Switch Sunload Sensor
Sunload Sensor
ECON A/C REAR
A/C
- +
AUTO MODE
Front windscreen defroster is used to remove mist The SLD (Sun Load Sensor) measures the intensity
and ice from the front windshield and side windows of the light falling on it and adjusts the cooling &
quickly. Press the switch to turn ON front defroster. Blower speed to compensate for the sun’s heat felt
The switch will illuminate once front defroster is by the occupants. Never place anything over the
turned ON. AC is turned ON and air is discharged sunload sensor which is located on the instrument
through the windshield defroster vents, side defroster panel to ensure better control of the heating and
vents and side vents. If the defrost mode is selected, cooling system.
the fresh mode will be activated to improve
windshield defrosting. Rear Air Conditioning Switch
Rear Windshield Defroster Switch

REAR
A/C
ECON A/C REAR

A/C Press rear air conditioning switch to turn ON the rear
- + air conditioning. Switch will illuminate when rear
AUTO MODE
blower fan is switched ON.
Notice
The front air conditioning controls override
the rear air conditioning controls i.e. when
the front air conditioning switch is turned
OFF, the rear air conditioning will not turn
ON.
To remove frost, fog and thin ice from the interior and
exterior of the rear windshield, press rear windshield
defroster switch.
The switch will illuminate once rear defroster is
turned ON. The rear windshield defroster
automatically turns OFF depending upon ambient
temperature.

MAN-00162
Rear Blower Fan Speed Control Dial
1 2
3
0
Rear blower fan speed control dial is located near

RH third row seat.
This is used to select the blower fan speed. The
blower fan speed, and the volume of air delivered
from the system, may be controlled manually by
setting the blower fan speed control between the 1
and 3 position. 1 is the lowest blower fan speed and
3 is the highest blower fan speed. Setting the fan
speed control dial to the 0 position turns OFF the
blower fan.

MAN-00162

HVAC Layout
H
G
C
A
E
F
D
A. Rear A/C vent at quarter trim LH F. Foot duct for second row RH
B. Rear A/C vent at quarter trim RH G. Front HVAC
C. B-Pillar A/C vent LH H. Condenser
D. B-Pillar A/C vent RH I. Muffler in A/C line
E. Foot duct for second row LH J. Rear HVAC

MAN-00162
Front HVAC
I A
B
H
C
E D
F
A. Nozzle for defroster ducts F. Heater core
B. Nozzle for IP panel ducts G. Particle filter
C. Opening for B-Pillar vents H. Actuator
D. Second foot duct opening I. Evaporator core
E. Front row foot duct opening

MAN-00162
Floor A/C Duct
C
B
A
D
I H
A. B-Pillar duct IP HVAC end F. Floor grommet

B. Floor foot duct LH G. B-Pillar floor duct RH
C. HVAC assembly H. B-Pillar floor duct middle
D. Floor foot duct RH I. B-Pillar floor duct LH
E. Screw

MAN-00162
Rear A/C Duct
B
I
C H
G
E
F
D
A. Rear duct LH top F. Rear HVAC unit

B. Rear duct LH middle G. Rear duct RH top
C. Rear duct LH bottom H. Grommet plastic
D. Rear duct middle I. Screw
E. Rear duct HVAC end

MAN-00162

Precautions to be taken while servicing air WARNING
conditioning system.
When R134a is mixed with other refrigerants, it
• Air Conditioning System in this vehicle uses
may become flammable. Never use or mix any
R134a (HFC-134a) as refrigerant and PAG
other refrigerant.
(Polyalkylene Glycol) Oil' as refrigerant oil.
• Never use or mix other refrigerants (e.g. R12)
and other oil.
• Environment friendly refrigerant R134a is not WARNING
an ozone depleting substance but its release
Always disconnect the negative cable from
would add to the green house warming effect.
battery if HVAC system repair require removal
• Refrigerant R134a is transparent and colorless of Supplemental Restraint System (SRS) com-
in both the gaseous and liquid state. At
ponents. Refer to the relevant section of man-
ambient temperature and pressure it will be in
vapour state. The vapour is heavier than air ual for additional care which must to be taken
and is non-flammable, non-explosive, non- while handling SRS components.
poisonous and non-corrosive (except when in
contact with moisture).
CAUTION
WARNING It must be noted that R134a must always be
extracted from the system and collected
Refrigerant is stored under high pressure
using the recommended servicing units.
inside the system, hence under certain circum-
stances, refrigerant lines and other system Care should be taken when discharging the
components may be extremely hot or cold. air conditioning system to ensure the
refrigerant is not released into atmosphere
but captured for recycling..
WARNING
Exposure of refrigerant in liquid or vapor form
to skin or eyes may cause irritation and frost-
bite. Avoid exposure to skin, eyes and cloth-
ing.
WARNING
R134a vapors are heavier than air and can
cause suffocation, dizziness and loss of con-
centration. Always work in well ventilated
space.
WARNING
R134a when mixed with compressed air or
oxygen, forms flammable mixture. Never use
compressed air for pressure testing or leak
testing of system/components.

MAN-00162
The following precautions in handling R134a 11.Do not drop, dent or abuse refrigerant gas
should be observed at all times: cylinders.
1. R134a is a hazardous gas and when not 12.Always chain or strap cylinders in place to
handled properly can cause serious injury. prevent them from tripping over.
Suitable protective clothing must be worn when 13.Always keep refrigerant cylinders capped.
carrying out servicing operations on the air
conditioning system. 14.Never heat a cylinder with open flame or place
it in direct contact with an electric heater.
Notice 15.Always double check that you have the correct
refrigerant container. The refrigerant cylinders
When handling refrigerant, always wear pro- are color coded to avoid confusion. (R 134a is
tective goggles and gloves, made of suitable generally BLUE)
material like fluoroelastomer. Leather or plas-
tic gloves are unsuitable. 16.Use proper size spanners, wrenches to avoid
damages to valve & threads.
2. R134a is odorless and colorless. Do not 17.Make sure that tools, measuring equipment
handle or discharge in an enclosed area, or in and replacement parts are clean and dry.
any area where the vapor or liquid can come in 18.Never use oxygen for pressure testing a
contact with naked flame or hot metal. R134a system. It may explode in presence of oil.
is non- flammable, but can form a highly toxic Instead use nitrogen from a cylinder equipped
gas so always work in a well ventilated area. with proper pressure regulator.
3. Do not smoke or weld in areas where R134a is 19.When filling a refrigerant cylinder, never
in use. Inhalation of concentrations of the completely fill it. Always leave space for
vapor can cause dizziness, disorientation, expansion. If the cylinder was completely filled
narcosis, nausea or vomiting. and the temperatures increases, the hydraulic
4. Do not allow fluids other than R134a or pressure with its tremendous force would result
compressor lubricant to enter the air to cylinder bursting accidents.
conditioning system this may lead to One of the most important requirements when filling
spontaneous combustion. the air conditioning system is to use clean
5. Avoid contact with liquid refrigerant R134a. At refrigerant. Any foreign substances – including air,
atmospheric pressure R134a evaporates at moisture and dirt - in the air conditioning circuit
approximately -26ºC and causes frost bite. In influence temperature and pressure of the system.
the event of skin or eye contact with liquid This will have an adverse effect on the operation of
refrigerant, wash the affected areas the system. In addition, these foreign substances
immediately with plenty of water. Seek medical can cause defects such as failure of the
treatment immediately. compressor due to excessive wear.
6. The refrigerant used in an air conditioning
system must be reclaimed in accordance with
the recommendations given along with the
Refrigerant Recovery Recycling Recharging
Station.
7. Do not weld or steam clean on or near any air
conditioning components when pressurized.
This may cause a dangerous pressure build up
in the system.
8. When purging a system, discharge the
refrigerant slowly.
9. Refrigerant cylinders should always be
protected from the radiant heat of the sun and
kept in a cool place.
10.Never discharge a system or do brazing /
welding/ operation when the main engine is
ON.

MAN-00162
First aid measures • Do not spill the refrigerant and oil on the
• In case refrigerant is inhaled, move to fresh air. vehicle. It may damage the paint. If it gets on
Get immediate medical attention. Artificial the paint, wash it OFF immediately.
respiration and/or oxygen may be necessary. • Care must be taken while handling the
• If refrigerant comes in contact with skin, take refrigeration system components. Hoses and
off all contaminated clothing immediately. Flush lines should not be twisted or stressed. Ensure
skin with lukewarm water until all chemical is that hoses are positioned in their correct run
removed. Do not use hot water. If there is before fully tightening the joints. Torque
evidence of frostbite, do not rub and never use wrenches must be used while tightening
hot water. If water is not available, cover with a refrigerant connections to specified value.
clean, soft cloth or similar covering. Get • Do not operate compressor without enough
immediate medical attention. refrigerant and oil in the system, otherwise
• If refrigerant vapors come in contact of eyes, compressor may burnout.
hold eyelids apart and flush eyes with plenty of • When the engine is running, never discharge
water for at least 15 minutes. If there is the refrigerant system, which may damage
evidence of frostbite, water should be both compressor and refrigerant handling
lukewarm, not hot. Get immediate medical equipment.
attention. • When discharging the system, do not let
Precautions to be taken while servicing HVAC refrigerant escape too fast. It may draw lot of
system the refrigerant oil out of the system.
• Only trained and certified person should Refrigerant Oil Replacement
service the HVAC system, if repair involves
refrigerant handling. The Polyalkylene glycol (PAG) oil is used as
refrigerant oil. The PAG oil in the compressor
• Ensure that the refrigerant handling equipment circulates through the A/C system with the
and accessories are compatible with R134a refrigerant. The PAG oil is added to the compressor
(HFC-134a). when replacing any component or after large
• While recovering, recycling or recharging refrigerant leakage has occurred.
refrigerant always follow the instructions of
refrigerant handling equipment manufacturer.
• In case leakage is detected from the HVAC CAUTION
system, repair should be done only after Lack of oil in the compressor leads to
recovering all the refrigerant from the system. compressor seizing. Excessive oil in the
• For purging the system only Nitrogen should compressor may cause inadequate cooling.
be used. Compressed air should never be
used, which will produce flammable mixture.
• Keep moisture and dirt out of the HVAC
system and refrigerant handling equipments/
CAUTION
fittings. When disconnecting any system Since PAG oil is highly hygroscopic
components, plug or cap the fittings (moisture absorbent) in nature, open the PAG
immediately. Do not remove the caps or plugs oil containers only when they are ready to
until just before you reassemble the use and cover the containers with the cap
component. Absorption of moisture and dirt will immediately after usage.
adversely affect system working and cabin
cooling performance.
• Immediately after using the oil, reinstall the cap
on the container, and seal it to avoid moisture WARNING
absorption. Avoid PAG oil contacting the bare skin or
• Before connecting any hose or line, always vehicle body. It is toxic and corrosive in
apply few drops of refrigerant oil to the O-ring. nature.
However prevent oil from coming in contact
with threaded joints, else joint may get loosen
afterwards.

MAN-00162
Refrigerant Recovery Recycling

CAUTION and Recharging
Mixing different types or different The charging procedure comprises of the following
manufacturer‘s oil may form a glue like distinct steps
substance which causes failure of • Discharging the system
lubrication and seizure of the compressor.
• Evacuation of the system and checking for low
vacuum leak
Only pale yellow color PAG oil must be used when
adding or changing the PAG oil. This PAG oil is not • Purging – if required
compatible with any other PAG oil. It is not • Preliminary charging & High Pressure leak test
necessary to regularly check the oil level in the
• Charging the system.
system. It should be remembered that the PAG oil
gets circulated within the whole system. Therefore, Discharging the system
whenever the AC system component is replaced a
certain quantity of new refrigerant oil must be
added to the system. CAUTION
If there is a major loss of system oil, due to
Avoid discharging the refrigerant in an
• A broken hose or leak. enclosed area, or in any area where the vapor
• Collision damage. In this case ensure or liquid may contact naked flame or hot metal.
following: R134a is not flammable, but can form highly
1. Recover refrigerant from the A/C system and toxic gas.
remove the compressor.
2. Carefully drain the refrigerant oil.
3. Using R134a refrigerant, flush the remaining oil
from the A/C system.
WARNING
4. Add recommended quantity of new refrigerant Do not smoke or weld in areas where R134a is
oil to the compressor. in use. Inhalation of concentrations of the
5. Replace the suction and discharge O-rings if vapor can cause dizziness, disorientation, nar-
damaged. cosis, nausea or vomiting.
6. Install the compressor.
7. Evacuate and recharge the A/C system.

MAN-00162
The following procedure is recommended for Evacuation of the system

evacuation. 1. The evacuation and leak test ensues that the
1. Connect the hose of Recovery unit to the system does not leak under low-pressure
vehicle circuit. Red hose to the high pressure conditions.
charging port. Blue hose the low pressure 2. Ensure that the hoses are connected to the
charging port. charging ports and valves on the hoses. Tank
2. Open the quick coupler valves on the hose & manifold are open.
after they are connected to the system. 3. Choose vacuuming program (Shift/Reset
3. Check the manifold gauges the units control option) from the control panel.
pane. They should register above zero. If it is 4. Set up the vacuuming time in minutes.
indicating zero then either the hose is not Approximately 15 minutes of vacuuming time is
connected properly/or/quick coupler valves are recommended.
not opened or the system is empty.
5. The unit displays the complete message after
4. Make sure that the drain valve at the bottom is the vacuuming is over.
closed.
6. Check the moisture indicator. If it is green, it
5. Open both the manifold valves on the control means that the system is ready for recharging.
panel. If it is not green then manual recycling has to
6. Open the Gas (vapor valve and liquid valve on be done for one hour. In case the moisture
the tank). indicator still does not turn green, the reason
7. Switch on the power. could be saturated receiver drier. It should be
replaced.
8. Choose Recover option from the panel.
7. The charging station is equipped with recycling
9. To assure that the complete recovery of the facility. During evacuation the refrigerant is
refrigerant. Wait for 5 minutes and watch the automatically recycled to assure recharging
manifold gauges for a rise above zero. with the cleanest possible refrigerant.
10.If a rise occurs, press HOLD/CONT. repeat Recycling begins automatically after 5 second
until the system pressure hold for at least 2 of the vacuum pump starting. Non condensable
minutes gases (mostly air) are automatically vented
11.The system displays the weight of the from the tank.
refrigerant recovered. 8. The system must hold the vacuum of –100
12.Confirm that the oil catch bottle is empty. Then Kpa for a minimum of 15 minutes. If vacuum is
slowly open the drain valve and allow the oil to held then the system has no and should be
be drained into the bottle. When all the oil has evacuated for further 15 minutes
been recovered, close the valve immediately. This completes the evacuation process.
New clean oil must be added to system before
recharging with the refrigerant. Purging – if required
13.The automatic recovery unit will operate until Where the system has been ruptured,
the air conditioning system has been emptied contaminated, or a compressor has to be removed,
of refrigerant down to atmospheric pressure. reinstalled or replaced, the system should be
The cylinder can now be closed. checked for contamination, and if so then the entire
system must be flushed.
The system can be flushed with Nitrogen.

MAN-00162
Preliminary Charging and High Charging the System

Pressure Leak Test 1. If no leaks are found then do charging as per
This ensures that the system does not leak under below given quantity.
high pressure conditions. – 600 gms for single AC
1. Confirm that the hoses are connected to the – 800 gms for Dual AC
charging ports and valves on the hose, Tank &
2. However in case of leakage, the system should
manifold are open
be discharged. After that repeat, the steps from
2. Enter the refrigerant quantity by weight and evacuation onwards till the above steps. Then
press ENTER. (At least 200 grams of charge proceed.
are required to do the high] pressure leakage
3. In case the system was checked for High
test).
pressure leaks by using Nitrogen, Evacuation
3. Press CHG to start charging. The unit displays should done first and then system should be
the completed message after the charging is directly charged.
completed.
4. Close both the manifold valves and then start
4. Use the electronic leak detector to probe the the vehicle.
leakages. Leakage checking to be done at the
5. Start the vehicle’s AC system and set it to
following points
maximum cooling. Check the pressure gauges
• Expansion valve joints and temperatures in the vehicle.
• All pipe joints 6. Turn off the engine.
• Suction & discharge ports 7. Disconnect the high side hose and start the
• Both the charging ports vehicle. Open both the manifold valves to pull
the refrigerant from both the hoses into the
Notice system.
8. At the lowest operating pressure close the low
Inspect for leaks by slowly moving the probe
side valve and switch off the vehicle.
of the detector around all the hose connec-
Disconnect the low side hose and remove
tions and points of possible leakage’s. The
adapters if used.
R134A is heavier than air; hence, any leak-
age will be more apparent at the bottom of 9.Close the high side manifold valve. Both the
fitting. valves should now be in closed position.
CAUTION
• Do not start the engine when the valve on
the manifold and tank are open.
• Ensure that the valves are closed before
starting the engine.
• Never run the compressor without the
refrigerant in the system as the lubricant
relies on the refrigerant flow.

MAN-00162
Accurate system refrigerant charge can only be Contaminated Refrigerant Handling

determined by charging the correct amount of
R134a.
If in doubt as to gas charge, e.g.
CAUTION
Any contaminated R134a refrigerant should
Suction pressure low
be extracted only by a suitable servicing
Or unit designed for the purpose of collecting
and storing contaminated refrigerant.
Discharge pressure low
Or 1. If the A/C system is damaged, or the
Air outlet temperature at the face high. compressor is removed, reinstalled or replaced,
the A/C system should be checked for
Then: Evacuate the system and recharge contamination of oil, if so the entire system
Carry out cooling system pressure test and suction must be flushed with refrigerant R134a.
(low side) pressure reading comparison.
CAUTION
To avoid possible internal damage avoid
flushing the compressor.
2. Recover/recycle the flushing refrigerant. The

recovery device will remove contaminants
through the filtering system.

MAN-00162
Do’s & Dont’s

SL.NO DO’S REASONS
1. Clean the condenser during Dirty and clogged condenser results in HVAC tripping and
regular service of the inefficient cooling.
vehicle.
2. Maintain the proper Low refrigerant level results in inefficient cooling. Excessive
refrigerant level. refrigerant results in HVAC tripping and again inefficient cooling.
3. Add recommended oil Adequate quantity of the compressor oil prevents poor pumping
quantity in the compressor and premature wearing of internal components.
during refrigerant charging.
4. Clean the evaporator Clogged evaporator results in less air flow and reduced cooling.
periodically to remove dust
and foreign particles.
6. Check coolant level and To prevent overheating of the engine.

ensure proper engine tuning.
7. Check for proper belt Loose belt will slip and overtightened belt will result in noise and
tension. premature failure of compressor clutch of the A/C compressor.
8. Ensure proper usage of Proper usage of HVAC controls will give optimum level of cooling.
HVAC control.
9 Check the coolant reservoir Sufficient coolant level should be maintained to avoid overheating
cap pressure and check the of the engine.
coolant level in the reservoir.
SL.NO DONT’S REASONS
1. Do not operate HVAC This will result in premature failure of the compressor.
without refrigerant.
3. Do not leave HVAC joints Moisture tends to enter the HVAC system if the joints remain
open. open for a long time.
4. Do not charge the refrigerant Improper evacuation in the HVAC system results in improper
in the HVAC system unless cooling conditions.
proper evacuation is carried
out.
5. Do not by pass/short It may seize the compressor if pressure goes above 435.1psi (30
pressure switch. bars)
6. Do not by pass/short the Formation of ice in the evaporator liquid return line to compressor
thermosensor. and it may cause compressor to seize.

MAN-00162
Incar Repairs Removal

1. Remove the Mahindra Body Functional Module
Fresh/Recirculation Actuator (MBFM). For additional information refer to
MBFM removal and installation section.
HVAC ACTUATOR
HCC D267- AP9BA01
WORRY
ED F/L - TEMP

connector (A), Unscrew the three mounting
screws (B) and remove the fresh / recirculation
actuator (C) from the HVAC unit.
Inspection
1. Inspect the actuator for mechanical damage.
2. Check and clean the connector pins for
sulphation and deposits.
Installation

MAN-00162
Temperature (Hot/Cool) Actuator 3. Press the lock and disconnect the electrical
screws (B) and detach the temperature (hot/
cool) actuator (C) from the HVAC unit.
B
A
Inspection
Installation
Removal
1. Remove the Mahindra Body Functional Module
(MBFM). For additional information refer to
MBFM removal and installation section.

MAN-00162
Thermistor / Thermosensor Removal

1. Pull out the side trim (A) from RHS of the floor
console.
Notice

connector (A) from the thermistor.

MAN-00162
3. Rotate the thermistor (A) in anticlockwise Installation

direction to unlock.
Notice
A Carefully remove the side trims without
1. Place the thermistor (A) in unlock position into

the evaporator housing.
4. Remove the thermistor from the HVAC unit.
2. Rotate the thermistor (A) in clockwise direction

and fix the thermistor into the HVAC unit.
3. Connect the electrical connector to the

thermistor.

MAN-00162
Particle Filter Removal

1. Pull out the side trim (A) from RHS of the floor
console.
Notice
2. Press the lock (A) and pull out the particle filter
cover (B) from HVAC unit.
HVAC Filter is fitted on the HVAC unit, can be seen

behind the Clutch Pedal.
B

MAN-00162
3. Pull out the particle filter (A) from the HVAC Mode Actuator
unit.
Notice
There are two particle filters available in the
HVAC unit. Pull the filters by using a small
pliers or hand.
Inspection
Check if the particle filter is completely blocked or
dusty. Clean if required or replace if necessary.
Installation
Notice
While installing the filters check the slot
seating position and install them in proper
position.

MAN-00162
Removal Blower Motor

1. Remove the lower glow box. For additional
screws (B) and remove the mode actuator (C)
from the HVAC unit.
A
B
Inspection
Installation
Removal


MAN-00162
3. Press the lock and disconnect the electrical 5. Loosen the two blower motor mounting screws
connector (A) from the blower motor. (A) from the blower motor.
4. Remove the two blower motor cover mounting 6. Remove the blower motor (A) from the HVAC
screws (A) and detach cover (B) from the unit.
HVAC unit.
Inspection
1. Hand rotate the blower motor and check for
any noise due to bearing wear.
2. Check the blower motor fan blade for damage.

Replace the blower motor if necessary.
Installation

MAN-00162
Blower Resistor 3. Unscrew the two blower resistor mounting

screws (A) and remove the resistor from the
HVAC unit.
Inspection
Visually check the blower resistor electrical
connector. Replace the blower resistor if necessary.
Installation
Removal

connector (A) from the blower resistor.

MAN-00162
HVAC Water Drain Hose 3. Remove the HVAC unit water drain hose (A)
from bottom of the HVAC unit and remove the
hose separately.
Removal
1. Pull and remove the floor console LHS trim (A) Inspection
from the floor console. Check the water drain hose for damaged.Replace if
necessary.
Installation
1. Insert and fix the water drain hose into the
HVAC unit and vehicle floor.
2. Remove the HVAC unit water drain hose (A)

which is located in bottom of the HVAC unit.

MAN-00162
Expansion Valve 4. Remove the mounting nut (A) on the

expansion valve safety cover and detach the
safety cover from the expansion valve.
Removal
1. Remove the negative terminal of the battery. 5. Remove the 12mm expansion valve high and
For additional information refer to Battery low pressure pipes mounting bolt (A).
2. Recover the A/C Gas. For additional

information refer to Refrigerant Recovery
Recycling and Recharging section.
installation section. A
6. Loosen the two 10mm expansion valve

mounting bolts (A), remove the high and low
pressure pipes and separately remove the
expansion valve (B).
B
A

MAN-00162
A/C Pressure Switch

Notice
Protect the high and low pressure hoses and
Removal
expansion valve using suitable cover, to 1. Discharge the A/C refrigerant. For additional
avoid contaminaton and moisture entry. information refer to Refrigerant Recovery
Installation 2. Remove the RHS headlamp assembly.
2. Recharge the Refrigerant. For additional connector (A) from the A/C pressure switch.
4. Loosen the 19mm nut A/C pressure switch (A)

by rotating anti-clockwise direction and remove
A/C pressure switch from the high pressure
hose.
Installation
2. Recharge the Refrigerant. For additional


MAN-00162
Front HVAC Unit 5. Unclip the heater core coolant hose clip (A)
and remove the two heater core coolant hoses
(B).
Removal
1. Remove the negative terminal of the battery. 6. Remove the HVAC unit water drain hose (A)
For additional information refer to Battery which is located in bottom of the HVAC unit.
2. Remove the Cross Beam (CCB). For
additional information refer to Cross Car
Beam (CCB) removal and installation
section.

4. Remove the expansion valve. For additional
information refer to Expansion Valve
WARNING
7. Remove the 13mm LHS HVAC unit mounting
Do not open the degassing tank cap when the nut (A).
coolant is hot. Failure to follow this instruction
will lead to personal injury.
Notice
• Before removing the heater core hoses,
open the degassing tank cap for releasing
the coolant pressure.
• Coolant will leak, while removing the heat- A
er core hoses, as a result drain the coolant
into a container.

MAN-00162
8. Remove the 13mm RHS HVAC unit mounting Floor Foot Duct LH
nut (A) and detach the HVAC unit from the fire-
wall.
Removal
Installation 1. Remove the floor console. For additional
Notice 2. Remove the co-driver seat.
• Start the engine, check the coolant level. 3. Remove the A-pillar lower trim LHS.
Refill if required.
4. Remove the floor carpet
• Check the Coolant leak when engine is
started. 5. Remove the floor insulation front LH.
• Check the A/C system cooling and operation. 6. Remove the three floor screws (A) which is
fixed in the floor foot duct LH (B).
Recycling and Recharging section. A B
7. Remove the floor foot duct LH separately.
Inspection
1. Inspect the duct for any damage.
2. Check and clean the duct.

MAN-00162
Installation Floor Foot Duct RH

Notice
Fix the floor foot duct LHS into the HVAC
unit properly for avoiding the air leakage and
poor A/C cooling.
Removal
1. Remove the floor console. For additional
2. Remove the driver seat.
3. Remove the A-pillar lower trim RHS.
4. Remove the floor carpet.
5. Remove the floor insulation front RH.
6. Remove the three floor screws (A) which is

fixed in the floor foot duct RH (B).
7. Remove the floor foot duct RH separately.
Inspection

MAN-00162
Installation B Pillar Floor Duct LH

Notice
Fix the floor foot duct RHS into the HVAC
unit properly for avoiding the air leakage and
poor A/C cooling.
Removal
2. Remove the Co-driver seat.
3. Remove the B-pillar lower trim LHS.
5. Remove the floor insulation rear LH.
6. Remove the two floor screws (A) which is fixed

in the B pillar floor duct LH (B).
7. Remove the B pillar floor duct LH separately.
Inspection

MAN-00162
Installation B Pillar Floor Duct RH

Notice
Fix the B pillar floor duct LH into the B pillar
floor duct middle properly for avoiding the
air leakage and poor A/C cooling.
Removal
2. Remove the Driver seat.
3. Remove the B-pillar lower trim RHS.
5. Remove the floor insulation rear RH.

in the B-pillar floor duct RH (B).
A
B
7. Remove the B pillar floor duct RH separately.
Inspection

MAN-00162
Installation B-Pillar Floor Duct Middle

Notice
Fix the B pillar floor duct RH into the B pillar
floor duct middle properly for avoiding the
Removal
2. Remove the B-pillar floor duct LH .
3. Remove the B-pillar floor duct RH .
4. Remove the gear shifter assembly.

in the B-pillar floor duct middle (B).
A
B
6. Remove the B-pillar floor duct middle separately.
Inspection
Installation

MAN-00162
B-Pillar Duct IP HVAC End

Notice
Fix the B-pillar floor duct middle into the B-
Pillar IP HVAC end properly for avoiding the
Removal
2. Remove the B-pillar floor duct middle. For
additional information refer to B-Pillar Floor
Duct Middle removal and installation section.
3. Remove the B-pillar duct IP HVAC end (A)

separately.
Inspection
Installation
Notice
Fix the B-pillar duct IP HVAC end into the
HVAC unit properly for avoiding the air
leakage and poor A/C cooling.

MAN-00162
Rear RHS Quarter Trims (Upper 4. Remove the rear door RHS scuff plate (A).
and Lower)
RHS Lower Quarter Trim
5. Loosen the 16mm second row RHS seat belt

mounting bolt (A) and release the seat slowly.
RHS Upper Quarter Trim
Removal 6. Loosen the 16mm third row RHS seat belt

1. Remove the luggage and rear RHS door
beadings.
2. Remove the third row RHS seat.
3. Remove the second row RHS seat.

MAN-00162
7. Loosen the three tool kit tray mounting screws, 10. Loosen the four screws (A) from the lower
(A) and remove the tool kit tray (B). trim, pull and remove the lower trim slowly.
A B A
8. Remove the striker plate cover (A) and detach 11. Press the lock and pull out the electrical
the tail gate scuff plate (B). connector (A) of the rear A/C blower dial
control knob.
A
B
9. Remove the lower trim mounting screw cover

(A). 12. Remove the seat belts covers (A) from the
RHS upper quarter trim.

MAN-00162
13. Open the grab handle cover and unscrew the Installation
grab handle two mounting screws (A) and
remove the grab handle (B) from top of the 1. To install, reverse the removal procedure.
RHS quarter trim.
Notice
A Check the quarter panel trims mounting
clips, metal clips condition.Fix the trims into
proper position.
B
Notice
Check the scuff plate riblock plastics condi-
tion.
14. Loosen the two RHS upper quarter trim

mounting screws (A) and remove the upper
quarter trim. SCUFFPLATE
RIBLOCK PLASTIC
A
Notice
Check the tailgate scuff plate riblock plas-
tics condition.
RIBLOCK PLASTIC
TAILGATE SCUFFPLATE

MAN-00162
Rear LHS Quarter Trims (Upper 5. Remove the washer fluid bezel (A) and fuel lid
bezel (B) from the rear LHS lower quarter trim.
and Lower)
B
LHS Lower Quarter Trim
6. Loosen the 16mm second row LHS seat belt

mounting bolt (A) and release the seat belt
slowly.
LHS Upper Quarter Trim
Removal
1. Remove the luggage and rear LHS door
7. Loosen the 16mm third row LHS seat belt
beadings.
2. Remove the third row LHS seat.
3. Remove the second row LHS seat.

4. Remove the rear door LHS scuff plate (A).

MAN-00162
8. Loosen the three tool kit tray mounting screws, 11. Loosen the four screws (A) from the lower
(A) and remove the tool kit tray (B). trim, pull and remove the lower trim slowly.
A B A
9. Remove the striker plate cover (A) and detach 12. Loosen the fuel lid knob screw (A) and
the tail gate scuff plate (B). remove the knob (B) from the lower quarter
trim.
B
A
A B
10. Remove the lower quarter trim mounting

screw cover (A). 13. Remove the seat belts covers (A) from the
LHS upper quarter trim.
A
A
A

MAN-00162
14. Open the grab handle cover and unscrew the Installation
grab handle two mounting screws (A) and
remove the grab handle (B) from top of the 1. To install, reverse the removal procedure.
RHS quarter trim.
Notice
proper position.
B
Notice
Check the scuff plate riblock plastics condi-
tion.
15. Loosen the two LHS upper quarter trim

SCUFFPLATE
quarter trim.
RIBLOCK PLASTIC
A Notice
Check the tailgate scuff plate riblock plas-
tics condition.
RIBLOCK PLASTIC
TAILGATE SCUFFPLATE

MAN-00162
Rear Blower Motor

4. Detach the air hose (A), unscrew the three
blower motor mounting screws (B) and remove
the blower motor (C) from the rear HVAC unit.
C
B
Removal
Inspection
1. Hand rotate the blower motor and check for
2. Remove the rear RHS lower quarter trim. For
any noise due to bearing wear.
additional information refer to Rear RHS
Quarter Trims (Upper and Lower) removal 2. Check the blower motor fan blade for damage.
and installation section. Replace the blower motor if necessary.
3. Press the lock and pull out the electrical Installation
connector (A) from the blower motor.

MAN-00162
Rear Blower Resistor 3. Unscrew the two mounting screws (A) and
remove the resistor (B) from the rear HVAC
unit.
B
A
Removal
1. Remove the rear RHS lower quarter trim. For Inspection
additional information refer to Rear RHS Visually check the blower resistor electrical
Quarter Trims (Upper and Lower) removal connector. Replace the blower resistor if necessary.
Installation
connector (A) from the blower motor resistor. 1. To install, reverse the removal procedure.

MAN-00162
Rear HVAC Water Drain Hose Rear HVAC Unit
Removal Removal
1. Remove the rear RHS lower quarter trim. For 1. Remove the negative terminal of the battery.
additional information refer to Rear RHS For additional information refer to Battery
Quarter Trims (Upper and Lower) removal removal and installation section.
2. Remove one end of the rear HVAC unit water information refer to Refrigerant Recovery
drain hose (A) from bottom of the HVAC unit, Recycling and Recharging section.
and remove the other end from the vehicle
floor and detach the hose separately. 3. Remove the RHS rear lower quarter trim. For
Quarter Trims (Upper and Lower) removal
4. Remove the rear duct HVAC end. For

additional information refer to Rear Duct
HVAC End removal and installation section.
5. Remove the rear duct RH top. For additional

information refer to Rear Duct RH Top
A
Inspection
Check the water drain hose for damaged.Replace if
necessary.
Installation

MAN-00162
6. Remove one end of the rear HVAC unit water 9. Remove the two 10mm evaporator pressure
drain hose (A) from bottom of the HVAC unit, hoses mounting bolts (A).
and remove the other end from the vehicle
floor and detach the hose separately.
10. Remove the four mud flap retaining (A) and

detach the mud flap (B) from the wheel arch.
7. Press the lock and disconnect the blower
motor electrical connector (A).
11. Remove the six retaining clips and four 10mm

nuts from the wheel arch and detach the rear
8. Press the lock and disconnect the electrical RHS wheel arch.
connector (A) from the blower resistor. 12.Remove the rear HVAC high pressure and low
pressure hoses mounting nuts (A) from rear
RHS wheel arch area.

MAN-00162
13. Remove the two 13mm rear HVAC mounting Rear Duct LH Top
bolts (A), nut (B) and detach the rear HVAC
unit separately.
B
Removal
Installation 1. Remove the lower quarter trim LHS. For
additional information refer to Rear LHS
1. To install, reverse the removal procedure. Quarter Trims (Upper and Lower) removal
information refer to Refrigerant Recovery 2. Unscrew the rear duct LH top mounting screw
Recycling and Recharging section. (A) and remove the rear duct LH top (B)
separately.
Installation

MAN-00162
Rear Duct LH Middle Rear Duct LH Bottom
Removal Removal
1. Remove the lower quarter trim LHS. For 1. Remove the rear duct LH middle. For
additional information refer to Rear LHS additional information refer to Rear Duct LH
Quarter Trims (Upper and Lower) removal Middle removal and installation section.
2. Unscrew the rear duct LH bottom mounting
2. Remove the rear duct LH top.For additional screw (A) and remove the rear duct LH bottom
information refer to Rear Duct LH Top (B) separately.
3. Unscrew the two rear duct LH middle mounting

screws (A) and remove the rear duct LH
middle (B) separately.
A
A
B B
Installation
Installation

MAN-00162
Rear Duct Middle 3. Remove the striker plate cover (A) and detach
the tail gate scuff plate (B).
The rear duct middle, one end is connected to the 4. Unscrew the rear duct middle mounting screw
rear duct LH bottom another end is connected to (A) and remove the rear duct middle (B)
the rear duct HVAC end. separately.
Removal
1. Remove the rear duct LH bottom. For
additional information refer to Rear Duct LH B
Bottom removal and installation section.
2. Loosen the three tool kit tray mounting screws,
(A) and remove the tool kit tray (B).
A
Installation
A B

MAN-00162
Rear Duct HVAC End Rear Duct RH Top
Removal Removal
1. Remove the RH lower quarter trim. For 1. Remove the RH top quarter trim. For
additional information refer to Rear RHS additional information refer to Rear RHS
Quarter Trims (Upper and Lower) removal Quarter Trims (Upper and Lower) removal
2. Remove the rear duct middle. For additional 2. Unscrew the three rear duct RH top mounting
information refer to Rear Duct Middle screws (A) and remove the rear duct RH top
removal and installation section. (B) from the rear HVAC unit.
3. Unscrew the two rear duct HVAC end
mounting screws (A) and remove the rear duct
HVAC end (B) separately. A
A
A
B
Installation
4. Remove the rear duct HVAC end separately.
Installation

MAN-00162
Compressor 7. Press the lock and disconnect the electrical

connector (A) from the compressor.
A B
A
E
D F
A. A/C compressor pulley with A/C clutch

8. Remove the 13mm high pressure and low
B. A/C coil
pressure hoses mounting nuts (A) and remove
C. High pressure port (compressor outlet) the high and low pressure hoses (B) from the
D. A/C coil electrical connector compressor.
E. Low pressure port (compressor inlet)
F. A/C compressor
CAUTION
Removal Cover the high and low pressure hoses with
1. Remove the negative terminal of the battery. dust caps to avoid entry of air and
For additional information refer to Battery contamination of the refrigerant.
2. Remove the accessory drive belt. For

Drive Belt removal and installation section.. B
3. Remove the underbody cover. For additional
information refer to Engine Oil Filter
4. Remove the engine front mounting. For A
additional information refer to Front Engine
Mount Removal removal and installation
section.
5. Discharge the A/C refrigerant. For additional

6. Remove the power steering pump high
pressure hose. For additional information
refer to Power Steering Pressure Hose
section.

MAN-00162
9. Remove the four 13mm compressor mounting A/C Condenser

bolts (A) and remove the A/C compressor from
the bracket.
Removal
Notice 1. Remove the negative terminal of the battery.
Cover the high and low pressure ports in the removal and installation section.
compressor before removing from the
vehicle to avoid spilling of PAG oil. 2. Discharge the A/C refrigerant. For additional
3. Remove the five grill mounting retaining clips (A)

CAUTION and loosen the two mounting screws (B) from
Cover the high and low pressure ports in both sides of the grill.
the compressor with dust caps to avoid
entry of air and contamination of the
refrigerant.
10. Push the engine towards back and remove A/

C compressor form the engine.
Installation
B B
CAUTION
During installation, fix the new O-ring into
the compressor without any damage.
Damage to the O-ring may cause A/C 4. Detach the grill from the front bumper.
refrigerant leakage which leads to A/C
failure.


MAN-00162
5. Remove the four retaining clips (A) from the bot- 8. Remove the bumper retaining screw (A) from
tom of the front bumper RHS and LHS. bottom of the RHS and LHS headlamps.
6. Unlock the lock and disconnect the electrical 9. Remove the three retaining clips (A) from the
connectors (A) from both side RHS and LHS of front bumper and detach the front bumper from
the fog lamp. the vehicle.
7. Remove the plastic cover (A) located below the 10.Remove the two 10mm front bumper top
headlamp RHS and LHS from the bumper. deflector mounting bolts (A) and detach the
front bumper top deflector (B).
B A

MAN-00162
11.Remove the two 10mm power steering cooler 14. Loosen the 10mm low and high pressure
pipe mounting bolts (A) and detach the power hoses nuts (A) and remove the low and high
steering cooler pipe (B). pressure hoses (B) from the A/C condenser.
12. Disconnect the RHS and LHS horn electrical 15. Unlock the A/C condensor snap fit locks (A)
connectors, loosen the both horn mounting on top and bottom of the A/C condenser.
bolts (A) and remove the RHS and LHS horn
(B) .
A A
B B
A
A
16. Carefully remove the A/C condenser assembly

13. Remove the two 10mm front bumper RHS and (A) without damage.
LHS de-flector mounting bolts (A) and detach
the front bumper RHS and LHS deflector (B),
lower deflector (C).
A
A
B
Installation
C

MAN-00162
Condenser Cartridge (desiccant)

CAUTION
During installation, fix the new O-ring into
the low and high pressure pipe mounting
joint without any damage. Damage to the O-
ring may cause A/C refrigerant leakage.
2. Recharge the refrigerant. For additional

Receiver/Drier is integrated with condenser.

Receiver drier contains a cartridge having filter and
desiccant. Desiccant helps in removing moisture
and other non condensable gases from circulating
refrigerant. Filter or strainer helps in removing
impurities/debris from system.
Removal
WARNING
R134a vapors are heavier than air and can
cause suffocation, dizziness and loss of con-
centration. Always work in well ventilated
space.
WARNING
Avoid PAG oil contacting the bare skin or
vehicle body. It is toxic and corrosive in
nature.
1. Remove the A/C condensor. For additional

information refer to A/C Condenser removal

MAN-00162
2. Using a 8mm Allen key remove the condenser Front A/C Hoses
cartridge mounting nut (A).
3. Using a suitable tool separately remove the

Removal
cartridge (A) from the condensor. 1. Disconnect and isolate the battery negative
cable.For additional information refer to
A information refer to Refrigerant Recovery
Recycling and Recharging section..
3. Remove the under body cover. For additional

5. Remove the front bumper. For additional
information refer to Front Bumper removal
Installation
6. Remove the RHS headlamp. For additional
1. To install, reverse the removal procedure. information refer to Headlamp removal and

MAN-00162
7. Press the lock and pull up the ABS module 9. Remove the high pressure hose (A) and low
electrical connector lock lever (A) and pressure hose (B) from the joint.
disconnect the electrical connector.
A B C
A
CH
B
BOSCH
BOSCH
PRESS
A . Lever release lock

B . Lever pull up to disconnect
C . Lever pull down to connect
10. Remove the mounting nut (A) on the
expansion valve safety cover and detach the
safety cover from the expansion valve.
A
CH
Press
8. Remove the two 10mm high and low pressure

hoses joints mounting nuts (A) and 10mm
bracket mounting nut (B) from adjacent the 11. Remove the 12mm expansion valve high and
steering column universal joint. low pressure hoses mounting bolt (A) and
detach hoes (B).
A
A

MAN-00162
12.Remove the two 10mm front bumper top

deflector mounting bolts (A) and detach the B
B A
15. Loosen the four 10mm coolant tank mounting

nuts (A) detach and place the coolant aside.
13. Loosen the 10mm high pressure hose nut (A)

and remove the high pressure hose (B) from
the A/C condenser.
A
14. Remove the 13mm low pressure hose

mounting nut (A) and remove the low pressure
hose (B) from the compressor.
CAUTION
Cover the high and low pressure hoses with
dust caps to avoid entry of air and
contamination of the refrigerant.

MAN-00162
16. Loosen the two 10mm high and low pressure 19.Using a suitable stand (A) and wooden block
hoses mounting bolts (A) and detach the hoses (B), support the oil pan bottom as shown
(B) from bottom of the coolant tank area. below.
MAX
B MIN B
A
A
17. Loosen the two 10mm high and low pressure 20. Remove the 17mm RHS (Hydro) mount
hoses mounting bolts and detach the hoses bracket mounting bolts (A) and a 18mm nut (B)
bracket (A). on the engine mounting bracket, and detach
the RHS (Hydro) mount mounting bracket.
B
A
18. Press the lock and disconnect the A/C high

pressure switch electrical connector (A). 21. Remove the two 18mm RHS (Hydro) mount
mounting bolts (A), nut (B) and detach the
RHS (Hydro) mount engine mounting (C).
C
B

MAN-00162
22. Detach high and low pressure hoses from the A/C High Pressure Hose
vehicle and remove the hoses separately.
(compressor to condensor)
Notice
When removing the A/C hoses Slightly move
the engine.
Installation
The high and low pressure hoses, one end is

connected to the rear evaporator another end is
connected to the underbody joint.
Removal
WARNING
Do not release the refrigerant into the
atmosphere. Use approved recovery/
recycling equipment to capture the
refrigerant whenever the air conditioning
system is discharged.
WARNING
Always wear eye and hand protection
(goggles and gloves) when working with any
refrigerant or air conditioning system.
CAUTION
Close the high pressure and low pressure
refrigerant lines with dust caps to avoid air
entry and/or contamination.


MAN-00162

information refer to Front Bumper Grill
A
4. Remove the two 10mm front bumper top
deflector mounting bolts (A) and detach the
B A
B
7. Remove the high pressure hose separately.
Installation
5. Loosen the 10mm high pressure hose nut (A)

and remove the high pressure hose (B) from
the A/C condenser.
6. Remove the 13mm low pressure hose

mounting nut (A) and remove the low pressure
hose (B) from the compressor.
CAUTION
Cover the high and low pressure hoses with
dust caps to avoid entry of air and
contamination of the refrigerant.

MAN-00162
Rear A/C Hoses (evaporator to 2. Remove the four mud flap retaining (A) and
detach the mud flap (B) from the wheel arch.
underbody)
3. Remove the rear wheel arch. For additional

The high and low pressure hoses, one end is information refer to Rear Wheel Arch
connected to the rear evaporator another end is removal and installation section.
connected to the underbody joint. 4. Remove the two high and low pressure hoses
mounting nuts (A) from the wheel arch area.
Removal
WARNING A
refrigerant whenever the air conditioning
WARNING
refrigerant or air conditioning system.
CAUTION


MAN-00162
5. Remove the 10mm A/C hoses mounting nut 7. Loosen the 19mm (A) and 17mm (B) high
(A) and detach the bracket (B) from the wheel pressure hose joint nuts and remove the 27mm
arch area . (A) and 24mm (B) low pressure pipe joint nuts.
A
B
A
6. Remove the 10mm A/C hoses mounting nuts

(A) from the two clamps (B) and detach hoses
A
from the under chassis adjacent the fuel tank.
B
A
A
B
B
8. Remove the high and low pressure hoses
separately.
CAUTION
Carefully remove the high and low pressure
hoses without any damage. Damages in the
high pressure hoses cause of A/C
refrigerant leakage.
Installation

MAN-00162
Rear A/C Hoses (under body to 3. Remove the two 13mm mounting bolts (A) and
18mm mounting nut (B) from the cradle
front A/C joint) bracket (C), detach the bracket from cradle.
The high and low pressure hoses, one end is 4. Loosen the 19mm (A) and 17mm (B) high
connected to the underbody joint another end is pressure hose joint nuts and remove the 27mm
connected to the front HVAC joint. (A) and 24mm (B) low pressure pipe joint nuts.
Removal
WARNING
refrigerant whenever the air conditioning A
B
WARNING
refrigerant or air conditioning system. A
CAUTION



MAN-00162
5. Remove the two 10mm high and low pressure 8. Remove the high and low pressure hoses
hoses joints mounting nuts (A) and detach separately.
hoses from the front A/C joints.
CAUTION
Carefully remove the high and low pressure
pipes without any damage. Damages in the
high pressure hose causes A/C refrigerant
A leakage.
Installation
6. Remove the 10mm rear A/C hoses clamp

mounting bolt (A) and remove the clamp (B)
from top of the front cradle RHS.
7. Remove the 10mm A/C hose mounting bolt (A)

and remove the clamp (B).

MAN-00162
Disassembly and Assembly 9. Unscrew the HVAC wiring harness screws (A),
disconnect the electrical connectors (B) and
remove the wiring harness (C) from LHS of the
Front HVAC Unit HVAC unit.
C
A
Disassembly 10. Unscrew the three HVAC wiring harness

1. Remove the Front HVAC Unit. For additional screws (A), disconnect the electrical
information refer to Front HVAC Unit connectors (B) and remove the wiring harness
removal and installation section. (C) from RHS of the HVAC unit.
2. Remove the fresh / recirculation actuator. For

additional information refer to Fresh/ C
Recirculation Actuator removal and
3. Remove the temperature (Hot/Cool) actuator.
For additional information refer to Tempera- A
ture (Hot/Cool) Actuator removal and instal-
lation section.
B
4. Remove the thermistor. For additional
information refer to Thermistor /
Thermosensor removal and installation
section.
5. Remove the particle filter. For additional

information refer to Particle Filter removal
6. Remove the mode actuator. For additional

information refer to Mode Actuator removal
7. Remove the blower motor. For additional

information refer to Blower Motor removal
8. Remove the blower resistor. For additional

information refer to Blower Resistor

MAN-00162
11. Unscrew the two safety cover screws (A) and 15. Loosen a screw (A) from the evaporator cover
remove the cover (B) from the heater core. (B).
A
A
12. Remove the heater core from the HVAC unit. 16. Remove the two clips (A) using a suitable tool
from the HVAC bottom housing (B).
13. Remove the two fresh/recirculation flap
assembly screws (A) from the fresh/
recirculation flap assembly (B).
B
A
B
14. Unlock the LHS and RHS fresh/recirculation

flap assembly locks (A) and remove fresh/
recirculation flap assembly from the HVAC unit.

MAN-00162
17. Remove the five screws (A) from the HVAC 19. Remove the evaporator (A) from the HVAC
unit. housing.
A
A
20. Remove the evaporator mounting cover (A)

from the evaporator.
18. Remove the HVAC unit bottom housing (A) A

slowly from the top housing.

MAN-00162
21. Remove the six locks (A) and eleven screws Assembly
(B) from the HVAC unit.
1. To assemble, reverse the disassembly
procedure.
Notice
A
• When assembling the HVAC unit, fix the flaps
at proper position.
• W h i l e a s s e m b l i n g t h e H VA C u n i t , u s e
recommended sealant if applicable.
• Before assembling the HVAC unit, inspect
the crack and damage.
B
Recycling and Recharging removal and
B
22. Unlock the locks and disassemble the HVAC

unit slowly.

MAN-00162
Rear HVAC Unit 7. Remove the evaporator (A) with the expansion
valve (B) from the housing.
Disassembly
2. Remove the rear HVAC unit. For additional

A B
information refer to Rear HVAC Unit
3. Remove the rear blower motor. For additional

information refer to Rear Blower Motor
4. Remove the rear blower motor resistor. For

additional information refer to Rear Blower
Motor removal and installation section.
8. Loosen the two 8mm allen key bolts (A) on the
5. Remove six screws (A) and two clips from the
thermal expansion valve (B).
evaporator.
A
A
A
9. Remove the A/C hoses (A) from the thermal

6. Detach the bottom cover (A) of the rear HVAC
expansion valve.
unit.
A
A

MAN-00162
10. Detach the thermal expansion valve (A) and

evaporator (B) separately.
A
B
Notice
While removing the A/C pipelines, cover the
A/C pipeline with the air mask to avoid
moisture absorption of the system.
Assembly
procedure.


MAN-00162
Compressor
Model Name HS - 18
Make HCC
Displacement 180 cc/rev
Mechanism Fixed swash plate
Pulley Size 120 mm
Condensor
Type Integrated Receiver Drier Condensor with compact

thin fin & tube
Refrigerant
Type R134A
Quantity 600 gms for single AC
800 gms for Dual AC
Compressor Oil
Type FD46XG
Quantity 150 cc for single AC
210 cc for for Dual AC
Triple Pressure Switch is a combination of
Low Pressure Switch Opens less than 2 bar and closes more than 2 bar
High Pressure Switch Opens at 32 bar and closes less than 32 bar
Medium Pressure Switch Opens less than 14 bar and closes more than 18
bar

MAN-00162
Torque in
Nm
SCREW HEX FL
Front HVAC to body 2 7±1
M8X1.25X20X8.8
SCREW HEX FL
Front HVAC unit HVAC to CCB front side 2 7±1
M8X1.25X20X8.8
NUT HEX FL
HVAC to CCB back side 2 7±1
M8X1.25X8X8
BOLT HEX FL - Rear HVAC to quarter inner panel/

2 10 ± 2
M6X1X25X8.8 wheel housing bracket
NUT HEX FL Rear HVAC to quarter inner panel/

Rear HVAC unit 1 10 ± 2
M6X1X6X8 wheel housing bracket
BOLT HEX FL - Rear AC unit evap flange bracket to

2 10 ± 2
M6X1X25X8.8 bracket on the wheel housing
BOLT HEX FL -
Tube buckets to body 4 10 ± 2
M6X1X25X8.8
NUT HEX FL
To condenser 1 10 ± 2
M6X1X6X8
Front Suction & BOLT HEX FL

TXV to evaporator 2 10 ± 2
liquid line M6X1X45X8.8
NUT HEX FL
At rear AC connection to body 1 10 ± 2
M6X1X6X8
NUT HEX FL
TXV to TXV protection cover 1 10 ± 2
M6X1X6X8
BOLT HEX FL -
Tube brackets to body 3 10 ± 2
M6X1X25X8.8
NUT HEX FL
Rear lines to front line 2 10 ± 2
M6X1X6X8
Rear Suction &
liquid line
NUT HEX FL
Tube brackets to body 2 10 ± 2
M6X1X6X8
NUT HEX FL Tubes to rear AC flange on the rear

2 10 ± 2
M6X1X6X8 wheel housing
NUT HEX FL Discharge hose one end to condens-

Discharge hose 1 10 ± 2
M6X1X6X8 er
Evaporator grom- SCREW TPRF CR

Evaporator grommet to dash panel 2 2
met ST 6.3X1.8X16 C,A
Swivel nut Suction

Rear Suction line Rear AC pipe joint suction 1 20 ~ 26
line

MAN-00162
Torque in
Nm
Swivel nut liquide

Rear Liquid line Rear AC pipe joint liquid 1 12 ~ 16
line
M8 Nut Suction pipe joint to compressor 1 10 ~ 12

Front suction &
Discharge
M8 Nut Discharge pipe joint to compressor 1 10 ~ 12
Screw Flanged Self

Rear quater trim Tapping To BIW 6 2.0 ± 0.5
4.8X1.6X18XC

MAN-00162
Repair Manual SRS Nov 2011/ Rev 2
SUPPLEMENTRY RESTRAINT SYSTEM (SRS)
CONTENTS

Driver Airbag ...................................................................................... 2
Passenger Airbag............................................................................... 2
Thorax Airbags................................................................................... 3
Curtain Airbags .................................................................................. 3
Seat Belt Pre-tenioners ...................................................................... 3
Load Limitor ....................................................................................... 3
Clock Spring....................................................................................... 4
Side Impact Sensor............................................................................ 4
SRS Warning Indicator....................................................................... 4
Incar Repairs .................................................................................... 6
Clock Spring .................................................................................6

Removal ............................................................................................. 6
Installation .......................................................................................... 7
Driver Airbag................................................................................. 7
Removal ............................................................................................. 7
Installation .......................................................................................... 9
Passenger Airbag ......................................................................10

Removal ........................................................................................... 10
Installation ........................................................................................ 10
Curtain Airbag ...........................................................................11

Removal ........................................................................................... 11
Installation ........................................................................................ 11
Side Impact Sensor ...................................................................12

Removal ........................................................................................... 12
Installation ........................................................................................ 12

MAN-00162
SRS ECU ..................................................................................... 13

Removal ........................................................................................... 13
Installation ........................................................................................ 13
Front Seat Belt Buckle................................................................ 14

Removal ........................................................................................... 14
Installation ........................................................................................ 14
Second Row Seat Belt Buckle .................................................. 15

Removal ........................................................................................... 15
Installation ........................................................................................ 15
Mahindra Special Tool (MST) ....................................................... 16

MAN-00162
Supplementary Restraint System (SRS)

1 3
2
1. Driver airbag 2. Front passenger airbag 3. Side airbag 4. Curtain airbag
Occupant Restraints are provided in a vehicle to

protect the occupants in case of collision.
"Primary restraints system" includes the seat belts
which are designed for controlled occupant
movement during an accident. This reduces the risk
of hard contacts with vehicle interiors.
"Supplementary restraints system (SRS)" is the
inflatable system with airbags and seat belt buckles
and load limiters which are designed to further
enhance level of occupant protection in accidents.
Relevant SRS module assemblies are provided for
protection of occupants in case of front and side
accidents.

MAN-00162
Component Location Index Passenger Airbag

Driver Airbag
PAB
Driver Airbag
RES
CE
SOUR
+
CRUISE
+
V
OFF SET
V -
-
The passenger airbag module is located on LH side

of Instrument panel, above the upper glove box and
The driver airbag module is located in the steering its functioning is controlled by the SRS ECU. A bag
wheel and its function is controlled by the SRS within the module inflates to protect the passenger
ECU. A bag within the module inflates to protect in the event of a collision severe enough to deploy
the driver in the event of a collision severe enough the system.
to deploy the system.
Within the passenger airbag module is a squib
The driver airbag module connects to the steering which, when given the correct current by the SRS
column wiring harness via a rotary coupler called ECU, inflates the airbag by initiating a chemical
as clock spring. Within the driver airbag module is reaction. In deployment, the airbag inflates within a
a squib which, when given the correct current by fraction of a second and then deflates at a
the SRS ECU, inflates the airbag by initiating a controlled rate as the passenger body regions;
chemical reaction. In deployment, the airbag typically head and chest interact with airbag. Vents
inflates within a fraction of a second and then in the airbag control its deflation.
deflate at a controlled rate as the driver body
regions; typically head and chest interact with
airbag. Vents in the airbag control its deflation

MAN-00162
Thorax Airbags In the vehicle, folded curtain airbag is installed

behind roof headliner on side of the vehicle. When
collision occurs the curtain airbag is deployed,
pushes the headliner out of the way and position
itself between occupant and side window of the
vehicle to protect the occupant's head from having
SR
S
AIR
BA
G Airbag hard contact with side structure of vehicle or with
the intruding external objects. The curtain airbag
also enhances protection for the second row
outboard occupant.
Seat Belt Pre-tenioners

.Seat belt pre-tensioner is a device installed in
vehicles to reduce slack that may exist in a seat
belt system at the moment of a frontal collision.
Having the seat belt system snug allows the
Thorax airbags are located in the front seats and supplemental restraint airbag system to work most
inflate between the seat occupant and the door and effectively. A loose seat belt system does not keep
their function is controlled by the SRS ECU. These the occupant in the proper position during the
airbags are designed to reduce the risk of injury to forces of a crash. In order for airbags to reduce or
the occupant during side impact. eliminate injury, the occupant must be seated,
belted and in the correct position in the vehicle.
Curtain Airbags
Load Limitor
In high speed frontal crashes, passenger moves
forward due to inertia at a very high speed. If the
Airbag seat belt gets locked during such crashes it may
SRS
AIRBAC
cause injuries to the passenger as he is forcibly

held by the seat belt against the inertia force.
Load limiters are provided to limit the seat belt
loads to a pre-defined value. Load limiters are to
be used only in airbag equipped vehicles. The load
limiter fitted inside the retractor unit is basically a
torsion bar. Whenever the belt load increases
beyond the pre-defined limit, some length of the
belt is released due to twisting of the torsion bar.
The activation of the load limiter does not depend
on signal from the ECU.
SRS
AIRBAC
Airbag

MAN-00162
Clock Spring SRS Warning Indicator
3 4
100 120 x1000rpm
80 140
2 5
60 160 H
40 180 6
1
200 c
20
22 0 7
0
It warns the vehicle driver when the air bag

FRON
PULL
T
REAR
OFF
ON
S
MIS
OFF T
INT
LOW
electrical system malfunctions which could
HIG
potentially affect the operation of the air bag

H
system. These malfunctions could result in

unintended performance of the system.
A warning light should never come ON unless there
Clock spring
is a fault in vehicle's air bag system. The air bag
control module (ECU) runs a self-check every
ignition cycle. If it finds a fault in a crash sensor, in
Clock spring is a spirally wound wire coil mounted
one of the restraint components, the wiring or itself,
to steering column. It ensures most reliable contact
it will set a code, turn on the warning light.
possible between air bag module assembly and
crash sensor. It also provides the electrical
continuity for airbag, horn, vehicle cruise control
Notice
and infotainment system. For SRS warning lamp condition, refer to
SRS diagnostic manual
Side Impact Sensor
Side impact sensor
These sensors are positioned on the "B Pillar" on

both sides of the vehicle. It senses the structural
deformation which is caused by side impact (Side
Collision) which is then sent signal to SRS ECU.
This helps in activating the side airbags to cushion
the occupants from severe injuries.

MAN-00162
Service Tips and Precautions • Do not install used SRS components from
another vehicle. When replacing SRS system,
The SRS system contains components which could only use genuine Mahindra parts.
be potentially hazardous to the technician if not
• It is essential that SRS components are fitted
serviced and handled correctly. The following
using the recommended torques. Always use
guidelines are intended to alert the technician to
specified earth fixings tightened to the correct
potential sources of danger and emphasize the
torque. Poor earthing can cause intermittent
importance of ensuring the good condition of SRS
problems that are difficult to diagnose.
components fitted to the vehicle.
• Do not allow the air bag module assemblies to
• Always disconnect the battery first before
come into contact with electrical current.
carrying any operation on SRS components.
• Never hammer on any SRS component - it
• The airbag modules contain extremely
might get damaged internally.
flammable components. Contact with water,
acid or heavy metals may produce harmful or • Prior to commencing any test procedure on the
explosive compounds. Do not dismantle burn vehicle, ensure that only test equipment
or bring into contact with electricity. approved for the purpose is being utilized and
that it is in good working order. Ensure any
• Do not expose an airbag module or seat belt
harness or connectors are in good condition
pre-tensioner to heat.
and any warning lamps are fully functional.
• The inflator is intended not to fire below the
• Only use the diagnostic tool to probe faults in
threshold current. To avoid inadvertent
the Airbag system, NEVER use electrical
triggering of the airbag, NEVER apply a current
probing instruments like Multi-meter as the
through the squib except with the specified test
probing current may deploy the airbag.
equipment and procedures.
• Never attach anything to the airbag cover or
• Never dispose the airbag module undeployed
allow anything to rest on top of the airbag
without proper instructions as this may result in
module.
possible injury. All deployments must follow
special safety instructions. All units should be • Always store airbag module in a dry, cool and
activated (deployed) prior to disposal. secured area.
• The airbag modules or their components must • Never attempt to modify any splice or repair
not be adapted or installed in any other vehicle SRS wiring harness.
other than the specific vehicle for which they • Always ensure airbag wiring is routed correctly.
are designed and manufactured. Any attempt Be careful to avoid trapping or pinching the
to adapt or install airbag modules or their airbag wiring. Look for possible points of
components in any other vehicle can result in chafing.
personal injury to the occupants in the event of
• Ensure all airbag harness connectors are
accidents.
mated correctly and securely fastened. Do not
• Wait for at least ONE minute after leave the connectors hanging loose or allow
disconnecting the battery before servicing the SRS components to hang from their
vehicle to prevent accidental deployment and harnesses.
personal injury.
• When using electric welding, first disconnect
• In order to assure system integrity, it is the all the airbag connectors, ECU and
essential that the SRS system is regularly sensors. If such activities are to be conducted
checked and maintained so that it is ready for in the vicinity of SRS component then remove
effective operation in the event of a collision. those components also.
Carefully inspect SRS components before
installation. Do not install a part that shows
signs of being dropped or improperly handled,
such as dents, cracks or deformation. Dropped
modules may get damaged.
• Ensure SRS components are not contaminated
with oil, grease, detergent or water. It is
essential that SRS components are fitted using
the recommended torques.

MAN-00162
Incar Repairs 5. Remove the combination switch lower shroud

(A) and combination switch upper shroud (B).
Clock Spring
B
Removal
2. Remove the steering wheel. For additional
information refer to Steering Wheel removal A
3. Remove the two mounting screws (A) from the
combination switch shroud.
80
100 120
140
3
x1000rpm
4 6. Press the lock and disconnect the white
5
60
40
160
180
1
2
H
6
connector (A), slide the lock and disconnect
c
20
0 22
200
0 7 the yellow connector (B) from the clock spring.
FRON
T
REAR
OFF MIS
PULL OFF T
INT
ON
LOW
S HIG
H
A
A
4. Remove the three mounting screws (A) from

A B
the combination switch lower shroud (B).
B
7. Slide and unlock the white lock (A) and
disconnect the electrical connector from the
clock spring (B).
A A

MAN-00162
8. Lift and unlock the clock spring lock at the top Driver Airbag
(A), press and unlock two side locks (B) of the
clock spring. Removal
1. Switch off the ignition. Disconnect and isolate
the negative terminal of the battery and wait for
a minute. For additional information refer to
2
2
2. Remove the three mounting screws (A) of
A
220
steering column lower shroud.
F
MIST
OFF
INT
LOW
REAR OFF HIGH
FRONT S
ON
PULL RES
CRUISE SET
OFF
-
SOURCE
V
+
V
B B
9. Remove the clock spring separately from the

steering column.
Installation A
A
1. Press and install the clock spring into the
steering column.
Notice 3. Rotate the steering wheel such that two

mounting screws (A) of steering column lower
Carefully install the clock spring without shroud are easily accessible. Remove these
damaging the locks. two screws (A) and remove the lower shroud.
CAUTION
SRS CLOCK SPRING : This is not a
repairable part. do not disassemble or
tamper. if defective replace entire unit per
service manual instructions. To re-center
A
rotate clockwise until tight. Then rotate in
opposite direction approximately 3 turns
and align ZY failure to follow to instructions
risking serious driver injury.

MAN-00162
6. Rotate the steering wheel to 12 o’clock position

such that slot A can be accessible.
100 120
3 4
7. Insert the DAB removal special tool (1) (Special
80 km/h 140 x1000 rpm
60
40
H
I
-
5
6
tool part no. 0112AAW0001ST) into slot A from
upper side of combination switch and push so
C
7
RADIO
[00]
n 91.90MH z
19.5oc
set temp
that DAB gets unlocked from that side.
AC on
EXIT
4 5
ROM
6
APT
EQ TR
9 0 #
INFO MUTE
A
AC AR
A/C
MOC
ESP
OFF
4. Pull out the steering column upper shroud (A).
A 1
8. Rotate the steering wheel such that slot B can

be accessible.
9. Repeat the operation no 7 so as to unlock the
DAB from another side (slot B).
5. There are two slots (A & B) located behind the

steering where DAB removal special tool to be
inserted in order to access DAB locks.
B A

MAN-00162
10. Using a suitable tool (A), lift and unlock the Installation
DAB yellow connector (B). 1. To install, reverse the removal procedure.
Notice
MIST
REAR OFF OFF
INT
LOV
A
ON S
When installing the DAB, make sure that all

H
OFF
SOURCE electrical connectors are fixed in proper

position.
2. Reconnect the battery.
B 3. Using diagnostic tool check and erase the fault

codes, if any.
Notice
When installing the driver airbag into
steering wheel, make sure the horn pad
11. Press the two locks and disconnect the DAB buttons are fixed properly and correct
electrical connector (A) and remove the DAB. position.
MIST
REAR OFF OFF
INT
LOV
ON S H
OFF
OFF
SOURCE
RES
CURU
ISE +
OFF SET
_

MAN-00162
Passenger Airbag
Notice
Place the passenger air bag carefully in
proper position as shown below.
Removal
2. Unlock the passenger air bag locks (A) and
remove the passenger air bag (B) from the
LHS top cover.
B
Installation

MAN-00162
Curtain Airbag 8. Loosen the three 10mm curtain airbag

mounting bolts (A) and remove the curtain
Removal airbag (B).
2. Remove the A-Pillar trims both RHS and LHS.
A
3. Remove the B-Pillar trims both RHS and LHS.
A
4. Remove the quarter trims both RHS and LHS.
5. Remove the roof liner.
6. Slide to unlock the curtain airbag orange color
lock (A) and disconnect curtain airbag electrical
connector. B
A
9. Loosen the two 10mm curtain airbag mounting
bolts (A) from rear side of the curtain airbag
(B).
A
A
7. Loosen the 10mm curtain airbag rope mounting
bolt (A) and detach curtain airbag rope (B)
from the clip lock (C).
B
10. Separately detach the curtain airbag from roof.
Installation
B
C

MAN-00162
Side Impact Sensor 4. Remove the 10 mm side impact sensor

mounting bolt (A) and detach the sensor (B)
separately.
TRW J5
Q1
01 0 0 0 01 6 4 0 8 0 0 8 82
0120CW0100N
A
B
Removal
1. Disconnect and isolate the negative terminal of Installation
2. Remove the B-pillar lower trim. For additional
information refer to B-Pillar Lower Trim
3. Unlock the lock (A) and disconnect the side
impact sensor connector (B).

MAN-00162
SRS ECU 3. Unlock the lock and disconnect the two SRS
module electrical connectors (A) from the SRS
module which is located below the RHS HVAC
unit.
A. SRS ECU A
Removal
the battery. For additional information refer 4. Loosen the 10mm SRS ECU earth mounting
to Battery removal and installation section. nut (A) and disconnect the earth connection,
remove the three SRS ECU mounting nuts (B)
2. Pull out the side trims (A) from both the sides
and detach the SRS ECU.
of the floor console.
Installation
Notice 1. To install, reverse the removal procedure.

MAN-00162
Front Seat Belt Buckle Installation

PR
ES
S
Removal
2. Unlock and disconnect the electrical connector
(A) of the front seat belt buckle.
3. Loosen the seat belt buckle 14mm mounting

bolt (A) and detach the buckle (B) separately.
PR
ES
S

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Second Row Seat Belt Buckle
PRESS
Removal
1. Remove the 14mm seat belt buckle mounting
bolt (A) and detach the buckle separately.
Installation
Notice
Follow the similar procedure to remove the
third row seat belt buckle.

MAN-00162

0112AAW0001ST DAB Removal Tool
Torque in
Nm
Airbag ECU 6 NUT HEX FL

Airbag ECU to BIW 3
SQUIB M6X1X6X8 GR
Airbag ECU 10 NUT HEX FL

Airbag ECU to BIW 3
SQUIB M6X1X6X8 GR
8.0±0.5
Airbag Sensor SCREW HEX FL
Airbag sensor to BIW 2
Side Satellite M6X1X20X8.8XZN
Airbag Sensor SCREW HEX FL

Airbag sensor to BIW 2
Front Satellite M6X1X20X8.8XZN
COMBI SCREW
Passenger Airbag
M8X1.25X21 (HEX Airbag to CCB 2 25.0±5.0
- Single Stage
PH RC)
SCREW HCC P
Cur Airbag 6 6.0±0.5
M6X1X20X4.6
SCREW HCC P
Cur Airbag 8 6.0±0.5
M5X0.8X20X6.6XZN

MAN-00162
Repair Manual Propeller Shaft Nov 2011/ Rev 2
PROPELLER SHAFT
CONTENT

Exploded View ................................................................................... 1
Incar Repairs ....................................................................................3
Propeller Shaft ..............................................................................3

Removal ............................................................................................. 3
Inspection ........................................................................................... 3
Installation .......................................................................................... 3
Propeller Shaft Disassembly and Assembly ................................. 4

Disassembly....................................................................................... 4
Assembly ............................................................................................ 5
Mahindra Special Tools (MST) ........................................................6
Torque Specification ....................................................................... 6

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Propeller Shaft
The function of the propeller shaft is to transmit power from one point to another. The shaft is designed to
transmit torque from transmission to the rear axle.
The propeller shaft has to operate through constantly changing length while transmitting torque. The axle
rides suspended by spring in floating motion. The propeller shaft must be able to change the transmission
angle when going through the various road surfaces. This is done through Universal joints which permit the
propeller shaft to operate at different angles.
Exploded View
A
G
B
C D
E
F
A. Flange Slip Shaft Assembly Propeller Shaft

B. Rubber Boot Propeller Shaft
C. Constant Velocity Joint Propeller Shaft
D. Flange Joint Propeller Shaft
E. Center Bearing Assembly Propeller Shaft
F. Tube Assembly Propeller Shaft
G. Coupling Flexible Propeller Shaft
.

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A. Propeller Shaft

MAN - 00162
Incar Repairs 4. Loosen the three 17mm mounting bolts (A)

from the yoke and remove the rear side of the
propeller shaft from the IRDA.
Propeller Shaft
5. Loosen the two 13mm center bearing mounting

Removal bolts (A) from the under chassis frame and
detach the propeller shaft from the vehicle.
DANGER
Improper jacking will lead to vehicle slippage
and cause damage to both to the vehicle and A
person.

information refer to Jacking and Lifting
Section.
2. Mark the propeller shaft yoke universal joint
before removing the propeller shaft.
3. Loosen the four 13mm mounting bolts (A) from
the yoke and remove the front side of the
propeller shaft from the PTU.
Inspection
1. Inspect the play and rotation of the joints by
turning in clockwise direction.
Installation

MAN - 00162
Propeller Shaft Disassembly and 3. Remove the 17mm mounting bolt (A) from the
cv joint yoke (B) and separately remove the
Assembly yoke.
Disassembly
1. Remove the three 17mm propeller shaft flexible
coupling mounting bolts (A) from the IRDA
side.
4. Fix the bearing remover (A) (Special tool No:

0502EAA0007ST) at the back side of centre
A bearing, install the three leg puller (B) (Special
tool No: 0502CAA0026ST), and remove the
bearing (C) separately by rotating the three leg
2. Remove the six 5mm allen key mounting bolts puller.
(A) from the cv joint and disassemble the
propeller shaft front and rear separately. Notice
Remove the centre bearing along with the rub-
ber mounting using a puller, and then sepa-
A rately remove the bearing

MAN - 00162
5. Using a suitable tool, remove the propeller 8. Remove the joint bearing stopper washer (A)
shaft joint bearing back plate (A). and joint bearing back plate (B).
6. Using a circlip plier (A), remove the propeller Assembly

shaft joint bearing circlip (B).
procedure.
7. Fix the bearing remover (A) (Special tool No:

0502EAA0007ST) at the back side of bearing,
install the three leg puller (B) (Special tool No:
0502CAA0026ST), and remove the joint
bearing (C) separately by rotating the three leg
puller.

MAN - 00162

Three leg puller standard 8 inch (C/s

0502CAA0026ST shaft on Transaxle, Pinion Bearing on
Catridge, Pinion Bearing on IRDA)
Flat bearing puller for differential cage

0502EAA0007ST
bearing
Torque in
Nm
SCREW HEX FL
6 40.0~50.0
M10X1.5X30X8.8XZN
Propeller Shaft Propeller shaft and C/B mounting
BOLT HEX FL
3 100.0~120.0
M12X1.25X50X8.8,A

MAN-00162
Repair Manual RPAS Nov 2011/ Rev 2
REVERSE PARKING ASSISTANCE SYSTEM (RPAS)

CONTENTS
Incar Repairs .................................................................................... 5
RPAS Sensor ................................................................................ 5

Removal ............................................................................................. 5
Installation .......................................................................................... 6
RPAS ECU .................................................................................... 6

Removal ............................................................................................. 6
Installation ........................................................................................... 6

MAN-00162
Reverse Parking Assistance System

Description and Operation Limitations of RPAS
• System may not sense obstacles like wire
Reverse parking assistance system is provided to aid
the driver while parking the vehicle in reverse at a mesh, handrail, small objects which are below
speed of less than 5 kmph. While reversing, RPAS the bumper level.
will detect the obstacles at the rear side of the vehicle • System may not sense obstacles with cotton or
within the sensing zone, which cannot be viewed spongy surface, which will absorb ultrasonic
through the internal rear view mirror and the outside waves emitted by RPAS.
rear view mirrors. The RPAS will then alert the driver
by a beep sound about the location of the detected • System performance is dependent on the
obstacle and the distance from the vehicle. The alert reflection angle of the obstacle.
sound level will vary proportional to the distance. • System may alert with beep sound while
Smaller the distance shorter the interval between the reversing the vehicle on grasslands and bumpy
beeps.
roads, considering it to be an obstacle.
RPAS Sensors • System may give signal while the vehicle
moves from plain ground to a slope terrain vice
versa.
• System may give signal by sensing the ground
when the bumper is tilted more from the
normal position or when the vehicle is heavily
overloaded.
• System may sound an alarm during heavy rain,
snow and heavy wind conditions.
CAUTION
• RPAS is an aiding system. Under no
circumstances Mahindra will accept any
responsibility or can be held liable for any
direct or indirect, incidental or consequential
Four RPAS sensors are located at the rear bumper to damage caused by this system.
provide complete rear view to the driver for hassle • System will not sense pot holes, trenches
free parking. or drainages which are below the ground
level.
Notice • Repainting of the sensor will affect the
Always keep the sensors clean and free from performance of the system.
ice formation, dust, water etc. for proper
working of the system. Engaging and Disengaging of RPAS
• Engine should be in running condition to
engage reverse parking assistance system.
• RPAS will be activate automatically when
reverse gear is engaged and deactivate when
reverse gear is disengaged.

MAN-00162
RPAS Information on Infotainment Screen 3. Start moving the vehicle in reverse direction.
RPAS display on infotainment screen gives the 4. Display bars in the respective direction will glow
following information: according to obstacles in its path.
• Left zone indicates obstacle on left hand side. a. If the obstacle is between 100 to 120 cm bar
4 will be turned ON
• Center zone indicates obstacle in the center.
b. If the obstacle is between 75 to 100 cm bar 3
• Right zone indicates obstacle on right hand & 4 will be turned ON
side.
c. If the obstacle is between 50 to 75 cm bar 2,
Display bars 1, 2, 3 and 4 indicate how close the 3 & 4 will be turned ON
obstacle is from the vehicle rear bumper, with bar 1 d. If the obstacle is less than 50 cm all bars in
being very close and bar 4 being distant. that direction will be turned ON and a STOP
Distance indicator will display a STOP symbol if the symbol will be displayed
obstacle is less than 50 cm from the vehicle rear
bumper.
Operation of RPAS
1. Start the vehicle.
2. Engage the gear in reverse - RPAS will be dis-
played in the infotainment screen.
5. Distance indicator will display the distance in

multiples of 2 cm, whichever is shortest.

MAN-00162
6. The alert sound can be heard from the driver Along with this beep sound can be heard from driver
side speaker. Frequency of the beep will side speaker. Frequency of the beep will increase if
increase if obstacle comes closer (crossing each obstacle comes closer (crossing each zones) and the
display bar) and the sound will be continuous if sound will be continuous if any of the obstacles is
any of the obstacle is less than 50 cm. less than 50 cm.
Pay Attention
1. If display bars in any one of the sides are
d i s p l a y e d w i t h c r o s s m a r k s , c o n ta c t a n
7. Optical indication will be displayed without any

obstacle once the gear is shifted from reverse to
any other gear, for 10 seconds or until the
vehicle reaches 10 kmph (whichever is earlier).
2. If all display bars are displayed with cross
Example marks, contact an Authorised Mahindra Dealer.
Assume 3 obstacles are placed as mentioned below.
• Obstacle at left at 110 cm
• Obstacle at center at 80 cm
• Obstacle at right at 60 cm
On engaging the gear in reverse, infotainment will
display as below.
Since obstacle is at 60cm in right - minimum distance

is shown in the distance indicator.

MAN-00162
3. Obstacle in the blind zone cannot be sensed by 6. Not all obstacles are detected from 120 cm. For
the system. instance, a person is detected from 75 cm
because of the weak reflection or absorption of
Sensing Zone the waves of the clothes.
Blind Zone
Sensing Zone
Blind Zone
Obstacle
4. Please check the condition of the obstacle

behind your vehicle before reversing. In some
cases, the display may be not as same as reality 7. The distance indication may move up and down
due to the installed sensor level, obstacle shape, due to different sizes of the obstacle at different
reflection condition. Some examples are given positions.
below.
Sensing Zone
Blind Zone
Obstacle
Obstacle Sensing zones

Blind zone
8. Though the obstacle is in the sensing zone,
5. Point B will be detected sooner or later, but A o b s ta c l e m a y n o t b e d e t e c t e d s i n c e t h e
may not be detected at all. ultrasonic waves are not reflected back to the
sensor.
Sensing Zone
Blind Zone
Obstacle
Sensing zones
Blind zone
Obstacle

MAN-00162
9. The obstacle of a conical shape may not be Incar Repairs

detected, since the ultrasonic waves get
reflected away.
RPAS Sensor
Sensing zones
Blind zone Obstacle
Removal
1. Remove the rear bumper. For additional infor-
mation refer to Rear Bumper removal and
connector (A) from the RPAS sensor.

MAN-00162
3. Unlock the two locks (A) and remove the RPAS ECU
RPAS sensor (B) from the rear bumper.
Installation Removal
1. Insert and fix the RPAS sensor into the bumper. 1. Remove the LHS rear lower quarter trim. For
2. Connect the electrical connector into RPAS sen- Quarter Trims removal and installation Sec-
sor. tion.
connector (A), loosen the two 10mm mounting
bolts (B) and remove the RPAS ECU
(Electronic Control Unit) separately.
C
B
Installation

MAN-00162
Repair Manual TPMS Nov 2011/ Rev 2
TYRE PRESSURE MONITORING SYSTEM (TPMS)
CONTENTS

Operation of TPMS ............................................................................ 1
TPMS Warning Indicator .................................................................... 1
General Procedure............................................................................. 3
Tyre Swapping ................................................................................... 4
Incar Repairs ....................................................................................5
TPMS Sensor ................................................................................5

Procedure for TPMS Learning ........................................................... 5
Removal ............................................................................................. 7
Inspection........................................................................................... 7
Installation .......................................................................................... 7

MAN-00162
Tyre Pressure Monitoring System

Notice
TPMS is an electronic system designed to monitor
the air pressure inside the pneumatic tyres. This • The TPMS is not intended to replace normal
system will alert the driver if the tyre pressure falls tyre care and maintenance or to provide
below the low pressure warning limit for any reason, warning of a tyre failure or condition
including low temperature effects and natural • The TPMS should not be used as a tyre
pressure loss through the tyre. The TPMS will pressure gauge while adjusting vehicle tyre
continue to alert the driver and will not turn off until pressure
the tyre pressure is inflated to the recommended
pressure. • Driving with under-inflated tyres cause the
tyres to overheat and may lead to tyre failure.
Operation of TPMS
• Under-inflated tyres also reduce fuel
TPMS uses wireless technology with wheel rim efficiency and tyre tread life, and may affect
mounted electronic sensors to monitor tyre pressure the vehicle's manoverability and braking
levels. Sensors mounted to the valve stem of each ability.
wheel, transmit tyre pressure readings to the receiver
module. Receiver module in turn will communicate • The TPMS is not a substitute for proper tyre
this information to the instrument cluster and maintenance, and it is the driver's
infotainment system. Tyre locations will display as responsibility to maintain correct tyre
OK, if all tyre pressure and temperature are in the pressure using an accurate pressure gauge,
recommended range. even if under-inflation has not reached the
level to trigger illumination of the TPMS
warning indicator.
CAUTION
• The TPMS has been customised only for the Notice
manufacturer’s genuine tyres and wheels.
TPMS pressure limits and warning messages Seasonal temperature changes will affect tyre
have been es t a b l i s h e d f o r t h e t y r e size pressure, and the TPMS will monitor the
equipped on your vehicle. Replacement of actual tyre pressure in the tyre.
manufacturer’s parts with a different size, type
or style of components may damage the
TPMS Warning Indicator
sensor and also it may give incorrect readings.
• Do not use aftermarket tyre sealants or
balance beads if your vehicle is equipped with
TPMS. Failure to comply may lead to sensor
damage.
TPMS warning indicator will blink for 75 seconds and

remain ON in the instrument cluster, if any of the
below mentioned condition occurs in the tyres:
• Sensor signal missing
• Sensor faulty
During this infotainment also will display as below.

MAN-00162
For example: Front left tyre High pressure
High temperature
If above condition occurs, contact the nearest
Authorised Mahindra Dealer for further assistance.
TPMS warning indicator will illuminate in the
instrument cluster, if any of the below mentioned
errors occur in the tyres.
• Low pressure (<24 psi / 1.65 bar)
• High pressure (> 48 psi / 3.31 bar)
• Air leakage (> 3 psi/sec / 0.25 bar/sec)
• High temperature (>98 Deg C)
During the above alerts infotainment will be displayed
as below:
Example: Front right Low pressure
Air leakage
Notice
After tyre rotation or TPMS sensor
replacement, receiver must be learnt,
otherwise the system will show TPMS
malfunction indicator.

MAN-00162
TPMS Learning Switch 2. Start removing air from front left tyre, once the tyre
TPMS learning switch is located to the left hand side
of the instrument cluster.
as below.
General Procedure 3. Start removing air from front right tyre. Once the
Procedure for TPMS Learning tyre get learnt, vehicle alarm and hazard lamp will
1. Press the TPMS switch in the cluster and turn igni-
change as below.
tion ON along with the switch pressed, infotainment
will be displayed as below and TPMS warning lamp
in the cluster will start blinking.

MAN-00162
4. Start removing air from rear right tyre. Once the 6. Start removing air from spare tyre. Once the tyre
tyre get learnt, vehicle alarm and hazard lamp will get learned, vehicle alarm and hazard lamp will alert
alert once and the screen in the infotainment will 3 times to indicate all the tyres were learned and the
change as below. screen in the infotainment will change as below to
5. Start removing air from rear left tyre. Once the tyre
get learnt, vehicle alarm and hazard lamp will alert 7. If there were any problem in learning, system will
once and the screen in the infotainment will change alert through alarm and hazard lamp 5 times to
as below. indicate the tyre learning is not complete.
Tyre Swapping
If the tyres were swapped with the spare tyre, then
system will alert the user through infotainment as
tyres swapped. Infotainment system will display
below message.
User needs to press the TPMS switch in the cluster

to acknowledge the same.
TPMS warning indicator will continue to glow if the
spare tyre is having any pressure or temperature
alert. After correction, user needs to press the TPMS
switch to acknowledge the spare tyre has been
corrected and to remove the alert in the cluster and
infotainment.

MAN-00162
Incar Repairs
CAUTION TPMS Sensor
• Please note, if swapping is done for more
than one tyre or with the other running tyres, Procedure for TPMS Learning
system cannot identify the same and the 1. Press the TPMS switch in the cluster and turn
system needs to be relearned by manual ignition ON along with the switch pressed,
learning process infotainment will be displayed as below and
• After correcting the spare tyre, user needs to TPMS warning lamp in the cluster will start
press the TPMS switch in cluster to blinking.
acknowledge the correction, since system
cannot understand on its own for spare tyre.
2. Start removing air from front left tyre, once the tyre
as below.

MAN-00162
3. Start removing air from front right tyre. Once the 5. Start removing air from rear left tyre. Once the tyre
tyre get learnt, vehicle alarm and hazard lamp will get learnt, vehicle alarm and hazard lamp will alert
alert once and the screen in the infotainment will once and the screen in the infotainment will change
change as below. as below.
4. Start removing air from rear right tyre. Once the 6. Start removing air from spare tyre. Once the tyre
tyre get learnt, vehicle alarm and hazard lamp will get learned, vehicle alarm and hazard lamp will alert
alert once and the screen in the infotainment will 3 times to indicate all the tyres were learned and the
change as below. screen in the infotainment will change as below to
7. If there were any problem in learning, system will

alert through alarm and hazard lamp 5 times to
indicate the tyre learning is not complete.

MAN-00162
Removal Inspection
1. Remove the tyre. For additional information 1. Ensure that the TPMS Sensor is not damaged
refer to Tyre Changing removal and while removing the tyre.
installation Section. 2. Check the tyre inner surface for cuts and
2. Using a tyre tool (A), lift the inner tyre bead (B) punctures.
over the rim.
Installation
Notice
Tighten the sensor at proper position,
without damage.
A
B
3. Using the tool, remove the TPMS sensor (A)

from the wheel rim.
Notice
The TPMS and Valve cannot be replaced sepa-
rately. These can be replaceable as assembly.

MAN-00162
Repair Manual Cruise Control System Nov 2011/ Rev 2
CRUISE CONTROL SYSTEM
CONTENT
InCar Repairs ....................................................................................3
Steering Wheel Control Switches................................................... 3

Removal ............................................................................................. 3
Installation .......................................................................................... 3

MAN-00162
Cruise Control System The steering wheel switches operate as follows:

Cruise Control enables the driver to maintain a
constant road speed without the accelerator pedal.
This is particularly useful for motorway cruising or for
any journey where a constant speed can be
3
maintained for a long period. Cruise Control is +
SOURC
V
E
RES
CRUISE
OFF
+
SET
-
RES
designed to activate for all gears except 1st when the

-
vehicle speed is above 20 km/hr. +

CRUISE
OFF
SET
Notice 1
- 2
Always ensure following conditions met

while operating Cruise Control:
• Vehicle speed should be more than 20 km/
hr with gears in 2nd,3rd, 4th, 5th or in 6th
1. CRUISE OFF : Press to suspend / cancel the
gear.
cruising speed
• Clutch pedal should not be in pressed
condition. 2. SET(+ / -) : Press (+) to increase the cruising
• Brake pedal should not be in pressed speed. Press (-) to decrease the cruising speed
condition. 3. RES : Press to resume the cruising speed
• Once the Cruise Control is activated with
the help of SET (+) button, user has to To Operate
remove the foot from the accelerator pedal. Accelerate until the desired cruising speed is
• Vehicle should follow the cruising mode. reached. This must be above the system's opera-
tional minimum speed i.e. 20 kmph.
Press the (+) switch to set the vehicle speed in the
system's memory. Cruise Control will now maintain
CAUTION that road speed.
Always observe the following precautions:
• Do not use cruise control in traffic RES
conditions where a constant speed cannot +
easily be maintained. CRUISE

OFF SET
-
• Do not use cruise control on winding or
slippery road surfaces, or in off-road
conditions such as rough tracks or on sand.
• When the 'SET (+)' button is pressed, if the
acceleration is felt to be too fast and vehicle
goes beyond control, press brake or clutch
immediately for safety and coming out of
Cruise Control.

MAN-00162
The warning indicator in the instrument cluster To Resume Cruising Speed

illuminates. With Cruise Control operating, speed can
be increased by normal use of the accelerator e.g. RES
for overtaking. When the accelerator is released, +
road speed will return to the previously set cruising CRUISE

OFF SET
-
speed.
By pressing the RES switch, the last set cruise

speed can be resumed, provided the ignition switch
is ON and the vehicle speed is above 20 kmph.
To Disengage / Suspend Cruising Speed

To Increase Cruising Speed
RES
+
RES CRUISE
OFF SET
-
+
CRUISE
OFF SET
-
Cruise Control can be suspended by a single press

of the CRUISE OFF switch. The warning indicator in
Press and hold the (+) switch; the vehicle will
the instrument cluster extinguishes.
accelerate. Release the switch as soon as the
desired speed is reached. Cruise Control will also suspend when the brake
pedal is pressed, when the gear selector is moved
The vehicle speed at the point of switch release
into neutral or if HDC or ESP becomes active.
becomes the new set speed.
A l t e r n a t i v e l y, t h e s p e e d c a n b e i n c r e a s e d Override Function
incrementally by tapping the (+) switch. This function enables user to ramp up the cruising
Each press of the switch will increase the speed by 2 speed to overtake the vehicle in front. The cruising
km/hr. speed can be increased by using accelerator pedal.
User has to complete this action within 30 seconds,
A further alternative is to increase speed by normal
to maintain the cruise mode. If user exceed the 30
use of the accelerator. When the desired speed is
seconds limit, cruise mode will be deactivated.
reached, press the (+) switch to set the Cruise
Control.
Notice
Cruise Control will not operate at speeds below 20
kmph.
To Reduce Cruising Speed
RES
+
CRUISE
OFF SET
-
Press and hold the (-) switch, the vehicle will

decelerate. Release the switch as soon as the
desired speed is reached.
The vehicle speed at the point of switch release
becomes the new set speed.
A l t e r n a t i v e l y, t h e s e t s p e e d c a n d e c r e a s e
incrementally by tapping the (-) switch. Each press of
the switch will decrease the speed by 2 km/hr.

MAN-00162
InCar Repairs 4. Remove the steering wheel switches (A) from

the steering wheel.
Steering Wheel Control Switches
Removal
A 100 120 3
4 A
1. Remove the Driver airbag. For additional 60
40
80 km/h 140
160
180 1
2
x1000 rpm
5
information refer to Driver Airbag removal

20 200
0
7
0
and installation Section. SOUR

CE
RES
+
+
V
OFF SET
2. Pullout and remove the steering wheel chrome

V
(A).
100 120
80 140 3 4
60
160 2 5
40 H
180
20 1
200 6
c
0 220
7
Installation
3. Press the lock and disconnect the two

electrical connectors (A), and unscrew the two
20 mm steering wheel switches mounting
screws (B).
A
B
100 120 3
4
80 km/h 140 x1000 rpm
B 60
40
160
180 1
2
5
6
20 200
0
7
0
RES
CE
SOUR
+
+
V
OFF SET
V -
-

MAN-00162
Repair Manual Incar Entertainment Nov 2011/ Rev 2
INCAR ENTERTAINMENT
CONTENTS

Level 1 - Audio Infotainment System ................................................. 1
Bezel and Button Functions ............................................................... 2
Features ............................................................................................. 2
Level 2 - Audio Infotainment System ................................................ 3
Features ............................................................................................. 4
Level 3 - Audio Infotainment System ................................................. 5
Features .............................................................................................. 6
Audio Controls on the Steering Wheel ............................................... 7
Incar Repair ....................................................................................10
Audio Unit ................................................................................... 10

Removal ........................................................................................... 10
Installation ........................................................................................ 10
Infotainment Unit ........................................................................11

Removal ........................................................................................... 11
Installation ........................................................................................ 11
Front Door Speaker ................................................................... 11

Removal ........................................................................................... 11
Installation ........................................................................................ 12
Rear Door Speaker ..................................................................... 12

Removal ........................................................................................... 12
Installation ........................................................................................ 13

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Incar Entertainment
Level 1 - Audio Infotainment System

MAN-00162
Bezel and Button Functions

NO. KEY NAME FUNCTION / DESCRIPTION
1 POWER / SELECT Power ON / OFF, Select
2 VOLUME KNOB Volume up / down
3 1 Programmed memory 1
5 3 / FLR- Programmed memory 3 / Folder down
6 4 / FLR+ Programmed memory 4 / Folder up
9 CLK Clock settings and toggling between 12 and 24 hrs
10 BAND Band selection
11 SEEK DOWN Previous track / fast rewind
12 SEEK UP Next track / fast forward
13 EQ Equalizer settings
14 FAV Favorite tuner memory selection
15 RPT Repeat
16 RDM Random
17 SOURCE Source selection
18 INFO Track information
19 MUTE Audio mute
20 EJECT CD eject
Features
• AM / FM tuner
• Manual / Auto seek frequency tune
• Six tuner frequency memory pre-sets
• 18 - FM and 12 - AM manual preset store
• CD supports CDDA, MP3 and WMA9 formats
• AUX audio input support
• Power output - 4 X 25 watts (10% THD)
• Clock display
• Audio adjustments - bass treble balance fade
• EQ settings - Classic, Pop, Jazz, rock

MAN-00162

MAN-00162

This Switch Bank contains 19 buttons and volume knob. The bank will be illuminated if the head lamps are turned
on.

1 POWER / SELECT Power ON / OFF, Select
2 VOLUME KNOB Volume up / down
3 1 Recall or save Preset #1 / Dial #1
6 4\ ↵ Recall or save Preset #4 / Exit menu / Dial #4
7 5 / RDM Recall or save Preset #5 / Random / Dial #5
8 6 / RPT Recall or save Preset #6 / Repeat / Dial #6
9 CLK / * Clock / Dial *
10 7 / BAND Interchange tuner bands (AM 1 / 2, FM 1 / 2 / 3) / Dial number 7
Tuner seek down / Previous track / Other menu associated activity / Dial num-
11 8 / SEEK DOWN
ber 8
12 9 / SEEK UP Tuner seek up / Next track / Other menu associated activity / Dial number 9
13 O / EQ Equalizer adjust / Dial number 0
14 #TA Traffic Enable / Disable / Dial number #
15 Menu Menu options
16 List Show list of tracks / folder / accept a phone call / enter Phone Book
17 SOURCE Inter change media sources (Tuner / AUX-in / CD / USB / BTA / iPod / RAI
18 INFO Show cluster details / warnings / Reject a phone call
19 MUTE Mute / Un-mute Audio Sources
20 EJECT CD eject
Features • Steering Wheel Controls (SWC)

• AM / FM tuner • Speaker - 4x25 Watts
•Auto Seek with RDS
•18-FM and 12-AM manual preset store
• CD, USB, iPod
•Supports CDDA, MP3 and WMA9 formats
•Browsing
•Random / Repeat
• AUX Audio Input
• Bluetooth (BT)
•Hands Free
•Phone Book Access
•Music Streaming
• Audio adjustments
•Bass, Treble, Balance, Fade
•Normal, Classic, Pop, Jazz, Rock
•Mahindra Modes
• Infra Red Remote Control (IRRC)
• Voice Recognition (VR)

MAN-00162

MAN-00162

This Switch Bank contains 19 buttons and volume knob. The bank will be illuminated if the head lamps are turned
on.

1 VOL/POWER/SEL Power ON / OFF, Select
VOL/POWER/SEL
2 Volume Up / Down
(Rotary)
3 MUTE Mute / Un-mute Audio Sources
4 VIDEO Video playback from source
5 EQ Equalizer adjustments
6 Now Playing Change the screen to the current source play screen
7 Audio, video, list browse up / Previous page / Phonebook browse up
8 Audio, video, list browse down / Next page / Phonebook browse down
9 SEEK Tuner seek down / Previous track / Fast Rewind
10 SEEK Tuner seek up / Next track / Fast Forward
11 LIST List browse screen
12 TA Traffic enable / disable
13 MENU Menu setting options
14 INFO Infotainment will change the display to vehicle info screen
15 NAV Navigation mode selector
16 PHONE Bluetooth phone selector / Accept a phone call / Display phone menu
17 HOME Home screen selector
18 MUSIC Music mode selector / call rejection
19 RADIO Tuner mode selector
20 EJECT Disc eject
Features • Infra Red Remote Control

• Voice Recognition
• Touch screen color display
• GPS Navigation
• AM / FM tuner
• Rear View Camera Support*
•Auto Seek with RDS
• Rear Sear Entertainment system*
•18-FM and 12-AM manual/Auto preset store
• Steering Wheel Support
• CD, CD VIDEO,DVD, USB, iPod
• Power Output - 4x25 Watts
•Supports CDDA, MP3, WMA9, Divx, MPEG4
* Features described herein are subjected to avail-
•Browsing
ability depending on vehicle variants.
•Random / Repeat
• AUX Audio Input
• Bluetooth (BT)
•Hands Free
•Phone Book Access
•Music Streaming
• Audio adjustments
•Bass, Treble, Balance, Fade
•Normal, Classic, Pop, Jazz, Rock
•Mahindra Modes

MAN-00162
Audio Controls on the Steering Wheel
RES
SOURCE
+
CRUISE
+
V
OFF SET
V -
-
2 5
RES 8
1
+
3 CRUISE
4 OFF
SET
-
6 7
Audio Control
1. Mute: Press to mute the audio sound
2. Source: Press to select Radio or CD
3. Volume control: Press (+) to increase the
volume. Press (-) to decrease the volume
4. Phone call accept or reject / Seek
When Bluetooth function is ON, Press to accept

incoming call. Press to reject incoming call.
When Radio is ON, pressing of or will func-
tion as auto seek.
When CD is ON, short pressing of or will
change the track and long pressing of or will
function as fast forward / reverse.
Cruise Control
5. RES: Press to resume the cruising speed
6. CRUISE OFF: Press to suspend / cancel the
cruising speed
7. SET (+ / -): Press (+) to increase the cruising
speed. Press (-) to decrease the cruising speed.
Voice Recognition
8. : Press to activate voice recognition function.

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80 10
60 0
km 12
/h 0
40
14
F 0
20
R
ODO 16
0
0 E km
18
0
3
2
1
x1
20 00
2 0 0
rp 4
m
CL
K
3 22
0
BA
ND
7 H
VOL
5
POW
8 SELER 4
EXIT
5
RDM SOURCE C
6
RPT +
6
9
EQ
V
ME -
7
NU 0 TA V
#
LIS
T
SO
UR
CE
A
INF
O
MU
TE
ECO
N
A/C
OFF
REA RES
AU A/C R
TO
M CRU
ISE
OFF
+
SET
AWD
LOC
K PASS
ENGE
R
STAR
T
A
STOP
ES
OF P
F
A. Infotainment System
B. Steering Wheel Switches

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Since dust tends to accumulate in the CD opening,

Service Tips and Precautions clean it periodically. Remember that compact disks
(CD) may get scratched if placed in the CD opening
To avoid risk of damage and/ or fire, observe the which has dust accumulated in it.
following precautions:
• To avoid short circuits, never insert metallic
objects (for instance coins or metallic tools) into
the unit.
• Pay attention not to let the unit fall down, nor
beat the device strongly. Glass and other
i n t e r n a l c o m p o n e n ts o f t h e u n i t m a y g e t
damaged, making it non-operative.
• If the LCD (Liquid Crystal Display) is damaged
or broken as a result of a crash, never touch the
liquid crystal fluid inside it. The liquid crystal fluid
may be harmful to your health. If the liquid gets
in contact with the body or clothes, wash it
promptly with water and soap and seek medical
help.
• Do not place 8 cm (3 inches) compact disks into
the CD opening. If you try to place a 8 cm CD
with an adaptor in the device, it may separate
from the CD and damage the unit.
Cleaning of the unit

If the front panel of this unit is dirty, clean it with a dry
cloth or slightly damp cloth. If the front panel is very
dirty, clean it with a cloth moistened with neutral soap
and then repeat the prior operation.
WARNING
Do not use any cleaning spray on the unit, as
that it can affect its mechanical parts. Cleaning
the front panel with a rough cloth or using a
volatile liquid, like solvent or alcohol, may
scratch the surface or erase some characters.
CD Opening Cleaning

MAN-00162
Incar Repair 3. Unscrew four 20mm mounting screws (A) on

the audio unit.
Audio Unit
4. Pull the audio unit slightly in the forward

direction and disconnect the electrical
Removal connectors (A, B) and antenna connector (C)
of the audio unit.
CAUTION
Store the removed audio unit in a dust free B C
environment. Avoid direct sunlight, exces-
sive heat or humidity.
Notice A
Press the Power ON/OFF button on the face
plate to Turn ON/OFF the audio system.

5. Remove the audio unit from the instrument
2. Remove the center bezel. For additional panel.
informtion refer to Central Bezel removal
and installation section. Installation
Notice
Properly route the audio unit wiring harness to
avoid the short circuit and malfunction.
2. Check the audio unit operation after installation.

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Infotainment Unit Front Door Speaker
Removal Removal
1. Remove the center bezel. For additional 1. Remove the front door trims. For additional
informtion refer to Central Bezel removal informtion refer to Front Door Trim removal
2. Remove the four 20mm flower mounting 2. Remove the insulation cover (A) from the door.
screws (A) and detach the infotainment display
unit (B) from the center bezel. A
3. Disconnect the electrical connector (A) of the

speaker.
Installation
2. Check the infotainment unit operation after
installation.

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4. Unscrew the four speaker screws (A) and Rear Door Speaker
remove the speaker from the door.
Removal
Notice 1. Remove the rear door trims. For additional
informtion refer to Rear Door Trim removal
Do not connect speaker leads to any inputs on
external amplifiers. This will cause damage to
2. Remove the insulation cover (A) from the door.
the internal amplifier of this unit.
Installation
Notice
Follow the same procedure for removing
Front Door Speaker (RHS).
3. Disconnect the electrical connector (A) of the

speaker.

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4. Unscrew the four speaker screws (A) and

remove the speaker from the door.
Notice
Do not connect speaker leads to any inputs on
external amplifiers. This will cause damage to
the internal amplifier of this unit.
Installation
Notice
Follow the same procedure for removing
Rear Door Speaker (LHS).

MAN-00162
Repair Manual Locks and Keys Nov 2011/ Rev 2
LOCKS AND KEYS
CONTENTS

Remote Key Battery Replacement ..................................................... 1
Locking/Unlocking the vehicle with Remote Key ............................... 2
Central Locking with Driver Door-lock Knob ..................................... 4
Engine Immobilizer System ................................................................ 4
Incar Repairs .................................................................................... 6
Ignition Key Barrel ...................................................................... 6

Removal ............................................................................................. 6
Installation .......................................................................................... 7
Bonnet Latch ................................................................................7

Removal ............................................................................................. 7
Installation .......................................................................................... 8
Bonnet Lock ..................................................................................8

Removal ............................................................................................. 8
Installation .......................................................................................... 9
Bonnet Hinges .............................................................................. 9

Removal ............................................................................................. 9
Installation ........................................................................................ 10
Bonnet Cable ..............................................................................11

Removal ........................................................................................... 11
Installation ........................................................................................ 12
Door Outer Handle .................................................................... 12

Removal ........................................................................................... 12
Installation ........................................................................................ 13
Door Key Barrel .........................................................................14

Removal ........................................................................................... 14
Installation ........................................................................................ 14

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Door Latch ................................................................................. 15

Removal ........................................................................................... 15
Installation ........................................................................................ 17
Door Latch Actuator .................................................................. 17

Removal ........................................................................................... 17
Installation ........................................................................................ 18
Door Striker Plate ....................................................................... 18

Removal ........................................................................................... 18
Installation ........................................................................................ 18
Door Link Arm ............................................................................ 19

Removal ........................................................................................... 19
Installation ........................................................................................ 19
Tailgate Latch ............................................................................ 20

Removal ........................................................................................... 20
Installation ........................................................................................ 20
Tailgate Latch Actuator ............................................................. 21

Removal ........................................................................................... 21
Installation ........................................................................................ 21
Tailgate Striker Plate 21

Removal ........................................................................................... 21
Installation ........................................................................................ 22

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Locks and Keys • Unfold the key using key release button (refer
Locks and Alarms for key button description).
Description and Operation • Carefully remove the battery cover in the

direction as shown in below image.
Vehicle is supplied with two remote keys which
operate all the locks of the vehicle. The operation of
all transmitter buttons on the remote key will be
inhibited while a key is in ignition switch except few
functions. The operating range of the remote control
is approximately 15 metres. But this range of the
remote control may be reduced if the batteries are
weak.
• Remove the discharged battery from the key.
CAUTION
• The key contains delicate electronic circuits
and must be protected from impact and water
damage, high temperatures and humidity,
direct sunlight and the effects of solvents,
waxes and abrasive cleaners.
• The keys supplied with vehicle are
programmed with vehicle security system. The
• Insert the new battery. Ensure that the "+"
engine cannot be started without a key
symbol on the battery is facing upwards. The
programmed to the vehicle.
correct polarity is shown on the battery cover.
Remote Key Battery Replacement

Each remote key contains a battery which is
housed under the cover.
The fact that the battery needs replacement will be
apparent from the following:
1. Transmitter light will flash at a slower rate or

does not flash at all.
2. A gradual deterioration in range and

performance will be noticed.
If you find above symptoms, replace the battery as
follows:

MAN-00162
• Position the battery cover on the key and press Lock

it until it gets locked in its place.
CAUTION
Disposal of the used battery should be in
accordance with environmental regulations.
Notice
• Pay attention to the correct polarity when
changing the battery.
• The replacement battery must have the
same specification as the original battery
• Remote key battery specification: CR
2032H 3V Press to lock all doors and tailgate. If all doors are
closed, the hazard warning lamps will blink once to
indicate that all doors are locked. However, if any
Locking/Unlocking the vehicle with one of the doors remain open, the hazard warning
Remote Key lamps will blink 5 times along with the alarm.
Unlock
1 2 3 4
1. Key Release Button

2. Lock Button
3. Tailgate Unlock Button Press to unlock all doors. The hazard warning lamps
4. Unlock Button will blink twice indicating that the doors are unlocked.
Notice
• If theft is attempted when vehicle is locked,
hazard warning lamps and alarm will sound
4 times.
• If the vehicle is involved in a collision
forceful enough to cause a restraints devices
to deploy, all door-locks will become
unlocked and the hazard warning lamps will
start to flash.

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Tailgate Unlock Mute/Unmute the Alarm
Press to unlock the tailgate. The hazard warning Alarm can be muted / unmuted on pressing the lock button
lamps will blink four times to indicate that the tailgate for more than 3 seconds. Hazard warning lamps will flash
is unlocked. once to indicate the change in status.
Notice Panic Alarm
• Tailgate will automatically lock, if the

tailgate door is not opened within 45
seconds.
• When the vehicle is centrally locked (either
by remote key or using driver door lock
knob), the tail gate cannot be opened by
means of the tailgate release switch.
• In case of remote key failure, tailgate can
also be opened from inside the vehicle. Refer
“Tailgate” section.
Key Release
The panic alarm function can be used to attract

attention in the event of an emergency.
To activate panic alarm, press the unlock button
continuously for more than 3 seconds, when the key
is in ignition switch. Once panic alarm is activated,
hazard warning lamps will flash along with alarm.
Press unlock button once to deactivate the panic
alarm.
Press to release the folded key.

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Search Alarm
Lock
Unlock
Engine Immobilizer System

The search alarm function can be used to locate the The engine immobilizer system is a theft prevention
vehicle in the parking area. system. When you insert the key inside the ignition
switch, the transponder chip in the key's head
To activate search alarm, press the unlock button transmits an electronic code to the vehicle. The
continuously for more than 3 sec. Once search alarm engine will start only when the electronic code inside
is activated, hazard warning lamps will flash along the chip corresponds to the registered ID code for the
with alarm. vehicle. The immobilizer system is automatically set
Press unlock button once to deactivate the search when the key is removed from the ignition switch.
alarm. The indicator lamp will start flashing to show the
system is set. If any of the following indicator
Auto Lock conditions occur, that means some malfunction has
occured.
All doors lock automatically, when
1. The indicator lamp remains ON
• The vehicle speed is more than 20 kmph and
• All doors are in closed position.
Auto Relock
After unlocking the vehicle using the remote key,
vehicle will relock automatically if none of the
doors, tailgate and bonnet are opened / closed for 2. The indicator lamp does not flash when the key
45 seconds. is removed from the ignition switch
3. The indicator lamp flashes inconsistently
Vehicle Unlocking in an Emergency Inserting the registered key in the ignition switch
If the vehicle is involved in a collision forceful automatically cancels the system, which enables the
enough to cause a restraints device to deploy, all engine to start. The indicator lamp will go OFF.
door locks will become unlocked and the hazard
warning lamps will start to flash. Notice
Do not modify, remove or disassemble the
Central Locking with Driver Door-lock Knob engine immobilizer system. If any
All doors and the tailgate lock automatically when the unauthorised changes or modifications are
driver's door-lock knob is pushed inside. All doors made, proper operation of the immobilizer
and the tailgate unlock when the driver's door-lock system cannot be guaranteed.
knob is pulled out.
While turning ignition to ON position, Key blade and
the key base cover should be kept straight as in
below picture. If not there is a chances of vehicle
getting immobilized.

MAN-00162
How to Turn OFF an Armed System

An armed system can be turned OFF by any one of
the following methods:
1. Unlock the doors using remote key.
2. Insert the key into the ignition switch and turn

it to ON position.
The hazard warning lamp will flash twice to indicate
that the system is turned OFF.
What Turns ON the Alarm
The alarm will be activated if any of the following
occurs while the vehicle is parked and the system is
armed
1. A front or rear door is opened, without using the
Theft Deterrent Alarm System key.
Theft deterrent alarm system increases the level of
protection against people seeking to break into the 2. The tailgate is opened without using the
vehicle. The system triggers audible and visual remote key.
warning signals if an attempt is made to break into
3. The bonnet is opened.
the vehicle.
How to Arm the System 4. Battery terminals disconnected and
reconnected.
1. Park the vehicle and stop the engine
The alarm will sound and the turn signal lamps will
2. Remove the ignition key from the ignition blink continuously for 30 seconds.
switch and exit the vehicle To Stop an Alarm
3. Make sure that all doors, tailgate and bonnet A triggered alarm can be turned OFF by any one of
are properly closed the following methods:
4. Lock the doors using the remote key 1. Unlock the door with the remote key.
After completion of the above steps, the hazard 2. Turn ON the ignition.
warning lamps will blink once to indicate that the
system is armed.
The system can also be armed by locking the doors
with the key, however, the hazard warning lamps will
not blink. If any door or engine hood remains open,
the hazard warning lamps will not blink and the
system will not get armed.

MAN-00162
Incar Repairs 5. Press the lock (A) and disconnect the ignition
key barrel electrical connector (B) from the
ignition key barrel.
Ignition Key Barrel
6. Unsrew the immobilizer mounting screw (A)

Removal and detach the immobilizer (B) from the
1. Remove the negative terminal of the battery. ignition key barrel.
2. Remove the steering wheel.For additional
and installation Section.
3. Remove the combination switch. For
additional information refer to Combination B
Switch removal and installation Section.
4. Disconnect the immobilizer electrical connector
(B) from the ignition key barrel .
A 7. Using a suitable tool, remove the two ignition

key barrel mounting bolts (A) and remove the
ignition key barrel (B) from the steering
column.
2
2
220

MAN-00162
Installation Bonnet Latch

1. Install the ignition key barrel to the steering
column.
Notice
Tighten the ignition key barrel mounting bolts
untill the mounting bolts head breaks.
Removal
1. Open the bonnet and fix the stay rod (A) in a
2. Remove the lock pin (A), pull out the cable (B)
and disconnect other end of the bonnet cable
(C) from the latch.
A
B
C

MAN-00162
3. Remove the three bonnet latch mounting bolts Bonnet Lock

(A) and remove the bonnet latch (B) from the
bulkhead.
Removal
Installation 1. Open the bonnet and fix the stay rod (A) in a
Notice
Align and fix the bonnet latch properly failure
to follow this bonnet gets stuck in locking
position.
2. Remove the 12mm bonnet lock mounting bolts

(A) and separately detach the bonnet lock (B)
from the bonnet.
B
A

MAN-00162
Installation Bonnet Hinges

Notice
Align and fix the bonnet lock properly failure
to follow this bonnet gets stuck with latch in
locking position.
Removal
2. Remove the two 12mm RHS bonnet hinges

mounting bolts (A) from the bonnet.

MAN-00162
3. Remove the two 12mm LHS bonnet hinges Installation

mounting bolts (A) from the bonnet.
Notice
When fixing the hinges and bonnet properly
A align and fix failure to follow this bonnet gets
stuck with locking position.
4. Remove the bonnet separately.

5. Remove the two 12mm LHS bonnet hinges
mounting bolts (A) and detach hinges (B)
separately from the vehicle.
6. Remove the two 12mm RHS bonnet hinges

mounting bolts (A) and detach hinges (B)
separately from the vehicle.

MAN-00162
Bonnet Cable 3. Remove the lock pin (A), pull out the cable (B)
and disconnect other end of the bonnet cable
Removal (C) from the latch.

position to support the bonnet. A
B
C
4. Remove the bonnect cable (A) from the clip (B)

and detach from the fire wall (C).
2. Lift and detach the NVH cover at back side

(A), slide and remove the NVH cover (B)
towards windscreen. C
A
A A


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6. Slide and remove the bonnet lever (A) from the Door Outer Handle
instrument panel.
Removal
Notice 1. Remove the door trim. For additional
Bonnet lever as three holding locks at the information refer to Front Door Trim
top. slowly remove the lever from instrument removal and installation Section. For
panel to avoid damaging of locks. additional information refer to Rear Door
Trim removal and installation Section.
2. Remove the dust cover from the door.
Installation
3. Fully raise the front door window glass.
Notice
When fixing the hinges and bonnet properly
align and fix failure to follow this bonnet gets
stuck with locking position.

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4. Remove the two 10mm door glass channel 7. Loosen the screw (A), unlock the handle
mounting bolts (A) and remove the channel (B) retainer lock (B) and remove the handle
from the door. retainer (C).
A A
C
A
5. Unlock the lock (A) and detach the outer 8. Remove the two outer handle mounting nuts
handle link (B). (A), turn and remove the outer handle (B) from
the door.
6. Remove the lock (A) and detach the handle

retainer (B) and spring from the door outer
handle.
Installation

MAN-00162
Door Key Barrel 4. Unlock the lock (A) and detach the outer
handle link (B).
A
B
B
A. Key Barrel
5. Remove the key barrel lock (A) and detach the
B. Key Barrel Lock front door key barrel (B) from the door.
Removal
1. Remove the door trim. For additional A
information refer to Front Door Trim
removal and installation Section. For
additional information refer to Rear Door
Trim removal and installation Section.
B
A
Installation

MAN-00162
Door Latch
4. Remove the two 10mm door glass channel
mounting bolts (A) and remove the channel (B)
from the door.
Removal A
1. Remove the door trim. For additional informa-
tion refer to Front Door Trim removal and
5. Unlock the lock (A) and detach the outer
installation Section. For additional informa-
handle link (B).
tion refer to Rear Door Trim removal and
6. Unlock the lock (A) and detach the outer

handle link (B).

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7. Press the lock (A) and disconnect the door

actuator electrical connector (B).
A
B
B
10. Detach the latch with actuator from the door.
8. Remove the three 30mm flower door latch

mounting screws. (A).
11. Detach the two door latch cables (A) from the
latch bracket (B) and remove cables from fixed
with latch levers (C).
9. Unlock the three latch cover locks (A) and
remove the cover (B) from the latch.
A
B A
C A
B
A
Notice
Carefully remove the cables from the plastic
latch lever without expanding to avoid free
moment of cables.properly rotate and
remove the cables.

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Door Latch Actuator

Notice
Expanded plastic latch levers will not hold
the cables properly.
12. Remove the four actuator mounting screws (A)

and detach the actuator (B) from the door
latch.
Removal
1. Remove the door latch. For additional
information refer to Door Latch removal and
B 2. Unlock the three latch cover locks (A) and
remove the cover (B) from the latch.
Installation
A
B A

MAN-00162
3. Remove the four actuator mounting screws (A)

and detach the actuator (B) from the door
Door Striker Plate
latch.
B
Removal
Installation 1. Loosen the two striker plate flower mounting
1. To install, reverse the removal procedure. bolts (A) and remove the striker plate (B).
Installation
Notice
Align and fix the striker plate properly to
avoid the door align.

MAN-00162
Door Link Arm 3. Loosen the three 12mm door link arm
mounting bolts (A) and remove the link arm (B)
from the door .
Notice
Door link arm can be remove from inside of
the door.
Removal A
1. Remove the door trim. For additional A
information refer to Front Door Trim removal
and installation Section.For additional
information refer to Rear Door Trim removal
Installation
A
Notice
Align and fix the link arm properly.

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Tailgate Latch
3. Remove the three 12mm tailgate latch
mounting bolts (A) and remove the tailgate
latch (B) from the tailgate.
Removal
1. Remove the tailgate trim. For additional
information refer to Tailgate Trim removal
4. Remove the three tailgate actuator mounting
screws (A) and remove the tailgate actuator
2. Press the locks (A) and disconnect the two (B) and detach the tailgate latch.
tailgate actuator electrical connectors (B).
A A
B B
A
Installation

MAN-00162
Tailgate Latch Actuator Tailgate Striker Plate

Removal
1. Remove the tailgate latch. For additional
information refer to Tailgate Latch removal
2. Remove the three tailgate actuator mounting
screws (A) and remove the tailgate actuator
(B) from the tailgate latch.
Removal
A 1. Remove the striker plate cover (A) from the
cargo area.
Installation A
2. Loosen the two striker plate flower mounting

bolts (A) and remove the striker plate (B).

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Installation
Notice
Align and fix the striker plate properly to
avoid the door align.

MAN-00162
Torque in
Nm
BOLT COMBI LP Check Arm Bkt to Inner

4 6.5±1.5
M6X1X16X8.8XZN panel
LATCH MOUNTING Side Door Latch to Inner

6 6.5±1.5
SCREW panel
SCREWHLBSKC LP Check Arm Bkt to Body

2 25.0 ± 3.0
M8X1.25X20X8.8 side
Front door locking SCREW HXLBSK SL Side Door Latch Striker to

4 28.0±7.0
system M8X1.25X18X10.9 Body side
NUT HEX FL M6X1X6X8 Outer Handle to Outer

4 4.0 ± 0.5
GR Panel
SCREW TPRF CR ST Inner Handle (With Trim)

2 2.0 ± 0.5
4.8X1.6X18 R to Inner panel
SCREW TPRF CR ST Pusher assy to Outer han-

2 4.0 ± 0.5
6.3X1.8X16 C dle
BOLT COMBI LP Check Arm Bkt to Inner

4 6.5±1.5
M6X1X16X8.8XZN panel
LATCH MOUNTING Side Door Latch to Inner

6 6.5±1.5
SCREW panel
SCREWHLBSKC LP Check Arm Bkt to Body

2 25.0 ± 3.0
M8X1.25X20X8.8 side
Rear door locking SCREW HXLBSK SL Side Door Latch Striker to

4 28.0±7.0
system M8X1.25X18X10.9 Body side
NUT HEX FL M6X1X6X8 Outer Handle to Outer

4 4.0 ± 0.5
GR Panel
SCREW TPRF CR ST Inner Handle (With Trim)

2 2.0 ± 0.5
4.8X1.6X18 R to Inner panel
SCREW TPRF CR ST Pusher assy to Outer han-

2 4.0 ± 0.5
6.3X1.8X16 C dle

MAN-00162
Torque in
Nm
SCREW HXLBSK SL Tail Gate Latch Striker to

2 36.0±7.0
M8X1.25X18X10.9 Under Body
SCREW HEX FL Thrust Pad to Tail Gate &

8 6.5±1.5
M6X1X20X8.8XGR D- Pillar
Tailgate locking
SCREW HEX FL Tail Gate Latch to Tail
system 3 6.5±1.5
M6X1X20X8.8XGR Gate Inner panel
BALL STUD TAIL GATE Ball stud to tailgate 2 20.0~25.0
SCREWHLBSKC LP
Gas Strut Bkt to D- Pillar 4 28.0±5.0
M8X1.25X20X8.8
CLIP CABLE HOOD

Cable holding clips 1 NA
LOCK RELEASE
Hood / Bonnet
SCREW HEX FL Hood latch to FEM &
locking system 5 11.0±1.0
M8X1.25X20X8.8 Hood Inner panel
COTTER PIN 1.58 X 15.8 Cable to Bottom latch 1 NA

MAN-00162
Repair Manual Interior Trims Nov 2011/ Rev 2
INTERIOR TRIMS
CONTENTS

Floor Trim Exploded View .................................................................. 1
Floor Carpet ...................................................................................... 2
Floor Insulation ................................................................................... 2
A -Pillar Upper Trim ............................................................................ 3
A -Pillar Lower Trim ............................................................................ 4
B -Pillar Upper Trim ............................................................................ 5
B -Pillar Lower Trim............................................................................ 6
Front Scuff Plate ................................................................................ 7
Rear Scuff Plate ................................................................................. 8
Tailgate Scuff Plate ............................................................................ 9
Rear Quarter Trim Upper ................................................................. 10
Rear Quarter Trim Lower ................................................................. 11
Overhead Console Trim ................................................................... 12
Incar Repairs ..................................................................................13
Driver Sunvisor ...........................................................................13

Removal ........................................................................................... 13
Installation ........................................................................................ 13
Co-Driver Sunvisor .....................................................................14

Removal ........................................................................................... 14
Installation ........................................................................................ 14
A-Pillar Upper Trim .................................................................... 15

Removal ........................................................................................... 15
Installation ........................................................................................ 15
A-Pillar Lower Trim ....................................................................16

Removal ........................................................................................... 16
Installation ........................................................................................ 17
B-Pillar Lower Trim ....................................................................17

Removal ........................................................................................... 17
Installation ........................................................................................ 18

MAN-00162
B-Pillar Upper Trim ................................................................... 19

Removal ........................................................................................... 19
Installation ........................................................................................ 19
Front Scuff Plate ........................................................................ 20

Removal ........................................................................................... 20
Installation ........................................................................................ 20
Rear Scuff Plate ......................................................................... 21

Removal ........................................................................................... 21
Installation ........................................................................................ 21
Rear RHS Quarter Trims............................................................ 22

Removal ........................................................................................... 22
Installation ........................................................................................ 25
Rear LHS Quarter Trims ............................................................ 26

Removal ........................................................................................... 26
Installation ........................................................................................ 29
Tailgate Scuff Plate ................................................................... 29

Removal ........................................................................................... 29
Installation ........................................................................................ 30
Tool Box Bin ............................................................................... 30

Removal ........................................................................................... 30
Installation ........................................................................................ 30
Floor Carpet ................................................................................ 31

Removal ........................................................................................... 31
Installation ........................................................................................ 31
Floor Insulation .......................................................................... 32

Removal ........................................................................................... 32
Installation ........................................................................................ 32
Overhead Console Trim ............................................................ 32

Removal ........................................................................................... 32
Installation ........................................................................................ 34

MAN-00162
Interior Trims
Floor Trim Exploded View
F
C
B
A
A. Front Carpet
B. Floor Insulation Rear RH
C. Floor Insulation Front RH
D. Floor Insulation Front LH
E. Floor Insulation Rear RH
F. Rear Carpet

MAN-00162
Floor Carpet
A. Front Carpet B. Rear Carpet
Floor Insulation
A. Floor Insulation Rear RH C. Floor Insulation Front LH

B. Floor Insulation Front RH D. Floor Insulation Rear RH

MAN-00162
A -Pillar Upper Trim
A. Trim Cap A-Pillar Upper

B. Trim A-Pillar Upper
C. Locating Lugs In IP
D. Mounting Clips In BIW
E. Bolt Mounting In BIW

MAN-00162
A -Pillar Lower Trim
A. Trim Cap A-Pillar Lower D. Metal Clip

B. Trim A-Pillar Lower E. Z-Locator In BIW
C. Self Tapping Screw F. Mounting Clips In BIW

MAN-00162
B -Pillar Upper Trim
C
E
G
G
A. Trim Cap B-Pillar Upper

B. Spring
C. Height Adjuster Knob
D. Ram Snaps To Be Hooked In BIW
E. Trim B-Pillar Upper
F. Bolt Mounting In BIW
G. Mounting Clips In BIW

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B -Pillar Lower Trim
A. Mounting Clips In BIW

B. Snaps To Be Locked In B-Upper
C. Locating Lugs In BIW
D. Metal Clip

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Front Scuff Plate
A C
A. Branding Plate
B. Scuff Plate Front Moulding RH
C. Riblock Plastic
D. Riblock Plastic

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Rear Scuff Plate
C
B
D
A
A. Branding Plate
B. Scuff Plate Rear Moulding RH
C. Riblock Plastic
D. Riblock Plastic

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Tailgate Scuff Plate
D
A
A. Tailgate Scuff Plate Latch Cover

B. Tailgate Scuff Plate Winch Mech Cover
C. Tailgate Scuff Plate Moulding
D. Riblock Plastic

MAN-00162
Rear Quarter Trim Upper

A
E
D
C B
A. Ramp Snaps To Be Hooked In BIW

B. Belt Bezel Third Row
C. Vent Cover
D. CD Trim
E. Belt Bezel Second Row
F. Screw Mounting

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Rear Quarter Trim Lower
C D
A. HVAC Controller
B. Seat Belt Retainer
C. Trim Cap RQT
D. Mounting Clips In BIW
E. Screw Mounting

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Overhead Console Trim
A. Sunvisor Support Bracket and Screw

B. Sunvisor Driver and Codriver
C. X Mas Tree Clip

MAN-00162
Incar Repairs Installation

Driver Sunvisor
Removal
1. Remove the driver sunvisor mounting screw
cap (A).
2. Remove the two sunvisor mounting screws (A)

and detach driver sunvisor from the sunvisor
support bracket (B).

MAN-00162
Co-Driver Sunvisor 3. Disconnect the co-driver sunvisor electrical

connectors (A) and remove the co-driver
sunvisor separately.
Removal
1. Remove the co-driver sunvisor mounting screw Installation
cap (A). 1. To install, reverse the removal procedure.
2. Remove the two sunvisor mounting screws (A)

and detach sunvisor from the sunvisor support
bracket (B).

MAN-00162
A-Pillar Upper Trim

A
Installation
Removal
1. Remove the A-pillar door beading (A). Notice
A Before installing the A-Pillar upper trim check
the mounting clips condition.
2. Using a suitable tool open the A-pillar upper MOUNTING CLIPS

trim mounting bolt cap (A) from the A-pillar
trim.
Notice
When installing the A-Pillar upper trim insert
the locating lugs into IP.
A
SRS
3. Remove the A-pillar upper trim 10 mm

mounting bolt (A) from the A-pillar upper trim
(B) and pull out the trim gently.

MAN-00162
A-Pillar Lower Trim
TRIM CAP A-PILLAR UPPER
LOCATING LUGS IN IP
Removal
1. Remove the A-pillar door beading.
2. Pull out and remove the front door scuff plate
(A).
3. Remove the A-pillar lower trim mounting screw

cap (A) and remove the mounting nut (B) from
the A-pillar lower trim.
B A

MAN-00162
4. Unscrew the A-pillar lower trim mounting screw B-Pillar Lower Trim
(A) and remove A-pillar lower trim (B)
separately.
Removal
Installation 1. Remove the A-pillar door beading from front
door side (A). Remove the B-pillar door
beading from front door side (A).
Notice
Before installing the A-Pillar lower trim check
the mounting clips and metal clips
condition.When installing the A-Pillar lower
trim insert the locator.
METAL CLIPS
2. Remove the front door scuff plate (A).
MOUNTING CLIPS IN BIW
Z-LOCATOR IN BIW

MAN-00162
3. Remove the B-pillar door beading (A) from rear 6. Remove the seat belt 14 mm mounting bolt (A)
door side. from the B-Pillar lower trim and detach the B-
Pillar trim separately.
4. Remove the rear door scuff plate (A).

Installation
Notice
Before installing the B-Pillar lower trim check
the mounting clips and metal clips condition.
When installing the B-Pillar lower trim insert
the locator.
5. Lift the seat belt mounting bolt cover (A).
METAL CLIPS
LOCATING LUGS IN BIW

MAN-00162
B-Pillar Upper Trim 3. Remove the B-pillar upper trim 10mm

mounting bolt (A) from the B-Pillar upper trim
(B) and detach the B-Pillar upper trim
SRS
separately.
Removal
1. Remove the B-pillar lower trim. For additional
information refer to B-Pillar Lower Trim Installation
removal and installation section. 1. To install, reverse the removal procedure.
2. Remove the B-pillar upper trim mounting bolt
cap (A). Notice
Before installing the B-Pillar upper trim, check
SRS the mounting clips condition.
Notice
When installing the B-Pillar upper trim insert
the ram snaps in position.

MAN-00162
Front Scuff Plate

RAM SNAPS TO BE
HOOKED IN BIW
Notice
When installing the B-Pillar upper trim match Removal
the height adjuster into seat belt mounting 1. Pull out and remove the front door scuff plate
bolt. (A).
Installation
Notice
Check the scuff plate rib lock plastics condi-
tion.

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Rear Scuff Plate
SCUFFPLATE
RIBLOCK PLASTIC
Removal
1. Remove the rear door scuff plate (A).
Installation
Notice
tion.

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Rear RHS Quarter Trims
a.Rear RHS Quarter Trim Lower
SCUFFPLATE
RIBLOCK PLASTIC
RHS Lower Quarter Trim
b.Rear RHS Quarter Trim Upper
RHS Upper Quarter Trim
Removal
1. Remove the rear RHS door beadings (A).

MAN-00162
2. Remove the tailgate beading (A). 6. Loosen the 16mm second row RHS seat belt
3. Remove the third row RHS seat. For

additional information refer to Third Row 7. Loosen the 16mm third row RHS seat belt
Seats removal and installation section. mounting bolt (A) and release the seat slowly.
4. Remove the second row RHS seat. For

additional information refer to Second Row
RHS Seats removal and installation section.
5. Remove the rear door RHS scuff plate (A).
8. Using a tool box latch (A) open the tool box.

A

MAN-00162
9. Loosen the three tool box bin mounting 12. Loosen the four screws (A) from the lower
screws, (A) and remove the tool box bin (B). trim, pull and remove the lower trim slowly.
A B A
10. Remove the striker plate cover (A) and detach 13. Press the lock and pull out the electrical
the tail gate scuff plate (B). connector (A) of the rear A/C blower dial
control knob.
A
B
11. Remove the lower trim mounting screw cover

(A). 14. Remove the seat belts covers (A) from the
RHS upper quarter trim.

MAN-00162
15. Open the grip handle cover and unscrew the Installation
grip handle two mounting screws (A) and
remove the grip handle (B) from top of the 1. To install, reverse the removal procedure.
RHS quarter trim.
Notice
proper position.
B
Notice
tion.
16. Loosen the two RHS upper quarter trim

quarter trim. SCUFFPLATE
RIBLOCK PLASTIC
A
Notice
Check the tail gate scuff plate rib lock plas-
tics condition.
RIBLOCK PLASTIC
TAILGATE SCUFFPLATE

MAN-00162
Rear LHS Quarter Trims 2. Remove the tailgate beading (A).
a.Rear LHS Quarter Trim Lower
3. Remove the third row LHS seat. For

LHS Lower Quarter Trim
additional information refer to Third Row
Seats removal and installation section.
4. Remove the second row LHS seat. For

b.Rear LHS Quarter Trim Upper additional information refer to Second Row
LHS Seat removal and installation section.
5. Remove the rear door LHS scuff plate (A).
LHS Upper Quarter Trim A
Removal
1. Remove the rear LHS door beadings (A).
6. Remove the washer fluid bezel (A) and fuel lid
bezel (B) from the rear LHS lower quarter trim.
A A

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7. Loosen the 16mm second row LHS seat belt 10. Loosen the three tool box bin mounting
mounting bolt (A) and release the seat belt screws, (A) and remove the tool box bin (B).
slowly.
A B
11. Remove the striker plate cover (A) and detach

8. Loosen the 16mm third row LHS seat belt the tail gate scuff plate (B).
A
12. Remove the lower quarter trim mounting
9. Using a tool box latch (A) open the tool box. screw cover (A).

MAN-00162
13. Loosen the four screws (A) from the lower 16. Open the grip handle cover and unscrew the
trim, pull and remove the lower trim slowly. grip handle two mounting screws (A) and
remove the grip handle (B) from top of the
RHS quarter trim.
A A
14. Loosen the fuel lid knob screw (A) and

remove the knob (B) from the lower quarter
trim. 17. Loosen the two LHS upper quarter trim
quarter trim.
B
A
15. Remove the seat belts covers (A) from the

LHS upper quarter trim.
A
A

MAN-00162
Installation Tailgate Scuff Plate

Notice
Check the quarter panel trims mounting
proper position.
Notice
tion.
Removal
1. Remove the tailgate beading (A).
SCUFFPLATE
RIBLOCK PLASTIC
Notice
A
tics condition.
2. Remove the striker plate cover (A) and detach
the tail gate scuff plate (B).
RIBLOCK PLASTIC
A
TAILGATE SCUFFPLATE

MAN-00162
Installation Tool Box Bin

Notice
tics condition.
Removal
RIBLOCK PLASTIC 1. Using a tool box latch (A) open the tool box.
TAILGATE SCUFFPLATE
2. Loosen the three tool box bin mounting

screws, (A) and remove the tool box bin (B).
A B
Installation

MAN-00162
Floor Carpet 11.Remove the third row LH seat. For additional

information refer to Third Row Seats
Notice
The front and rear carpets are stuck to the
floor.
Installation
Removal
2. Remove the A pillar lower trims from both LHS

and RHS. For additional information refer to
A-Pillar Lower Trim removal and installation
section.
3. Remove the B pillar lower trims from both LHS
and RHS. For additional information refer to
B-Pillar Lower Trim removal and installation
section.
4. Remove the RHS lower quarter trim. For
Quarter Trims removal and installation
section.
5. Remove the LHS lower quarter trim. For
section.
6. Remove the driver seat. For additional
information refer to Driver Seat removal and
7. Remove the co-driver seat. For additional
information refer to Co-driver Seat removal
8. Remove the second row RH seat. For
RHS Seats removal and installation section.
9. Remove the second row LH seat. For
LHS Seat removal and installation section.
10.Remove the third row RH seat. For additional
information refer to Third Row Seats

MAN-00162
Floor Insulation Overhead Console Trim
Removal Removal
1. Remove floor insulation front LH, front RH, rear 1. Remove the A pillar upper trim. For additional
LH and rear RH. information refer to A-Pillar Upper Trim
Installation
2. Remove the B pillar upper trim. For additional
1. To install, reverse the removal procedure. information refer to B-Pillar Upper Trim
3. Remove the RHS upper quarter trim. For
section.
4. Remove the LHS upper quarter trim. For
section.
5. Remove the driver sunvisor. For additional
information refer to Driver Sunvisor removal
6. Remove the co-driver sunvisor. For additional
information refer to Co-Driver Sunvisor

MAN-00162
7. Open the driver sunvisor support bracket cover 13. Open the grip handle cover and unscrew the
(A) and remove the support bracket mounting grip handle two mounting screws (A) and
screw, detach the support bracket (B) from the remove the five grip handles (B) from the
overhead console trim. overhead console trim.
A
B
B
8. Open the co-driver sunvisor support bracket

cover (A) and remove the support bracket
mounting screw, detach the support bracket (B)
from the overhead console trim.
A
B B
14.Remove three overhead console trim clips (A)

and detach the overhead console trim
separately.
9. Remove the front roof lamp / overhead console

lamp. For additional information refer to
Roof Lamp - Front / Overhead console lamp
- Front removal and installation section.
10. Remove the vanity mirror lamp. For A
additional information refer to Vanity Mirror
Lamp removal and installation section.
11.Remove the rear roof lamp. For additional
information refer to Roof Lamp - Rear
12.Remove the map reading lamps. For
additional information refer to Map Reading
Lamp removal and installation section.

MAN-00162
Notice
Remove the overhead console trim carefully
without damaging the overhead console trim
four hidden clips.
HIDDEN CLIPS
Installation
Notice
Before installing the overhead console trim
fix the overhead console trim hidden clips
properly to avoid rattling noise.
Notice
Before installing the overhead console trim
properly route the electrical wiring harness.
HIDDEN CLIPS

MAN-00162
Torque
in Nm
SCREW HCC P
Floor console To BIW 6
M6X1X20X4.6,A
4.0±0.5
A and B - pillar up- SCREW HCC P
To BIW 4
per trim M6X1X20X4.6,A
SCREW FLANGED SELF

Rear quarter trim To BIW 6
TAPPING 4.8X1.6X18XC ZN
CD pillar trim /
SCREW FLANGED SELF
rear quarter trim 2
upper
SCREW FLANGED SELF

Grab handle Grab handles to doors 12 2.0±0.5
Body trim - lug-

SCREW FLANGED SELF
gage compart- To floor 3
ment
SCREW FLANGED SELF

Grip handles to BIW 12
Grip handle
SCREW HCC P
Grip handle bracket to BIW 12
M6X1X20X4.6,A
4.0±0.5
SCREW FTCS CR Sunvisor to driver and Co-driver
Sunvisor 6
M6X1X20X6.6,A side
SCREW FLANGED SELF

A pillar lower trim Open grommet to BIW 2
2.0±0.5
SCREW FLANGED SELF
B pillar duct Ducts to B pillar and floor 7
Footrest Assem- SCREW TPRF CR ST LHD Plastic foot rest bracket to

1 2.0±0.5
bly LHD 4.8X1.6X18 R BIW brackets (Side Mounting)
Bracket Plastic RHD Plastic foot rest bracket to

Assembly Foot NUT HEX FL M6X1X6X8 GR BIW brackets (tucker stud to 3 4.0±0.5
Rest RHD nut)

MAN-00162
Repair Manual Lighting System Nov 2011/ Rev 2
LIGHTING SYSTEM
CONTENTS
Exterior Lighting.................................................................................. 1

Auto Headlamp ................................................................................. 1
Headlamp Levelling System............................................................... 2
Headlamp Alignment By Visual Method ............................................. 3
Head Lamp Bulb Arrangement........................................................... 4
Headlamp Alignment .......................................................................... 5
Follow me Home ............................................................................... 9
Lead me to Vehicle ........................................................................... 9
Entry Assist Lamp ........................................................................... 10
Static Bending Lamp ........................................................................ 10
ORVM (Outside Rear View Mirror) Indicator .................................... 10
High Mounted Stop Lamp ................................................................ 10
Component Location Index ...........................................................11

Roof Lamp ........................................................................................ 11
Map Reading Lamps ........................................................................ 12
Foot well Lamps ............................................................................... 13
In Car Repairs .................................................................................14
Headlamp ................................................................................... 14
Removal ........................................................................................... 14
Installation ........................................................................................ 14
Fog Lamp ....................................................................................15

Removal ........................................................................................... 15
Installation ........................................................................................ 15
Tail Lamp ....................................................................................15

Removal ............................................................................................ 15
Installation ........................................................................................ 16
High Mount Stop Lamp ..............................................................16

Removal ........................................................................................... 16
Installation ........................................................................................ 17

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Number Plate Lamp .................................................................. 18

Removal ........................................................................................... 18
Installation ........................................................................................ 18
Bulb Replacement...................................................................... 19
Head Lamp Low Beam Bulb .......................................................... 19
Removal ........................................................................................... 19
Installation ........................................................................................ 19
Head Lamp High Beam Bulb ......................................................... 20
Removal ........................................................................................... 20
Installation ........................................................................................ 20
Head Lamp Static Bending Light .................................................. 20
Removal ........................................................................................... 20
Installation ........................................................................................ 20
Front Turn Lamp ............................................................................ 21
Removal ........................................................................................... 21
Installation ........................................................................................ 21
Fog Lamp Bulb ............................................................................... 21
Removal ........................................................................................... 21
Installation ........................................................................................ 22
Tail Lamp Bulb - Turn Indicator Bulb ........................................... 22
Removal ........................................................................................... 22
Installation ........................................................................................ 22
Rear Position Lamp Bulb .............................................................. 23
Removal ........................................................................................... 23
Installation ........................................................................................ 23
Interior Lighting ................................................................................. 24
Roof Lamp - Front / Overhead console lamp - Front ............. 24

Removal ........................................................................................... 24
Installation ........................................................................................ 25
Roof Lamp - Rear ...................................................................... 25

Removal ........................................................................................... 25
Installation ........................................................................................ 26
Map Reading Lamp ................................................................... 26

Removal ........................................................................................... 26
Installation ........................................................................................ 27

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Vanity Mirror Lamp .................................................................... 27

Removal ........................................................................................... 27
Installation ........................................................................................ 28
Camping Lamp .......................................................................... 28

Removal ........................................................................................... 28
Installation ........................................................................................ 29
Door Ajar Lamp ......................................................................... 29

Removal ........................................................................................... 29
Installation ........................................................................................ 29
Puddle Lamp ..............................................................................30

Removal ........................................................................................... 30
Installation ........................................................................................ 30
Ambience Lighting .....................................................................31

Foot Well Lamp .............................................................................. 31
Removal ........................................................................................... 31
Installation ........................................................................................ 31
Foot Well Lamp (Below Front Seat) .............................................. 32
Removal ........................................................................................... 32
Installation ........................................................................................ 32
Map Pocket Lamp ........................................................................... 32
Removal ........................................................................................... 32
Installation ........................................................................................ 32
Inner Handle Lamp ......................................................................... 33
Removal ............................................................................................ 33
Installation ........................................................................................ 33
Glove Box Lamp ........................................................................ 33

Removal ........................................................................................... 33
Installation ........................................................................................ 34
Glove Box Lamp Switch ...........................................................34

Removal ........................................................................................... 34
Installation ........................................................................................ 35

MAN - 00162
Repair Manual Lighting System Nov 2011/Rev 2
Lighting System 3. Auto headlamp symbol will illuminate in an

infotainment screen indicating that the feature
is activated.
Exterior Lighting
Auto Headlamp
Rain Light Sensor (RLS), located on front windshield,
turns the headlamp ON or OFF whenever it senses
the ambient light intensity (eg. vehicle enters in a
tunnel or in dim light condition)
4. Once enough light is present, headlamps will

go OFF.
Rain sensor Notice

• There is difference between ambient light
intensity sensed by sensor and by the
human eye. It may be possible that during
evening time, headlamp will activate early as
RLS sensor senses it as low intensity. This
Operation is absolutely a normal behavior.
• In Auto headlamp mode, headlamps will
1. Turn ON the Ignition. remain ON until enough ambient light
intensity is not available. Once enough light
is present, headlamps will go OFF. This is a
designed feature to avoid false switching ON
/ OFF of headlamp.
WARNING
• Do not put any band/tape outside the sensor
on windshield.
• Do not use any Chemical or Thinner to clean
inner surface of front windshield to avoid any
damage to the sensor.
2. To activate auto headlamp, rotate the outer

switch in anti-clockwise direction.
CAUTION
• In case of any damages/scratches to
windshield, new sensor needs to be installed/
assembled along with new windshield.
• Old sensor cannot be used on the new
windshield as it is calibrated for a particular
windshield.

MAN - 00162
Headlamp Levelling System
Headlamp low beam can be adjusted using

headlamp levelling switch. It has positions marked 0,
1, 2, 3. Select the suitable switch position depending
on pay load as advised in the table. The level of the
headlamp beams can be adjusted according to the
vehicle load. Turn the thumbwheel downward to
lower the beams and upward to raise the beam. The
following table shows the control positions for various
loading conditions.
S.No Load Position
1 Driver/Driver with front

0
passenger
2 Driver + front passenger

+ second row seat occu- 1
pied
3 All seats occupied 2
4 All seats occupied with

luggage or driver with lug- 3
gage at extreme rear side

MAN - 00162
Headlamp Alignment By Visual Method
10 Meters
Ensure that the:

a. Vehicle and 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.

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Head Lamp Bulb Arrangement
RH SIDE HEADLAMP LH SIDE HEADLAMP
A - High Beam C- Low Beam

B - Static Bending Lamp D - Turn Indicator Lamp

MAN - 00162
Headlamp Alignment
1. Low Beam Setting Procedure
Vertical Line Corresponding

to Vehicle Centerline
LOW BEAM-
CENTER LINE
o o Low Beam
15 15
Cut-off Line
Low beam Low beam
cut-off pattern cut-off pattern
X
X-1.3%
High Beam-
Y CENTER LINE
V V GROUND
Z Z
X = 935mm V = 495mm
Y = 905mm Z = 645mm
X- 1.3% = 922mm
1. 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.

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LHS and RHS Headlamp Low Beam Alignment Procedure
A
[A] Horizontal Adjustment
Left: Anti-clockwise
Right: Clockwise B [B] Vertical Adjustment
Up: Anti-clockwise
Down: Clockwise
1. Set screw [A] to adjust low beam horizontal

movement.
2. Set screw [B] on leveling motor to adjust low
beam vertical movementt.
3. Check the function of system, by operating the
switch from '0' to '3' and observe the cutoff
pattern movement in downward direction
accordingly.
4. At zero position of switch, the cut.off should
come at .1.3% heights (9..2mm) on screen.

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2. High Beam Setting Procedure
Vertical Line Corresponding

to Vehicle Centerline High Beam Hotspot
LOW BEAM-
CENTER LINE
Low Beam
Cut-off Line
X
X-1.3% High Beam-
Y CENTER LINE
GROUND
X = 935mm V = 495mm
Y = 905mm Z = 645mm
X- 1.3% = 922mm
1. 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.

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LHS and RHS Headlamp High Beam Alignment Procedure
[C] Vertical Adjustment

Up: Anti-clockwise
D Down: Clockwise
[D] Horizontal Adjustment

Left: Anti-clockwise
C Right: Clockwise
1. Set screw [C] to adjust low beam horizontal

movement.
2. Set screw [D] to adjust low beam vertical
movement.
Notice
• 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.

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905 935
990
1290
Follow me Home Follow me home lamps can be extended up to

maximum 2 min from first activation.
Follow me home will help to reach the home by
automatically turning ON the headlamp and entry Lead me to Vehicle
assist lamp in dark and cloudy conditions.
Lead me to the vehicle will help to find and reach the
This feature will activate the lamps for 20sec. vehicle in dark and cloudy conditions by turning ON
This function will get activated on satisfying the the headlamp and entry assist lamp.
following conditions: This feature will activate the lamps for 20sec.
• Vehicle driven with position lamp / parking lamp • If the vehicle is equipped with auto headlamp
in ON position or vehicle driven with auto feature, lead me to the vehicle will be activated
headlamp in ON position. automatically on pressing the unlock button and
• Vehicle driven with position lamp / parking lamp if the outside is dark or cloudy.
in OFF position (applicable only in case vehicle Or
is driven without auto headlamp mode). • If the vehicle is not equipped with auto headlamp
feature, lead me to the vehicle will be activated
• Ignition in OFF position.
automatically on pressing the unlock button if
• Opening the driver door. follow me home was activated while locking the
Follow me home lamps can also be kept ON for an vehicle previously.
extended period for 20sec or turned OFF as per the If any of the doors are opened or ignition is turned
convenience. ON the system will turn OFF the lead me to the
To extend or turn OFF Follow me home lamps: vehicle lamps.
• First pressing of lock button after follow me Lead me to the vehicle lamps can also be kept ON
home activation, will lock the vehicle for an extended period for 20sec or turned OFF as
per the convenience.
• Subsequent pressing of lock button will turn
OFF/ON the follow me home lamps based on To extend or turn OFF lead me to the vehicle lamps:
the current status i.e. if the follow me home • First pressing of unlock button once will activate
lamps are ON, pressing the lock button will turn the lead me to the vehicle lamps.
OFF the lamps and vice versa.

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• Subsequent pressing of unlock button will turn ORVM (Outside Rear View Mirror)
OFF/ON the lead me to the vehicle based on the Indicator
current status i.e. if the lead me to the vehicle
The ORVM indicator will illuminate
lamps are ON, pressing the unlock button will
turn OFF the lamps and vice versa.
• Lead me to the vehicle lamps can be extended
up to maximum 2 min from first activation.
Entry Assist Lamp
• When the turn signal indicator switch is ON

• When the hazard warning indicator switch is ON
High Mounted Stop Lamp

The high mounted stop lamp will illuminate, when the
brake pedal is pressed.
Entry assist lamp is located on both ORVM (Outside
Rear View Mirror). It is used to guide the user to see
the area near the driver and passenger door. These
lamps will come ON whenever the follow me and
lead me functions are activated.
Static Bending Lamp
Notice
High mounted stop lamp should be replace
as a assembly.
A - Static bending lamp
The static bending lamp assists the driver while

taking a turn. It will be activated when headlamp is
ON and steering wheel is turned more than 90° at 5
kmph or 45° at 100 kmph.

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Roof Lamp
FRONT
A. R1 - Front Roof lamp

B. R2 - Rear Roof Lamp

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Map Reading Lamps

FRONT
1. Driver Side
2. Co-driver Side
3. Rear Passenger RH side
4. Rear Passenger LH side

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Foot well Lamps
FRONT
A - 1 . Driver Side
A - 2 .Co-Driver Side
B - 1 .Driver Seat Below
B - 2 .Co-Driver Seat Below

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In Car Repairs 3. Loosen the four 10mm headlamp mounting

bolts (A) and remove the headlamp.
Headlamp
A
Non Projectile Headlamp
B
A
A
4. Press the lock and disconnect the two head

lamp electrical connectors (A), and remove the
head lamp assembly from the vehicle.
A. High beam bulb
B. Position / Parking bulb
C. Low beam bulb
D. Turn indicator bulb
A
Projectile Headlamp
D
C
A B
Installation
Notice
Mount the headlamp properly into the fender.
A. High beam bulb 2. Check the head lamp operation.

B. Static bending bulb
C. Low beam bulb
D. Turn indicator bulb
Removal

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Fog Lamp Tail Lamp
Removal A. Stop lamp

1. Disconnect and isolate the negative terminal of B. Turn Indicator Lamp
the battery. For additional information refer C. Reverse lamp
D. Rear fog lamp
E. Position / Parking lamp
and installation section. Removal
3. Loosen the four fog lamp mounting screws (A), 1. Disconnect and isolate the negative terminal of
and remove the fog lamp (B) from the front the battery. For additional information refer
bumper. to Battery removal and installation section.
2. Remove the three tail lamp top trim mounting
screws (A), and detach the trim (B) slowly from
the quarter panel.
A
B
A
Installation
2. Check the fog lamp operation.

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3. Unscrew the screw (A), loosen the three 10mm High Mount Stop Lamp
mounting bolts (B) and remove the tail lamp
assembly (C).
A
A
B
C C B
Removal
4. Disconnect the tail lamp electrical connector 1. Disconnect and isolate the negative terminal of
(A) and separately remove the tail lamp the battery. For additional information refer
assembly (B). to Battery removal and installation section.
2. Remove the tail gate upper trim. For
additional information refer to Tailgate Trim
3. Disconnect the high mount stop lamp electrical
connector (A) and wiper washer hose (B), and
A loosen the four stop lamp mounting screws
(C).
B
C
B
Installation
A C

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4. Remove the high mount stop lamp separately.

5. Remove the wiper injector hose (A) from the
wiper nozzle.
A A
Installation
6. Press and remove the two wiper nozzles (A)

from the stop lamp.
A A
7. Unlock the stop lamp finish chrome lock (A)

and detach the finish chrome (B) from the stop
lamp.
B A

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Number Plate Lamp 5. Loosen the two 10mm tail gate outer handle
mounting nuts (A) from the tail gate.
Removal
2. Remove the tailgate main trim. For additional
3. Disconnect the two number plate lamp
electrical connectors (A).
A
A
A
6. Remove the tail gate outer handle (A) from the
tail gate.
4. Disconnect the tail gate open button electrical

connector (A).
A
7. Press the number plate lamp lock (A) and

remove the two number plate lamps (B) from
the tail gate.
A
B
A
Installation

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Bulb Replacement 3. Remove the low beam bulb (A) from the head
lamp.
Head Lamp Low Beam Bulb
Removal
1. Pull and remove the low beam bulb sealing
cover (A) from the head lamp.
A
Installation
2. Remove the low beam bulb electrical

connector (A) and unlock the low beam bulb
retaining spring (B).

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Head Lamp High Beam Bulb Head Lamp Static Bending Light
Removal Removal
1. Pull and remove the high beam bulb sealing 1. Pull and remove the static bending light sealing
cover (A) from the head lamp. cover (A) from the head lamp.
A A
2. Remove the high beam bulb electrical 2. Remove the static bending light electrical
connector (A) and unlock the high beam bulb connector (A), unlock the retaining spring (B)
retaining spring (B), and remove the high beam and remove the static bending light bulb (C)
bulb (C) from the head lamp. from the head lamp.
C
A B
A B

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Front Turn Lamp Fog Lamp Bulb

Removal Removal
1. Turn the indicator bulb holder into anti- 1. Remove the four retaining clips (A) from the bot-
clockwise and remove the holder from the tom of the front bumper.
head lamp.
2. Unlock the lock and disconnect the electrical

2. Slightly push and remove the bulb from the connectors (A) from the fog lamp.
holder.
3. Rotate the fog lamp holder in anti-clockwise

Installation direction and remove the fog lamp bulb (A)
1. To install, reverse the removal procedure. from the fog lamp.

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Installation Tail Lamp Bulb - Turn Indicator Bulb

1. To install, reverse the removal procedure. Removal
1. Turn the tail lamp bulb holder into anti-
clockwise and remove the holder from the tail
lamp.
LOCK
EN
OP
2. Rotate the bulb in anti-clockwise direction and

remove the bulb from the holder.
Installation
Notice
R & R procedure for remaining tail lamp
bulbs (except position lamp) is similar to
turn indicator lamp.

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Rear Position Lamp Bulb

Removal
1. Turn the rear position lamp bulb holder into
anti-clockwise and remove the holder from the
tail lamp.
2. Pull and remove the bulb from the holder.
Installation

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Interior Lighting
Roof Lamp - Front / Overhead

console lamp - Front
3. Disconnect the front roof lamp two electrical

connectors (A) and remove the overhead
console lamp.
Removal A
Notice
In case of front roof lamp failure, replace the
front roof lamp assembly.

2. Insert a wedge/flat screw driver in the roof to
press the lock (A), and then pull out the
overhead console assembly (B).
CAUTION
Do not remove the overhead console from roof
lamp side, failure to follow this instruction will
lead to damage of the roof lamp.

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Installation Roof Lamp - Rear

1. Fix the roof lamp into the assembly Overhead
console lamp.
Notice
Before installing the assembly overhead
console lamp, check the mounting clips F
OR OF
condition to avoid rattling and falling down. ON DO
Removal
Notice
In case of rear roof lamp failure, replace the
rear roof lamp assembly.

2. Insert the roof lamp side locks (A) into
overhead consosle trim.
2. Insert a wedge/flat screw driver in the window
provided in the roof to press the lock (A), and
pull out the rear roof lamp (B) from the
overhead console trim.
A A
3. Press and fix the assembly overhead console

lamp into overhead console trim.

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3. Unlock the lock and disconnect the rear roof Map Reading Lamp
lamp electrical connector (A) and remove the
roof lamp.
Removal
Installation Notice
1. Connect the electrical connector into rear roof
lamp. In case of map reading lamp failure, replace
2. Press and install the rear roof lamp into the map reading lamp assembly.
overhead trim.
2. Insert a wedge/flat screw driver in the window
provided in the roof to press the lock (A), and
remove the map reading lamp (B) from the

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3. Press the lock and disconnect the map reading Vanity Mirror Lamp
lamp electrical connector (A), and remove the
map reading lamp separately.
Removal
Installation Notice
1. Connect the electrical connector into map
reading lamp. In case of vanity lamp failure, replace the
2. Press and install the map reading lamp into vanity lamp assembly.
overhead trim.
2. Using a wedge/flat screw driver, press the lock
and remove the vanity mirror (A) from the

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3. Press the lock and disconnect the vanity mirror Camping Lamp
lamp electrical connector (A) and remove the
vanity mirror lamp separately.
Removal
Installation Notice
1. Connect the electrical connector into vanity
mirror lamp. In case of camping lamp failure, replace the
2. Press and install the vanity mirror lamp into camping lamp assembly.
overhead trim.
2. Remove tailgate trim. For additional
3. Press the lock (A) and disconnect the camping
lamp electrical connector.

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4. Loosen the four 20mm flower mounting screws Door Ajar Lamp
(A) and remove the camping lamp from the
tailgate trim.
A
B
Removal
Installation Notice
In case of door ajar lamp failure, replace the
door ajar lamp assembly.

2. Remove door trim. For additional information
refer to Front Door Trim removal and installa-
tion section. For additional information refer
to Rear Door Trim removal and installation
section.
3. Loosen the three 20mm flower mounting
screws (A) and remove the door ajar lamp (B)
from the door trim.
Installation

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Puddle Lamp 2. Press the lock (A), disconnect the puddle lamp
electrical connector and remove the puddle
separately.
Removal
1. Using a wedge /flat screw, press the lock and Installation
remove the puddle lamp (A) from the door. 1. Connect the electrical connector into puddle
lamp.
CAUTION 2. Press and install the puddle lamp into the door.
Carefully remove the puddle from the door,

failure to follow this instruction will lead to
damage the door painting and puddle lamp.

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Ambience Lighting 2. Press the lock (A), disconnect the foot well
lamp electrical connector and remove the foot
Foot Well Lamp well lamp (B) separately.
1. Connect the electrical connector into foot well
Notice lamp.
In case of foot well lamp failure, replace the 2. Press and install the foot well lamp into the
foot well lamp assembly. door.
1. Unscrew the two 20mm flower mounting screw

(A) and remove the foot well lamp (B) from the
instrument panel.
A
B

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Foot Well Lamp (Below Front Seat) Map Pocket Lamp
Removal Removal
Notice Notice
In case of foot well lamp failure, replace the In case of map pocket lamp failure, replace
foot well lamp assembly. the map pocket lamp assembly.
1. Press the lock and disconnect electrical 1. Disconnect and isolate the negative terminal of
connector (A), loosen the two 20mm flower the battery. For additional information refer
mounting screws (B) and remove the foot well to Battery removal and installation section.
lamp (C) from the below front seat. 2. Remove door trim. For additional information
tion section. For additional information refer
section.
A
3. Unscrew the 20mm flower mounting screw (A)
and remove the map pocket lamp from the
door trim.
B
Installation
Installation

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Inner Handle Lamp Glove Box Lamp
Lamp
Removal Removal
Notice Notice
In case of inner handle lamp failure, replace
In case of glove box lamp failure, replace the
the inner handle lamp assembly.
glove box lamp assembly.

2. Remove door trim. For additional information
tion section.For additional information refer
section. 3. Press the lock and disconnect the glove box
lamp electrical connector (A) from the glove
3. Unscrew the five 20mm flower mounting screw
box lamp (B).
(A), remove the inner handle (B) and detach
the inner handle lamp (C) from the door trim.
A
C
B
A
Installation

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4. Unscrew the two 20mm flower mounting Glove Box Lamp Switch
screws (A) and remove the glove box lamp (B)
from the glove box. Removal
A
B removal and installation section.
3. Disconnect the two glove box lamp switch
Installation
4. Press the lock and disconnect the glove box

lamp electrical connector (A) from the glove
box lamp (B).

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5. Unscrew the two 20mm flower mounting

screws (A) and remove the glove box lamp
switch (B) from the glove box.
Installation

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Bulb Description Bulb Type Volts, Power Qty / Veh
Front High Beam H15 - 15 / 55W 12V, 55W 2
Front Low Beam H7 55W 12V, 55W 2
Front Position / Parking Lamp W 5W 12V, 5W 2
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
Torque
in Nm
BOLT HEX FL -
4
M6X1X25X8.8XZN
Head Lamp 5±0.5
BOLT HEX FL -
4
M6X1X40X8.8XZN
SELF TAPPING SCREWS M4

Fog Lamp 8 3±0.5
X 1.46 X 14
SCREW HEX FL
6 4±0.5
M6X1X15X8.8XGR
Tail Lamp
SCREW FLANGED SELF
2 2±0.5
High Mount Stop SCREW TPRF CR ST

4 4±0.5
Lamp 4.8X1.6X18 R

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Repair Manual Seats Nov 2011/ Rev 2
SEATS
CONTENT

Front Seats......................................................................................... 1
Second Row Seats ............................................................................. 2
Third Row Seats ................................................................................. 3
Seat Belts ........................................................................................... 4
Seat Belt Height Adjuster .................................................................. 4
Seat Belt Warning Indicator ............................................................... 5
InCar Repairs ....................................................................................7
Driver Seat ....................................................................................7

Removal ............................................................................................. 7
Installation .......................................................................................... 8
Co-driver Seat ...............................................................................9

Removal ............................................................................................. 9
Installation .......................................................................................... 9
Second Row RHS Seats............................................................... 9

Removal ............................................................................................. 9
Installation ........................................................................................ 10
Second Row LHS Seat ...............................................................10

Removal ........................................................................................... 10
Installation ........................................................................................ 11
Third Row Seats ......................................................................... 11

Removal ........................................................................................... 11
Installation ........................................................................................ 12
Driver Seat Belt ...........................................................................13

Removal ........................................................................................... 13
Installation ........................................................................................ 13

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Repair Manual Seats Nov 2011/ Rev 2
Second Row Seat Belt .............................................................. 14

Removal ........................................................................................... 14
Installation ........................................................................................ 14
Third Row Seat Belt .................................................................. 15

Removal ........................................................................................... 15
Installation ........................................................................................ 15

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Repair Manual Seats Nov 2011/Rev 2
Seats Seat Recline
Description and Operation Backward Forward

The seats are designed based on modern
ergonomics to suit the driver’s and passenger’s
comfort level as top priority. The seats are provided
with all necessary adjustments to enhance the
passenger’s comfort.
Front Seats
Seat Slide Lever
To adjust the seat back-rest, lean forward and pull up

the recliner lever found on the outboard right hand
side of the seat. Now lean back until the desired seat
back angle is achieved. To lock the seat back into
position, release the recliner lever.
Ensure that the lever returns to its original position
Lift bar
and back-rest is locked.
Lumbar Support
Backward Forward
To adjust the driver/co-driver seat forward or
backward, pull the lift bar beneath the seat, upwards
and exert slight body pressure to position the seat in
the desired direction. Release the lift bar to lock the
position. Make sure that the seat is arrested properly
once the lift bar is released. Push the seat forward
and backward to check.
Adjusting
Wheel
Lumbar supports are placed to enhance comfort

level. The lumbar contour of the lumbar support can
be adjusted by means of the adjusting wheel found
on the inboard side of the back-rest to provide
supplementary support to the spinal column of the
driver, and to maintain a relaxed upright posture
while driving.

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Seat Height Adjustment Second Row Seats

Seat Folding
Up
Lever Pull
Lower
The seat height adjuster is located on the outboard
side of the seat. To raise the seat, pull the lever
upward until the seat is at the desired height. To Second row seats can be folded using seat folding
lower the seat, push the lever downward until the lever, located on the upper corner of the second row
seat is at the desired height. seat back-rest.
To fold the back-rest, pull the lever. To return the
Head Restraint second row seat to a seating position, lift the back-
rest and push it to an upright position till it locks in to
position.
Second Row Seat Recline
Backward Forward
Upward
Stop-catch release
Down
Pull
Adjust the head restraint so that the top of the
restraint is at the same height as the top of the
occupant’s head. This position reduces the chances
of a neck injury in a crash.
To adjust the seat back-rest, lean forward and pull up
To raise the head restraint, push and raise the head
the seat folding lever located on the upper corner of
restraint upward. the second row seat back-rest. Now lean back until
To lower the head restraint, push and hold the stop- the desired seat back angle is achieved. To lock the
catch release, and push the head restraint down. seat back into position, release the folding lever.
To remove the head restraint, push and hold the
stop-catch release, pull the head restraint up to the
highest position and remove it from the seat.

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Passenger Access to Third Row Passenger Exit from Third Row
FOLDING
LEVER
Pull
The second row seats are designed as foldable type The passenger seated in the third row can exit the
to enable the passenger to gain entry into the third vehicle by pulling the lever found behind the second
row. row seat facing the third row passenger.
To gain access to third row, first fold the second row Third Row Seats
seat using the seat folding lever. Then push the lever,
located beside the seat, forward to double fold the Seat Folding
seat. The lever decal information available in the
seat.
Pull
Lever The third row back-rest can be folded flat so that they
are at the same level as the rear cargo area. This
To return the seat back to the original position once allows more cargo space. The rear seats can be
the passenger enters the third row, move the back- folded by means of the lever located on back of the
rest till it gets locked into position. seat to release the back-rest and push the back-rest
forward until it lies flat.

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Seat Belts
WARNING
• Belts should not be worn with twisted straps.
Each seat belt assembly must only be used by
one occupant. It is dangerous to put a belt
around a child being carried on the occupant's
lap. No modifications or additions should be
made, which either prevents the seat belt
adjusting devices from operating to remove
slack or prevent the seat belt assembly from
being adjusted to remove slack. Belt retraction
may become difficult if the belts and rings are
soiled. Ensure they are always clean.
• Replace the damaged seat belts after an
The seat belt system helps in reducing the severe accident. If not replaced, it will increase the
injury during accidents, collision and sudden stops. level of injury during the next collision. Failure
to comply can lead to major injury or death.
Vehicle is fitted with 3 point type seat belts with
retractors, inertia locks and pretensioners. The locks
allow the belts to remain comfortable on users, but Seat Belt Height Adjuster
will lock itself in position during a sudden impact or
collision. The seat belts provided are designed to suit Press
and protect people of various sizes, right from a child
to an adult.
WARNING
• Seat belts should be adjusted as firmly as
possible, consistent with comfort, to provide Upward
the protection for which they have been
designed. Slack in the belt greatly reduces the
purpose of the belt.
• Care should be taken to avoid contamination
Down
of the webbing with polishes, oils and
chemicals. Cleaning should be carried out The seat belt height adjuster makes possible for you
using mild soap and water only. to adapt the routing of the front seat belt in the area
• The belt should be replaced if webbing of the shoulder to match your body size.
becomes frayed, contaminated, or damaged. • To adjust the belt height press the height
adjuster and move it up or down.
• Then pull firmly on the belt to ensure that the
seat belt height adjuster has correctly locked in
place.

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Seat Belt Warning Indicator

ECON A/C REAR
A/C
- +
OFF AUTO MODE
PASSENGER
START
@
STOP
ESP
OFF
Driver Passenger
Driver
Once the ignition is turned ON, driver seat belt
reminder warning lamp will flash till the driver seat
belt is engaged.
Once the engine is turned ON, buzzer will sound for
30 seconds if the driver seat belt is not engaged.
Passenger
When the front passenger does not wear seat belt,
the seat belt warning indicator glows on the central
bezel switch bank.

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A C
E
FRONT
B D
A. Driver Seat
B. Co-driver Seat
C. Second Row RHS Seat
D. Second Row LHS Seat
E. Third Row RHS Seat
F. Third Row LHS Seat

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Service Tips and Precautions InCar Repairs

Driver Seat
WARNING
To avoid the risk of neck injury in the event of
a crash, ensure that the driver and co-
passenger seat head restraints are properly
locked. Never adjust the head restraint while
the vehicle is in motion.
CAUTION
After locking the backrest, pull the backrest to
ensure that it is fully latched. An unlatched
seat may cause danger during a sudden stop.
Removal
CAUTION For additional information refer to Battery
Never adjust the driver’s seat or backrest 2. Press the lock (A) and pull out the headrest (B)
when the vehicle is moving. from the driver seat.

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3. Press the lock (A) and disconnect the three 6. Loosen and remove the two 16mm mounting
electrical connectors from the driver seat. bolts (A) from rear sides of the driver seat and
separately detach the driver seat.
POWER
CLK BAND SEL
EQ TA
7 8 0 #
9
ECON A/C REAR

A/C
OFF AUTO MODE
A AWD
LOCK
START
PASSENGER
ESP
A
STOP
OFF
A A
A

connector (A) from the pretensioner.
CAUTION
Care should be taken while inserting the elec-
trical connector because it might damage the
seat or injure the person involved.
A
Installation
5. Loosen and remove the two 16mm mounting

bolts (A) from front sides of the front driver
seat.

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Co-driver Seat Second Row RHS Seats
Removal Removal
1. For removing the co-driver seat refer the 1. Press the lock (A) and remove the headrest
Driver Seat removal and installation section. (B) from the second row RHS seats.
Installation

bolts (A) from front side of the second row
RHS seats.

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3. Pull the second row RHS seats folder handle Second Row LHS Seat
(A) and fold the second row RHS seats.
140
160
180
200
A
+
4. Loosen and remove the three 16mm mounting Removal

bolts (A) from rear side of the second row RHS 1. Press the lock (A) and pull out the headrest (B)
seats. from the second row LHS seat.
A B
5. Separately detach the second row RHS seats. 2. Loosen and remove the two 16mm mounting
bolts (A) from front side of the second row LHS
Installation seat.

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3. Pull the second row LHS seat folder handle (A) Third Row Seats
and fold the center seat backrest. Pull the
double folding lever (B) to fold the seat.
B
Removal
4. Loosen and remove the two 16mm mounting 1. Press the lock (A) and pull out the headrest (B)
nuts (A) from rear side of the second row LHS from the third row seats.
seat.
A
A

5. Separately detach the second row LHS seat bolts (A) from front side of the third row seats.
along the door side of the vehicle.
Installation

MAN-00162
3. Pull the third row seats folder handle (A) and 5. Loosen the three tool box bin mounting screws
fold the third row seats. (A) and remove the tool box bin (B).
A B
4. Using a tool box latch (A) open the tool box. 6. Loosen and remove the two 16mm mounting
bolts (A) from rear side of the third row seats.
A A
7. Separately detach the third row seats.
Installation

MAN-00162
Driver Seat Belt 4. Remove the 15mm mounting bolt (A) from the
bottom of the seat belt mechanism (B)
Removal separately.
1. Remove the seat belt 14 mm mounting bolt (A)
from the B-Pillar lower trim and detach the B-
Pillar trim separately.
A 5. Remove the two 6mm allen key mounting bolts

(A) and detach the seat belt height adjuster (B)
separately.
2. Remove the B-Pillar upper trim. For additional
information refer to B-Pillar Upper Trim
3. Remove the 17mm mounting bolt from top of
the seat belt (A) and detach the seat belt from
the height adjuster. B
A
Notice
Follow the similar procedure to remove the
co- driver seat belt.
Installation
Notice
During the trim installation, properly fix the
trim into the seat belt height adjuster.

MAN-00162
Second Row Seat Belt 4. Remove the 16mm mounting bolt (A) and
detach the second row seat belt mechanism
Removal (B) separately.
1. Loosen the 16mm second row RHS seat belt
A
A
Notice
2. Remove the rear RHS upper quarter trim. For Follow the similar procedure to remove the
additional information refer to Rear RHS second row seat belt (LHS).
section.
Installation
3. Remove the 16mm mounting bolt (A) from top
of the second row seat belt.

MAN-00162
Third Row Seat Belt 4. Remove the 16mm mounting bolt (A) and
detach the third row seat belt mechanism (B)
Removal separately.
1. Loosen the 16mm third row RHS seat belt
A
Notice
2. Remove the rear RHS upper quarter trim. For Follow the similar procedure to remove the
additional information refer to Rear RHS third row seat belt (LHS).
section.
Installation
3. Remove the 16mm top mounting bolt (A) of the
third row seat belt.

MAN-00162
Torque
in Nm
BOLT COMBI LP
1st row seat 8
M10X1.5X35X8.8XZN
BOLT COMBI LP
4
M10X1.5X35X8.8XZN 45.0±5.0
BOLT COMBI LP
2nd row seat M12X1.5X35X10.9 Seats to BIW 3
(60% rear)
NUT HEX FL
2
M10X1.5X12X8 ZN
45.0±5.0
BOLT COMBI LP
3rd row seat 8
M10X1.5X35X8.8XZN
SCREW HEX FL
1st row seat belt 2
G11.11X1.27X25X8.8,A
SCREW HEX FL Seat belt lower anchor and retractor

2nd row seat belt 2 45.0±5.0
G11.11X1.27X25X8.8,A mounting
SCREW HEX FL
3rd row seat belt 2
G11.11X1.27X25X8.8,A
1st row seat belt SCREW SOCKET

Front row seat belt height adjuster 4 25.0±5.0
adjuster M8X1.25X20X8.8XZN

MAN-00162
Repair Manual Bumpers Nov 2011/ Rev 2
BUMPERS
CONTENT
Component Location and Index .....................................................1

Front Bumpers Exploded View ........................................................... 1
Rear Bumpers Exploded View ........................................................... 2
Incar Repairs .................................................................................... 3
Front Bumper Grill .......................................................................3

Removal ............................................................................................. 3
Installation .......................................................................................... 3
Front Bumper................................................................................ 3
Removal ............................................................................................. 3
Installation .......................................................................................... 5
Front Bumper Support Bar ..........................................................6

Removal ............................................................................................. 6
Installation .......................................................................................... 6
Front Bumper Cross Bar .............................................................6

Removal ............................................................................................. 6
Installation .......................................................................................... 6
Rear Bumper .................................................................................7

Removal ............................................................................................. 7
Installation .......................................................................................... 8
Rear Bumper Reinforcement ...................................................... 9

Removal ............................................................................................. 9
Installation .......................................................................................... 9
Rear Bumper Side Bracket .......................................................... 9

Removal ............................................................................................. 9
Installation .......................................................................................... 9
Rear Bumper Lower Bracket ..................................................... 10

Removal ........................................................................................... 10
Installation ........................................................................................ 10

MAN-00162
Repair Manual Bumpers Nov 2011/ Rev 2
Rear Side Air Vent ...................................................................... 10

Removal ........................................................................................... 10
Installation ........................................................................................ 11
Fender ......................................................................................... 11
Removal ........................................................................................... 11
Installation ........................................................................................ 13

MAN-00162
Repair Manual Bumper Nov 2011/Rev 2
Bumpers
Component Location and Index
Front Bumpers Exploded View
A
C
A. Front Bumper
B. Front Bumper Pad
C.Plastic Cover
D.Fog lamp

MAN-00162
Rear Bumpers Exploded View
D
B E
A
G
A. Rear Bumper
B. Rear Bumper Reinforcement
C. Bumper Pad
D.Rear Bumper Cross Bar
E.RPAS Wiring Harness
F.Rear Bumper Side Bracket
G.Rear Bumper Lower Bracket
H.Reflector

MAN-00162
Incar Repairs Front Bumper

Front Bumper Grill
Removal
Removal information refer to Front Bumper Grill
9. Remove the five grill mounting retaining clips removal and installation section.
(A), unscrew the two mounting screws (B) and
detach the bumper grill (C).
front cradle.
A
B B
C
B
Installation
Notice
When installing the bumper grill insert the
grill bottom mounting locks and fix the
bumper.

MAN-00162
3. Remove the four retaining clips (A) from wheel 6. Remove the two retaining clips (A) from bottom
arch of the front bumper RHS and LHS. of the front bumper RHS and LHS.
A
A
4. Remove the 10mm bumper mounting bolt (A)

from inside of the wheel arch RHS and LHS.
7. Remove the two retaining clips (A) from bottom

of the front bumper.
5. Remove the bumper mounting screw (A) from

inside of the wheel arch RHS and LHS.
A A

MAN-00162
8. Unlock the lock and disconnect the electrical 11. Remove the three retaining clips (A) and
connectors (A) from both RHS and LHS of the detach the front bumper from the vehicle.
fog lamp.
12. Loosen the four fog lamp mounting screws (A)

9. Remove the two plastic covers (A) located and remove the fog lamp (B) from the front
below the headlamp RHS and LHS from the bumper.
bumper.
A
B
13. Unlock the five clips (A) and remove the

10. Remove the two bumper retaining screws (A) bumper pad (B) from the front bumper.
from bottom of the RHS and LHS headlamps.
B A
Installation

MAN-00162
Front Bumper Support Bar Front Bumper Cross Bar
Removal Removal
1. Remove the front bumper. For additional infor- 1. Remove the front bumper. For additional infor-
mation refer to Front Bumper removal and mation refer to Front Bumper removal and
installation section.. installation section.
2. Remove the four 12mm bumper support bar 2. Remove the two 10mm mounting bolts (A), eight
mounting bolts (A) and detach support bar (B). 14mm mounting bolts (B) and detach bumper
cross bar (C).
B
B
A A
A C A
Installation
1. To install, reverse the removal procedure. Installation
Notice
Align and install the bumper support bar in
Notice
proper position. Align and install the bumper cross bar in
proper position.

MAN-00162
Rear Bumper 3. Remove the two retaining clips (A) from bottom
of the rear bumper of the RHS and LHS.
Removal
1. Remove the four retaining clips (A) and detach
the rear mud flap (B) from RHS and LHS.
A
A
B 4. Unlock and disconnect the RPAS electrical con-

nector (A) from LHS bottom of the bumper.
2. Remove the two retaining clips (A) and 10mm

bumper mounting bolt (B) from RHS and LHS.

MAN-00162
5. Remove the bumper mounting screw (A) which 8. Remove the RPAS Sensor. For additional
is located adjacent the RHS tail lamp. information refer to RPAS Sensor removal
9. Unlock the four locks (A) and remove the
bumper pad (B).
6. Remove the bumper mounting screw (A) which B

is located adjacent the LHS tail lamp.
10. Remove the four RPAS covers from the rear

bumper.
11. Remove the 10mm reflector mounting nut (A)
and detach the reflector (B) from the bumper.
7. Remove the four retaining clips (A) from the

bottom of the rear bumper and detach the B
bumper separately.
Installation

MAN-00162
Rear Bumper Reinforcement Rear Bumper Side Bracket

Removal Removal
1. Remove the rear bumper. For additional infor- 1. Remove the rear bumper. For additional infor-
mation refer to Rear Bumper removal and mation refer to Rear Bumper removal and
installation section. installation section.
2. Remove the five 10mm reinforcement bolts (A) 2. Unscrew the four side bracket screws (A) and
and detach reinforcement (B) separately. remove the side bracket (B) from RHS and LHS.
A
A
B
B
Installation
Installation

MAN-00162
Rear Bumper Lower Bracket Rear Side Air Vent

Removal
mation refer to Rear Bumper removal and
2. Unscrew the two lower bracket screws (A) and
remove the lower bracket (B) from RHS and
LHS.
Removal
A mation refer to Rear Bumper removal and
2. Unlock and remove the two side air vents (A)
B from RHS and LHS.
Installation
A

MAN-00162
Installation Fender
Removal
2. Remove the headlamp. For additional informa-

tion refer to Headlamp removal and installa-
tion section.
3. Remove the 12mm bulkhead mounting bolt (A)
and two 10mm fender mounting bolts (B).
B A
4. Remove the 10mm fender mounting bolt (A)

from bottom of the bulkhead.

MAN-00162
5. Remove the 12mm fender mounting bolt (A) 8. Remove the fender retaining clip (A) from
located below the headlamp area from the bulk- adjacent to the bonnet hinges.
head.
9. Unlock the cowl side cover (A) and remove the

6. Remove the two 10mm fender mounting bolts fender retaining clip (B).
(A) from adjacent to the wiper tank area.
A
A
10. Remove the finish cover (A) from bottom of

7. Open the front door and remove fender the fender at running board.
retaining clip (A) from the A-Pillar at the front
door area.

MAN-00162
11. Remove the two fender mounting bolts (A) 13. Remove the fender assembly separately.
from bottom of the fender at running board.
Installation
Notice
Align and install the fender properly, to avoid
damage of fender and door.
A
12. Open the front door and remove the 10mm
mounting bolt (A) from bottom of the fender at
running board.

MAN-00162
Torque in
Nm
SCREW HEX FL
2
M6X1X15X8.8XGR
SCREW PHCR
Front bumper 2
M6X1X16X8.8XBK U nut mounting 4.0±0.5
assembly
M4.8X1.6X13 PAN
HD CR RCSS TPG 2
SCREW
SCREW HEX FL
12 8.0±1.0
M6X1X15X8.8XGR
SCREW HEX FL 4.0±0.5

2
M6X1X15X8.8XGR
Plastic Fender Fender mounting.
SCREW ST 2.0±0.5
2
4.8X1.6X18
NUT HEX FL 4.0±0.5

2
M6X1X6X8 GR
SCREW HEX FL
M8X1.25X25X8.8XZ Bolt to weld nut (front rail) 2
N
SCREW HEX FL
Bolster 20.0±3.0
M10X1.5X30X8.8XZ Bolt to weld nut (front end panel) 8
N
M8X1.25X40
Bolt to weld nut (short gun) 2
FLANGE BOLT
SCREW HEX FL
Upper Stiffener Upper stiffener to FEC 4 6.0±1.0
M6X1X15X8.8XGR
BMPR- BLSTR SCREW HEX FL

With FEC 4 4.0±0.5
BRACKET M6X1X15X8.8 GR
SCREW PHCR
Radiator grill Radiator grill mounting 2 4.0±0.5
M6X1X16X8.8XBK

MAN-00162
Torque in
Nm
SCREW FLANGED
SELF TAPPING Rear Bumper to BIW and platform 14 2.0±0.5
4.8X1.6X18XC ZN
FLANGE BOLT M6 2.0±0.5

Rear Bumper to mounting bracket 2
X 1.0 - 20
BOLT HEX FL - 4.0±0.5

5
Rear Bumper M6X1X25X8.8XZN
4.0±0.5
NUT HEX FL -
6 (plastic
M8X1.25X8X8XZN Plastic bracket To panel
beam)
20.0±2.0
NUT HEX FL -
6 (steel
M8X1.25X8X8XZN
beam)

MAN-00162
Repair Manual Doors Nov 2011/ Rev 2
DOORS
CONTENTS
Mirrors ...............................................................................................1
Power Side View Mirrors .................................................................... 1
Mirror Folding - Electrical ................................................................... 2
Power Windows ...............................................................................2

Window Opening and Closing ............................................................ 2
Express-Down Window ...................................................................... 3
Rear Window Child Lock Switch ........................................................ 3

Door Exploded View ........................................................................... 4
Incar Repairs ....................................................................................5
Power Side View Mirror ............................................................... 5

Removal ............................................................................................. 5
Installation .......................................................................................... 5
Front Door .....................................................................................6

Removal ............................................................................................. 6
Installation .......................................................................................... 7
Front Door Trim ........................................................................... 7

Removal ............................................................................................. 7
Installation .......................................................................................... 9
Front Door Open Lever ................................................................ 9

Removal ............................................................................................. 9
Installation .......................................................................................... 9
Front Door Window Glass ......................................................... 10

Removal ........................................................................................... 10
Installation ........................................................................................ 11
Front Door Window Regulator ................................................. 12

Removal ........................................................................................... 12
Installation ........................................................................................ 12

MAN-00162
Repair Manual Doors Nov 2011/ Rev 2
Rear Door .................................................................................... 13

Removal ........................................................................................... 13
Installation ........................................................................................ 14
Rear Door Trim........................................................................... 14

Removal ........................................................................................... 14
Installation ........................................................................................ 16
Rear Door Open Lever .............................................................. 16

Removal ........................................................................................... 16
Installation ........................................................................................ 16
Rear Door Window Glass .......................................................... 17

Removal ........................................................................................... 17
Installation ........................................................................................ 19
Rear Door Window Regulator ................................................... 19

Removal ........................................................................................... 19
Installation ........................................................................................ 20

MAN-00162
Repair Manual Doors Nov 2011/Rev 2
3. Adjust the mirror angle by depressing the

Doors appropriate perimeter switch as illustrated.
Mirrors
Power Side View Mirrors
ROR
L
MIR
4. After adjusting the mirror, lock the control by
moving the selector switch to the middle posi-
tion.
Be sure to adjust mirror angles before driving.

Vehicle is equipped with both left hand and right
hand rear view mirrors on the exterior of the vehicle.
ROR
L
MIR
The controls for the outside power mirrors are
located on the driver's door armrest.
To adjust the position of either mirror:
1. The ignition switch must be in the ON position.
2. Move the selector switch to the right or left to
activate the adjustable mechanism for the
corresponding door mirror.
R
ROR
L
MIR

MAN-00162
Mirror Folding - Electrical Power Windows
ROR
L
MIR
OR
L
MIRR
This switch controls mirrors on both the sides. To fold
/ unfold press the folding mirrors switch. The ignition switch must be in the ON position for the
power windows to operate. The driver’s door has a
master power window switch that controls all the
CAUTION windows in the vehicle whereas other doors have
single power window switch.
Folding/Unfolding operation is limited to 2
times/minute. Avoid unnecessary usage of
Window Opening and Closing
folding/unfolding switch. Driver Door Power Window Switches
Notice Close
• The side view mirrors fold automatically
when locked through remote key. Open
• The side view mirrors unfold automatically
when unlocked through remote key and
ignition ON.
1 2 3 4
1. Front Passenger’s door power window switch.
2. Driver’s door power window switch.
3. Rear left passenger’s door power window
switch.
4. Rear right passenger’s door power window
switch.
Opening a Window
Press the switch downward to open the window.

MAN-00162
Closing a Window
Pull the switch upward to close the window.
Express-Down Window
The window switch has an express-down feature that
allows the window to be lowered without
continuously holding the switch.
Press the switch all the way down for a moment and
release it, the window will roll down automatically. To
stop the window while it is lowering, press and
release the top of the switch.
Rear Window Child Lock Switch
Press the child lock switch to isolate the window

switches in the rear doors.
Press the switch again to restore independent
control.

MAN-00162

Door Exploded View
C
E
A. Handle Outer Cover

B. Door Trim
C. Inner patch
D. Door Assembly
E. Latch Cables
F. Latch Assembly

MAN-00162
Incar Repairs 3. Press the lock and disconnect the electrical

connector (A), loosen the three 10mm
mounting nuts (B) and detach the power side
Power Side View Mirror view mirror separately.
1. Remove the front door trim. For additional 1. To install, reverse the removal procedure.
removal and installation section. Notice
2. Pull and remove the side view mirror cover (A) Check the side view mirrors operation after
from the front door. installation.

MAN-00162
Front Door 3. Press the lock and disconnect the two front
door electrical connectors from the A-pillar.
Notice
Front door electrical connectors can be easily
accessed by removing the A-Pillar trim.
Removal
1. Remove the A-pillar lower trim. For additional
information refer to A-Pillar Lower Trim
2. Detach the front door electrical connector
rubber (A) from the A-pillar. 4. Remove the 12mm door link arm mounting bolt
(A) from the A-pillar.

MAN-00162
5. Remove the four 12 mm door hinges mounting Front Door Trim

bolts (A) and detach the front door separately.
6. Remove the front door trim. For additional Removal

information refer to Front Door Trim 1. Using a suitable tool, pry out and remove the
removal and installation section. power window switch (A) from the door trim.
7. Remove the front door speaker. For additional
information refer to Front Door Speaker
8. Remove the door outer handle. For additional
information refer to Door Outer Handle
9. Remove the door key barrel. For additional A
information refer to Door Key Barrel
R
OR
L
MIRR

11. Remove the door link arm. For additional
information refer to Door Link Arm removal
and installation section. 2. Press the lock and disconnect the three
electrical connectors (A) from the switch.
12. Remove the door wiring harness from the front
door.
Installation
Notice
Align and fix the front door properly. check
the front door open and close operation after
align the front door.
A A

MAN-00162
3. Insert the suitable tool into the handle outer 6. Pull out the door trim (A) from the front door.
cover slot (A) and remove the handle outer
cover (B).
A 7. Press the lock and disconnect the three

electrical connectors (A) from the door trim.
4. Remove the door trim mounting screw cover
(A) from the door trim.
A
A
A
A
8. Unlock the lock (A) and remove the two latch

cables (B) from the lever mechanism.
the door trim panel.
A
B
B
A A

MAN-00162
9. Unlock the cables from locking position (A) and Front Door Open Lever
remove the two latch cables (B) from the lever
mechanism and remove the door trim Removal
separately. 1. Remove the front door trim. For additional
2. Remove the five 20mm mounting screws (A)
A and remove the lever mechanism (B) from the
door trim.
A
Installation
A
CAUTION B
Carefully install the door trim panel without
damaging the clips. Damaged clips may Installation
cause rattling noise from the door.
CAUTION
Fix the cables properly without damaging the
cable locks, damage of cables locks will not
operate properly.

MAN-00162
Front Door Window Glass 4. Remove the dust cover (A) from the door.
5. Remove the inner weather strip (A) from the

Removal front door.
1. Remove the front door trim. For additional
2. Unscrew the outer weather strip mounting A
screw (A) from the front door.
6. Raise the power window glass upward to fully

closed position.
from the door.
3. Remove the outer weather strip (A) from the
front door.
A

MAN-00162
8. Move the window glass downward to access Installation

the window glass mounting screws. 1. Fix the window glass into the groove provided
in the window regulator.
Notice
Align the window glass properly and tighten
the window glass. check the window glass
operation before fixing the door trim.
9. Unscrew the two window glass mounting

screws (A) and remove the window glass from
the door.
A CAUTION
Do not overtighten the window glass
mounting screws to avoid the damage of
window glass.
CAUTION
To avoid scratching or breaking of the
window glass, carefully place the window
glass on a secure area.

MAN-00162
Front Door Window Regulator 3. Unlock the lock (A) and disconnect the
electrical connector from the window motor and
remove the window regulator assembly from
the door.
Removal
1. Remove the front door window glass. For
additional information refer to Front Door Installation
Window Glass removal and installation
section.
2. Remove the three 10mm window motor
mounting nuts (A), two regulator assembly
mounting nuts (B).

MAN-00162
Rear Door 3. Remove the 12mm door link arm mounting bolt
(A) from the B-pillar.
Removal 4. Remove the four 12 mm door hinges mounting

1. Detach the rear door electrical connector bolts (A) and detach the rear door separately.
rubber (A) from the B-pillar.
5. Remove the rear door trim. For additional

2. Press the lock and disconnect the rear door information refer to Rear Door Trim removal
electrical connector (A) from the B-pillar. and installation section.
6. Remove the rear door speaker. For additional
information refer to Rear Door Speaker
A removal and installation section.
7. Remove the door outer handle. For additional
information refer to Door Outer Handle
9. Remove the door link arm. For additional
information refer to Door Link Arm removal
10. Remove the door wiring harness from the rear
door.

MAN-00162
Installation Rear Door Trim

Notice
Align and fix the rear door properly. check
the rear door open and close operation after
align the rear door.
Removal
1. Using a suitable tool remove the power window
switch (A) from the door trim.
2. Press the lock (A) and disconnect the electrical

connector from the switch.

MAN-00162
3. Insert the suitable tool into the handle outer 6. Pull out the door trim (A) from the rear door.
cover slot (A) and remove the handle outer
cover (B).
B
A
A 7. Press the lock and disconnect the three

electrical connectors (A) from the door trim.
4. Remove the door trim mounting screw cover
(A) from the door trim.
A
A
A
A
8. Unlock the lock (A) and remove the two latch

cables (B) from the lever mechanism.
the door trim.
A
B
B
A A

MAN-00162
9. Unlock the cables from locking position (A) and Rear Door Open Lever
remove the two latch cables (B) from the lever
mechanism and remove the door trim Removal
separately. 1. Remove the rear door trim. For additional
2. Remove the five 20mm mounting screws (A)
A and remove the lever mechanism (B) from the
door trim.
A
Installation
A
CAUTION B
Carefully install the door trim panel without
damaging the clips. Damaged clips may Installation
cause rattling noise from the door.
CAUTION
Fix the cables properly without damaging the
cable locks, damage of cables locks will not
operate properly.

MAN-00162
Rear Door Window Glass 4. Unscrew the two outer weather strip mounting
screws (A) from the rear door.
A
A
Removal 5. Remove the outer weather strip (A) from the

1. Remove the rear door trim. For additional rear door.
2. Pull and remove the inner cover (A) from the
rear door.
A
6. Unscrew the two outer cover mounting screws

(A) from the rear door.
3. Pull and remove the inner glass weather strip

(A) from the rear door.
A
A

MAN-00162
7. Pull and remove the two outer cover mounting 11. Move the window glass downward to access
screws (A) from the rear door. the window glass mounting screws.
8. Remove the dust cover (A) from the rear door. 12. Unscrew the two window glass mounting
screws (A) and remove the window glass from
the door.
9. Raise the power window glass upward to fully

closed position.
from the door.
CAUTION
To avoid scratching or breaking of the
window glass, carefully place the window
A glass on a secure area.

MAN-00162
Installation Rear Door Window Regulator

1. Fix the window glass into the groove provided
in the window regulator.
Notice
Align the window glass properly and tighten
the window glass. check the window glass
operation before fixing the door trim.
Removal
1. Remove the rear door window glass. For
additional information refer to Rear Door
Window Glass removal and installation
section.
2. Remove the three 10mm window motor
mounting nuts (A), two regulator assembly
mounting nuts (B).
CAUTION
Do not overtighten the window glass
mounting screws to avoid the damage of
window glass.

A

MAN-00162
3. Unlock the lock (A) and disconnect the

electrical connector from the window motor and
remove the window regulator assembly from
the door.
Installation

MAN-00162
Torque in
Nm
SCREW HEX FL
16
M8X1.25X28X8.8
Front door LH and
Front doors to BIW 28.0±3.0
RH
SCREW HEX FL
4
M8X1.25X14X8.8XPH
Run channel front SCREW HEX FL SL

Run channel to front doors 4 10.4±2.0
door LH and RH M6X1X12X8.8XZN
SCREW HEX FL
16
M8X1.25X28X8.8
Rear door LH and
Rear doors to BIW 28.0±3.0
RH
SCREW HEX FL
4
M8X1.25X14X8.8XPH
Run channel rear SCREW HEX FL SL

Run channel to rear doors 4 10.4±2.0
door LH and RH M6X1X12X8.8XZN
NUT HX NYL FL Window Regulator assembly to Front

10 8.0 ± 2.0
M6X1X9X8 Door Inner panel
Front door / win-
dow regulator
SCREW TPRF CR ST Window Glass to Window Regulator
4 1.9 ± 0.25
6.3X1.8X16 C Spider
NUT HX NYL FL Window Regulator assembly to Front

10 8.0 ± 2.0
M6X1X9X8 Door Inner panel
Rear door / win-
dow regulator
SCREW TPRF CR ST Window Glass to Window Regulator
4 1.9 ± 0.25
6.3X1.8X16 C Spider
NUT HEX FL ORVM assembly to Front Door As-

Mirror 6 6.5±1.5
M6X1X6X8 GR sembly
SCREW FLANGED
Door open switch SELF TAPPING 5 2±0.5
4.8X1.6X18XC ZN

MAN-00162
Repair Manual Tailgate Nov 2011/ Rev 2
TAILGATE
CONTENTS

Opening the Tailgate with Switch....................................................... 1
Unlocking the Tailgate with Cable ...................................................... 1
Closing the Tailgate ........................................................................... 1

Tailgate Trims Exploded View............................................................ 2
Incar Repair ......................................................................................4
Tailgate Shock Absorber ............................................................. 4

Removal ............................................................................................. 4
Installation .......................................................................................... 5
Tailgate Height Adjuster ............................................................. 5

Removal ............................................................................................. 5
Installation .......................................................................................... 5
Tailgate Stopper ...........................................................................6

Removal ............................................................................................. 6
Installation .......................................................................................... 6
Tailgate Aligner ............................................................................6

Removal ............................................................................................. 6
Installation .......................................................................................... 6
Tailgate Illumination Switch ........................................................ 7

Removal ............................................................................................. 7
Installation ........................................................................................... 7
Tailgate Trim ................................................................................. 7

Removal ............................................................................................. 7
Installation .......................................................................................... 8
Tailgate.......................................................................................... 8
Removal ............................................................................................. 8
Installation ........................................................................................ 10

MAN-00162
Repair Manual Tailgate Nov 2011/ Rev 2
Number Plate Lamp .................................................................. 10

Removal ........................................................................................... 10
Installation ........................................................................................ 11

MAN-00162
Repair Manual Tailgate Nov 2011/Rev 2
Tailgate Unlocking the Tailgate with Cable

In case of electrical failure of tailgate release switch
Description and Operation and remote key, tailgate can also be unlocked by
using the cable from inside the vehicle.
Opening the Tailgate with Switch • Unclip the warning triangle cover clips and
remove the warning triangle from the location.
Refer “Warning triangle” section
• Remove the cable hook from it’s place and pull
out so as to unlock the tailgate
Press
Tailgate release switch
Press the tailgate release switch in the tailgate

handle and swing the tailgate upwards.
Notice Cable hook
• Tailgate will automatically lock, if the tailgate Closing the Tailgate

door is not opened within 45 seconds.
• When the vehicle is centrally locked (either
by remote key or using driver door lock knob),
the tailgate cannot be opened by means of the
tailgate release switch.
Pull the tailgate down and close it with a slight swing

MAN-00162

Tailgate Trims Exploded View
A
E
A. Tailgate Upper Trim

B. Tailgate Side Trim RH
C. Tailgate Side Trim LH
D. Tailgate Main Trim
E. Tailgate

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A. Warning Triangle Cover

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Incar Repair 2. Using a suitable tool release the strut lock (A),
detach the other end of the shock absorber (B)
Tailgate Shock Absorber fixed at the tailgate and remove the shock
absorber separately.
Removal 3. Remove the two 13mm shock absorber bracket

mounting bolts (A) and detach the bracket (B)
Notice from the quarter panel side.
Hold the tailgate when removing the tailgate
shock absorber.
1. Using a suitable tool release the shock A

absorber lock (A) and detach one end of the
shock absorber (B) fixed at the quarter panel
side.
B
A
4. Remove the 13mm ball shock absorber
mounting bolt (A) from the tailgate.

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Installation Tailgate Height Adjuster

Removal
1. Rotate the tailgate height adjuster (A) in
anticlockwise direction and remove the
insulator.
Installation

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Tailgate Stopper Tailgate Aligner

Removal Removal
1. Remove the tail lamp. For additional 1. Remove the two 10mm tailgate aligner
information refer to Tail Lamp removal and mounting bolts (A) and remove the aligner (B)
installation section. from the tailgate.
2. Remove the two 10mm tailgate stopper
mounting bolts (A) and detach the stopper (B)
separately. A
Installation
Installation

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Tailgate Illumination Switch Tailgate Trim

Removal Removal
1. Unscrew the tailgate illumination switch 1. Pull and remove the tailgate upper trim (A), LH
mounting screw (A) and remove the side trim (B) and RH side trim (C) from the
illumination switch (B) from the tailgate. tailgate.
B C
2. Disconnect the electrical connectors (A) from 2. Remove the four retaining clips (A) from the
the illumination switch (B). tailgate main trim, and unlock the lock and
remove the cover (B) from the tailgate.
A A B
3 4
140
160
2 5
H
T
180
1 6
200 C
SOURCE
Installation

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3. Open the triangle cover (A) on the tailgate Tailgate

main trim.
Removal
1. Remove the rear RHS upper quarter trim. For
section.
connector (A) of the RHS tailgate wiring
harness.
4. Remove the cable hook (A) from its place.

A
4. Press the lock and disconnect the stop lamp
electrical connector (A), rear wiper hose (B),
and unlock and disconnect the windshield
defogger electrical connector (C).
5. Pull and remove the tailgate main trim (A) from
the tailgate.
C
B
Installation

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5. Detach the wiper hose and wiring harnesses of 13. Disconnect the tailgate open button electrical
defogger and stop lamp from the tailgate LHS. connector (A).
6. Remove the tailgate shock absorber. For
additional information refer to Tailgate
Shock Absorber removal and installation
section.
7. Remove the four 12mm mounting bolts (A)
from the tailgate hinges.
A A
14. Loosen the two 10mm tailgate outer handle

mounting nuts (A) from the tailgate.
8. Separately detach the tailgate assembly.

9. Remove the tailgate latch. For additional
information refer to Tailgate Latch removal
10. Remove the rear wiper motor. For additional
information refer to Rear Wiper Motor A
11. Remove the high mount stop lamp. For
additional information refer to High Mount 15. Remove the tailgate outer handle (A) from the
Stop Lamp removal and installation section. tailgate.
A
A

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16. Press the number plate lamp lock (A) and Number Plate Lamp
the tailgate. Removal
B
A
A
A
17. Remove the tailgate wiring harness from the

tailgate.
Installation
4. Disconnect the tailgate open button electrical

connector (A).

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5. Loosen the two 10mm tailgate outer handle

mounting nuts (A) from the tailgate.
6. Remove the tailgate outer handle (A) from the

tailgate.
7. Press the number plate lamp lock (A) and

the tailgate.
B
A
Installation

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Torque in
Nm
Tailgate lower
M6 Eyelet ring terminal Ground (on door panel) 1 4±0.5
harness
SCREW HEX FL
4
M8X1.25X20X8.8XPH
Tailgate Tailgate to BIW 28.0±3.0
NUT HEX FL -
4
M8X1.25X8X8XZN
Tailgate locking
BALL STUD TAILGATE Ball stud to tailgate 2 20.0~25.0
system

MAN-00162
Repair Manual Wipers and Washers Nov 2011/ Rev 2
WIPERS AND WASHERS
CONTENTS
Description and Operation...............................................................1

Front Wiper Control Lever .................................................................. 1
Rear Wiper Control Lever ................................................................. 3
Rear Window Wiper ........................................................................... 3
Rear Window Washer ........................................................................ 4
Incar Repairs ...................................................................................4
Front Wiper Blade ........................................................................4

Removal ............................................................................................. 4
Inspection........................................................................................... 5
Installation .......................................................................................... 5
Wiper Rubber ................................................................................5

Removal ............................................................................................. 5
Inspection ........................................................................................... 6
Installation .......................................................................................... 6
Front Wiper Arms .........................................................................6

Removal ............................................................................................. 6
Inspection ........................................................................................... 7
Installation .......................................................................................... 7
Front Washer Nozzle.................................................................... 8

Removal .............................................................................................. 8
Inspection ........................................................................................... 8
Installation .......................................................................................... 8
Cowl Beeding ................................................................................8

Removal ............................................................................................. 8
Installation .......................................................................................... 8
Wiper Cowl ....................................................................................9

Removal ............................................................................................. 9
Inspection ........................................................................................... 9
Installation .......................................................................................... 9

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Cowl Side Cover ......................................................................... 10

Removal ........................................................................................... 10
Inspection ......................................................................................... 10
Installation ........................................................................................ 10
Beeding Between Glass and Cowl ........................................... 10

Removal ........................................................................................... 10
Inspection ......................................................................................... 10
Installation ........................................................................................ 10
Front Wiper Assembly ............................................................... 11

Removal ........................................................................................... 11
Installation ........................................................................................ 11
Front Wiper Motor ...................................................................... 12

Removal ........................................................................................... 12
Inspection ......................................................................................... 12
Installation ........................................................................................ 12
Front Wiper Hose ....................................................................... 13

Removal ........................................................................................... 13
Installation ........................................................................................ 14
Front Washer Tank .................................................................... 14

Removal ........................................................................................... 14
Inspection ......................................................................................... 15
Installation ........................................................................................ 15
Front Washer Motor ................................................................... 16

Removal ........................................................................................... 16
Inspection ......................................................................................... 16
Installation ........................................................................................ 16
Front Wheel Arch ....................................................................... 16

Removal ........................................................................................... 16
Installation ........................................................................................ 17
Rear Wiper Blade ....................................................................... 17

Removal ........................................................................................... 17
Inspection ......................................................................................... 18
Installation ........................................................................................ 18

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Rear Wiper Arm ..........................................................................18

Removal ........................................................................................... 18
Inspection ......................................................................................... 19
Installation ........................................................................................ 19
Rear Wiper Motor .......................................................................19

Removal ........................................................................................... 19
Installation ........................................................................................ 21
Rear Wiper Motor Bush ..............................................................21

Removal ........................................................................................... 21
Installation ........................................................................................ 22
Rear Washer Nozzle ...................................................................22

Removal ........................................................................................... 22
Inspection......................................................................................... 22
Installation ........................................................................................ 22
Rear Washer Tank ......................................................................23

Removal ........................................................................................... 23
Inspection ......................................................................................... 23
Installation ......................................................................................... 23
Rear Washer Motor .................................................................... 24

Removal ........................................................................................... 24
Inspection ......................................................................................... 24
Installation ........................................................................................ 24
Rear Washer Hose.......................................................................24

Removal ........................................................................................... 24
Installation ......................................................................................... 25
Rear Wheel Arch .........................................................................26

Removal ........................................................................................... 26
Installation ......................................................................................... 26

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Wipers and Washers Flick Wipe (MIST)

Front Wiper Control Lever F RO N
T REAR
OFF
PULL
M
IS
ON OF T
F
INT
F RO N T
REAR LO
W
OFF HIG
PULL H
MI
S
ON OF T
F
INT
LOW
HIGH
For a single wiping cycle, push the lever upward and

release it. The wipers will operate continuously if the
lever is pushed and held upward.
Intermittent (INT)
• OFF / Normal position
• Flick Wipe (MIST) Speed Intensity switch
• Intermittent (INT) F RO N
T RE
AR OFF
• Low Speed (LOW) PULL
M
IS
• High Speed (HIGH) ON OF T
F
INT
• Auto Wipe LO
W
HIG
• Intensity switch (Vary speed) H
The windshield wiper and washer operates when the
ignition switch is in ON position.
OFF/Normal position
F RO N T
REAR Push the lever downward to select intermittent (INT)
OFF
PULL
MI
wiping. Wiper operates intermittently at the same
S
ON OF T
F
INT
wiping intervals. Use this mode in light rain or mist.
LOW To vary the speed setting, rotate the speed intensity
HIGH switch.
This is the normal position of the wiper lever, where

the wiper is not in operation.

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Low Speed Wiping (LOW) Auto Wipe

Vehicle is fitted with rain light sensor (located on front
windshield) which operates the front wiper when rain
F RO N
T
drops falling on front windshield is detected.
REAR
OFF
PULL
M
IS
ON O T FF
INT
LO
W
HIG
H
Rain sensor
Push the lever further downwards to select the low

speed wiping (LOW).
High Speed Wiping (HIGH)

Operation
1. Turn ON the Ignition
2. To activate the "AUTO WIPE" feature, press
Auto Wipe switch
F RO N
T RE
AR OFF
PULL
M
IS
ON OF T
F
INT
LO
W
HIG
H
A
Press F RO N
T REAR
OFF
PULL
M
IS
ON OF T
F
INT
LO
W
HIG
H
Push the lever again downwards to select the high

speed wiping (HIGH).
3. Once "AUTO WIPE" mode is activated, system

will give one wipe on a windshield and Auto wipe
indicator illuminates in the Infotainment system,
indicating that AUTO WIPE feature is activated.

MAN-00162
WARNING
• Do not put any band/tape outside the sensor
on windshield
• Do not use any Chemical or Thinner to clean
inner surface of front windshield to avoid any
damage to the sensor
• After sensing the water on windshield, wiping
will start automatically. It might be possible
that even after there is no water on windshield
but still wipers will keep on wiping. This is
because of the mist may present on wind-
shield. This is absolutely a normal behavior
• Sensor can not detect difference between
4. Wiper speed will vary as per rain intensity.
water and mud, ice, snow, oil etc. Under these
5. Sensitivity of the sensor can be varied by using conditions, sensor may not behave properly.
speed intensity switch.
If required, turn OFF "AUTO WIPE" mode man-
ually
Speed Intensity switch
F RO N
T REAR Rear Wiper Control Lever
OFF
PULL
M
The rear wiper and washers operate when the
IS
ON OF T ignition switch is in the ON position.
F
INT
LO
HIG
W Rear Window Wiper
H
F RO N
T REAR
OFF
PULL
M
IS
ON OF T
F
INT
LO
W
HIG
6. This feature will get deactivated either by turning H
OFF the ignition or repressing the AUTO WIPE
switch.
CAUTION
• In case of any damages/ scratches to
windshield, new sensor needs to be installed/ To turn ON the rear window wiper, rotate the lever in
assembled along with new windshield clockwise direction to rear wiper ON position.
• Old sensor can not be used on the new
windshield as it is calibrated for a particular
windshield

MAN-00162
Rear Window Washer Incar Repairs

Front Wiper Blade
F RO N
T RE
AR OFF
PULL
M
IS
ON OF T
F
INT
LO
W
HIG
H
To turn ON the rear window washer, rotate the lever

in clockwise direction to rear wiper washer position.
Once rear washer is turned ON, rear wiper will wipe 3
times. Removal
Automatic Operation Notice
When reverse gear is engaged, rear wiper will While attempting to remove the front wiper
operate automatically, provided front wiper is in ON
blade, ensure that the wiper arm is at the park
position.
position and the ignition switch is in OFF
position.
1. Lift the front wiper arms (A) to raise the wiper

blade, until the wiper arm hinge is moved to
the center position.
A A

MAN-00162
2. Press the wiper blade retaining lock (A), and Wiper Rubber
pull down the wiper blade from the wiper arm.
Removal
CAUTION Notice
Do not allow the wiper arm to spring back While attempting to remove the front wiper
against the glass without the wiper blade in rubber, ensure that the wiper arm is at the park
place. It may lead to the damage of the wind- position and the ignition switch is in OFF
shield glass. position.
Inspection 1. Remove the front wiper blade. For additional

information refer to Front Wiper Blade
1. Check the wiper blade for bend or variability,
2. Unclip the wiper rubber from the wiper blade,
Installation locks (A) and remove the wiper rubber
1. Insert the wiper blade to the arm, and lock into separately (B).
the slot (A) by gently pulling the wiper blade.
A B
Notice CAUTION
Make sure that the wiper blade retaining locks Do not allow the wiper arm to spring back
fit and engage properly. against the glass without the wiper rubber in
place. It leads to the damage of the windshield
2. Lower the wiper arm to the original position. glass.

MAN-00162
Inspection Front Wiper Arms

1. Check the wiper rubber for tear or worn-out.
Installation
Notice
Make sure that the wiper rubber retaining
locks fit and engage properly.
Removal
Notice
While attempting to remove the front wiper
arms, ensure that the wiper arm is at the park
position and the ignition switch is in OFF posi-
tion.
CAUTION
Do not allow the wiper arm without the wiper
blade to spring back against the glass, this
may lead to the damage of the glass.

MAN-00162
1. Pull the hood release lever (A) located at the 4. Remove the two 14mm mounting nuts (A) from
right bottom side of the instrument panel to the LHS wiper arm, and one 14mm mounting
unlock the hood lock and open the hood. nut (B) from the RHS wiper arm.
B
A
2. Remove the two LHS wiper arm mounting nuts

chromet (A) using a suitable tool. Notice
While attempting to close the hood, ensure
that the wiper arm cover is closed.
5. Close the hood, lift the wiper arms, and

separately remove the wiper arms.
Inspection
1. Inspect the wiper arms for any damage or
bend, and replace if required.
A 2. If there is any lateral play in the wiper arm
hinge, replace the wiper arm.
Installation
3. Open the RHS wiper arm mounting nut cover
(A).

MAN-00162
Front Washer Nozzle Cowl Beeding
The washer nozzle consists of three nozzles Removal

positioned and angled to spray water onto the 1. Pull and remove the cowl beading (A) from the
windshield. The nozzles can be adjusted by using a wiper cowl.
pin for correcting the spray angle with respect to
the windshield. Always direct the nozzles to hit the
middle of the windshield to enhance the wiping
action of the wiper blades. A
Removal
1. Using the suitable tool to remove a washer
nozzle (A) from the cowl panel.
MAX
Installation
A 1. Fix the beeding to the original position.
2. Remove the water hose from the washer

nozzle.
Inspection
1. Inspect the washer nozzle for clog.
2. Inspect the washer nozzle lock for any damage
or crack, and replace if required.
Installation
1. Insert the water hose to the washer nozzle.
2. Fix the washer nozzle at proper position by
gently pushing it.

MAN-00162
Wiper Cowl 3. Unclip both sides of the cowl side cover (A)
from A-pillar.
Removal 4. Remove the eight cowl retaining clips (A) from

1. Remove the front wiper arms. For additional the cowl.
information refer to Front Wiper Arms
2. Remove the wiper washer hose (A) that is
located near the RHS side of the shock
absorber mounting.
5. Remove the cowl separately.
Inspection
1. Check the wiper cowl for damage.
2. Inspect the wiper cowl locks are broken or
damage.
Installation
Notice
While attempting to install the wiper cowl,
check the locks are seated properly which is
located below the windscreen.

MAN-00162
Cowl Side Cover Beeding Between Glass and Cowl
Removal Removal
1. Remove the wiper cowl. For additional 1. Remove the wiper cowl. For additional
information refer to Wiper Cowl removal information refer to Wiper Cowl removal
2. Unscrew the two 20mm flower mounting 2. Pull out the beeding (A) from the wiper cowl.
screws (A) and detach the cowl side covers.
A
A
Inspection
Inspection 1. Check the cowl beeding for damage and tear.
1. Check the cowl side cover for damage.
Installation
2. Inspect the cowl side cover locks are broken or
damage. Notice
Installation While attempting to install the wiper cowl,
check the locks are seated properly which is
Notice located below the windscreen.
While attempting to install the wiper cowl,
check the locks are seated properly which is 1. Fix the beeding to the original position.
located below the windscreen.

MAN-00162
Front Wiper Assembly 4. Remove the three 12mm mounting bolts (A)
from the wiper linkage.
Removal 5. Remove the wiper linkage from the mounting

1. Disconnect the battery negative terminal. For hole (A) provided at the vehicle body.
2. Remove the wiper cowl. For additional
information refer to Wiper Cowl removal
3. Disconnect the wiper motor electrical connector
(A).
A
6. Remove the wiper motor along with the wiper

A linkage from the vehicle.
Installation

MAN-00162
Front Wiper Motor Inspection

1. Check the wiper motor for correct operation.
2. Inspect the wiper linkage for corrosion or
damage.
3. Check the wiper linkage thread for any
damage or worn out, and replace if required.
Installation
Removal
Notice
Ensure that the wiper arm is at the park
position.

2. Remove the front wiper assembly. For
additional information refer to Front Wiper
3. Remove the 12mm wiper motor output shaft
mounting nut (A) and the four 10mm wiper
motor mounting bolts (B) from the bracket, and
separately remove the wiper motor.

MAN-00162
Front Wiper Hose 4. Remove the wiper washer outlet hose (A) from
one end of the water outlet jet that is located
near the wiper cowl.
Removal
1. Remove one end of the wiper washer outlet 5. Remove the wiper cowl. For additional
hose (A) that is located near the RHS side of information refer to Wiper Cowl removal
the shock absorber mounting. and installation section.
6. Pull out the water hose (A) from the washer
nozzle.
A
A
2. Remove the front RHS wheel arch.

3. Remove another end of the wiper washer
outlet hose (A) from the washer motor.

MAN-00162
Installation Front Washer Tank

The front washer tank is located in the right front

wheel fender. The tank stores the washer fluid
which is pumped by the washer motor and sprayed
onto the front windshield through the washer jet.
Removal
CAUTION
Never use petroleum-based cleaners or
solvents in the washer system.
1. Remove the front RHS wheel. For additional

2. Remove the four retaining clips (A) from wheel
arch of the front bumper RHS and LHS.

MAN-00162
3. Remove the two retaining clips (A) from bottom 6. Pull out the water filling neck hose (A) from the
of the front bumper RHS. washer tank.
4. Detach the wheel arch (A) to access the 7. Remove the two 10mm mounting bolts (A) and
washer tank. the nut (B) from the washer tank.
A
B
5. Disconnect the washer motor electrical 8. Separately remove the washer tank.
connector (A) and the water outlet hose (B) 9. Pull out and remove the front washer motor
from the washer motor. from the washer tank.
Inspection
1. Inspect the washer tank for any damage or
crack.
A
Installation

MAN-00162
Front Washer Motor Front Wheel Arch

Removal
CAUTION
1. Remove the front washer tank. For additional

information refer to Front Washer Tank
2. Pull and remove the washer motor (A) from the
washer tank.
Removal
1. Remove the front wheel. For additional
2. Remove the four mud flap retaining clips (A)
A and detach the mud flap (B) separately.
Notice
Carefully remove the washer motor without
damaging the O-rings.
Notice B
While removing the washer motor from the

washer tank, drain the water from the washer
tank.
Inspection
crack.
2. Inspect the washer motor O-rings for damage.
Installation

MAN-00162
3. Remove the thirteen wheel arch retaining Rear Wiper Blade

mounting clips (A) and six 10 mm wheel arch
mounting nuts (B).
Removal
Installation Notice
While attempting to remove the rear wiper
blade, ensure that the wiper arm is at the park
position and the ignition switch is in OFF posi-
tion.
1. Lift the rear wiper arm to raise the wiper blade,

until the wiper arm hinge is moved to the
center position.
2. Pull out the wiper blade (A) from the wiper arm
(B), and separately remove the wiper blade.
CAUTION
Do not allow the wiper arm to spring back
against the glass without the wiper blade in
place. It may lead to the damage of the
windshield glass.

MAN-00162
Inspection Rear Wiper Arm

1. Check the wiper blade for damage or loss of
resilience in the material.
2. Check the wiper blade for bend or variability,
Installation
1. Insert the wiper blade to the arm, and lock into
the slot (A) by gently pressing the wiper blade.
Removal
Notice
A While attempting to remove the rear wiper
arm, ensure that the wiper arm is at the park
position and the ignition switch is in OFF
position.
2. Lower the wiper arm to the original position.
1. Open the wiper arm cap (A).

MAN-00162
2. Remove the 12mm mounting nut (A) from the Rear Wiper Motor
wiper arm.
Removal
CAUTION Notice
Do not allow the wiper arm to spring back Ensure that the wiper arm is at the park
against the glass without the wiper blade in position.
place. It may lead to the damage of the
windshield glass. 1. Disconnect the battery negative terminal. For
3. Lift the wiper arm, and separately remove the removal and installation section.
wiper arm. 2. Remove the rear wiper arm. For additional
Inspection information refer to Rear Wiper Arm
1. Inspect the wiper arms for any damage and
bend, and replace if required. 3. Open the tailgate by using the button.
4. Pull out the tailgate upper trim (A), the LHS
2. If there is any lateral play in the wiper arm
trim (B) and the RHS trim (C).
hinge, replace the wiper arm.
Installation
B C

MAN-00162
5. Remove the four tailgate main trim retaining 7. Press and disconnect the wiper motor electrical
clips (A) and cover (B) from the tailgate main connector (A).
trim.
A B
A
3 4
140
160
2 5
H
T
180
1 6
200 C
SOURCE
8. Remove the three 10mm mounting bolts (A)

6. Pull and remove the main trim (A) from the from the wiper motor, and separately remove
tailgate. the wiper motor from the tailgate.
Notice Notice
Carefully remove the cargo lamp electrical The wiper motor is securely fixed in the
connector from tailgate big trim without tailgate using the vibration bush.
damage.

MAN-00162
Installation Rear Wiper Motor Bush

Notice
While installing the wiper motor, appropriately
match the slots of the wiper motor shaft with
the slots of the bushes.
Notice
While installing the bush in the tailgate,
ensure that the arrow mark provided on the
bush is always at the top position.
Removal
Notice
Ensure that the wiper arm is at the park
position.

2. Remove the rear wiper motor. For additional
information refer to Rear Wiper Motor
3. Remove the wiper motor bush (A) from the
tailgate.
Notice
The wiper motor is securely fixed in the
tailgate using the vibration bush.

MAN-00162
Installation Rear Washer Nozzle

Notice
While installing the wiper motor, appropriately
match the slots of the wiper motor shaft with
the slots of the bushes.
Notice
While installing the bush in the tailgate,
ensure that the arrow mark provided on the
bush is always at the top position.
Removal
1. Remove the high mount stop lamp. For
additional information refer to High Mount
Stop Lamp removal and installation section.
Inspection
1. Inspect the washer nozzle for any damage or
clog.
2. Inspect the washer nozzle for any damage or
crack.
Installation
1. To install, reverse the removal procedure. 1. Fix the wiper nozzle by gently pressing it.

MAN-00162
Rear Washer Tank 3. Remove the two 10mm mounting nuts (A) from
the washer tank, and separately remove the
washer tank along with the washer motor.
Removal
4. Pull out and remove the washer motor from the
washer tank.
CAUTION
Inspection
solvents in the washer system. 1. Inspect the washer tank for any damage or
crack.
1. Remove the LHS lower quarter trim. For 2. Inspect the washer motor O-rings for any
additional information refer to Rear LHS damage.
section. Installation
2. Press the lock, and disconnect the washer 1. To install, reverse the removal procedure.
motor electrical connector (A). Pull out the
water hose (B) from the washer motor.

MAN-00162
Rear Washer Motor Rear Washer Hose

Removal
CAUTION
1. Remove the rear washer tank. For additional

information refer to Rear Washer Tank
2. Pull and remove the washer motor (A) from the
washer tank.
Removal
CAUTION
A
1. Remove the rear LHS upper quarter trim. For
section.
2. Pull out the water hose (A) from the washer
motor.
Notice
While removing the washer motor from the
washer tank, drain the water from the washer
tank.
Notice
Carefully remove the washer motor without
damaging the O-rings.
A
Inspection
crack.
2. Inspect the washer motor O-rings for any
damage.
Installation

MAN-00162
3. Remove the water hose from the washer jet 7. Remove the water hose (A) from the washer
(A) near LHS quarter glass. jet near the defogger relay.
1502BAA00031N
4. Remove the water hose from the washer jet 8. Remove the water hose (A) from the washer
(A) near LHS of the third row seat belt. jet at the high mount lamp.
5. Remove the tailgate side trim LHS. For Installation

additional information refer to Tailgate Trim
6. Remove the water hose (A) from the washer
jet at the tailgate.
1502BAA00031N

MAN-00162
Rear Wheel Arch 3. Remove the seven wheel arch retaining

mounting clips (A) and seven 10 mm wheel
arch mounting nuts (B).
Removal
1. Remove the rear wheel. For additional Installation
2. Remove the four mud flap retaining clips (A)
and detach the mud flap (B) separately.

MAN-00162
Torque in
Nm
BOLT HEX FL
M8X1.25X30X8.8XZ Wiper assembly 3 15.0±2.0
Windshield wiper - N
front
NUT HEX FL 25.0±2.0
Arm to wiper 3
M10X1.5X9X10,A
FLANGE BOLT M6
Motor to BIW 3 6.5±1.5
X 1.0 - 20
Windshield wiper -
rear
NUT HEX 9.0 ± 1.0
Wiper arm to motor spindle 1
M8x1.25x6.5
FLANGE BOLT M6
1
X 1.0 - 20
Windshield wash-
er - front 6.5±1.5
NUT HEX FL
Washer bottle to BIW 3
M6X1X6X8 GR
Windshield wash- NUT HEX FL

2
er - rear M6X1X6X8 GR


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REPAIR MANUAL

TECHNICAL PUBLICATION CELL

www.teknetmahindra.com Rev2 – NOVEMBER 2011

GENERAL INFORMATION ............................................................................. 1

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General Precautions ........................................................................3

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Sensors, Switches, and Relays ............................................................. 9

Identification Information ............................................................. 11

Jacking and Lifting ........................................................................ 16

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Introduction The danger, warning, caution and notice are

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Contents in the manual Trouble Shooting Chart

Service Tips And Precautions Torque Specification

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Preparation before dismantling the

Dismantling of the vehicle parts

Accessories and Conversions

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Towing the Vehicle Towing Equipment

Rear Tow Hook

2. Rotate in anti-clockwise direction to tighten the

If the vehicle cannot be transported by flat-bed

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Removal of Parts • Specified oil/lubricant should be applied to the

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ECU and electrical parts precautions Electrical Parts

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Precautions for Engine Control Unit

wait for at least 2 minutes before disconnecting NO HEAT !

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3. Get the proper diagnostic materials together

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MAHINDRA & MAHINDRA LTD.

Vehicle Identification Number (VIN) System

WMI - World Manufacturer Identification

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Code Manufacturing Plant - location

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TABLE - III (I,O,Q.U,Z,0 - NOT ALLOWED)

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Engine Number Location

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After Sales Service Sticker

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Jacking and Lifting Jacking & Lifting Points

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Description and Operation ..............................................................1

Component Location Index .............................................................2

Service Tips and Precautions ........................................................9

General Procedures .......................................................................10

In Car Repairs .................................................................................14

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Fuse Box ..................................................................................... 19

Engine Oil Filter ........................................................................ 20

Crankshaft Front Seal ................................................................ 26

Crankshaft Rear End Oil Seal ................................................... 28

Timing Chain and Sprockets ................................................... 30

Hydraulic Lash Adjuster (HLA) ................................................. 48

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