Maintenance Manual

MAINTENANCE MANUAL
MAN-00167
RELEASED BY –
TECHNICAL PUBLICATION CELL

MAHINDRA & MAHINDRA LTD.
Rev1 – FEBRUARY 2012

www.teknetmahindra.com
ALL INFORMATION CONTAINED IN THIS MANUAL IS MOST UP-TO-DATE AT THE TIME OF PUBLICATION.
HOWEVER, SPECIFICATIONS AND PROCEDURES ARE SUBJECT TO CHANGE WITHOUT NOTICE. THIS
© 2012IS
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FOR reserved. This
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INTERNAL be reproducedWITHIN
CIRCULATION or copied,M&M
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About the Maintenance Manual
The maintenance manual outlines the correct standard operating procedures (SOPs) for carrying
out maintenance operations in a Mahindra XYLO mHawk vehicle. Carrying out the periodic
maintenance operations, as specified, is crucial for safe and trouble-free operation of the vehicle.
The recommended maintenance schedule /operations are published in the owner’s handbook.
This manual covers the correct method of carrying out the maintenance operations, using the
correct process/procedures, tools, parts and lubricants. The manual consists of –
Soft Copy - The Maintenance Manual pdf copy is presented with bookm arks. Each
Maintenance activity/ SOP is just at one click access through the items listed in Content. To go
back to the Index page from any page of the manual, just click on word Xylo m Haw k existing on
top-left side of each page.
Maintenance Schedule – The maintenance schedules outlines the operations to be carried

out a specified interval. These operations are Adjust (A), Inspect & Correct (I), Replace (.R),
Clean (C). The maintenance periods are specified in Kilometers (Kms).
Standard Operating Procedures (SOP) – Each maintenance operation is coded by a

operation code – 712-MAT-xxxx. Here 712 stands for the model family code, MAT indicating it
is a maintenance operation and xxxx the operation number.
Each maintenance operation is explained step-by-step, in the SOP section of the manual. The
man-hours required to complete the operation is also mentioned along with the operation code.
The correct grade of lubricants /coolants to be used, torque values, special tools are also
mentioned wherever applicable.
Check Sheets – Check sheets for each service list outs the operation which need to be carried
out by the technician, when the vehicles report for scheduled maintenance service. These check
sheets need to be attached to the Repair order.
Job Description Repair Time {Manhours}
Repair Code Torque Specified
Lubricant Quantity Tool Specified
Lubricant Recommended
This chart is only a sample.

© 2012 Mahindra & Mahindra Ltd. All rights reserved. This book may not be reproduced or copied, in whole or in
part, without the written permission of Mahindra & Mahindra Ltd.

Good Workshop Practices
Attire/Dress
• Always wear clean uniform

• Wear safety shoes
• Wear gloves, when required
• Wear belt cover
Vehicle Protection
• Put seat cover, fender cover, steering wheel cover, before starting the operations.
Safety
• When working with 2 or more persons, be sure to check safety for one another
• When working with engine running, make sure to provide ventilation for exhaust
fumes in the workshop
• If working on high temperature, high pressure, rotating, moving or vibrating parts,
you should wear appropriate safety gear and take extra care not to injure yourself or
others.
• When jacking up the vehicle, be sure to support the specified location with a safety
stand.
• When lifting up the vehicle, use appropriate safety equipment.
Parts and tools
• Before starting operation, prepare tool stand, MST, Gauges, oils and parts for
replacement.
Removed Parts
• Place removed parts in a separate box to avoid mixing them up with new parts or
contaminating new parts.
• For non-reusable parts such as gaskets, O-rings, and self-locking nuts, replace them
with new ones as instructed in the manual
• Retain the removed parts for customer inspection, if requested.

• Legend of the Safety Symbols
To emphasize information and procedures regarding safety, use, maintenance, etc., the
following symbols are used throughout the manual.
Term/ Symbol Denotation
DANGER indicates an imminently

hazardous situation which, if not avoided,
will result in death or serious injury.
WARNING indicates a potentially

could result in death or serious injury.
CAUTION indicates a potentially

may result in minor or moderate injury.
CAUTION used without the safety alert

symbol indicates a potentially hazardous
situation which, if not avoided, may result in
property damage.
Indicates important information relevant to

the vehicle, the vehicle's use or to sections
of this manual to which particular attention
must be paid for optimum use of the
vehicle.
If you see this symbol, it indicates “no”,

“do not,” “do not do this,” or “never”.
• Legend of the Procedure/ Action Symbols

To emphasize illustrations and standard operation procedures, the following symbols are used
throughout the manual.
Symbol Denotation
Set / Place / Check here
Locate / Show
Move forward / Fit
Rotate / Turn Clockwise
Rotate / Turn anti-clockwise

Maintenance Manual MAN-00167
XYLO mHawk February 2012/ Rev1
Refer below Maintenance Schedule for XYLO mHawk:

MAINTENANCE SCHEDULE
XYLO E9 Distance Covered (in Kms) / Months in service
whichever is earlier for free service
12 Months
4 Months
8 Months
20000 /
10000 /
100000
110000
120000
5000 /
30000
40000
50000
60000
70000
80000
90000
Maintenance item
Engine
Engine oil 1 R I R I R I R I R I R I R
Engine oil filter R R R R R R R
Auto tensioner I I R
Accessory drive belts I I R
Coolant 3 I I I I I I R I I I I I I
Air,Fuel & Exhaust
Air filter element (In dusty conditions
R R
replace at 30,000 Kms)
Fuel filter element R R R R R R
Fuel tank & stainer C
Water sediments drain-Fuel filter (or
C C C C C C C
when indicator glows)
Transmission
Transmission oil 2 R I R
Axles,wheels & tyres
Differential oil (Rear) 2 R I R I
Tyre rotation A A A A A A A A A A A A
Brakes
Brake & Clutch fluid - level & leak
I I I R I I I R I I I R
check B
Brake pads/ Callipers I I I I I I I I I I I
Brake drum and lining I I I I I I
Parking brake operation A A A A A A A
Suspension
Front Suspension bolts torque I I I I I I I I
Rear Suspension bolts torque I I I I I I I I
Front suspension bushes- inspect I I I
Link bushes- inspect I I I I I
Steering
Power steering fluid - level & leak
I I I I I I I I I I I I
check
Wheel alignment * Inspect if abnormal conditions are noticed or 40000kms ,whichever is earlier
Electricals
Battery electrolyte level I I I I I I I I I I I I I
Battery specific gravity I I I I I I I I I I I I
All Lights, Horns, Wipers & Washers I I I I I I I I I I I I I
Head light aiming I

Air Conditioner
Clean mesh C C C C C C C C C C C C
Check the system for leaks and
Once in every 2 years
recharge if required
Body
Door setting A
Final inspection
Tyre pressure A A A A A A A A A A A A A
Body mounting bolts for tightness I I I I I I I
Exhaust pipe mountings & damage /
I I I I I I I
leakage
Road Test- if any complaints reported I I I I I I I I I I I I I
Legends * On chargeable basis I = Inspect and correct R- Replace A-Adjust C-Clean
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes
introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or
whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the
Authorized Service Centre of Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution © 2012 Mahindra & Mahindra Ltd.

Refer below Recommended Lubricants Chart for XYLO mHawk -
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are
manufactured. The reproduction, translation, transmission, in part of or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra Ltd., will
amount to unauthorized use and shall be liable for penalty/prosecution © 2012 Mahindra & Mahindra Ltd.

XYLO mHawk (712 - MAT-xxxx)

Sr. No. Maintenance item Operation Code Page No.
1 Engine oil - Replace 712 - MAT - 0001 08
2 Engine oil - Level Check 712 - MAT - 0002 09
3 Engine oil filter - Replace 712 - MAT - 0003 10
4 Auto tensioner - Inspect 712 - MAT - 0004 11
5 Auto tensioner – Replace (AC-Water pump drive
712 - MAT - 0005 12
belt)
6 Auto tensioner – Replace (Alternator-Stg. Pump) 712 - MAT - 0006 12
7 Accessory drive belts – Inspect 712 - MAT - 0007 13
8 Accessory drive belts – Replace (AC-Water pump) 712 - MAT - 0008 15
9 Accessory drive belts – Replace (Alternator-Stg.
712 - MAT - 0009 16
Pump)
10 Coolant - Check 712 - MAT - 0010 17
11 Coolant - Replace 712 - MAT - 0011 18
12 Air filter element - Replace 712 - MAT - 0012 19
13 Fuel filter element - Replace 712- MAT - 0013 20
14 Fuel tank - Clean 712 - MAT - 0014 21
15 Water sediments drain – Fuel filter 712 - MAT - 0015 22
16 Transmission oil – Check & Replace 712 - MAT - 0016 23
17 Differential oil (Rear) – Check & Replace 712 - MAT - 0017 25
18 Tyre rotation 712 - MAT - 0018 26
19 Brake+ Clutch fluid - level & leak Check 712 - MAT - 0020 27
20 Brake+ Clutch fluid - Replace 712 - MAT - 0021 28
21 Brake pads/ Calipers - Check 712 - MAT - 0022 32
22 Brake drum and lining - Check 712 - MAT - 0023 33
23 Parking brake operation - Check & Adjust 712 - MAT - 0024 34
24 Front Suspension bolts torque - Check 712 - MAT - 0025 36
25 Rear Suspension bolts torque - Check 712 - MAT - 0026 36
26 Front suspension bushes- Inspect 712 - MAT - 0027 37
27 Rear Suspension Link bushes- Inspect 712 - MAT - 0028 39
28 Power steering fluid - level & leak Check 712 - MAT - 0029 41
29 Wheel alignment * 712 - MAT - 0031 42
30 Battery electrolyte level - Check 712 - MAT - 0032 45
31 Battery specific gravity - Check 712 - MAT - 0033 46
32 All Lights, Horns, Wipers & Washers - Check 712 - MAT - 0034 48
33 Head light aiming - Check & Adjust 712 - MAT - 0035 56
34 HVAC Filter / Clean mesh 712 - MAT - 0036 61
35 Door setting 712 - MAT - 0037 62
36 Tyre pressure - Check & Adjust 712 - MAT - 0038 63
37 Body mounting bolts for tightness-Check & Adjust 712 - MAT - 0039 64
38 Exhaust pipe mtgs. & damage/leakage - Check 712 - MAT - 0040 65
39 Road Test- if any complaints reported 712 - MAT - 0041
40 MAINTENANCE CHECK SHEET (FOR ALL SERVICE INTERVALS) 67
*on chargeable basis.
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the
manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part of or whole of the present document,
are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra
Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution © 2012 Mahindra & Mahindra Ltd.

712-MAT-0001 : 0.30 hrs.

ENGINE OIL – REPLACE
Nut/ Bolt description Quantity Nos. Spanner Size Torque Value – Nm.
 Oil Sump drain plug 01 22 mm 27.5 ± 2.5
Engine oil – MAXIMILE Feo
Capacity – 6.0 Lit.
Oil Filling Point
Oil Drain & Refill –

1. Open the oil filler cap.
2. Place the oil collecting tray below the sump, loosen & remove the oil sump drain plug. Allow
the oil to drain for 15 min.
3. Fit the drain plug with a new gasket/ washer. Torque tightens the Drain Plug.
Torque - 27.5 ± 2.5 Nm.
4. Fill fresh oil as per the recommended quantity and specification.
5. Refit the oil filer cap & check the oil level as per procedure 712-MAT-0002.
 Park the vehicle on level ground/2 post lift /4 post lift

 Engine should be hot while draining the oil.
 For other than Maximile brand, the oil change interval has to be reduced to 10000kms if the
oil meets minimum of API CH-4 SAE 15W-40 specification.
 Recommended intervals for Maximile Feo engine Oil change are at 5000, 20000kms & then
at every 20000kms.
Page 8
712-MAT-0002: 0.05 hrs.

ENGINE OIL – LEVEL & LEAK – CHECK
A B
DIPSTICK
DIPSTICK
GUIDE
DIPSTICK
MAX
MIN
Oil Level Check – Refer illustrations shown.

1. Pull out the dip stick gauge and wipe it clean with a cloth/paper.
2. Insert the dip stick gauge into the dip stick guide fully till the end.
3. Pull out the dip stick slowly and check for the oil level between Maximum and Minimum
level - if found below, top up with recommended oil.
4. Start the engine and check for oil leakage/ seepage at –
Refer illustration [C] checkpoints are shown with arrows.
 Oil sump & crankcase joint.
 Oil sump drain plug.
 Oil filter mounting point.
 Ensure that the vehicle is parked on level ground/2 post lift/4 post lift.
 Ensure that the engine is not running.
Page 9
712-MAT-0003 : 0.20 hrs.

ENGINE OIL FILTER– REPLACE
A B
Oil Leak - Check Points near Oil Filter
Oil Filter & Cooler disassembly
Oil filter Removal – Refer illustrations.

1. Remove the oil filter by unscrewing it in anti-clockwise direction, using an oil filter wrench.
2. Check the oil cooler stud for tightness – Torque 27.5 ± 2.5 Nm.
3. Smear a layer of fresh engine oil on the oil filter “O” ring
4. Fit the oil filter and turn it clockwise till the “O” ring touches the oil cooler face.
5. Turn the filter another 3/4th turn by hand.
6. Check for Oil leakage/ seepage at –
Refer illustration [A] checkpoints are shown with arrows.
 Oil pan & crankcase joint
 Oil pan Drain Plug.
 Oil filter joint.
 Oil cooler joint
 Never use a wrench/spanner to tighten the oil filter.

 Oil filters need to be replaced during engine Oil change. Recommended replacement intervals are
at 5000, 20000kms & then at every 20000kms. Use Maximile Universe oil filter.
Page 10
712-MAT-0004 : 0.10 hrs.

AUTO TENSIONER – CHECK (on AC-Water pump and Alternator-Steering Pump drive belt)
A B
1
Auto Tensioner mounting on Engine B
2
A
Auto Tensioner [1] & [2]
And Drive Belts [A] & [B] Layout
C Marking on Autotensioner 1 D
Marking on
Autotensioner 2
Auto Tensioner Inspection:

Refer illustrations shown.
Inspect automatic tensioner carefully for symptoms such as cracked arms, excessive vibration
during idle speeds, looseness, noise (clatter or rattling) and sticking or seized operation. These can
all be signs that a tensioner needs replacing.
Refer slots/ marking shown by arrow marks on Auto tensioner in sketch [C] & [D]. Two or three
slots marked on Auto tensioner arm, and one slot marked on its coil hub. The slot marked on coil
hub should always match in between two slots marked on Tensioner Arm when the belt is in its
position. If there is mismatch, either the belt needs to be check and replaced or Auto tensioner
needs to be replaced.
 Auto tensioner to be check at 60000, 80000kms and it is recommended to replace it at every

100000kms.
Page 11
712-MAT-0005 : 0.70 hrs. & 712-MAT-0006 : 0.50 hrs.

AUTO TENSIONER – REPLACE (AC-Water pump and Alternator-Steering Pump drive belt)
Nut/ Bolt description Qty. Nos. Spanner Size Torque Value Nm.
 Auto tensioner mtg. bolt (Alt/ PSP) 01 12 mm. 25 ± 3
 Auto tensioner (AC Comp) mtg. bolts 01 8mm Allen 32.5 ± 2.5
01 12 mm 25 ± 3
AUTOTENSIONER – REPLACE
[A] Alternator/Power Steering Pump Drive Belt
[B] AC Compressor /Water Pump Drive Belt
Refer illustrations.
1. Using the special tool, rotate the Auto Tensioner

in the direction shown in the figure. Lock the
Auto Tensioner in that position using a pin.
2. Remove the belt.
3. Take the locking pin out & release the Auto
Tensioner.
4. Remove auto tensioner assembly by removing its
mounting bolts.
5. Replace the components in reverse to the
assembly procedure.
1. Remove Power Steering drive belt before

attempting the said auto tensioner removal.
2. Using the spanner, rotate the Auto Tensioner in
the direction shown in the figure. Lock the Auto
Tensioner in that position using a pin.
3. Remove the belt.
4. Take the locking pin out & release the Auto
Tensioner.
5. Remove auto tensioner assembly by removing its
2 nos. mounting bolts.
6. Replace the components in reverse to the
assembly procedure.
 Auto tensioner to be inspected at 60000, 80000kms and to be replaced at 100000kms.

 Check the auto tensioner free arm position. Ensure that end of travel is not reached.
Page 12
712-MAT-0007 : 0.50 hrs.

ACCESSORY DRIVE BELT – INSPECT (AC-Water pump and Alternator-Steering Pump drive belt)
ACCESSORY DRIVE BELT - LAYOUT ACCESSORY DRIVE BELT TO BE CHECK FOR –

Refer illustrations below.
1. Abrasion
2. Cracking
3. Improper Install
4. Uneven Rib Wear
5. Misalignment
6. Chunk-out
7. Gravel penetration
8. Pilling
NOTE: It is recommended to remove & check the
drive belts thoroughly if any abnormality noticed.
1. Abrasion – Each side of belt appears shiny or
glazed. In advanced stages, fabric becomes
exposed.
2. Cracking – Small, yet visible cracks along the

length of a rib or ribs.
3. Improper Install – A belt rib begins separating

from the joined strands. If left unattended, the
cover will often separate, causing the belt to
loosen.
4. Uneven Rib Wear – Belt shows damage to the

side with the possibility of breaks in the tensile
cord or rough edged ribs. A thumping noise may
also be heard when running.
Page 13
5. Misalignment – Sidewalls of the belt may appear

glazed or the edge cord may become frayed and
ribs removed. A noise may result. In severe
cases, the belt can jump off the pulley.
6. Chunk Out – Pieces or chunks of rubber material

have broken off from the belt. When chunk-out
has occurred, a belt can fall at any moment.
7. Gravel Penetration – Small pinholes are visible

on the backside of the belt. Bumps may be visible
and the fabric around the holes can be frayed.
8. Pilling – Belt material is sheared off from the ribs

and builds up in the belt grooves.
 Main accessory Drive Belts to be inspected at 60000, and 80000 kms.

 Accessory Drive Belts to be inspected first at 60000 kms and 80000 kms and to be replaced
at every 100000 kms.
Page 14
712-MAT-0008 : 0.50 hrs.

ACCESSORY DRIVE BELT – REPLACE (AC-Water Pump Drive Belt)
 Cooling Fan mtg. nut 01 34 mm. 55± 05
Removal Steps –
Refer illustrations.
1. Remove NVH cover.
2. Remove Fan & shroud.
3. Remove Alternator/Power steering drive belt

(712-MAT-0120).
4. Turn Auto-tensioner in clockwise direction,

to loosen drive belt.
5. Remove AC/Water pump belt.
Assembly Procedure –
1. Turn auto-tensioner in clockwise direction and refit accessory drive belt.
2. Refit AC Compressor/Water Pump drive belt.
3. Refit Alternator/power steering drive belt (712-MAT-0009).
4. Refit Fan & shroud and NVH cover.
 Replace Accessory drive belts at every 100000 kms.
Page 15
712-MAT-0009 : 0.40 hrs.

ACCESSORY DRIVE BELT – REPLACE (Alternator-Steering Pump Drive Belt)
 Cooling Fan mtg. nut 01 34 mm. 55 ± 05
Removal Steps –
Refer illustration shown.
1. Remove NVH cover.
2. Remove Fan & shroud.
3. Turn Auto-tensioner in clockwise direction, as
shown in sketch to loosen drive belt.
4. Remove accessory drive belt (On
Alternator/Steering Pump).
Assembly Procedure –
1. Refit accessory drive belt. Turn auto-tensioner

in clockwise direction for ease of belt fitment.
2. Refit Alternator/power steering drive belt.
3. Check Power steering drive belt tension.
4. Refit Fan & shroud.
5. Refit NVH cover.
 Replace Accessory drive belts at every 100000 kms.
Page 16
712-MAT-0010 : 0.05 hrs.

COOLANT LEVEL – CHECK
Coolant – MAXIMILE ULTRA COOL (Pre-mixed)
Degassing Tank Cap 1
Degassing Tank Fluid Level Marking
COOLANT LEVEL - INSPECT
Check the coolant level when the engine is cold.
1. Check the coolant level in the degassing

tank [1] – it should be between MAX and
MIN marks. If below MIN, Open the
degassing tank cap and top it up with
Maximile Coolant.
2. Check for evidence of leakage at Water pump hose, Oil cooler hose. Radiator top and bottom
hoses and HVAC heater hoses.
 Use Maximile ULTRA COOL only.

 Never remove the radiator cap when the engine is hot.
 Never mix MAXIMILE coolant with water. It is pre-mixed.
 Check coolant level and leak at every service interval.
Page 17
712-MAT-0011 : 0.60 hrs.

COOLANT – REPLACE
Coolant – MAXIMILE ULTRA COOL (Pre-mixed)
Capacity – @ 08 Lit.
A B
COOLANT – REPLACE
Refer illustration shown A & B.
1. Open the degassing tank cap
2. Place coolant collection tray below and remove the drain plug on the Radiator bottom [A]
and Engine block [B]
3. Let coolant get complete drain in coolant drain tray.
4. Refit the drain plugs & fill new coolant in degassing tank.
5. Check all the coolant hoses & clips for proper fitting and no leakage; correct if required.
6. Start the engine and run at approx. 1200 rpm for 2-3 min.
7. Check coolant level in degassing tank and add coolant as per requirement.
8. Fill coolant in the degassing tank up to MAX level.
9. Refit the degassing tank cap.
10. Start the engine again and run at approx. 1200 rpm for 2-3 min.
11. Check coolant level in degassing tank and top-up as required.
 Never remove the degassing cap when the engine is hot.

 Never mix MAXIMILE coolant with water. Maximile coolant is premixed/ ready to use.
Recommended to change the coolant at 60000kms, 140000kms and then every 80000kms.
 Use Maximile ULTRA COOL
 Don’t use other brand coolants for top up.
Page 18
712-MAT-0012 : 0.25 hrs.

AIR FILTER - REPLACE
 Air filter top cover allen bolt 07 6 mm 4.5 ± 0.5
 Hose clamps – air cleaner to manifold 02 11 mm. 2.5 ± 0.5
02 11 mm. 4.5 ± 0.5
A B C
5
2
1 3
4
1
Air Filter Assy. –

Exploded View
AIR FILTER ELEMENT – REPLACE

Refer illustration shown above –
1. Open the clean and dirty sides hose clip & remove the hose.
2. Open the Air cleaner Top cover bolts.
3. Remove the Air filter element along with grates and clean the bottom bowl.
4. Separate the top as well as bottom grates and replace the air filter element; assemble the
grates & put the assembly back in place. Position the new element properly. Take care of
lug projections.
5. Assemble the top cover & tighten the top cover bolts diagonally.
6. Assemble the clean hose on the air cleaner outlet-Air Mass Sensor neck and tighten the
hose clip.
 Never try to clean and reuse the Air filter cartridge.

 It is recommended to replace the air filter cartridge at every 60000kms. In case vehicle runs in
very dusty condition replace air filter cartridge at 30000kms or red band in chock indicator
appears.
Page 19
712-MAT-0013 : 0.50 hrs.

FUEL FILTER – REPLACE
Fuel Filter Location in Xylo mHawk Engine Compartment

• Remove the ‘Water in Fuel Sensor’ connector
and remove the sensor by rotating it in anti-
clockwise direction.
NOTE: Water in Fuel Sensor is fitted at the bottom

of the Fuel Filter element and it can be accessed
from front right side wheel housing.
WATER SEDIMENT DRAIN
PLUG IN FUEL FILTER
• Remove the Fuel Filter Element [1]

• Fit a new fuel filter element and tighten it by
hand [4]
• Refit the “Water in fuel” sensor [3]
• Remove the fuel tank cap
• Switch the Ignition to ‘ON’ position
• Bleed the system using hand primer and bleed
screw on the banjo.
• Bleed the fuel system by operating the priming pump several times until you feel more
resistance. The engine may take longer to start [B].
 Always replace with genuine fuel filter assembly.
Page 20
712-MAT-0014 : 1.00 hrs.

FUEL TANK AND STAINER – CLEAN
Pre removal activities –

• Lift vehicle on certified hoist.
• Keep tray below the fuel tank to avoid spillage of fuel while tank removal.
• Remove the fuel tank drain plug* (if applicable) and ensure for complete fuel drain and Refit the
drain plug.(27.5 ± 2.5 Nm)
• Check the fuel quantity before removing tank from the vehicle if the drain plug is not provided.
More care to be taken while removing fuel filled tank from vehicle. Use proper support and
additional manpower to avoid personal injury and other damages.
• Disconnect the fuel lines – Main and return

line hoses.
• Disconnect the fuel filler hose and the

breather hose.
• Disconnect the tank unit WH connector.
Xylo mHawk Fuel Tank – Bottom Side View

• Remove the fuel tank from the vehicle, by
removing 04 nos. mounting bolts. Refer
sketches.
• Remove the ‘Fuel Strainer with main line

assembly’ by removing the fastening bolts.
Xylo mHawk Fuel Tank – Top Side View

• Blow the compressed air gradually with low
pressure as per the direction indicated by the
arrow in the illustration above.
• Clean the fuel tank.
• Refit the fuel tank and reconnect the main

line, return line, filler hose, breather hose
and tank unit connections.
Fuel Strainer - Schematic

Post installation activities -
• Refill fuel in the fuel tank. (Use recommended fuel. Tank MAX capacity is 60L approx.)
• Bleed the fuel system, if required. (Refer 712-MAT-0013)
Page 21
712-MAT-0015 : 0.20 hrs.

WATER SEDIMENTS DRAIN - FUEL FILTER
FUEL FILTER LOCATION IN XYLO mHawk
Water in Fuel Sensor is fitted at the bottom of the

Fuel Filter element and it can be accessed from
front right side wheel housing.
WATER SEDIMENT DRAIN
PLUG IN FUEL FILTER
• Remove the ‘Water in Fuel Sensor’ connector

and remove the sensor by rotating it in anti-
clockwise direction.
• ‘Water in Fuel Sensor’ to be rotated by 2 turns

[1] to open.
• Allow the Water accumulated in the filter to

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

in clockwise direction.
• Bleed the fuel system by operating the priming pump several times until you feel more
resistance. The engine may take longer to start.
 Always replace with genuine fuel filter assembly.
Page 22
712-MAT-0016 : 0.30 hrs.

TRANSMISSION OIL - REPLACE
Transmission Oil – MAXIMILE Syntec F2

Capacity – @ 1.75 Lit.
5MT320 – TRANSMISSION SCHEMATIC
• Ensure that vehicle is lifted on certified hoist.

• If activity is being done out of workshop, ensure that vehicle is parked on leveled surface.
• Remove the Filler plug [A]; refer illustration.
• Place oil collection tray under transmission.

• Loosen & remove the drain plug [B].
• Allow the oil to drain out completely.

• Assemble & torque tight the drain plug with
new washer – 27.5 ± 2.5 Nm.
• Fill fresh transmission oil as per specified
capacity & assemble the filler plug with new
washer with 27.5 ± 2.5 Nm torque.
• Check for Oil leakage / seepage at –
- Transmission Housing Joints.
- Transmission Oil drain plug.
Page 23
Breather Cleaning -
• Remove the breather from the transmission; use screw driver.
• Clean it externally & blow compressed air from bottom.
• Fit back the clean breather.
• Recommended oil brand is Maximile Syntec F2. The oil change interval has to be first at
10000kms & then 100000kms. Inspect oil for level and leak at 50000kms.
• If Maximile GO Synchro 80W-90 is used, the oil change interval has to be reduced to 40,000 km.
For other than Maximile brand, the oil change interval has to be reduced to 20000 km if the oil
meets minimum of API GL-4 SAE 80W-90 specification.
Page 24
712-MAT-0017 : 0.20 hrs.

DIFFERENTIAL OIL – CHECK & REPLACE
Differential Oil – MAXIMILE Elite.

Capacity – @ 1.8 Lit.
Banjo Axle – Oil Replacement
Differential Oil – Replace. Refer illustration shown.

1. Remove the Filler plug [A]
2. Place drained oil collecting tray below the axle.
3. Remove the drain plug [B]. Allow the oil to drain out completely.
4. Clean the metal particles if any deposited on the drain plug. Assemble & torque tight the
drain plug with new washer – 47.5± 6.5 Nm.
5. Fill fresh transmission oil as per specified capacity & assemble the filler plug with new
washer and torque to 47.5± 6.5 Nm.
6. Check Oil leakage / seepage at –
• Differential covers joint face
• Differential Oil drain plug.
 Recommended oil brand is Maximile Elite. The oil change interval has to be first at
10000kms & then 100000kms. Level and leak to be checked at 50000kms, 120000 kms.
 For other than Maximile brand, the oil change interval has to be reduced to 20000 km if the
oil meets minimum of API GL-5 SAE 80W-90 specification.
Page 25
712-MAT-0018 : 0.60 hrs.

TYRE ROTATION
Xylo mHawk Tyre Rotation Illustration - Schematic
Tyre pressure value: Refer below chart –
COLD TYRE INFLATION PRESSURE

TYRE SIZE 215/75 R15 100S
Vehicle Load
Condition:
NORMAL/
PARTIAL
FRONT REAR
Psi 35 35
Kg/cm. sq. 2.4 2.4
Vehicle Load
Condition:
FULL
Psi 35 41
Kg/cm. sq. 2.4 2.8
• The proper cold tyre inflation pressure is listed in the Tyre Label (Vehicle Placard), located
on the front passenger side inner B-pillar.
• Ensure to check and adjust the tyre pressure in the spare tyre.
• Ensure to replace dust cap on valve seats after checking tyre pressure.
Page 26
712-MAT-0020 : 0.15 hrs.

BRAKE/CLUTCH FLUID – LEVEL & LEAK - CHECK
Brake/ Clutch Fluid – DOT4 standard.
----MAX------
----MIN------
Common Fluid Reservoir for Brake & Clutch System
BRAKE/CLUTCH FLUID – LEVEL & LEAK - CHECK

Refer above illustration –
1. Check for Brake/Clutch Fluid Level up ‘Max’ mark on the brake/clutch fluid reservoir.
2. Check for Brake/Clutch Fluid leakage and correct fitment at all joints –
 Hose connected from reservoir and Clutch master cylinder.
 Clutch Master Cylinder inlet and outlet.
 Clutch Bundy tube to flexible hose joint.
 Concentric clutch slave cylinder hose joint and bleeder screw.
 Xylo variants are fitted with common Fluid reservoir for Brake and Clutch System.
 There are three different compartments – 2 compartments for brake front and rear circuits
and another for clutch circuit
 In case anyone circuit fails, other circuits will not be affected.
 Always use recommended fluid and do not mix different brand fluids.
 In case brake fluid reservoir replaced, bleeding required for Brake as well as Clutch system.
 Recommended fluid: SHELL CLUTCH & BRAKE FLUID DOT 4/ Brake Fluid Meeting SAE J1703;
FMVSS No.116 DOT 4 or IS 8654 Type-2 Specification.
 Check fluid level and leak at every service interval after 10000kms.
Page 27
712-MAT-0021 : 0.70 hrs.

BRAKE/CLUTCH FLUID – REPLACE
Clutch /Brake Fluid – DOT4 Standard.

Capacity – 0.9 Lit
Brake Fluid Replacement/ Brake Bleeding ‐ Procedure
Use brake fluid DOT 4 standards only. Use fresh, clean fluid from a sealed container at all times.
Anti-lock Brake system requires conventional bleeding methods plus use of the diagnostic tool. Under
the normal conditions the diagnostic tool is not required to do the bleeding. The complete brake
bleeding can be done normally as per the defined sequence. It is recommended to do diagnostic
bleeding in case pedal found spongy.
1. Perform base brake bleeding. Sequence is RL/FL/FR/RR.

(Rear Left‐ Front Left‐Front Right‐ Rear Right)
2. Top up master cylinder fluid level and verify proper brake operation before moving vehicle.
Base brake bleeding procedure -
1. Open the fluid reservoir cap and fill the

brake fluid reservoir to the MAX mark.
2. Connect the bleed tube to the Rear Right

caliper bleed screw and place the other end
submerged in a transparent container
containing sufficient brake fluid.
*This is Sample illustration
Page 28
3. Depress the brake foot pedal and hold it

down.
4. Open the bleed screw. The fluid will flow into

the transparent container.
5. Tighten the bleed screw and release the

pedal.
6. After the pedal returns, allow an interval of

3 to 4 seconds before making the next
stroke. Steps 4 to 6 should be repeated until
there are no more air bubbles at the end of
*This is Sample illustration the bleed tube.
Now follow the same procedure at the other wheels as per the sequence given below.
1. Rear left 2. Rear right
3. Front left 4. Front right
Refer below schematic for brake fluid bleeding sequence –
EHCU Assembly
Brake Booster
& TMC
4
3
Front LHS Front RHS

Brake Caliper Brake Caliper
1 2
Rear LHS Rear RHS
Brake Drum Brake Drum
7. After the bleeding sequence is completed, remove the bleed tube and place the dust cap on the
bleed screw.
8. Ensure that the bleed screw is tightened to the specified torque.
Page 29
CLUTCH FLUID REPLACEMENT / CLUTCH BLEEDING
Bleeder Screw
on Concentric
Slave Cylinder
Concentric Slave
Cylinder mounting
Slave Cylinder
bolts – 3 nos.
Connector
Clutch
Slave Cylinder Housing
1. Remove the dust cap of the bleeder screw.
2. Connect bleeding tube, to bleeding screw

on slave cylinder.
Hose from Clutch
Master Cylinder - Ensure that the other end of the tube is
fully immersed in the bottle having clean
Bleeder on Concentric clutch /brake fluid.
Slave Cylinder
3. Fill the Reservoir up to the top level with recommended fluid.

4. Operate clutch pedal 3 or 4 times slowly to the full stroke. Holding the clutch in depressed
condition loosen the bleeding screw on slave cylinder by ½ to ¾ turn and allow all the air escape
in to the container bottle.
5. Repeat the exercise till no air bubble appears in the bottle.
6. During this operation ensure fluid level in reservoir.
7. Tighten the bleed screw properly.
8. Remove bleeding tube and place the dust cap on bleed screw.
9. Check the fluid level in container and top up it to the ‘max’ level.
Page 30
• Before bleeding the brake system refer to general brake service practice and brake fluid
pre‐cautions.
• Always use the recommended and specified brake fluid.
• Do not reuse the drained fluid and always use brake fluid from the sealed bottle.
• Entire bleeding operation should be done with ENGINE ON (running).
• The reservoir on the master cylinder must be at the Max (upper) level mark at the start of
bleeding procedure and should be checked after bleeding each brake caliper and brake fluid to
be topped up as required.
• If the brake system is opened i.e. all the wheel cylinders are opened and fluid has drained off.
Even then, since inside the EHCU the inlet valve is normally open, hence the complete brake
bleeding can be done normally as per the defined sequence.
• Do not spill brake fluid on the vehicle, it may damage the paint, if the brake fluid does contact
the paint, wash it off immediately with water.
• Make sure no dirt or other foreign matter is allowed to contaminate the brake fluid.
• At all times during the bleeding process, it has to be ensured that the fluid level in the
reservoir does not drop below minimum.
• The Brake fluid reservoir cap/ container should not be opened with dirty hands.
• Avoid direct water spray on reservoir while washing engine compartment.
• Brake fluid meeting SAE J1703 FMVSS NO. 116 DOT 4 or IS 8654 TYPE‐ 2 specification.
• During the bleeding operation ensure the container & pipe used is of transparent for better
visual.
Page 31
712-MAT-0022 : 0.60 hrs.

FRONT BRAKE - CHECK
7 mm FRONT BRAKE –
Check Pad Thickness CHECK SCHEMATIC
21 mm
Check Disc Thickness
Front Brake – Check. Refer illustration shown.

1. Check the disc for abnormal wear/grooves (Minimum usable thickness of the disc is
21mm. Do not check disc thickness near the outer edge of disc)
2. Loosen & remove the bottom side sliding pin bolt. Swing up the caliper. Remove the pads
& check the pad thickness. The minimum usable pad thickness is 7 mm. (without backing
plate) if observed less; replace the pads. (The groove at the center of the pad can also be
used as a reference. If the pad has worn up to the end of the groove; it should be
replaced)
3. Measure the thickness at the thinnest and worn area of the pad. Replace pad assembly
when pad thickness is less than the limit value.
4. Mechanical Pad wear indicator is provided to know pad wear limit; which will make rattle
noise when pad is worn out.
5. Check for the oil leakage from Calipers/piston seals.
 If any pad is worn out (inboard /outboard) then replace both the pads.
 If pads on one wheel only are worn, even then replace the other wheels also.
 Any excessive difference between inboard and outboard wear indicates either bent or seized
sliding pin. Please check the complete hydraulic system besides the calipers.
 Always replace the front pads and shims together as a set.
 Install inner pad with its wear indicator upward.
 Inspect at every 10000kms from 20000kms onwards.
Page 32
712-MAT-0023 : 0.80 hrs

BRAKE DRUMS/LINERS - CHECK
Brake Drum/ Liners – Check

Refer illustration shown.
1. Rear Brake – Open the drum & clean the brakes by blowing compressed air. Check the wheel
cylinder for oil leakage [1]. (It is recommended to check the oil seepage from wheel cylinder
by lifting the dust boots.)
2. Check the brake lining for wear/cracks. The minimum usable thickness [2] of the liner is 4.5
mm (The brake shoe must be replaced before the rib starts touching the drum).
3. Replace brake shoes when the liner thickness will remain 1 mm.
4. Measure the wear of the brake lining at the place worn the most.
5. Before removing brake shoes, collapse the auto-adjuster assembly which will help to remove
shoes easily.
6. After re-assembly, check the wheel freeness in both forward & reverse direction.
 Park the vehicle in inspection pit/ 2 post lift/ 4 post lift

 Whenever the brake shoes are replaced, replace both RH & LH assemblies as a set to prevent
car from pulling to one side when braking.
 If there is significant difference in the thickness of the liner on the left and right sides, check
parking brake operation/ wheel cylinders piston for free movement.
 Rear Brake drum & liners to be inspected at every 20000kms from 20000kms onwards.
Page 33
712-MAT-0024 : 0.30 hrs

PARKING BRAKE - CHECK
TYPE – Mechanical Hand operated acting on rear wheels brake Drum.
Xylo Parking brake Layout - Schematic
• Check Brake & Clutch Pedals for free play & sponginess. Refer SOP given in Repair Manual.
• Switch off the engine, keep transmission in neutral position.

• Check Parking Brake Lever operation & setting.
Page 34
• Rear parking brake cable on LH side to be adjusted through the Clamp provided. Refer
illustration.
• Rear parking cable can be adjusted with the help of the setting clamp and screw given on RH
side cable.
• After parking brake cable adjustment, release the handle and check for free rotation of both the
Rear Wheels.
Before parking brake adjustment –

- Check the parking cables for correct routing, before start adjustment.
After parking brake adjustment -
- Park the vehicle on a slope and apply Parking Brake to check the effectiveness.
- Release the Parking Brake & check the free rolling.
Page 35
712-MAT-0025 : 0.25 hrs. &

712-MAT-0026 : 0.20 hrs.
FRONT/REAR SUSPENSION BOLT TORQUE - CHECK
Type/Description: [A] Front - Double Wish-Bone Type IFS.

[B] Rear – Multi Link (5 Link) Rear Suspension.
A B
FRONT & REAR SUSPENSION BOLT TORQUE – CHECK

Refer suspension bolt torque chart.
1. Check front suspension bolt torque at -
 Camber bolt production level marking cross verification.
 If marking found distrub then follow step [a] otherwise follow step [b],
(a) Re-adjust the position and apply the 200 N-m torque.
(b) Apply 200 N-m torque to camber bolt with-out disturbing camber bolt position
If front suspension camber bolts found loose then the wheel alignment has to be done. Please
refer the Front Suspension section of the Repair Manual for details.
2. Apply 120 N-m torque to shock absorber to lower arm joint.

3. Apply 150 ± 10 N-m torque to rear suspension bolts at –
 Upper link, Lower link, Panhard Rod on chassis and axle mounting bolts.
 Always use 4-post lift or park vehicle on pit while checking suspension torque.
 Use calibrated torque wrenches & Do not over torque than recommended values.
 Inspect first at 5000kms, 10000kms, 20000kms and then every 20000kms.
Location Torque Nm
FRONT SUSPENSION
Lower Control Arm Front Mounting 200 Nm
Lower control Arm Rear mounting 200 Nm
Shock absorber Top- on body 40 ± 10 Nm
Shock absorber Bottom on LCA 120 ± 10 Nm
REAR SUSPENSION
Upper Link 150 ± 10 Nm
Lower Link 150 ± 10 Nm
Pan hard Rod 150 ± 10 Nm
Page 36
712-MAT-0027 : 0.20 hrs

FRONT SUSPENSION BUSH - CHECK
1 A B
1
4
C
2
Front Suspension Bush – Check

Refer illustrations shown.
1. Check lower control arm front and rear bush condition (both LH & RH) for wear & tear,
cracks & shift. Replace if necessary.
2. Check upper control arm front and rear bush condition (both LH & RH) for wear & tear,
cracks & shift. Replace if necessary.
3. Check the ball joint boots for damage, cracks. Replace if necessary.
4. Check Shock Absorber Bushes, dust boot & Stabiliser Bar Links and Bush for wear & tear,
cracks and shift. Replace if necessary.
 Observe following conditions even after wheel alignment –
(a) Problem in vehicle ride and handling.
(b) Noise from suspension joints even after specified joint torque values.
 Refer illustration shown below for direction of fitment of voided bush.

 Inspect front suspension bush at 40000kms and 80000kms.
Page 37
 Correct fitment/ identification of Front Suspension Bushes –
BUSH-LCA FRONT END BUSH-LCA REAR END BUSH - UCA
VOIDED BUSH - CORRECT POSITION ON VOIDED BUSH - CORRECT POSITION ON

UPPER ARM LOWER ARM
The washer has to

Wrong fitment of be crimped to
voided bush ensure bush
performance;
Refer SOP in
Repair Manual
 Upper arm is fitted with voided bush on both sides.

 Lower arm is fitted with voided bush at its rear end.
 Ensure that while fitting the voided bush on Upper arm or lower arm rear end, the Bush solid
rubber portion should be parallel to the Arm.
Page 38
712-MAT-0028 : 0.20 hrs

REAR SUSPENSION BUSH - CHECK
Rear Suspension – Exploded View
2
1
2
2
1
1
Rear Suspension Bush - Check

Refer illustration shown above.
1. Check all the suspension link Rubber Bushes for –
 Wear
 Ageing
 Cracks
 Metal sleeve separation.
2. Check the Upper & Lower Links & Pan hard Rod for damage/ bent etc.
3. Check shock absorber bushes for wear, crack and shift.
 Observe following conditions even after wheel alignment –
(c) Problem in vehicle ride and handling.
(d) Noise from suspension joints even after specified joint torque values.
 Refer illustration shown below for direction of fitment of voided bush.

 Inspect link bushes at 40000kms and then every 20000kms.
Page 39
 Correct fitment/ identification of Rear Suspension Bushes –
Lower Link Bush – Upper Link Bush – Axle/

Lower Link Bush–Axle Side Frame Side Frame Side
Pan hard Rod Bush-Axle Side Pan hard Rod Bush-Frame Side
VOIDED BUSH – CORRECT POSITION ON UPPER LINK
Wrong fitment of
voided bush
 While tightening the link & torquing ensure that wheels are resting on the ground/ 4 post lift. If
it is not done, the ride quality will get adversely affected.
 Ensure that while fitting the voided bush on Upper link both ends, the Bush solid rubber portion
should be parallel to the Arm.
Page 40
712-MAT-0029 : 0.10 hrs

POWER STEERING FLUID – LEVEL & LEAK - CHECK
Power Steering Fluid – SHELL "SPIRAX S3 ATF MD3" / CALTEX "TEXAMATIC 1888"
Capacity: 0.8 Lit.
Leak Check Points
POWER STEERING FLUID – LEVEL/ LEAK - CHECK

Refer illustration shown above.
1. Check the steering oil level in the reservoir [1] – it should be between MAX and MIN marks.
If below MIN, top it up with recommended oil.
2. Check hose joints for oil leakage / seepage at –
 Reservoir
 Power Steering Pump
 Rack & Pinion – Pipe ends & boots.
 Brand Specific and no other brand fluid should be used.

 Inspect Steering Fluid Level & Leak at every 10000kms.
 M&M Part No for SHELL SP I RAX S3 ATF M D3 Lubricants is 1102EA0032N .
Page 41
712-MAT-0031 : 0.40 hrs

WHEEL ALIGNMENT
Camber Bolt initial setting for wheel alignment –
Note:- 1. With front camber bolt easy to adjust camber value.

2. With rear camber bolt easy to adjust castor value.
CAMBER ADJUST
CASTOR ADJUST
CASTOR ADJUST
CAMBER ADJUST
Page 42
Pre Work for Wheel Alignment Process:

Tyre pressure : Should be as per recommendations in all the tyres.
Position of bolts : Observe the intial positon of the camber/ castor bolts.
Sequence :
• Do the runout compensation

Runout
• Adjust the camber setting by adjusting the front bolts

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

Castor sketch above)
Indivudal
• Set toe-in using the track rod ends.
Toe In
Turning
• Check the each wheel turning angle.
angle
 It is very important to torque all the camber/castor bolts to 200 Nm.

 Shock Absorber Projection Height – 26.0 ± 1.0 mm.
Refer below sketch and photo to adjust Shock Absorber Projection Height.
Use MST No.0401BAA0005ST & refer Repair Manual for SOP.
Page 43
Ride height - Is the verticle distance between front camber bolt nut side end center to the ground
plane.
The ride height should be 269 ± 5 mm.
If ride height is not within limits then please check for the coil spring damage or any issue is the rubber
or mounting bolt area or weak shock absorber. Also confirm if the shock absorber projection is as per
the specification. Last parameter to be checked should be the rubber bushes of the LCA and UCA.
Wheel alignmnet Parameters
Toe-in partial 0 to 1 mm ( 0 to 13’)

Toe-in Total 0 to 2 mm ( 0 to 26’)
Camber - 30' to + 10'
Difference between LH & RH camber 30’
Caster 1°45' to 3°45'
Difference between LH & RH caster 1°
King pin Inclination 42
Wheel turning angle- Inner (Max) 35˚ to 38˚
Wheel turning angle- Outer (Max) 34˚ to 36˚
Page 44
712-MAT-0032 : 0.10 hrs

BATTERY ELECTROLYTE LEVEL - CHECK
Battery Electrolyte Level Check
Refer above illustration –

1. Ensure the electrolyte level between MIN and MAX marks (if the electrolyte level is less than
the MIN mark, then top up the electrolyte to the recommended level with distilled water.
2. Check the terminals clamps for clean and tightness; if required clean it and fix it tightly.
3. Check the other end of battery cables for tightness.
 Battery rating: 12V, 65Ah.

 Toping up should be done with distilled water only.
 Never use normal water or mineral water to top battery electrolyte.
 Vent holes should be clear.
 Clean the terminals.
 Use petroleum jelly in case of terminals gets rusty.
 Tighten the terminals along with cable fitments properly.
 Battery Electrolyte Level Check to be inspected at every 10000kms.
Page 45
712-MAT-0033 : 0.10 hrs

BATTERY SPECIFIC GRAVITY - CHECK
BATTERY SPECIFIC GRAVITY - CHECK
Battery testing includes two basic procedures.

1. Visual Inspection 2. State of charge (a. Specific gravity & b. Open circuit voltage)
Visual Inspection - Battery service should begin with thorough visual inspection. This inspection may
reveal simple and easily correctable problems.
1. Check for cracks in the battery case and broken terminals which allows electrolyte leakage.
Replace the battery if necessary.
2. Check for corrosion on terminals and dirt/acid on the battery case top. Clean the terminals
and the battery case top with mixture of water and baking soda. A battery wire brush tool
can also be used to clear heavy corrosion on the terminals.
3. Check for a loose battery hold down and tighten it if necessary.
4. Check the electrolyte level by viewing through the translucent plastic case or removing the
vent caps and looking directly into the battery. Top up required amount of distilled water.
5. Check for cloudy or discolored electrolyte caused by overcharging or vibration of the battery.
This will cause high self discharge. Correct the cause or replace the battery if necessary.
Refer below chart for Specific gravity, Charge & Output Current Voltage comparison –
Page 46
State of Charge:
The state of charge of the battery can be easily

checked in two ways:
Specific gravity test:
The hydrometer compares the specific gravity of

electrolyte with water.
Specific gravity readings:

• By measuring the specific gravity of the electrolyte, you can identify whether the battery is fully
charged, requires charging, or must be replaced. The battery must be at least 75% charged to
perform load test or each cell must have a specific gravity of 1.230 or higher to proceed with
the load test.
1. Wear suitable eye protectors (goggles). Remove the vent caps or covers from the battery.
2. Squeeze the hydrometer bulb and insert the pickup tube into the cell close to the battery
positive terminal.
3. Slowly release the bulb to draw in only enough electrolytes to cause the float to rise. Do not
remove the tube from the battery.
4. Read the specific gravity indicated on the float. Be sure the float is drifting free, and does not
contact with sides of the barrel. Read the hydrometer at eye level. Disregard the slight
curvature of liquid on the float.
5. Note the reading for all the cells. The difference in specific gravity readings should not be more
than 0.05.
 Battery Specific Gravity to be inspected at every 10000 kms.

 Do not allow battery fluid to contact with skin, eyes, fabrics, or painted surfaces. Do not touch
or rub your eyes until you have thoroughly washed your hands. If acid contacts eyes,
immediately flush with water and seek medical attention if necessary.
 Specific gravity varies with the temperature. If the electrolyte temperature is substantially
above 27 deg. C add seven points (0.007) to the observed specific gravity reading for every 10
deg. C by which the actual temperature is above 27 deg. C. Deduct seven points per 10 deg C
where the observed reading is below 27 deg. C to obtain the temperature corrected reading at
27 deg. C.
Page 47
712-MAT-0034 : 0.30 hrs

LIGHTS/ HORN/ WIPER/ WASHER - CHECK
Xylo mHawk – Instrument Cluster Schematic
A Parking Brake/Low Brake Oil Warning Lamp * K High Engine Coolant Temperature Warning
Lamp *
B Turn Lamp - Left L Turn Lamp - Right
C Check Engine Lamp * M Low Engine Oil Pressure Warning Lamp **
D Water-in-Fuel Warning Lamp * N Low Fuel Warning Lamp *
E Fog Lamp - Rear O Head Lamp High Beam Lamp
F Anti-Brake System (ABS) Warning Lamp * P Seat Belt Warning Lamp *
G Vehicle Armed Status Lamp Q Door Ajar Warning Lamp
H OBD Check Lamp (BS IV only) ** R Electronic Brake Distribution (EBD) Lamp *
I Airbag Warning Lamp * S Cruise Control Lamp *
J Battery Charging System Lamp ** T Fog Lamp - Front
* These indications will come ON momentarily when the ignition is switched ON and will go OFF in
few seconds.
** These indications come ON momentarily when the ignition is switched ON and will remain ON till
the engine is started.
If any of the warning lamps marked * or ** do not come ON or remain ON after the engine is
started, it is an indication of a malfunction of that lamp or system. Check the vehicle with help of
Diagnostic tool and take corrective action.
Page 48
Digital Drive Assist System (DDAS) -
It displays the information of current vehicle

performance and environmental conditions.
Intellipark Reverse Assist System (IRAS)

(if equipped) –
Intellipark Reverse Assist System is a system

which aids the driver while reversing the
vehicle at a speed less than 5 kmph.
Hazard Flasher -
The hazard warning flasher switch is located

below the DDAS in the instrument panel. Press
the switch to turn ON the hazard warning
flashers, all directional turn signals should.
Electric ORVM Adjustment -
The switch houses the Left (L) / Right (R) ORVM

selection button and a four way navigation
button.
Pressing L / R selects Left / Right side exterior

mirror respectively. Pressing the navigation
knob in the required direction moves that
particular mirror (left or right) accordingly to
the desired position.
Page 49
Exterior Lamps –
Lighting Control Stalk

The lighting control stalk controls operations of
parking lamps, head lamps, head lamp beam
selection, high beam flashing and turn signals
when the ignition switch is ON.
Push the lighting control stalk backward
direction to indicate a right turn; and push the
stalk to forward direction to stop the position
B; again push it further forward direction to
indicate a left turn. The instrument cluster
arrow lamp pointing towards the right flashes.
If the turn signal lamps on the instrument panel flash faster than normal, there may be a possibility
that one or more of the turn signal lamp bulbs have blown. Replace the blown bulb immediately.
Rotate the outer rotary switch on the lighting
control stalk aligning the “dot” on the switch to
“OFF” on the stalk to switch OFF all lamps.
Parking Lamp ON
the “1st detente” position on the stalk to
switch ON the parking lamps.
The tail lamp, license plate lamp, side marker lamps, instrument panel illumination lamps and all
interior switches are also activated when the Parking lamp is switched ON.
Page 50
Head Lamp ON

the “2nd detente” position on the stalk to
switch ON the head lamps.
Head Lamp Low Beam
With the head lamp high beam ON, pull the

lighting control stalk up [A] towards the
steering wheel to switch ON the head lamp low
beam;
Pull the lighting control stalk down [B] away

from steering wheel to switch ON the head
lamp high beam.
Head Lamp Flash
Pull the lighting control stalk (from the head

lamp low beam position) towards the steering
wheel to instantaneously flash the head lamp
high beam. The head lamp flash works even
when the head lamp is OFF.
Front Fog Lamps ON
To switch ON the front fog lamps, switch ON

the ignition and the parking lamps. Turn the
inner rotary switch on the lighting control stalk
to align to the inner fixed stalk as shown.
Page 51
Front & Rear Fog Lamp
To switch ON the front and rear fog lamps,

switch ON the parking lamps; turn the inner
rotary switch on the lighting control stalk to
align with the inner fixed stalk as shown.
Windshield Wipers
Wiper Control Stalk
The wipe/wash function can be activated only

when the ignition is in “IGN” position.
Wiper Off
The wipe function is off when the wipe control

stalk is in neutral position (B).
Flick-Wipe (Mist)
Push the wipe control stalk to position A for a

flick-wipe, hold to operate the wipe
continuously (simultaneously lift the wiper
stalk towards the steering wheel to operate
the wash).
The stalk automatically comes back to position

B when released.
Intermittent (INT) Mode
Intermittent (INT) wiping is selected when the

wipe control stalk is pushed down to position
C. In the INT mode, the wiper operates on
preset intervals of 4 sec. The delay between
each wipe can be programmed from 1 to 60
sec according to the rain by the user.
Page 52
Programming of the INT delay time is as follows -
• Turn the wiper stalk to position C, wiper will start wiping

• Turn the wiper stalk to OFF position, before wiper starts second wipe
• Turn the wiper stalk to position C again after the required delay and the same delay will be
programmed.
• On keeping wiper ON position C, the wiper will wipe again with the programmed delay.
Low Speed Wiping
Push the wipe control stalk down to the

position D to operate the wiper at a fixed low
speed.
High Speed Wiping
Push the wiper control stalk down to position E

to operate the wiper at a fixed high speed.
Wipe/Wash
Pull/Lift the wiper control stalk towards the steering wheel from any position to activate wipe/wash
function. Washer fluid is sprayed on the front windshield and the wipers wipe the windshield 3 times
after the washer spray is stopped and wipe once after 5 sec.
Rear Wiper
Rotate the outer rotary switch on the wiper
control stalk to align the “dot” on the switch to
the “1st detente” position on the wiper stalk to
operate the rear wiper.
Auto-rear Wiping
With the front wipers ON and rear wipers OFF,
engaging the reverse gear activates the rear
wiper.
Page 53
Windshield Washer – Front

There are two nozzles with twin adjustable washer jets in the front (on the hood). Using a pin, the eye
ball jets can be adjusted precisely for direction. Always direct the washer jet to hit middle of the
windshield. This will enable the wiper blade to wipe the complete width of the windshield.
Windshield Washer – Rear
A single nozzle with twin adjustable washer jets is provided for the rear windshield wash. Adjust to
direct the washer jet to hit the middle of rear windshield using a pin. Rear windshield washer fluid is
supplied from rear washer reservoir located in the back door. Press the tab on the lid and pull open
the lid to access the rear wash reservoir.
Puddle Lamps
The Puddle lamps are provided at the bottom

of the front doors. They are switched ON
automatically when either of the front doors is
opened.
Horn
Press the pad on the steering wheel to

blow/sound the horn.
The horn should function even when the

ignition has been switched OFF.
• All Lights, Horns, Wipers & Washers to be inspected at every service interval.
Page 54
712-MAT-0035 : 0.30 hrs

HEADLAMP AIMING/ALIGNMENT – CHECK AND ADJUST
Headlamp alignment by visual Method (Refer below illustration):
Schematic – Headlamp alignment by Visual Method
Y=10meters
Ensure that:
a. Vehicle & screen/ board both are placed on the same Level surface.
b. Check and ensure all four tyre pressures as per specification.
c. Head lamp leveling switch position is on zero (0).
d. Keep the vehicle at a distance (Y) of 10 meter from the screen/ board.
Refer below illustration for the headlamp bulb arrangement –
RH Side Head Lamp LH Side Head Lamp
E A B C D D C B A E
A High & Low Beam - Halogen Bulb D Turn Indicator lamp

B Bulb Shield E Reflector Assembly
C Park Lamp
Page 55
Head Lamp Alignment Procedure –
STEP 1 – Setting the Low Beam

STEP 2 – Checking High Beam
STEP 1 – Low Beam Setting Procedure:
Refer below illustration for the headlamp low beam cut off pattern:
Xylo Head Lamp alignment Dimensions are - X: 869mm. h=(X-130)=739mm. Z: 1261mm.

h=X-1.3% of Y. Y=10meters (distance between vehicle and board)
 Set LH & RH head lamp (Low Beam) by setting the cut off pattern at a height marked on the board.
Refer above illustration for low beam cut off pattern.
 Refer illustration for LH & RH side head lamp low

beam alignment setting.
• Use 250mm size star screw driver and set

screw [A] to adjust low beam vertical
movement.
Xylo LH side head lamp – Rear View
Page 56
Rotation of the Screw driver –
Down/ Clockwise (Loose)
Up/ anti-clockwise (Tight)
LH side head lamp (assembled condition) – Rear View
 Check the horizontal setting of RH & LH head

lamp. Refer above illustration for low beam cut
off pattern and horizontal dimensions.
 Use 250mm size star screw driver and set screw

[B] to adjust low beam horizontal movement.
Refer above illustration for low beam cut off
pattern.
B
LH side head lamp (assembled condition) – Top View
Horizontal movement Setting screw [B] can be accessed from Headlamp top side when it is assembled on
vehicle.
Rotation of the Screw driver –

Down/ Clockwise (Right side movement)
Up/ anti-clockwise (Left side movement)
LH side head lamp Assembly – Rear View
Page 57
 Check the function of system by operating the

switch from ‘0’ to ‘3’ and observe the cut off
pattern movement in downward direction
accordingly.
 At zero position of switch, the cut off should

come at -1.3% heights on screen.
STEP 2 – Checking High Beam
Refer below illustration for the headlamp high beam cut off pattern:
Xylo Head Lamp alignment Dimensions are - X: 869mm. Z: 1261mm.
• Use above High Beam cut off pattern for checking purposes.
• High Beam cut off should automatically come after Low beam setting has been done.
• Do not try to set high beam independently as it will disturb the low beam setting.
Page 58
Xylo mHawk – Head Lamp Dimensions

- All Dimensions are in mm. - Tolerance value is +/- 30 mm.
Page 59
712-MAT-0036 : 0.20 hrs

HVAC FILTER – CLEAN
Open the Glove box assembly
Remove the Glove box stay supports
Remove the HVAC filter tray by opening the snap

clips on both sides.
Clean the Filter Element with air (If compressed

air is used, ensure the pressure is low). If the filter
tray found very dusty it can be cleaned using soap
solution and water. Dry it with help of low
pressure air before refitting.
Installation –
Installation process is reverse to the removal.
 Clean mesh every 10000kms

 Check the entire system for leaks and recharge if required
Page 60
712-MAT-0037 : 0.65 hrs

DOOR SETTING
DOOR STRIKER STRICKER MOUNTING SCREW - LOOSEN DOOR LATCH
Door Setting - For Side doors:

Refer photos shown.
1. Open the door and while closing it check whether striker is at the centre of latch. If it is
not at the centre of latch, striker will foul with top or bottom portion of latch. Loosen the
bolts of striker and move the striker up or down to remove the fouling.
2. Check whether door is over flush or under flush. If it is over flush move the striker towards
vehicle centre and check flushness. If it is under flush move the striker away from vehicle
centre and check flushness.
3. After above corrections are done tighten the striker mounting bolts with torque value 25
N-m to 30 N-m
Door Setting - For Back door:

Refer photos shown.
1. Open the door and while closing it check whether striker is at the centre of latch. If it is
not at the centre of latch, striker will foul with top or bottom portion of latch or dovetail.
Loosen the bolts of striker and move the striker up or down to remove the fouling.
Similarly loosen the bolts of dovetail and move the dovetail up or down to remove the
fouling.
2. Check whether door is over flush or under flush. If it is over flush move the striker towards
vehicle centre and check flushness. . If it is under flush move the striker away from vehicle
centre and check flushness.
3. After above corrections are done tighten the striker mounting bolts with torque value 25
N-m to 30 N-m
Page 61
712-MAT-0038 : 0.30 hrs

TYRE PRESSURE – CHECK AND ADJUST
Proper tyre inflation pressure is essential to the safe and satisfactory operation of the vehicle.
Three primary areas are affected by improper tyre pressure.
a. Safety
b. Economy
c. Ride Comfort and Vehicle Stability
Tyre pressure value: Refer below chart –
COLD TYRE INFLATION PRESSURE
TYRE SIZE 215/75 R15 100S
Vehicle Load
Condition:
NORMAL/
PARTIAL
FRONT REAR
Psi 35 35
Kg/cm. sq. 2.4 2.4
Vehicle Load
Condition:
FULL
FRONT REAR
Psi 35 41
Kg/cm. sq. 2.4 2.8
• The proper cold tyre inflation pressure is listed in the Tyre Label (Vehicle Placard), located
on the front passenger side inner B-pillar.
• Ensure to check and adjust the tyre pressure in the spare tyre.
• Ensure to replace dust cap on valve seats after checking tyre pressure.
Page 62
712-MAT-0039 : 0.40 hrs

BODY MOUNTING BOLTS - TIGHTEN
Nut/ Bolt description Spanner Size Quantity Nos. Torque Value – Nm.
• Body mtg. bolts 13 mm. 08 nos. 65 ± 05 Nm.
NOTE:
 Body mounts/ triggers on front both are denominated as LH1 & RH1.
 Front mounts LH1 & RH1 are smaller in size/ Dia. than rear.
 Refer above sketch for body mount location.
 Park the vehicle in inspection pit /2 post lift/ 4 post lift.

 Body mounts to be checked and torque tighten first at 5000 kms then 20000 kms and then at
every 20000 kms.
Page 63
712-MAT-0040 : 0.10 hrs

EXHAUST SYSTEM - CHECK
Xylo mHawk BS-III – Exhaust System Joints & Rubber Hanger Location Schematic
Xylo mHawk BS-IV – Exhaust System Joints & Rubber Hanger Location Schematic
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by the manufacturer in the production of the various component units and accessories from which the vehicles are
manufactured. The reproduction, translation, transmission, in part of or whole of the present document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of Mahindra & Mahindra
Page 64

EXHAUST SYSTEM - CHECK

Refer above illustrations.
1. Check all the Exhaust mountings for exhaust pipe fouling, if any and correct fittings if
required.
2. Check all the Exhaust joints shown by arrow marks for leakage and correct fittings.
3. Checks circled area for rubber hangers for crack and shift, replace it if required.
 Park the vehicle in inspection pit / 2 post lift / 4 post lift

 Exhaust system to be checked and torque tighten first at 5000 kms then 20000 kms and then at
every 20000 kms.
Page 65
The repair methods given by the manufacturer in this document are based on the technical specifications, current at the time of release. The methods may be modified as a result of changes introduced by
the manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part or whole of the present
document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd. The use of this document by any person other than the trained personnel, at the Authorized Service Centre of
Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2011 Mahindra & Mahindra Ltd.
Page 66
MAINTENANCE CHECK SHEET @ 5000 KMS
WORK STATUS Time Allotted

WORK NATURE ACTION
Complete Incomplete (Man-hours)
Engine oil 1 REPLACE 0.30
Engine oil filter REPLACE 0.20
3
Coolant I 0.05
C 0.20
Parking brake operation A 0.30

Front Suspension bolts torque I 0.25
Rear Suspension bolts torque I 0.20
Battery electrolyte level I 0.10
All Lights, Horns, Wipers & Washers I 0.30
Head light aiming I 0.30
Door setting A 0.65
Tyre pressure A 0.30
Body mounting bolts for tightness I 0.40
leakage
I 0.10
Road Test- if any complaints reported I
• Additional Repair Work carried out, if any -

1)
• Observations, Notes if any -

1)
Above Services Performed by –

Job Start Time:
Name of the Technician –
Date of Service –
Job End Time:
Repair order No.
Repair order date - Standard Time: 03.65 man-hrs.

MAINTENANCE CHECK SHEET @ 10,000 KMS

WORK NATURE ACTION
1
Engine oil I 0.05
3
Coolant I 0.05
C 0.20
Transmission oil 2 REPLACE 0.30

2
Differential oil (Rear) REPLACE 0.20
Tyre rotation A 0.60
check B
I 0.15

I 0.10
check
Battery specific gravity I 0.10
Clean mesh C 0.20
Road Test- if any complaints
I
reported

1)

1)

Job Start Time:
Date of Service –
Job End Time:
Repair order No.


WORK NATURE ACTION
1
Engine oil REPLACE 0.30
3
Coolant I 0.05
Fuel filter element REPLACE 0.50
check B
I 0.15
Brake pads/ Callipers I 0.60
Brake drum and lining I 0.80
check
I 0.10
Clean mesh C 0.20
leakage
I 0.10

1)
2)

1)
2)

Job Start Time:
Date of Service –
Job End Time:
Repair order No.

WORK STATUS Time

WORK NATURE ACTION Allotted
Engine oil 1 I 0.05
3
Coolant I 0.05
C 0.20

check B
I 0.15

Power steering fluid - level & leak check I 0.10
Clean mesh C 0.20

1)
2)

1)
2)

Job Start Time:
Date of Service –
Job End Time:
Repair order No.

WORK STATUS Time

3
Coolant I 0.05
B
Brake & Clutch fluid - level & leak check REPLACE 0.15
Front suspension bushes- inspect I 0.20
Link bushes- inspect I 0.20
Clean mesh C 0.20
leakage
I 0.10

1)

1)

Job Start Time:
Date of Service –
Job End Time:
Repair order No.

WORK STATUS Time

Engine oil 1 I 0.05
3
Coolant I 0.05
Water sediments drain-Fuel filter (or when
indicator glows)
C 0.20
Transmission oil 2 I 0.05

2
Differential oil (Rear) I 0.05
B
Brake & Clutch fluid - level & leak check I 0.15
Clean mesh C 0.20

1)

1)

Job Start Time:
Date of Service –
Job End Time:
Repair order No.

WORK STATUS Time

Auto tensioner I 0.10
Accessory drive belts I 0.20
3
Coolant REPLACE 0.60
REPLACE 0.25

B
Clean mesh C 0.20
leakage
I 0.10

1)

1)

Job Start Time:
Date of Service –
Job End Time:
Repair order No.

WORK STATUS Time

Engine oil 1 I 0.05
3
Coolant I 0.05
indicator glows)
C 0.20

B
Clean mesh C 0.20

1)

1)

Job Start Time:
Date of Service –
Job End Time:
Repair order No.

WORK STATUS Time

Auto tensioner I 0.10
Accessory drive belts I 0.20
3
Coolant I 0.05
Fuel tank & stainer CLEAN 1.00
2
Differential oil (Rear) REPLACE 0.20
B
Clean mesh C 0.20
Exhaust pipe mountings damage / leakage I 0.10

1)

1)

Job Start Time:
Date of Service –
Job End Time:
Repair order No.

WORK STATUS Time

Engine oil 1 I 0.05
3
Coolant I 0.05
indicator glows)
C 0.20

B
Clean mesh C 0.20

1)

1)

Job Start Time:
Date of Service –
Job End Time:
Repair order No.

WORK STATUS Time

Auto tensioner REPLACE
1.20
Accessory drive belts REPLACE
3
Coolant I 0.05
2
Transmission oil REPLACE 0.30
B
Clean mesh C 0.20
leakage
I 0.10

1)

1)

Job Start Time:
Date of Service –
Job End Time:
Repair order No.

MAINTENANCE CHECK SHEET @ 1,10,000 KMS
WORK STATUS Time

Engine oil 1 I 0.05
3
Coolant I 0.05
indicator glows)
C 0.20

B
Clean mesh C 0.20

1)

1)

Job Start Time:
Date of Service –
Job End Time:
Repair order No.

WORK STATUS Time

3
Coolant I 0.05
REPLACE 0.25

2
Differential oil (Rear) I 0.20
B
Clean mesh C 0.20
leakage
I 0.10

1)

1)

Job Start Time:
Date of Service –
Job End Time:
Repair order No.

Maintenance Manual

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MAINTENANCE MANUAL

TECHNICAL PUBLICATION CELL

Rev1 – FEBRUARY 2012

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

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

Job Description Repair Time {Manhours}

Repair Code Torque Specified

Lubricant Quantity Tool Specified

This chart is only a sample.

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• Always wear clean uniform

Parts and tools

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Term/ Symbol Denotation

DANGER indicates an imminently

WARNING indicates a potentially

CAUTION indicates a potentially

CAUTION used without the safety alert

Indicates important information relevant to

If you see this symbol, it indicates “no”,

• Legend of the Procedure/ Action Symbols

Set / Place / Check here

Move forward / Fit

Rotate / Turn Clockwise

Rotate / Turn anti-clockwise

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Refer below Maintenance Schedule for XYLO mHawk:

All Lights, Horns, Wipers & Washers I I I I I I I I I I I I I

Head light aiming I

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

Legends * On chargeable basis I = Inspect and correct R- Replace A-Adjust C-Clean

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Refer below Recommended Lubricants Chart for XYLO mHawk -

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XYLO mHawk (712 - MAT-xxxx)

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712-MAT-0001 : 0.30 hrs.

Oil Filling Point

Oil Drain & Refill –

 Park the vehicle on level ground/2 post lift /4 post lift

712-MAT-0002: 0.05 hrs.

Oil Level Check – Refer illustrations shown.

712-MAT-0003 : 0.20 hrs.

Oil Leak - Check Points near Oil Filter

Oil Filter & Cooler disassembly

Oil filter Removal – Refer illustrations.

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

712-MAT-0004 : 0.10 hrs.

Auto Tensioner Inspection:

 Auto tensioner to be check at 60000, 80000kms and it is recommended to replace it at every

712-MAT-0005 : 0.70 hrs. & 712-MAT-0006 : 0.50 hrs.

[A] Alternator/Power Steering Pump Drive Belt

[B] AC Compressor /Water Pump Drive Belt

1. Using the special tool, rotate the Auto Tensioner

1. Remove Power Steering drive belt before

 Auto tensioner to be inspected at 60000, 80000kms and to be replaced at 100000kms.

712-MAT-0007 : 0.50 hrs.

ACCESSORY DRIVE BELT - LAYOUT ACCESSORY DRIVE BELT TO BE CHECK FOR –

2. Cracking – Small, yet visible cracks along the

3. Improper Install – A belt rib begins separating

4. Uneven Rib Wear – Belt shows damage to the

5. Misalignment – Sidewalls of the belt may appear