Mahindra Genio DC BS-IV User manual

©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.
MAINTENANCEMANUAL

(BS-III/BS-IV)

www.teknetmahindra.com
ALL INFORMATION CONTAINED IN THIS MANUAL IS MOST UP-TO-DATE AT THE TIME OF PUBLICATION.
HOWEVER, SPECIFICATIONS AND PROCEDURES ARE SUBJECT TO CHANGE WITHOUT NOTICE. THIS
MANUAL IS STRICTLY MEANT FOR RESTRICTED INTERNAL CIRCULATION WITHIN M&M AUTHORIZED
DEALER SERVICE CENTERS.
RELEASED BY –
TECHNICAL PUBLICATION CELL
MAHINDRA & MAHINDRA LTD.
Rev1 – JULY 2011
MAN-00135

©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.
About the Maintenance Manual
The maintenance manual outlines the correct standard operating procedures (SOPs) for carrying out
maintenance operations in a Mahindra GENIO DC vehicle. Carrying out the periodic maintenance
operations, as specified, is crucial for safe and trouble-free operation of the vehicle.
The recommended maintenance schedule /operations are published in the owner’s handbook.
This manual covers the correct method of carrying out the maintenance operations, using the correct
process/procedures, tools, parts and lubricants. The manual consists of –
Maintenance Schedule – The maintenance schedules outlines the operations to be carried out a
specified interval. These operations are Adjust (A), Inspect & Correct (I), Replace (.R), Clean (C). The
maintenance periods are specified in Kilometers (Kms).
Standard Operating Procedures (SOP) – Each maintenance operation is coded by a operation code
– 705-MAT-xxxx. Here 705 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.
Repair Code
Repair Time {Manhours}Job Description
Lubricant Quantity
Lubricant Recommended
Tool Specified
Torque Specified
This chart is only a sample.
Crown
705

©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.
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, 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.
IMPORTANT
MahindraXylomEagleisfittedwithLSPV(LoadSensingPressureRegulatingValve)inthe
brakecircuit.HenceitisimperativethattheLSPVspringisdisconnectedbeforelifting
thevehicleona2‐postlift.Failuretodosocanleadtoelongationofthespring,
disturbingtheLSPVsettings,leadingtodifferentbrakingcharacteristics.
Ensuretore‐connecttheLSPVspringandmeasurethefittedlengthafterloweringthe
vehiclefromthe2‐postlift.

Maintenance Manual MAN-00135
GENIO DC (BS-III & BS-IV) JULY 2011/Rev1
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 © 2011 Mahindra & Mahindra Ltd.
1
Refer below Maintenance Schedule chart for GENIO DC (BS-III & BS-IV) models :-

Maintenance Manual MAN-00135
GENIO DC (BS-III & BS-IV) JULY 2011/Rev1
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 © 2011 Mahindra & Mahindra Ltd.
2
* on chargeable basis.
705 - MAT-xxxx
Maintenance item
Operation Code
Page No
Engine oil - Replace 705 - MAT - 0001 03
Engine oil - Level Check 705 - MAT - 0002 04
Engine oil filter - Replace 705 - MAT - 0003 05
Auto tensioner - Inspect 705 - MAT - 0004 06
Auto tensioner - Replace 705 - MAT - 0005 07
Accessory drive belts - Inspect 705 - MAT - 0006 08
Accessory drive belts - Replace 705 - MAT - 0007 10
Coolant - Check 705 - MAT - 0008 11
Coolant - Replace 705 - MAT - 0009 12
Air filter element - Replace 705 - MAT - 0010 13
Fuel filter element - Replace 705 - MAT - 0011 14
Fuel tank - Clean 705 - MAT - 0012 15
Water sediments drain – Fuel filter 705- MAT - 0013 16
Transmission oil - Replace 705 - MAT - 0014 17
Differential oil (Rear) - Replace 705 - MAT - 0015 18
Tyre rotation 705 - MAT - 0016 19
Rear Wheel Greasing 705 - MAT - 0260 20
Propeller Shaft Greasing 705 - MAT - 0221 24
LSPV setting 705 - MAT - 0017 25
Brake + Clutch fluid - level & leak Check 705 - MAT - 0018 26
Brake + Clutch fluid - Replace 705 - MAT - 0019 27
Brake pads/ Calipers - Check 705 - MAT - 0020 29
Brake drum and lining - Check 705 - MAT - 0021 30
Parking brake operation - Check & Adjust 705 - MAT - 0022 31
Front Suspension bolts torque - Check 705 - MAT - 0023 32
Front suspension bushes- Inspect 705 - MAT - 0025 33
Rear Suspension bolts torque - Check 705 - MAT - 0024 32
Rear Suspension bushes - Check 705 - MAT - 0026 35
Power steering fluid - level & leak 705 - MAT - 0027 36
Power steering belt - Check 705 - MAT - 0028 37
Power steering belt - Replace 705 - MAT - 0029 39
Wheel alignment * 705 - MAT - 0030 40
Battery electrolyte level - Check 705 - MAT - 0031 43
Battery specific gravity - Check 705 - MAT - 0032 44
All Lights, Horns, Wipers & Washers - Check 705 - MAT - 0033 45
Head light aiming - Check & Adjust 705 - MAT - 0034 47
HVAC – Clean mesh 705 – MAT - 0035 49
Door setting 705 - MAT - 0036 50
Tyre pressure - Check & Adjust 705 - MAT - 0037 51
Body & Cargo mounting bolts for tightness-Check & Adjust 705 - MAT - 0038 52
Exhaust pipe mtgs. & damage/leakage - Check 705 - MAT - 0039 53
Road Test- if any complaints reported 705 - MAT - 0040

Maintenance Manual MAN-00135
GENIO DC (BS-III & BS-IV) JULY 2011/Rev1
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 © 2011 Mahindra & Mahindra Ltd.
3
705-MAT-0001 : 0.30 hrs.
ENGINE OIL – REPLACE
Engine oil – MAXIMILE CROWN (SAE 15W-40) API CH4
Capacity – 6.0 Lit.
Park the vehicle on level ground/2 post lift* /4 post lift
If the activity is done on a 2 post lift, ensure that the LSPV spring is disconnected
before lifting the vehicle. After lowering, re-connect the LSPV spring and ensure
that the setting height is correct.
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 CROWN engine Oil change are at 5000,
20000kms & then at every 20000kms.
Nut/ Bolt description Quantity Nos. Spanner Size Torque Value – Nm.
Oil Sump drain plug 01 22 mm 27.5 ± 2.5
Oil Drain & Refill –
1. Open the oil filler cap.
2. Put 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 910-MAT-0002.
Oil Filler Cap

Maintenance Manual MAN-00135
GENIO DC (BS-III & BS-IV) JULY 2011/Rev1
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 © 2011 Mahindra & Mahindra Ltd.
4
705-MAT-0002: 0.05 hrs.
ENGINE OIL – LEVEL & LEAK – CHECK
Ensure that the vehicle is parked on level ground/2 post lift/4 post lift.
If the activity is done on a 2 post lift, ensure that the LSPV spring is disconnected
before lifting the vehicle. After lowering, re-connect the LSPV spring and ensure
that the setting height is correct.
Ensure that the engine is not running when oil level check is being done.
If the engine was running before, wait for 10-12 minutes to accumulate oil in the
sump and then do oil level check.
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 joint.
DIPSTICK
DIPSTICK
DIPSTICK
GUIDE
MAX
MIN
A
B
C

Maintenance Manual MAN-00135
GENIO DC (BS-III & BS-IV) JULY 2011/Rev1
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 © 2011 Mahindra & Mahindra Ltd.
5
705-MAT-0003 : 0.20 hrs.
ENGINE OIL FILTER– REPLACE
Never use a wrench/spanner to tighten the oil filter.
Oil filters need to be replaced during engine Oil change. Recommended intervals
are at 5000, 20000kms & then at every 20000kms. Use Maximile UNIVERSE oil
filter.
Oil filter Removal – Refer illustrations.
1. Remove the oil filter by unscrewing it in anti-clockwise direction, using an oil filter
wrench.
2. Check the oil cooler stud for tightness – Torque 27.5 ± 2.5 Nm.
3. Smear a layer of fresh engine oil on the oil filter “O” ring
4. Fit the oil filter and turn it clockwise till the “O” ring touches the oil cooler face.
5. Turn the filter another 3/4th turn by hand.
6. Check for Oil leakage/ seepage at –
Refer illustration [A] checkpoints are shown with arrows.
Oil pan & crankcase joint
Oil pan Drain Plug.
Oil filter joint.
Oil cooler joint
Oil Filter & Cooler disassembly
B
Oil Leak - Check Points near Oil Filter
A

Maintenance Manual MAN-00135
GENIO DC (BS-III & BS-IV) JULY 2011/Rev1
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 © 2011 Mahindra & Mahindra Ltd.
6
705-MAT-0004 : 0.05 hrs.
AUTO TENSIONER - CHECK
Auto tensioner to be check at 60000, 80000kms and it is recommended to
replace it at every 100000kms.
Auto Tensioner Inspection:
Refer illustrations shown.
Inspect automatic tensioner carefully for symptoms such as cracked arms, excessive vibration
during idle speeds, looseness, noise (clatter or rattling) and sticking or seized operation. These
can all be signs that a tensioner needs replacing.
Refer slots shown by arrow marks on Auto tensioner in sketch [C] & [D]. Two 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.
D
Marking on Auto Tensioner
Marking on Auto Tensioner
C
DRIVE BELTS - LAYOUT
B
Auto Tensioner mounting on Engine
A

Maintenance Manual MAN-00135
GENIO DC (BS-III & BS-IV) JULY 2011/Rev1
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 © 2011 Mahindra & Mahindra Ltd.
7
705-MAT-0005 : 0.60 hrs.
AUTO TENSIONER - REPLACE
Auto tensioner to be check at 60000, 80000kms and it is recommended to
replace it at every 100000kms.
Nut/ Bolt description Quantity Nos. Spanner Size Torque Value – Nm.
Auto tensioner mtg. bolt 01 12 mm. 35 ± 05
Removal Steps –
1. Remove NVH cover.
2. Remove fan & shroud
3. Remove power steering belt (705-
MAT-0029) & Accessory drive belt
(705-MAT-0007)
4. Remove Auto tensioner assy.
Assembly Procedure –
1. Refit Auto tensioner assy.
2. Refit Accessory drive belt (705-
MAT-0007) & power steering belt
(705-MAT-0029)
3. Refit fan & shroud.
4. Refit NVH cover.
NOTE: Auto tensioner is provided with dowel-pin on its mounting face for correct fitment;
while assembling the dowel should match & fixed carefully.
Refer sketch [D] Dowel Pin location shown by arrow mark.
DRIVE BELTS - LAYOUT
B
A
C
Auto Tensioner
D
Auto Tensioner dowel
Pin mounting hole

Maintenance Manual MAN-00135
GENIO DC (BS-III & BS-IV) JULY 2011/Rev1
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 © 2011 Mahindra & Mahindra Ltd.
8
705-MAT-0006: 0.20 hrs.
ACCESSORY DRIVE BELT – CHECK
Belt Type: 6PK, 1610mm, GATES make. Belt Tension Value: 114±5 Hz.
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
ACCESSORY DRIVE BELT - LAYOUT
Refer illustrations shown.
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 –
Refer illustration shown.
Belt shows damage to the side with the
possibility of breaks in the tensile cord or
rough edged ribs. A thumping noise may
also be heard when running.
5. Misalignment –
Refer illustration shown.
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.

Maintenance Manual MAN-00135
GENIO DC (BS-III & BS-IV) JULY 2011/Rev1
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 © 2011 Mahindra & Mahindra Ltd.
9
Recommended belt tension is 114±5 Hz. To be check between Alternator &
Dummy pulley.
Recommended belt tension for Power Steering Pump drive Belt is – New: 255
to 260 Hz & Used/ Stabilized belt: 215 to 225Hz.
Accessory Drive Belt tension to be check at 60000, 80000kms.
Accessory Drive Belt replacement interval is at every 100000kms.
Refer illustrations shown.
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.

Maintenance Manual MAN-00135
GENIO DC (BS-III & BS-IV) JULY 2011/Rev1
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 © 2011 Mahindra & Mahindra Ltd.
10
705-MAT-0007 : 0.55 hrs.
ACCESSORY DRIVE BELT – REPLACE
Belt Type: 6PK, 1610mm, GATES make. Belt Tension Value: 114±5 Hz.
Recommended belt tension is 114±5 Hz. To be check between Alternator &
A/c Compressor.
Accessory Drive Belt tension to be check at 60000kms & 80000kms.
Accessory Drive belt replacement interval is every 100000kms.
Nut/ Bolt description Quantity Nos. Spanner Size Torque Value – Nm.
Cooling Fan mtg. nut 01 34 mm. 45± 05
NOTE: For loosening accessory drive belt tension, insert Allen-key in the slot provided on Auto
tensioner and turn it in clockwise direction; the accessory belt tension will be loosened and it
can be removed safely. Refer illustration [B].
A
Remove Power Steering Drive Belt
Removal Steps –
Refer illustration shown.
1. Remove NVH cover.
3. Remove power stg. Belt; Refer
(705-MAT-0029).
4. Turn Auto-tensioner in clockwise
direction, as shown in above
sketch to loosen drive belt.
5. Remove accessory drive belt.
Assembly Procedure –
Refer illustration shown.
1. Refit accessory drive belt. Turn
auto-
tensioner in clockwise
direction for ease of belt fitment.
2. Refit power steering drive belt;
Refer (705-MAT-0029)
3. Check and adjust power steering
belt tension
4. Refit NVH cover.
B
Dummy Pulley
Stg. Pump drive belt

Maintenance Manual MAN-00135
GENIO DC (BS-III & BS-IV) JULY 2011/Rev1
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 © 2011 Mahindra & Mahindra Ltd.
11
705-MAT-0008 : 0.05 hrs.
COOLANT LEVEL – CHECK
Never remove the radiator cap when the engine is hot.
Never mix MAXIMILE coolant with water. Maximile coolant is premixed.
Use Maximile ULTRA COOL.
Recommended to check coolant level at every service interval.
Coolant Level - Check
Refer illustrations shown.
1. Check the coolant level in the recovery tank [A] – it should be between MAX and MIN
marks. If below MIN, top it up with Maximile Coolant.
2. Check the coolant level when the engine is cold.
3. Check the coolant level in the radiator [A] and top up if found less. Use MAXIMILE
Coolant directly from the container to top up. Maximile Coolant is pre-mixed and
hence do not dilute it with water.
4. Check for evidence of leakage at Water pump hose [B], Oil cooler hose [C]. Radiator
top and bottom hoses and HVAC heater hoses. Check points are shown by arrow mark.
B
C
MAX
MIN
1
2
Coolant
Level
Indication on
Reservoir
1
A

Maintenance Manual MAN-00135
GENIO DC (BS-III & BS-IV) JULY 2011/Rev1
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 © 2011 Mahindra & Mahindra Ltd.
12
705-MAT-0009 : 0.60 hrs.
COOLANT – REPLACE
Coolant Type: MAXIMILE ULTRA COOL (Pre-mixed)
Capacity: 8 Lit.
Never remove the radiator 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 60000 & then every 80000kms.
Use Maximile ULTRA COOL
Don’t use other coolants for top up. In case of emergency, coolant meeting JIS
K2234 specification should be used (30% concentration diluted with distilled
water) and coolant change period to be reduced as 30,000kms.
COOLANT – REPLACE
Refer illustrations shown.
1. Open the radiator cap
2. Remove the drain plug on the Engine block [B] and radiator bottom [A]
3. Drain the coolant and collect in drain tray.
4. Refit the drain plugs & fill new coolant in radiator
5. Check all the hoses & clips for leakage and correct fitment.
6. Start the engine and run at approx. 1200rpm for 2-3 min.
7. Check coolant level in radiator and add coolant as per requirement.
8. Fill coolant in the coolant recovery tank up to MAX level
9. Refit the radiator cap
10. Start the engine and run at approx. 1200rpm for 2-3 min.
11. Check coolant level in radiator and coolant recovery tank and add as required
B
Coolant Drain Plug on Block
A
Coolant Drain
cock on Radiator

Maintenance Manual MAN-00135
GENIO DC (BS-III & BS-IV) JULY 2011/Rev1
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 © 2011 Mahindra & Mahindra Ltd.
13
705-MAT-0010 : 0.25 hrs.
AIR FILTER - REPLACE
Never try to clean and reuse the Air filter cartridge.
It is recommended to replace the air filter cartridge at every 60000kms and in
case vehicle runs in very dusty condition replace air filter cartridge at 40000kms.
Nut/ Bolt description Quantity Nos. Spanner Size Torque Value – Nm.
Air filter top cover allen bolt
Hose clamps – air cleaner to
manifold
07
02
02
6 mm
11 mm.
11 mm.
4.5 ± 0.5
2.5 ± 0.5
4.5 ± 0.5
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.
5
2
1
3
4
1
A
B
C

Maintenance Manual MAN-00135
GENIO DC (BS-III & BS-IV) JULY 2011/Rev1
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 © 2011 Mahindra & Mahindra Ltd.
14
705-MAT-0011 : 0.30 hrs.
FUEL FILTER – REPLACE
Always use genuine fuel filter assembly.
Fuel filter to be replaced at every 20000kms or earlier if found choked.
FUEL FILTER – REPLACE
Refer above illustrations shown.
1. Place fuel collecting tray below fuel filter assembly;
2. Rotate water drain socket in anti clock wise direction and drain water from filter
assembly.
3. Rotate the fuel filter assembly in anticlockwise direction by hand and remove; refer
illustration for dismantling of Fuel filter [3]
4. Fit a new fuel filter element and tighten it by hand; refer illustration for assembling of
Fuel filter [4]
5. Remove the fuel tank cap.
6. Switch the Ignition to ‘ON’ position.
7. Start the Engine.
8. Check for fuel leak/ seepage if any.
Fuel Filter Assembly
Fuel Filter dismantling & assembly
procedure
2
4 3
Fuel Filter
Element

Maintenance Manual MAN-00135
GENIO DC (BS-III & BS-IV) JULY 2011/Rev1
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 © 2011 Mahindra & Mahindra Ltd.
15
705-MAT-0012 : 0.80 hrs.
FUEL TANK & STRAINER – CLEAN
If the activity is done on a 2 post lift, ensure that the LSPV spring is disconnected
before lifting the vehicle. After lowering, re-connect the LSPV spring and ensure
that the setting height is correct.
There is no drain plug provided on Fuel tank;
Take safety precaution while taking filled fuel tank down from vehicle. Ensure
not to spillage fuel while removing fuel tank from vehicle.
Fuel Tank & Strainer – Clean (Refer illustration shown)
1. Disconnect the fuel lines – Main and return line hoses on fuel tank.
2. Disconnect the fuel filler hose and the breather hose from fuel tank.
3. Disconnect the Fuel tank unit connector.
-Support Fuel tank from bottom side and loosen mounting nuts.
4. Remove the fuel tank from the vehicle.
-Take clean container and remove fuel from fuel tank.
-Clean the fuel tank from inside with help of clean cloth and then by blowing pressure
air. Remove dirt/ rust if any, from fuel tank inner wall.
5. Refit the Fuel tank unit along with gasket; and reconnect the main line, return line, filler
hose, breather hose and Fuel tank unit connections. Ensure that gasket is not damaged,
replace if necessary.
6. Refill fuel tank with clean fuel.
A
Fuel Tank, Float unit & Fuel Pipe Fitting
Fuel Tank mountings

Maintenance Manual MAN-00135
GENIO DC (BS-III & BS-IV) JULY 2011/Rev1
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 © 2011 Mahindra & Mahindra Ltd.
16
705-MAT-0013: 0.10 hrs.
WATER SEDIMENTS DRAIN - FUEL FILTER
Water sediments to be drain from Fuel filter first at 5000kms, 10000kms, and
then at every 20000kms.
Fuel Filter
Assembly
Fuel Filter Assembly
Fuel Filter water drain socket removal
2
Fuel Filter – Drain Water Sediments
Refer above illustrations –
1. Water in Fuel drain plug is fitted at the bottom of the fuel filter assembly.
2. Loosen Water in Fuel drain plug by rotating it in anticlockwise direction [2]
3. Allow the Water accumulated in the filter to drain out.
4. Hand tight the Water in Fuel Sensor in clockwise direction to refit it.
5. Check and ensure for no fuel leak after job completion; if any.

Maintenance Manual MAN-00135
GENIO DC (BS-III & BS-IV) JULY 2011/Rev1
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 © 2011 Mahindra & Mahindra Ltd.
17
705-MAT-0014 : 0.30 hrs.
TRANSMISSION OIL - REPLACE
Transmission Oil – MAXIMILE GO 80W90 SYNCHRO
Capacity – @ 2.0 Lit.
If the activity is done on a 2 post lift, ensure that the LSPV spring is disconnected
before lifting the vehicle. After lowering, re-connect the LSPV spring and ensure
that the setting height is correct.
Recommended oil brand is Maximile GO SYNCHRO 80W90 the oil meets
minimum of API GL-4 SAE 80W90 specification. The oil change interval has to be
first at 10000kms, & then every 400000kms.
Transmission Oil – Replace
Refer above illustration.
1. Remove the Filler plug*
(* vehicle should be parked on leveled surface)
2. Put oil collection tray under transmission, Loosen & remove the drain plug.
Allow the oil to drain out completely.
3. Assemble & torque tight the drain plug with new washer – 27.5 ± 2.5 Nm.
4. Fill fresh transmission oil as per specified capacity & assemble the filler plug with new
washer with 27.5 ± 2.5 Nm torque.
5. Check for Oil leakage / seepage at –
•Transmission Housing Joints.
•Transmission Oil drain plug.
Breather Cleaning -
1. Remove the breather using screw driver from the transmission.
•Clean it externally & blow compressed air from bottom.
2. Fit back the clean breather.
TM Breather
NGT 520 Transmission